AC Control For Resistance Welding Machine CS-NET … Operating Manual ENG R.2... · AC Control For Resistance Welding Operating Manual ... (EV 1,2,3,4) ... 12.1.7 SCR Cooling

Operating Manual Release: 2.10

AC Control For Resistance Welding Machine

CS-NET / STD

SALES

SERVICE

ENGINEERING

RWC LLC PO Box 3153 Bethlehem, PA [email protected] or 484.898.0257

mailto:[email protected]

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Resistance Welding Controls, llc. PO Box 3153, Bethlehem, PA 18017 [email protected] | www.RWCllc.net | 484.898.0257

Manual notes DATE: 10-2015 Terminal CS-NET/T Rel. 2.10 Logic Unit CS-NET/L Rel. 2.10 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 RWC LLC 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-NET. 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. RWC LLC 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 of the device only after reviewing the functionality of the product and verification of proper installation. Not intended for any use other than as described in this manual. The device is designed and built for industrial use by trained personnel, and 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.

While using the machine, operator must 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 RWC LLC. To prevent the misuse and for the safety of personnel, no other type of operation should be done without having first contacted us at [email protected]. Repairs and maintenance on the devices are not allowed without permission of RWC LLC. The manual can be used by customers for use of the product described in it and with the sole purpose of its proper installation. This manual cannot be reproduced, in whole or in part, without the prior approval in writing by RWC LLC. A transmission or dissemination of the manual in any form be it electronic, mechanical or printed without prior written approval by RWC LLC is prohibited. RWC LLC 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 RWC LLC on the comparability of product characteristics with those described in the manual of the product that was actually bought by the customer. No statement or phrase contained in the handbook will have the effect at the end of RWC LLC of additional legal obligations or restrictions or different than those contained in the individual contracts of sale or supply of products RWC LLC.

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WARRANTY: RWC LLC guarantees every unit produced free of defects in material and assembly for a period of 24 months. Damaged parts must be shipped to RWC LLC 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:

24 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.

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Index Index 5 1. CS-NET 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-NET/T warning lights, switches, buttons and their functionality .................... 13 2.4. Notes on installation ............................................................................................ 15 3. Installation and connectors .............................................................................. 15 3.1. Connecting the CS-NET/L ................................................................................... 15

3.1.1 Power supply section ....................................................................................... 15 3.1.2 Power output section ....................................................................................... 17 3.1.3 Description of the features of the connectors and signals. ............................... 18 3.1.3 Hydraulic connection ........................................................................................ 21

4. Operation of the control and parameters ........................................................ 22

4.1. System power on and first window ...................................................................... 22 4.2. EDIT Menù .......................................................................................................... 22

4.2.1 Set the basic configuration ............................................................................... 22 4.2.2 Input to program parameters, and first setting (Spot-weld or Seam-weld). ...... 24 4.2.3 Spot program parameters uicro/STD ............................................................... 25 4.2.4 Spot cycle parameters description ................................................................... 29

4.2.5 Forge ............................................................................................................... 38 4.2.6 Seam program parameters .............................................................................. 39

4.2.7 Seam cycle parameters description ................................................................. 41 4.2.8 System Parameters ......................................................................................... 46 4.2.9 Auto-Step ......................................................................................................... 52 4.2.10 Communications .............................................................................................. 54 4.2.11 Error Log .......................................................................................................... 57 4.2.12 Inputs / outputs test. ......................................................................................... 58

4.2.13 Machine Calibration ......................................................................................... 60

4.2.14 Copy Program .................................................................................................. 65 4.2.15 CAN bus Measures .......................................................................................... 66

5. RUN mode .......................................................................................................... 69

5.1. Start cycle inputs and anti-tiedown ..................................................................... 69 5.2. Selection of Running Programs .......................................................................... 70

5.3. Pre stroke function .............................................................................................. 70 5.4. External input weld current enable. ..................................................................... 71 5.5. Inputs Protection ................................................................................................. 71

5.5.1 Over temperature of the transformer / diode (Thermostat) .............................. 71 5.6. Control inputs ...................................................................................................... 72

5.6.1 Emergency ....................................................................................................... 72 5.6.2 Pressure switch ................................................................................................ 72 5.6.3 Current probe ................................................................................................... 72

5.6.4 Voltage probe ................................................................................................... 72

5.6.5 Reset alarms .................................................................................................... 72 5.6.6 Reset steps ...................................................................................................... 73

5.7. Control outputs .................................................................................................... 73

5.7.1 Main Solenoid valves (EV 1,2,3,4) ................................................................... 73 5.7.2 Forge solenoid valves and Roll motor (EV 5) .................................................. 73 5.7.3 Pre stroke solenoid valve (EV 6 PRE-STROKE) .............................................. 73 5.7.4 Proportional valve ............................................................................................ 73

5.8. Signalling outputs ................................................................................................ 73

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5.8.1 Ready .............................................................................................................. 73

5.8.2 End cycle ......................................................................................................... 74 5.8.3 Anti-tiedown ..................................................................................................... 74

5.8.4 End current increase (END STEPS) ................................................................ 74 5.8.5 Delta TS ........................................................................................................... 74 5.8.6 Out of range ..................................................................................................... 74 5.8.7 CURR ON ........................................................................................................ 74

6. Communications ............................................................................................... 74 6.1. Connecting a printer ............................................................................................ 74 6.2. Connecting a personal computer ........................................................................ 74 6.3. Connecting to a network ..................................................................................... 75 7. Control mode and features ............................................................................... 76 7.1. Duty rate D‰ ...................................................................................................... 76

7.2. Duty rate compensated primary voltage V‰ ....................................................... 76 7.3. Constant current IK ............................................................................................. 76 7.4. Welding mode "advanced" .................................................................................. 77

7.4.1 Tips connections to CS-NET/L ......................................................................... 77

7.4.2 Tips for the voltage acquisition ......................................................................... 77 7.5. Constant power, PK, introduction ........................................................................ 78

7.5.1 Constant power, PK, operative notes ............................................................... 78

7.6. Constant energy, EK, introduction ...................................................................... 79 7.6.1 Constant Energy, EK, operative notes ......................................................... 79

7.7. Adaptive, AD, introduction ................................................................................... 80 7.7.1 Adaptive, AD, operative notes ...................................................................... 80

8. Messaging and display ..................................................................................... 81 8.1. Main measures window and sub windows .......................................................... 82

8.2. Sub windows measures in different modes of work ............................................ 82 8.3. Selection mode, of the program to execute. ....................................................... 87 8.4. Control function of the welded spot ..................................................................... 88

9. Alarms and warnings ........................................................................................ 89 10. Alarms & warnings list ...................................................................................... 89

11. Expansions, Interfaces, Software Options ...................................................... 95 11.1. Parallel interface module Compact Com SM300CC ........................................... 95

11.2. CAN Bus Interface Module for measurements managements SM300-EXP5 ...... 95 11.3. PC adapter module from RS232 to RS485 ......................................................... 95 11.4. PC program ......................................................................................................... 95

12. Technical Data ................................................................................................... 96 12.1. Electrical characteristics power, inputs and outputs. ........................................... 96

12.1.3 Digital signal IN – OUT .................................................................................... 96 12.1.4 Analog signals IN – OUT.................................................................................. 96 12.1.6 Mechanical and environmental ........................................................................ 97

12.1.7 SCR Cooling .................................................................................................... 97 12.2. CS-NET/T mechanical dimension ....................................................................... 98 12.3. CS-NET/L mechanical dimension ....................................................................... 99

13. Attachments ..................................................................................................... 100

13.1. Connections schematics Rev.0 (Annex A) ........................................................ 100 13.2. Connections schematics Rev.0 without I/0 Card (Annex B) .............................. 101 13.3. Connections schematics Rev. A with I/O Card (Annex C)................................. 102 13.4. Connections schematics Rev. A without I/O Card (Annex D) ............................ 103

13.5. Module can bus expansion valve with proportional feedback, linear transducer and pressure sensor Rev.A (annex E) .............................................................. 104

13.6. Serial connection cable for personal computer (Annex F) ................................. 105 13.7. Network cable RS-232 TO RS-485 (Annex G) .................................................. 106

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13.8. Network cable USB TO RS-485 (Annex H) ....................................................... 107

13.9. Spot cycle timing diagram (Annex I).................................................................. 108 13.10. Seam cycle timing diagram (Annex J) ............................................................... 109

13.11. Product disposal at the end of its life................................................................. 110

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1. CS-NET system overview. CS-NET consists of two separate units, the unit of programming and visualization called

“CS-NET/T” that is the terminal for the panel installation or “CS-NET/T-H” for the table use, and the logic and control unity named “CS-NET/L”.

CS-NET/T-Panel

CS-NET/T-Handheld

CS-NET/L

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The units are connected via a high-speed communication line RS422 running at 120 Kbps. This high-speed communication allows the terminal to acquire almost real-time information from the CS-NET/L or to transmit data with no waiting time for the user, this power unit can be assembled in a single box with all necessary hardware resources to manage many different types of welding without the need of further options. The logic unit can be managed by the PLC through lines from any hardware or field bus. This unit is seen as a network node in the bus and not as a subnet device The CS-NET/L Logic Unit is a timer, current, input output, communications controller for functionality doesn’t required the connection to terminal unit CS-NET/T. The control unit is based on a powerful processor, the latest 32 bit, with a considerable calculation speed given by the clock of frequency of 80 MHz, this allows to perform the entire control loop in a time of 40 μs, such high speed permits use of the unit for AC Spot and Seam (Roll) applications The CS-NET/T programming and display terminal is operative only when connected to the CS-NET/L, and allows the programming and everything related to the user interface. The PC program connected via the RS232 or RS485 network performs the same task and allows you to store the parameters on the PC.

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2. Warnings and precautions for safe use

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 for

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 SCR and parts connected to it, in normal

operation generate magnetic fields. Prevent access nearby

to pacemaker carriers and do not place equipment sensitive

to magnetic fields close to the SCR 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 Synchronous drive for silicon controlled rectifiers with phase cut off current regulation. Regulation speed within 2 cycles for the first welding spot and then within 1 cycle User selectable primary or secondary current measurement. Six 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

Possibility for setting of welding current from external voltage reference 0-10V Gain adjustable current regulation loop. Cycle management of spot welding machines or seam welding machines set by user. Time management in cycles or half cycles Electrical insulation of input and output sections. Setup and execution of 64 programs, called by external input, internal, sequential or

associated with the start cycle IC1 or IC2 or field bus if present. Point to point serial communication line RS232, used to connect a printer or a personal

computer or a network serial communication line RS485. Availability of expansion of communication: Profibus – DeviceNet – CANopen -

Modbus/RTU - Profinet/IO - EtherNet/IP - Modbus/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 or decrement 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 flexibly associated to pre-squeeze and squeeze within programs. Proportional valve driving circuit galvanic insulated. Proportional valve full scale setting (99%) from 5 to 10V Forging solenoid-valve output. Pre-stroke solenoid -valve. Possible association of pressure in pre-squeeze, squeeze, preheat, welding and forging,

through the proportional valve (pressure cycle). Automatic Calibration of 4 transformer or welding systems. Four language setting, additional languages on request. Dedicated signals management by PLC.

Possibility of external 24V power supply in case of lack of power line to sustain Field Bus communications.

Monitoring of SCR Temperature, SCR heat sink, SCR short External temperature monitoring (transformer diode or coils). Automatic checking and errors reports on Rogowski coil open Check with eventual reporting when a start welding when electrodes are not closed.

Graphs trends of weld parameter on the terminal panel. Automatic duplication of the welding program in multiple programs Management via can bus of linear measurements of displacement and electrode

check, management or pressure welding force through proportional valve or load cell with feed-back

Management hardware optimized for welding lead-acid batteries

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2.3. CS-NET/T warning lights, switches, buttons and their functionality

On the front panel you can recognize three areas: in the left one there is a key switch equipped with indicator LED. The switch allows selecting “RUN” and “EDIT” mode, when in position on the LED lights EDIT

In the center is a large graphic display to the right

of which there are buttons that select the source of

the set of welding parameters in use. In edit mode the button also allows immediate exit from the menu in which you are, the other key allows

you to enable or disable the current During the EDIT this button allows the refresh of parameters or the retrieve the previous not jet stored value of a parameter

Below the display are the cursor keys "bolts", the key of increase "+", which functions as a confirmation or selection, and decrease button "-" these are described in the lines below:

Key “UP” In EDIT mode, allows moving up the various menu or in the menu to the superior parameter. In RUN mode, in the sub windows allows movement in to the top row.

Key “DOWN” In EDIT mode, allows movement down between the various menus or in the menu to the inferior parameter. In RUN mode, in the sub windows allows movement in the inferior row.

Key “LEFT,PAG-” In EDIT mode, allows movement of the pointer to the left of the internal parameters to menu, in the page program parameters it can decrease the number of the program. In RUN mode, if you are not in first window, it allows the return to the previous window.

Key “RIGHT,PAG+” In EDIT mode, allows movement of the pointer to the right of internal parameters to

menu, in the program page it can decrease the number of program. In RUN mode, if you are not in last window, it allows the moving to the next window.

Key “INCREASE AND SELECTION or CONFIRMATION” In RUN mode, allows you to select the desired menu; within the menu allows you to increase the value of the parameter up to its upper limit. Confirm exit from the menu when the cursor is placed on "EXIT". It is used to increment the parameter in the sub windows or edit until its upper limit. IT ALLOWS QUITTING ANY WARNING MESSAGE.

Key “DECREASE” In RUN mode, in the menu, you can decrease the value of the parameter down to its lower limit. In RUN mode, it can decrease the parameter in the sub windows down to its lower limit

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2.4. Notes on installation CS-NET is designed for panel amounting, for operation in a dry environment (relative humidity Max 80% non-condensing) and protected from dust and liquids. The operating room temperature must be within the range 0 / 50 º C. The unit should not be mounted in contact with parts subject to severe vibration.

3. Installation and connectors

3.1. Connecting the CS-NET/L

3.1.1 Power supply section

CAUTION

The operations of connection to the power supply must always be carried out with the main power line not connected. The operation of connection to power line involves risks and dangers not eliminable, it is recommended therefore be very careful in the course of this operation: make sure the ground terminal is properly connected to the terminal designated as PE cable section equal to that of power, and that the plant is equipped with efficient ground system . Select the appropriate section of power cables: the inappropriate use of cables can cause overheating and rupture, with serious consequences. Tighten the cables with an adequate and controlled torque avoiding the deforming the clamps compromising the efficiency. Ensure no fraying or leakage from the cables terminals, before powering the system. The electrical supply connections are connected to CS-NET/L with its power SCR group (firing unit), supplied with the same phase of SCR. No right phase sequence is necessary. The supply connections must be performed always after the voltage is switched off! On the upper side of the CS-NET/L are located:

Power Supply connector. Input/output and communication connectors (CAN bus, RS232 or RS485). Communication connector to CS-NET/T (RS422) On Frontal Side of the CS-NET/L is located: Field Bus communication (options)

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3.1.2 Power output section

For the connection to the welding system (transformer primary) use the output terminals as shown in the external connections picture. This operation must be done with CS-NET not-powered, due to several risks. Furthermore 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.

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3.1.3 Description of the features of the connectors and signals.

The CS-NET/T interfaces to the CS-NET/L through the supplied 9-pin plug-socket RS422 cable. Male connector is on the CS-NET/L, RS422 female on CS-NET/T. The input signals and inlets on the CS-NET/L are underneath explained: JPOWER Rev. 0 Power Supply, SCR drive and thermic (10 pin M) JPOWER Rev. A Power Supply, SCR drive and thermic (14 pin M) X1 CAN BUS (5 pin M) 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-NET/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

Pin Signal Descrizione Tipo

1 WELD + (+24VP) +24V referenced to GNDP max 250 mA to SCR firing

unit card. PWR

2 WELD - SCR Drive signal to Firing Unit Card. O

3 +24VP +24V referenced to GNDP max 250 mA PWR

4 Thermostat SCR Thermal alarm from SCR heat-sink. PWR

5 20Vac CS-NET/L Supply PWR



8 SHORT SCR SCR short Signal I

9 AUX PWR Auxiliary power supply input 20Vac or 24Vdc PWR

10 AUX PWR Auxiliary power supply input. 20Vac or 24Vdc PWR

Tabella 1a – JPOWER: Morsettiera Alimentazioni Rev.0

Pin Signal Descrizione Tipo

1 WELD + (+24VP) +24V referenced to GNDP max 250 mA to SCR firing

unit card. PWR

2 WELD - SCR Drive signal to Firing Unit Card. O


4 Thermostat SCR Thermal alarm from SCR heat-sink. PWR




8 SHORT SCR/EMERG Signal SCR short circuit/ Emergency (NO I/O CARD) I

9 C.T. Signal From Primary current transformer I

10 C.T. Signal From Primary current transformer I

11 BATT O + Dedicated output for lead acid battery unit management PWR

12 BATT O - Dedicated output for lead acid battery unit management O

13 AUX PWR Auxiliary power supply input. 20Vac or 24Vdc. PWR

14 AUX PWR Auxiliary power supply input. 20Vac or 24Vdc PWR

Tabella 1b – JPOWER: Morsettiera Alimentazioni Rev.A

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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


Table 1c – X1: CAN BUS terminal block


1 +24V +24V referenced 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


1 ROG Rogowski coil terminal I

2 ROG Rogowski coil terminal I


4 VSEC - Voltage TIP negative --- I

5 VSEC + Voltage TIP positive +++ I


Table 3 – X3: Input terminal block for analogue measurement


1 +24VP +24V Referenced 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 relay 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

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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



5 Prog-04 Binary signal selection, weight 04 of the program code execute in EXT mode..

I




execute in EXT mode.. I


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); mode Seamers, allows the exchange to the second current

I

11 PED.PRE-STROKE

(PED D) PeDal signal activation of the pre stroke electro valve. I


Table 5 – IN-2: Inputs terminal blocks for programs selections, control and protection


1 GNDP Reference Ground for +24VP GND

2 EV1 Matching output signal to the electro valves of

Pre-Squeeze, Squeeze or Seamer motor O


Pre-Squeeze, Squeeze or Seamer motor. O





6 EV5 FORGE/SEAM-

MOTOR

Output signal, in spot mode, it drives the forging

valve; in Seam mode, it drives the Seams 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 CS-NET Ready signal: the output indicates that

the drive is ready to receive a command beginning

of the cycle.

O


Table 6 – OUT-1: Output terminal block for solenoid valves and alerts



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 CS-NET ready to

provide current during hot cycles. O

5 ANTICONCOM. N.C.1 Normally closed contact 1 of no anti-tiedown relay

(interlock). O

6 ANTICONCOM. N.C.2 Normally closed contact 2 of no anti-tiedown 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


Table 7 – OUT-2: Output terminal block for the reporting States or alarms

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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)





Table 8 – Terminal block for RS422 communication line to CS-NET/T


1 TX/RX A. RS 485 channel A I/O

2 TXD Signal Data transmission O

3 RXD Receive signal Data I

4 TX/RX B RS 485 channel B I/O


6 GND (+5V) Reference Ground for +5V DIGITAL GND

7 RESERVED RESERVED

8 NC Not connected

9 NC Not connected

Table 9 – Terminal block communication line RS232/RS485 and programming JCOM

Warning: for connection to CS-NET/L RS232 to personal computer or printer, use cable as

shown in annex Never connect pins 1, 4, 6, 7

3.1.3 Hydraulic connection

NOTE: This paragraph applies only to SCR units with water-cooling.

We recommend:

Execute the water connection when the machine is not powered;

Use extreme caution and check for possible leakage on hydraulic junctions.

Any leakage of water can come into contact with electrical components and power electronics, giving the risk of explosions, electrical arcing or other more serious Damages. It is recommended to fix any leakage of water and not turn the unit if they should occur. In order to avoid corrosion Damages in the heat sink of the SCR never use demineralised water or antifreeze mixture like “Paraflu” as coolant. We recommend to use the antifreeze mixture AD 11 based on propylene glycol. Moreover this product is absolutely not toxic.

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4. Operation of the control and parameters

4.1. System power on and first window The home page shows the configuration parameters: Type cycle, and frequency of work. At this stage, the starting cycle inputs, and protection inputs are tested. After a time of home page viewing, the next window displays the position of the key switch, RUN or EDIT

4.2. EDIT Menù A CS-NET/T in mode "READY!” setting the key switch in position EDIT, you have access to the settings menu, as reported below: Display window

CS-NET EDIT MENU

Program Parameters Copy Program

System Parameters CAN bus Measures

Auto-Step Main Settings

Communications

Errors Log

Inputs/Outputs Check

Machine Calibration

With the "UP" arrows or the arrow "DOWN" you can select one of the seven-screen

menu, and the button "PLUS" to confirm the entry into one of these

4.2.1 Set the basic configuration

By selecting the menu "Main Settings" you can proceed, after the introduction of the appropriate Password to the basic setting of the inverter system or reset it. Display window

CS-NET Main Settings

Cycle Type Spot (Spot-Seam)

I/O ENABLE No (NO-SI’)

Machine ID 0 (0-99)

Init Vars No (NO-YES)

EXIT (PRESS +)

Safco Systems S.R.L.

Via Isonzo, 17/b

20090 Cesano Boscone

Milan – Italy

www.safcosys.it

Mode: Spot AC

http://www.safcosys.it/

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To highlight the parameter to edit use the arrow keys "Up" and "Down", and with the "plus" and "minus” change the values.

Description of the parameters in the display window. Cycle Type

Range value: Spot; Seam

The parameter sets the type of welding cycle for which the CS-NET is used and as a result of this setting the parameters of the program will be available. Any change of this setting, will reset all parameters.

I/O ENABLE:

Range value: No; YES

Enable or disable the Input Output card and the relative signal of the CS-NET/L, Default value = yes enabled

Init Vars:

Range value: No; YES

Setting "YES" on this parameter, at the exit from the configuration menu all the parameters of the CS-NET/T and CS-NET/L, exception made for those in Main settings, will be set to default values.

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4.2.2 Input to program parameters, and first setting (Spot-weld or Seam-weld). Entering the menu "Program Parameters", you can change the parameters of weld cycle for any of the 64 available programs. The type of cycle and the parameters depend on the type of setting made in the "CS-NET Main Settings". The display is made of 8 rows, the first is fixed and the other seven can be scrolled like “drum" with the UP and DOWN arrows. On the first line you can set the program number to change from 00 to 63, parameter flashing is available for the modification made by the "+" and "-“. A peculiar feature of editing functions is that being inside a menu on a parameter change, removal of the switch from editing position to that of Run and vice versa, the point of the parameter change does not go lost. This feature allows a quick "adjustment" of the parameter set. You can increase or decrease the number of program, when the cursor is not on the first or

last line, pressing the “SX,PAG -” decreases, or by pressing the “DX,PAG +” increases, this feature simplifies the editing. To exit this menu, after the setting of parameters, you simply highlight the line: "EXIT (Press +)" and press the "+" key, or on any line by pressing the immediate

exit key .

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4.2.3 Spot program parameters uicro/STD Display window

PROGRAM N° 00

Electrodes 1 (1-4)

Current NO (NO,YES)

Working Mode D‰

Limits Check NO (NO,YES)

Pressure 1 0 (0-99%)

SV Pre Squeeze NO (NO,EV1-EV4)

Pre Squeeze 0.0 (0.0-99.0)


SV Squeeze NO (NO,EV1-EV4)

Squeeze 0.0 (0.0-99.0)


Pre Heating time 0.0 (0.0-99.0)

Pre Heating Curr. 50 (50-999‰) (D‰,V‰)uicro

Pre Heating Curr. 0.10 (0.10-ImaxKA) (IK,EK,AD)uicro

Pre Heating Curr. 100 (100-999‰) (D‰,V‰)STD

Pre Heating Curr. 1.0 (1.0-ImaxKA) (IK,EK,AD)STD

Pre Heating POWER 0.2 (0.2-600.0KW) (PK)


Cold time 0 0.0 (0.5-99.0)

Slope-Up 0 (0-10)

Weld Time 1 0.5 (0.5-99.0) (D‰,V‰,PK,IK)

ENERGY 1 10 (10-60000J) (EK)

Res.Decrem.Trsh. 0.1 (0.1-50.0%))(AD)

Weld Current 1 50 (50-999‰) (D‰,V‰)uicro

Weld Current 1 0.10 (0.10-ImaxKA) (IK,EK,AD)uicro

Weld Current 1 100 (100-999‰) (D‰,V‰)STD

Weld Current 1 1.0 (1.0-ImaxKA) (IK,EK,AD)STD

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 50 (50-999‰) (D‰,V‰)uicro

Weld Current 2 0.10 (0.10-ImaxKA) (IK,EK,AD)uicro

Weld Current 2 100 (100-999‰) (D‰,V‰)STD

Weld Current 2 1.0 (1.0-ImaxKA) (IK,EK,AD)STD

Weld 2 POWER 0.2 (0.2-600.0KW) (PK)

Cold time 2 0.5 (0.5-99.0)

Impulse 2 1 (1-10)

Cold time Weld 1-2 0.5 (0.5-99.0)

Impulse Weld 1-2 1 (1-10)

Slope-Dw 0 (0-10)

Cold time 3 0.5 (0.5-99.0)

Temper Time 0 (0-999)

Temper Current 50 (50-999‰) (D‰,V‰)uicro

Temper Current 0.10 (0.10-ImaxKA) (IK,EK,PK,AD)uicro

Temper Current 100 (100-999‰) (D‰,V‰)STD

Temper Current 1.0 (1.0-ImaxKA) (IK,EK,AD)STD

Temper POWER 0.2 (0.2-600.0KW) (PK)

Hold time 0.5 (0.5-99.0)

Off time 0.0 (0.0-99.0)


Forge NO (NO,YES)

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Forge Delay 0.0 (0.0-99.0)

Repeat cycle NO (NO,YES)

Initial Blanking 0.5 (0.5-10)

Curr. Max Limit 0.10 (0.10-ImaxKA) (D‰,V‰)uicro

Curr. Min.Limit 0.10 (0.10-ImaxKA) (D‰,V‰)uicro

Curr. Max Limit 1.0 (1.0-ImaxKA) (D‰,V‰)STD

Curr. Min.Limit 1.0 (1.0-ImaxKA) (D‰,V‰)STD

Curr. Max.Limit 1 (1-30%) (IK,EK,AD)

Curr. Min.Limit 1 (1-30%) (IK,EK,AD)

P. Max. Limit 1 (1-30%) (PK)

P. Min. Limit 1 (1-30%) (PK)

Current Limit 1 (1-Imax) (PK)

T.Weld 1 Max. 0.5 (0.5-99.0) (EK,AD)

T.Weld 1 Min. 0.5 (0.5-99.0) (EK,AD)

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)

Pos.Elect.Close 0.1 (0.1-250.0mm)

Pos.Elect.Close Tol.+ 0.0 (+0.0-9.9mm)

Pos.Elect.Close Tol.- 0.0 (-0.0-9.9mm)

Pos.Current Cut 0.1 (0.1-250.0mm)

End Pos.Elect. 0.1 (0.1-250.0mm)

End Pos.Elect.Tol.+ 0.0 (+0.0-9.9mm)

End Pos.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

operating mode.

The Imaxs are related to the pair of electrodes selected in the

program, if the related parameter is disabled the pair is intended

“N°1”

If the parameter "VE input"is"NO":

The Working Mode can be set: D ‰, V ‰, IK

If the parameter "VE input" and Yes' "

The Working Mode can be set: D ‰, V ‰, IK, PK, EK, AD

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4.2.4 Spot cycle parameters description Electrodes:

Range value: from 1 to 4 Default Value: 1 Matches the pair of electrodes to the parameters of the program, and on the electrode pair, when set, makes life management, this parameter is also a reference for management of the alarm electrodes end of life and electrode life reset. Current:

Range value: NO; YES Default Value: NO If set to NO, the CS-NET will perform the welding program, meeting all the times set but will not activate the current; set to YES, will provide current flowing where required. 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-NET / 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 limits, on the measure in hot times; the control limits cannot be activated when the mode of work is AD. Pressure 1:

Range value: from 0 to 99% Default Value: 0 Sets the percentage of the voltage for the analogical output of the proportional valve, during the pre-squeeze time. SV Pre Squeeze:

Range value: from NO,1 to 4 Default Value: NO Set the output number to be used at Pre-Squeeze start. Pre Squeeze:

Range value: In cycles from 0.0 to 99.0 step 0.5 Cycles Default Value: 0.0 Set the Pre squeeze time.

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Pressure 2:

Range value: from 0 to99% Default Value: 0 It sets the percentage of voltage for the analogical output for the proportional valve during the squeeze time. If it is zero the previously set value is not changed. SV Squeeze:

Range value: from NO, 1 to 4 Default Value: NO It sets number of the output to be used at Squeeze start. (Even if the time is 0) Squeeze:

Range value: in cycles from 0.0 to 99.0 step 0.5 Cycles Default Value: 0.0 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: from 0.0 to 99.0 step 0.5 Cycles Default Value: 0.0

It sets the Pre heating time.

Pre heating current:

Range value: When in D‰ e V‰ = from 50/100 to 999

When in IK, EK, AD = from 0.10/1.0 to Imax When in PK = from 0.2 to 600.0KW Default value D‰ e V‰: 50/100 Default Value in IK, EK, AD: 0.10/1.0 Default Value in PK: 0.2 It sets the current or the pre heating power. Pressure 4:

Range value: from 0 to 99% Default Value: 0 It sets the percentage of voltage if the analogical output for the proportional valve. During the weld time, if zero does the previously set value does not change.

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Cool time 0:

Range value: from 1.0 to 99.0 step 1.0 Cycles Default Value: 1.0 IT Sets the Cool time 0. Slope-Up:

Range value: from 0 to 10 step 1 Cycles Default Value: 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: from 0.5 to 99.0 step 0.5 Cycles Default Value: 0.5 It sets the welding time 1. Weld current 1:

Range Value: When in D‰ or V‰ = from 50/100 to 999

When in IK or AD = from 0.10/1.0 to Imax When in PK = from 0.2 to 600.0KW When in EK = From 10 a 60000J Default Value D‰ e V‰: 50/100 Default Value IK, AD: 0.10/1.0 Default Value PK: 0.2 Default Value EK: 10 It sets the current or power during welding time 1. Cool time 1:

Range value: from 1.0 to 99.0 steps 1.0 Cycles Default Value: 1.0 It sets the pause time 1, made when the number of pulses 1 is greater than 1.

Pulses 1:

Range value: from 1 to 10 Default Value: 1 It sets the number of repetitions of welding 1.

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Cool time 1-2:

Range value: from 1.0 to 99.0 steps 1.0 Cycles Default Value: 1.0 It sets the cold time between weld cycles 1 and 2. Weld time 2:

Range value: from 0.0 to 99.0 steps 0.5 Cycles Default Value: 0.0 (not execute) It sets the Weld time 2

Weld current 2:

Range value When in D‰ or V‰ = from 50/100 to 999

When in IK or AD = from 0.10/1.0 to Imax When in PK = from 0.2 a 600.0KW When in EK = From 10 a 60000J Default Value D‰ e V‰: 50/100 Default Value IK, AD: 0.10/1.0 Default Value in PK: 0.2 Default Value in EK: 10 It sets the current or the power during weld time 2. Cool time 2:

Range value: from 1.0 to 99.0 steps 1.0 Cycles Default Value: 1.0 It sets the pause time 2, made when the number of pulses 2 is greater than 1. Pulses 2:

Range value: from 1 to 10 Default Value: 1 Set the number of repetitions of welding 2. Cool time weld 1-2

Range value: from 1.0 to 99.0 steps 1.0 Cycles Default Value: 1.0 It sets the pause time before repeating cycles of welding 1 and 2, it occurs when the number of Pulses for weld 1-2 if it is greater than 1. Pulses weld.1-2

Range value: from 1 to 10 Default Value: 1 It sets the number of repetitions for welding 1 and 2.

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Slope-Dw:

Range value: from 0 a 10 step 1 Cycles Default Value: 0 It sets the descent time of the last current supplied during the welding. Cool time 3:

Range value: from 0.0 to 99.0 steps 1.0 Cycles Default Value: 0.0 It sets the cold time 3 before the post weld. Temper Time:

Range value: from 0 to 999 steps 1 Cycles Default Value: 0 It sets the temper time (post weld).

Temper current:

Range value: When in D‰ or V‰ = from 50/100 to 999

When in IK, EK, AD = from 0.10/1.0 to Imax When in PK = from 0.2 to 600.0KW Default Value D‰ e V‰: 50/100 Default Value IK, PK, EK, AD: 0.10/1.0 Default Value in PK: 0.2

It sets the temper current or the temper power.

Hold time:

Range value: from 0.5 to 99.0 steps 0.5 Cycles Default Value: 0.5 It sets the hold time; electrodes are closed with no current. Off time:

Range value: from 0.0 to 99.0 steps 0.5 Cycles Default Value: 0.0 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.

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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 activate pressure 5. Set to YES, in D‰, v‰, IK and PK mode, it will set the pressure 5 and activate forging valve after delay forging time. Delay starts from beginning of weld. Forge delay:

Range value: from 0.0 to 99.0 step 0.5 Cycles Default Value: 0.0 It sets the delay time, from the start of welding, in D ‰ V ‰, IK PK modes, it activates the forging valve and set the pressure 5. Cycle repeat:

Range value: NO; YES Default Value: NO If set to “NO”, the cycle of welding will not repeat, if set to “YES” the unit will repeat the welding cycle, running the pre squeeze if the parameter "JMP B / A is set on B or the squeeze if this parameter is set to "A". Initial Blanking:

Range value: from 0.5 to 10 step 0.5 Cycles Default Value: 0.5 It sets the measure mask time during the welding time; it has impact on display and on control. Curr. Max, P. Max Limit:

Range value: in D‰-V‰- from 0.10/1.0 to ImaxKA in IK-PK-EK: from 1% to 30% Default Value: 0.10/1.0 It sets the upper limit for the monitoring of current, power.

Curr. Min, P. Min Limit:

Range value: in D‰-V‰ from 0.10/1.0 a ImaxKA

in IK-PK-EK: from 1% to 30% Default Value: 0.10/1.0 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 arrive in PK mode must always be less than Imax 1-2-3-4 in the calibration machine

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T.Weld 1 Max:

Range value: from 0.5 to 50.0 step 0.5 Cycles Default Value: 0.5 In EK and AD, it sets the maximum time for a "good" weld (1) T.Weld 1 Min:

Range value: from 0.5 to 50.0 step 0.5 Cycles Default Value: 0.5 In EK and AD, it sets the minimum time to obtain a "good" weld (1) T.Weld 2 Max:

Range value: from 0.5 to 50.0 step 0.5 Cycles Default Value: 0.5 In EK and AD, it sets the maximum time for a "good” weld (2) T.Weld 2 Min:

Range value: from 0.5 to 50.0 step 0.5 Cycles Default Value: 0.5 Milliseconds Default Value: 10 In EK , it sets the minimum time to obtain a "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%

Pos.Elect.Close

Range value: 0.0-250.0mm (FS) Range value 0.1 Sets the value of tolerance occurs with positive or negative on the absolute or relative measure of closure electrode on the piece.

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Pos.Elect.Close Tol.+

Range value: 0.0 a 9.9mm Range value 0.0 Positive tolerance within which there is no error on the measurement position closing electrodes

Pos.Elect.Close Tol.-

Range value: 0.0 a 9.9mm Range value 0.0 Negative tolerance within which there is no error on the measurement position closing electrodes Pos.Current Cut

Range value: 0.0 a 250.0mm (FS) Range value 0.1 Set the measure of absolute or relative position electrodes to stop current during welding End Pos.Elect.

Range value: 0.0-250.0mm (FS) Range value 0.1 Sets the value of tolerance occurs with positive or negative, the measure absolute or relative position of the final electrodes. End Pos.Elect.Tol.+

Range value: 0.0 a 9.9mm Range value 0.0 Positive tolerance within which there is no error on the final position electrodes End Pos.Elect.Tol.-

Range value: 0.0 a 9.9mm Range value 0.0 Negative tolerance within which there is no error on the final position electrodes 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 tolerance negative and positive pressure welding by which the cycle can continue

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Weld Force

Range value: 0-1000dN Range value: 0.0

Set the pushing force of the welding electrodes

Tol.Force

Range value: 0-20dN Range value: 0.0 Sets the tolerance negative and positive of the strength of welding cylinders within which the cycle can continue

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4.2.5 Forge The task of forge, is activated during the course of the spot program by setting the parameter "Forge" to "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 valve analogue output

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4.2.6 Seam program parameters Display windows

Program N° 0

Electrodes 1 (1-4)

Current NO (NO,YES)

Working Mode D‰

Limits Check NO (NO,YES)


Squeeze SV NO (NO,EV1-EV4)

Squeeze 0 (0-199)

Motor NO (NO,EV1-EV4)

Delay Weld Time 0.0 (0.0-99.0)

Slope up Initial Curr. 0 (0-50%)

Slope Up 0 (0-10)


Weld time 1 0.5 (0.5-99.0)

Cold time 1 0.0 (0.0-99.0)

Weld Current 1 50 (50-99‰)(D‰,V‰)CS-NET-uicro

Weld Current 1 0.10 (0.10-ImaxKA)(IK)CS-NET-uicro

Weld Current 1 100 (100-99‰)(D‰,V‰)CS-NET-STD

Weld Current 1 1.0 (1.0-ImaxKA)(IK)CS-NET-STD


Weld time 2 0.5 (0.5-99.0)

Cold time 2 0.0 (0.0-99.0)






Weld Time 3 0.5 0.5-99.0)

Cold time 3 0.0 (0.0-99.0)





Slope Dw 0 (0-10)

Slope DW Final Curr. 0 (0-50%)

Hold time 0.5 (0.5-99.0)

Off time 0.0 (0.0-99.0)

Initial Blanking 0.5 (0.5-10)

Curr. max Limit 1.0 (1.0-ImaxKA) (D‰,V‰)CS-NET-uicro

Curr. min Limit 1.0 (1.0-ImaxKA) (D‰,V‰)CS-NET-uicro

Curr. max Limit 1.0 (1.0-ImaxKA) (D‰,V‰)CS-NET-STD

Curr. min Limit 1.0 (1.0-ImaxKA) (D‰,V‰)CS-NET-STD

Curr. max Limit 1 (1-30%) (IK)

Curr. min Limit 1 (1-30%) (IK)

EXIT (Press +)

In Seam cycle the Working Mode will be set:

D‰, V‰, IK.

where specified the () parameter is only available in the indicated

operating mode.

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The Imaxs are related to the pair of electrodes selected in the

program, if the related parameter is disabled the pair is intended

“N°1”

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4.2.7 Seam cycle parameters description Electrodes:

Range value: from 1 to 4 Default Value: 1 It selects, when activated, the pair of electrodes in the running program, on which to perform the life management, this parameter is also a reference for management of the alarm electrodes end of life and for the electrode life reset. Current:

Range value: NO; YES Default value: NO If set to NO, the CS-NET will perform the welding program meeting 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-NET / 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 current limits. Pressure 0:

Range value: From 0 a 99% Default value : 0 Sets the output driving the proportional valve during squeeze time and delay weld time

Squeeze SV:

Range value: from NO,EV1 to EV4 Default value: NO It sets the output number to use at Squeeze start. Squeeze:

Range value: in cycles from 0.0 to 199 step 1 Default value in Cycles: 0 It sets the squeeze time.

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Roll Motor:

Range value: from NO,EV1 to EV4 Default value: NO Set the output number to be used to start the rolls motor. Weld Time delay:

Range value: in cycles from 0.0 to99.0 step 0.5 Default value in Cycles: 0.0 It sets the delay time for weld current activation, after the motor is started Slope-Up Initial Curr.:

The parameter sets the initial current of rise ramp as a percentage of the welding current request.

Slope-Up:

Range value: in cycles from 0 to10 Default value in Cycles: 0 It sets the rise time of the first weld current. Pressure 1:

Range value: From 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 Default value in Cycles: 0.5 It sets the weld time 1, used if cool time 1 is greater than 1, it is also used to define the test time window, If limit control is activated. Cool time 1:

Range value: in cycles from 0.0 to 99.0 step 0.5 Default value in Cycles: 0 It sets the pause time 1, if different from 0, enables pulsation cycle. Weld current 1:

Range value: When in D‰= from 50/100 to 999

When in IK = from 0.10/1 to Imax Default value in D‰ e V‰: 50/100 Default value in IK : 0.10/1 It sets the weld current 1 value.

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Pressure 2:

Range value: From 0 a 99% Default value: 0 Sets the output driving the proportional valve during welding 2 Weld time 2:

Range value: in cycles from 0.5 to 99.0 step 0.5 Default value in Cycles: 0.5 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 Default value in Cycles: 0.0 It sets pause time 1, if different from 0, enables pulsation cycle. Weld current 2:


When in IK = from 0.10/1 to Imax Default value in D‰ e V‰: 50/100 Default value in IK : 0.10/1 It sets the value of weld current 2 Pressure 3:

Range value: From 0 a 99% Default value: 0 Sets the output driving the proportional valve during welding 3 Weld time 3:

Range value: in cycles from 0.5 to 99.0 step 0.5 Default value in Cycles: 0.5 It sets the weld time 3, used if cool time 3 is greater than 1, it is also used to define the test time window, If limit control is activated. Cool time 3:

Range value: in cycles from 0.0 to 99.0 step 0.5 Default value in Cycles: 0.0 It sets the pause time 3, if greater than 0, enable pulsation cycle. Weld current 3:


When in IK = from 0.10/1 to Imax Default value in D‰ e V‰: 50/100 Default value in IK : 0.10/1

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It sets the weld current 3 value.

Slope-Dw:

Range value: in cycles from 0 to 10 Default value in Cycles: 0 It sets the decay time of the last current supplied during welding.

Slope DW Final Curr.:

The parameter sets the current end of the ramp down as a percentage of the welding current request. Hold time:

Range value: in cycles from 0.5 to 99.0 step 0.5 Default value in Cycles: 0.5 It sets the hold time, electrodes close with no current. Off time:

Range value: in cycles from 0.0 to 99.0 step 0.5 Default value in Cycles: 0 Set the off time, electrodes open. Initial Blanking:

Range value: in cycles from 0.5 to 10 step 0.5 Default value in Cycles: 0.5 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 0.10/1.0 to ImaxKA In IK: from 1% to 30% Default value: : 0.10/1.0 Set the upper limit for the control of welding current. Curr Min Limit:

Range value: in D‰-V‰ from 0.10/1.0 to ImaxKA

in IK: from 1% to 30% Default value: : 0.10/1.0 It sets the lower limit for the control of the welding current.

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4.2.8 System Parameters Display windows

CS-NET System Parameters

Language IT (IT-EN-DE-ES)

PSw B/A Squeeze B (B-A)

JMP B/A Pre Sq. B (B-A)

N Bad Spots 0 (0-9)

Program IC1 0 (0-63)

Program IC2 0 (0-63)

Seq. Start Program 0 (0-63)

Seq. End Program 0 (0-63)

VE Input NO (NO-YES)

PV Max Volt 5 (5-10)

Pre-Stroke E.C. Open NO (NO-YES)

Pre-Stroke Time 1 (1-99)

Src/Prg key en YES (NO-YES)

S/NS key en YES (NO-YES)

End Cycle Type 0 (0-1-2)

End Cycle Time 10 (1-99)

SV 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-YES) (Only Spot)

Off time YES (NO-YES) (Only Spot)

Repeat cycle YES (NO-YES) (Only Spot)

EXIT (Press +)

The system parameters affect all the programs and change the characteristics of the control. Language:

Range value: IT; EN; DE; ES Default value IT This parameter allows the selection of one of four languages available: Italian, English and German and Spanish (other languages are available on request). PSw B/A Squeeze:

Range value: B; A Default value B Set the reading and verification of the pressure switch input before (B) or after (A) the Squeeze time. Parameter not active in SEAM mode

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Latching outputs and the welding cycle occurs after the successful check of PSW input. When the PSw input is not present, the CS-I will wait until its closure, showing in the display state function line the message (WAIT PSw) in spot mode, or (WAITING FOR MOTOR START) in seam mode. After the successful reading of the contact pressure, the valves are activated and latched (the cycle continues automatically).

JMP B/A Pre Squeeze:

Range value: B; A Default value B In case of repeated cycles, it defines the point from which to repeat the cycle. B= Before or A=After the Pre squeeze. Parameter not active in SEAM mode

N° Bad spots

Range value: from 0 to 9 Default value 0 In spot mode, with the function of quality checking enabled, it allows the entry of the maximum permitted number of consecutive defective welds, before the warning signal and block the start cycle. Exceeding the limits of tolerance is reported with the activation output (OUT OF RANGE) and with a message on the display. The count of defective weld is reset with occurrence of welding within the set limits. In Seam mode the number of consecutive defective welds is considered inside the running cycle, and therefore current change are also counted as defects. Program IC1

Range value: from 0 to 63 Default value 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. Parameter not active 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. Parameter not active in SEAM mode Seq. Start Program

Range value: from 0 to 63 Default value 0 Represents the first program to run in sequential mode, and also that will run after the last one selected. Function is active when the selection mode is on Seq. Parameter not active in SEAM mode

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Seq. End Program

Range value: from 0 to 63 Default value 0 Represents the program of arrival the last one before the recycling in sequential mode occurs. Function is active when the selection mode is on Seq. Parameter not active in SEAM mode

VE Input(VOLTAGE ELECTRODES)

Range value: NO,YES Default value: NO This parameter allows for the reading of the voltage electrodes via the analog channel charge, the acquisition function of the set point of current analog, is disabled. Parameter not active in SEAM mode PV Max Volt

Range value: from 5 to 10 Default value 10 This parameter allows you to define the maximum scale value (99%) of the analog output for the proportional valve.

Pre-Stroke E.C. Open

Range value: NO, YES Default value NO Set the opening pre-stroke valve mode, at the end of the cycle if set to “YES” or manually if set to “NO”

Pre Stroke time

Range value: from 1 to 99 (CYCLES) Default value 20 Set the time in cycles required for latching the output of the pre stroke valve Src/Prg key en

Range value: NO, YES Default value YES

Allows the locking (NO) or unlocking (YES) of the CS-NET/T front button, , program source.

S/NS key en


Allows the locking (NO) or unlocking (YES) of the Button Weld/No Weld

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End of cycle mode

Range value: 0-1-2 Default value 0 Set in what stage of the cycle, the CS-NET activates the output “end of cycle”: 0=at the end of “off time” (standard) 1=at the beginning of “hold time” 2=at the end of “hold time”

End cycle time

Range value: from 1 to 99 (CYCLES) Default value 20 Set the time, in cycles, of the contact “end cycle” Water SV presence

Setting NO, YES Default value YES It sets the presence of the cooling water solenoid valve, of the fans and their diagnostic. Caution: Never deactivate the water valve if installed otherwise the water cannot circulate and cool the heat sink, anyway thermal protections are active!.

Current source

Range value: Int; Ext; Bus Default value Int In Seam mode it set the reference source of current, from parameter set, Int, or from external set 0-10V (Ext). referred to Imax, when this field bus is present, 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


Allows use, if YES , of input Pressure Switch on the terminal board or when unused place to NO, avoids having to make a jumper toward the +24VP S/NS Input


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Allows use, if YES, of input Weld / No weld from the outside on the terminal board or when unused place to NO, avoids having to make a jumper toward the +24VP

Password

Range value: NO, YES Default value NO It set the password in input at the menus: System Parameters, Communications, Inputs/Outputs Test,

Machine Calibration, Copy Program.

The password key sequence is: See the last one sheet (removable) of the manual. Electrodes connects or disconnects in the program parameters:

Electrodes 1 (1-4)

Current connects or disconnects in the program parameters: Current NO (NO,SI’)

Pre squeeze connects or disconnects in the program parameters:


SV Pre Squeeze NO (NO,EV1-EV4)

Pre Squeeze 0.0 (0.0-99.0)

Pre Heat connects or disconnects in the program parameters: Pressure 3 0 (0-99%)

Pre Heating time 0.0 (0.0-99.0)

Pre Heating Curr. 100 (100-999‰)

Cool time 0 connects or disconnects in the program parameters: Pressure 4 0 (0-99%)

Cold time 0 0.5 (0.5-99.0)

Weld 2 connects or disconnects in the program parameters: Cold time 1-2 0.0 (0.0-99.0)

Weld Time 2 0.0 (0-99.0)

Weld Current 2 100 (100-999‰)

Cold time 2 0.5 (0.5-99.0)

Impulse 2 1 (1-10)

Cold time Sald.1-2 0.5 (0.5-99.0)

Impulse Weld 1-2 1 (1-10)

Slope-DW activate/deactivate slope dw in the program parameters: Slope-Dw 0 (0-10)

Temper connects or disconnects in the program parameters: Cold time 3 0.5 (0.5-99.0)

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Temper Time 0 (0-999)

Temper Current 100 (100-999‰)

Forge connects or disconnects in the program parameters: Pressure 5 0 (0-99%)

Forge NO (NO,YES)

Forge Delay 0.0 (0.0-99.0)

Off Time connects or disconnects in the program parameters: Off time 0.0 (0.0-99.0)

Repeat Cycle connects or disconnects in the program parameters: Repeat cycle NO (NO,YES)

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4.2.9 Auto-Step Display windows

CS-NET Auto-Step

Electrodes 1

Steps: +/-9 Tot Spot: 15

Spots Inc/Dec(%) Tot Inc/Dec (%):1.9

1) 1 0.1

2) 1 1.1

3) 1 0.1

4) 7 0.1

5) 1 0.1

6) 1 0.1

7) 1 0.1

8) 1 0.1

9) 1 0.1

EXIT (Press +)

The function, combined with one of four pairs of electrodes, can automatically increase or decrease the welding current, (all hot cycles), to compensate the expected increase in the diameter of the tips due to normal wear or Warming of Tungsten electrodes. So you can define an approximated curve with a broken consisting on a maximum of 9 segments (steps). The number of segments (Steps) is initially set to NO (no auto increment or decrement) and can be increased up to 9+/-. For each step of increase or decrease set, it is displayed a new line that defines a segment made of N° spots and a percentage current increment (Inc%) or decrement (Dec%). The current will be increased or decrease at any spot, roughly the ideal curve which compensates the wear of the tips or Tungsten warming. When the total number of steps is reached, the CS-NET indicates the necessity of electrodes change, through the exit END STEPS and showing the message on the display, in case of decrement no alarm/message will be given. After replacing the tips you need to reset the CS-NET via the reset input STEPS, or sub-window Auto-Step, If not reset, giving a new start cycle, the CS-NET performs the welding current with the latest set by giving again the alert message. The maximum number of Spots settings for each step is 9999. The total maximum number of Spots is 65535. Everything is matched with one of four pairs of electrodes / transformer. The output and the message will be reset by selecting the program that lists the number of pairs of electrodes to be zero. Electrodes:

Range value: from 1 to 4 It selects the pair of electrodes to comply with the edited values.

Steps:

Range value: from NO, 1 to 9 +/- It sets the number of segments on which the increments are applied.

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Spots:

Range value: from 1 to 9999 Sets the number of points per segment on which to apply the desired percentage increase, the sum of the points of the segments cannot exceed 65535.

Inc/Dec%

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.

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4.2.10 Communications The CS-NET/T (Terminal) has two serial communication ports: one standard RS 422 for High speed communication with the power unit CS-NET/L and one standard RS232 for the field programming of the microcontroller (Software upgrade) The CS-NET/L has three communication ports: one standard RS232 for the field programming of the microcontroller (Software update) or for printer or PC connection, one RS 422 dedicated to the communication with the Terminal unit CS-NET/T and one Port CAN-BUS to communicate with optional devices and finally one optional parallel port for Compact Com communication cards as total support for field bus. The ports of the CS-NET/L RS232 and RS485, have 8 bits data, anyway you can change the baud rate, parity and stop bit. 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 configuration parameters CS-I and save and manage the parameters of the programs. Settings of RS-485 instead include the introduction of unique address of the node to access a communication network.

The RS485 is active, when in “RS-232 Direct.” is set to none.

Display Windows

CS-NET Communications

RS-232 Direct. PC

RS-232 Log Spots NO

RS-232 bps 4800

RS-232 Parity None

RS-232 Stop Bits 1

RS-485 bps 4800

RS-485 Parity None

RS-485 Stop Bits 1

RS-485 Unit Address 0

Active ANCC Card None

EXIT (Press +)

RS-232 Direct:

Range value: None-PC-Trace PC-PRN It selects the use of RS232 if “none” enable RS-485. In PC mode allows the communication with a PC by using dedicate PC Program, this for save, recall parameters, in Trace PC running log of the welding program on PC and saves it to a file in the PC hard disk, in PRN prints the log of printer. RS-232 Log spots:

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 mode stored in the programs. The possible settings for log of the points are three:

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NO: No print.

ALL: prints out all welds done in spot and in Seam modes.

BAD: prints only the welds out of range of control parameters, the unit must be Configured with the parameter control mode set.

If the parameter " RS-232 Direct." is set to none, the print will be completely inhibited.

If the parameter " RS-232 Direct." is different from none the print will have the following

format: Spot mode, PRN:

Prog. N° XX

Spot N° XX

Time 1 : 0.0~ IRMS 1: XXX.XX KA (*)

Time 2: 0.0~ IRMS 2: XXX.XX KA (*)

Seam mode, PRN:

Prog. N° XX

Spot N° XX

Irms 1 : XXX.XX KA (*)



Spot mode, Trace PC:

Data

Time

Program Number

Spot N°

Time1(~) Irms1(KA)

Time2(~) Irms2(KA)

Resistance(µohm)

Cl.El.Position(mm)

Final Position(mm)

Pressure(bar)

Force(daN

(*)= valid measure for Rog or CT on condition.

RS-232 bps:

Range value: 4800-9600-19200-38400 It selects the transmission rate of RS-232. RS-232 Parity:

Range value: none- odd- even- It selects the parity of the transmission of the RS-232.

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RS-232 Stop Bit:

Range value: 1-2 It selects the stop bit of the RS-232. RS-485 bps:

Range value: 4800-9600-19200 It selects the transmission rate of RS-485.

RS-485 Parity:

Range value: none-even-odd It selects the parity transmission of the RS485.

RS-485 Stop Bit:

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 on CS-I / P.

Network bps:

Range value: Kbps 10-20-50-100-125-250-500-800- 1Mbps Autodef Select the communication speed of the CAN Bus or device net. Bus Other parameters are available when the specific communication card is installed

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4.2.11 Error Log

Display windows

CS-NET Log Errors

1)

2)

3)

4)

5)

Clear Errors (Press +)

EXIT (Press +)

Description: Show the last 5 errors CS-NET unit. New error overrides the oldest

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4.2.12 Inputs / outputs test.

WARNING This window contains every Function that activates the solenoid valves,

!!TAKE ALL NECESSARY PRECAUTIONS!!

Display window

CS-NET Inputs-Outputs

Pg01:X Pg32:X Pb C:X R.St:X ENDS 0 EV1 0

Pg02:X W/NW:X Pb D:X R.Al:X OOR 0 EV2 0

Pg04:X PbCo:X PSw :X AUT 0 ION 0 EV3 0

Pg08:X Pb A:X TERM:X DTS 0 ANC 0 EV4 0

Pg16:X Pb B:X EMER:X RDY 0 ENDC 0 EV5 0

EXIT (Press +) PV 00 EV6 0

In this section you can view the status of inputs 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 (EVP) output, at desired value, setting its parameter from 0 to 99 The associations of the inputs and outputs are: -INPUTS-

Pg01 = Program selection line 1






W/NW = external Weld/no weld

PbCo = Common Push button

Pb A = Push button A

Pb B = Push button B

Pb C = Push button C

Pb D = Push button D (Pre stroke Push button)

PSw = Pressure Switch (CP)

TERM = Thermostat

R.St = Reset Steps

R.Al = Reset Alarm

EMER = Emergency

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-OUTPUTS-

EV1 = 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 1 or pedal 2, to the +24VP.)

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4.2.13 Machine Calibration

Display Windows

CS-NET Machine Calibration

Calib. Electrodes 1 NO (NO-YES)

Mindel1 XXXX

Mindel1 XXXX

Cosfi 1 XXXX

Transf. Ratio 1 XXX.XX (1.00-200.00)

Max Current 1 1 (note 1)

GAIN_I 1 +/-XXX (-100-+100)

Transducer type 1 Rog (No-Rog-CT)

K_Rog 1 150 (10-250)

K_filt. 1 2 (1-2-4)

EXIT (Press +)

Changing the number in calibration electrodes the inherent calibration parameters change as follows: Calib. Electrodes 2 NO (NO-YES)

Mindel2 XXXX

Mindel2 XXXX

Cosfi 2 XXXX



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)


Mindel3 XXXX

Mindel3 XXXX

Cosfi 3 XXXX



GAIN_I 3 +/-XXX (-100-+100)


K_Rog 3 150 (10-250)

K_filt. 3 2 (1-2-4)


Mindel4 XXXX

Mindel4 XXXX

Cosfi 4 XXXX



GAIN_I 4 +/-XXX (-100-+100)


K_Rog 4 150 (10-250)

K_filt. 4 2 (1-2-4)

note 1:

CS-NET uicro = 1-20KA

CS-NET STD = 1-120KA

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Calib. Electrodes

Enables or disables the automatic detection of the power factor and the starting angle, is used to optimize the operation of the transformer, up to 4 different plants

Mindel 1

Represents the initial delay of opening of the first semi-cycle of the first welding is used to optimize the operation of the transformer Mindel 2

Represents the initial delay of opening of the first half cycle of the first welding after a pause, serves to optimize the functioning of the transformer Cosfi

Sets the phase shift of the machine Trasf. Ratio

The parameter represents the turns ratio of the transformer used, although this parameter should be entered for each pair of electrodes / transformer, and it is essential to key in it when you want to make an adjustment of current-type primary using CT as current trasducer Max Current

It set the maximum current of the transformer used in accordance with the CS-NET, these data for each pair of electrodes / transformer, it represent the setting limits in the program parameters menu CS-NET uicro = 1-20KA

CS-NET STD = 1-120KA

GAIN_I

In the case of an excessive presence of OVERSHUT or UNDERSHUT for the type of work performed, the parameter GAIN_I will be useful to compensate the speed of control loop PI. Transducer type 1/2/3/4

Range value: NO-Rog-CT If you intend to perform the current reading on the secondary of the transformer (typically) one must set the parameter of the transducer "Type Transducer" on Rog. (Rogowski loop), you must correctly set the parameter of the K factor used Rogowski, typical 150mV/KA If you intend to do instead of reading on the current transformer primary, you must set the parameter of the transducer on CT (current transformer), it is also necessary to set the proper parameters of the transformer turns ratio, in the calibration menu, combined with electrode pair / processor in use during the execution of the program given by the ratio of primary voltage, typically 400V and the output voltage of the transformer. If you do not want to use in the manner and D ‰ V ‰, the secondary current transducer, you must set the parameter of the transducer "Type Transducer" No to prevent the connection test, which is automatically performed on the transducer. Please note that in seam mode, for long periods of welding,> 30'', and continuous (no breaks pulsation cycles of at least 2-3 times), the ring Rogowski is not suitable for the

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reading of the current due to secondary the natural drift of the integrated circuit, so it is mandatory to use the CT connected to dedicate input socket, the CT type is 1000/1 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. K_Filt 1/2/3/4

Range value: 1-2-4 Sets the filtering of the Rogowski Coil, and Current Transformer, it is necessary to increase this value when the signal from Rogowski coli / CT is noisy as in the case of a coil placed inside the welding transformer or when it is placed in particularly noisy position, reducing the value to a minimum you get a greater speed of acquisition of the current value decreases by increasing the speed, this also impacts on the speed of adjustment of the current itself, the optimal value is equal to 2 by default.

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4.2.14 Copy Program Display Windows

CS-NET Copy Program

Program To Copy N° 0

Copy Range From Prg.N° 0

To Prg.N° 0

Copy (NO/YES) NO

EXIT (PUSH +)

Program To 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: From 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 program. Copy (NO/YES):

Range value: from NO to YES Defaults to NO to bringing you start copying the program, once completed an OK appears next to the YES.

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4.2.15 CAN bus Measures Display Windows

CS-NET CAN bus Measures

Position Measure . NO (NO-STD-NUT)

Measure Pos.type ABS (ABS-REL1)

ES Position 0.0 (0.0-250.0mm)

Pos.Elect. Close NO (NO-YES)

Pos.Current Cut NO (NO-YES)

End Pos. Electr. NO (NO-YES)

Measure Press/Force NO (NO-Pr-Fr)

ES Out Press 0.0 (0.0-9.9bar)

ES In Press 0.0 (0.0-9.9bar)

ES Out Force 0.0 (0-1000dN)

ES In Force 0.0 (0-1000dN)

Feedback NO (NO-YES)

Feed-Bk Delay Time 0.5 (0.5-20.0)

EXIT (Press +)

This menu allows you, through the use of the card SM300-EXP5, to manage the measurements made on the movements of the cylinder welding using a linear potentiometer and check the pressure or force exerted on the piston of the same piece, all using the parameters described to follow.. The squeeze value must always be different from 0 if you use position test! Position Measure.

Range Value: NO;STD;NUT Default Value: NO Only in cycle spots, activate the control and management, via CAN bus, of position measuring electrodes. If set to NO, management is disabled. If set in STD is tested the position of squeeze electrodes, without the automatic recovery of wear electrodes, the management of the current cutting position, during the welding, and the electrodes final position, this after the electrodes Hold Time If set in NUT is tested the position of squeeze electrodes, with the automatic recovery of wear electrodes, the management of the current cutting position, during the welding, and the electrodes final position after the maintenance electrodes Measure Pos.Type

Range Value: ABS;REL;ABS1;REL1 Default Value: ABS

Sets the mode with which to perform the measurement and the presence or absence of the position limit switches of zero electrodes. In ABS, is carried out by measuring the increase of the initial position of zero and is then tested the stroke end, the values of the three test measures should be introduced for the absolute values or the measurement will be carried out in an incremental manner from the released position of the limit switch zero. In ABS1, the management is carried out, as in ABS, unless the non-consideration of the limit of zero.

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REL is done in a reset after each verification of the position measurement, the test values must be introduced as a shift from the zero, it can test the limit of zero, the measure part of its release. In Rel1, the management is carried out as in REL, unless the non-consideration of the limit of zero End Scale

Range Value: 0.0-250.0mm Default Value: 0.0

Sets the total displacement of the transducer for a proper fit

Pos. Elect. Close

Range Value: NO-SI’ Default Value: NO Arm / disarm the parameter and its management in the cycle spots Pos. Current Cut

Range Value: NO-SI’ Default Value: NO Arm / disarm the parameter and its management in the cycle spots

End pos. Elect.

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 the SM300-EXP5

ES Out Press

Range Value: 0.0-9.9 Default Value: 0.0

Sets the full scale output pressure corresponding to the maximum value of the output voltage (10V) ES In Press

Range Value: 0.0-9.9 Default Value: 0.0

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Sets the End-scale input pressure corresponding to the maximum value of input voltage (10V)

ES Out Force

Range Value: 0-1000 Default Value: 0 Sets the End scale output force corresponding to the maximum value of the 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: 0.5-20.0 Default Value: 0.5 Sets the maximum time within which you must obtain feed-back loop from PI adjustment before welding is the value in Cycles

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5. RUN mode In this condition, key in position "RUN", the CS-NET start cycle inputs are checked, and if active it is possible to start and manage the preset welding cycle.

5.1. Start cycle inputs and anti-tiedown If the start cycle inputs are present at CS-NET power on, it remains in NOT READY! indicate the presence and awaiting removal inputs. For the start of welding cycle the CS-NET operates a control signal connection between the common Pb Com and each of the other signals Pb A, Pb B, Pb C, Pb D (pre-stroke) The concomitantly time out is 400 ms, after which it is reported the request for removal of the Push button inputs. OTHERWISE IT REMAINS IN CHARGE AT THE CUSTOMER THE CERTIFICATION RULES "DUAL HANDS CONTROL" AS OFFICIAL RULES AND BY ALL OF THE SECURITY SYSTEMS OF OVERALL MACHINE. If the start cycle is operated 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: During 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 welding current depends on the initial presence or absence of inputs Pb B and Pb C, at the beginning of the cycle:

D During the welding cycle Seam, the presence or absence of inputs Pb B and Pb C causes the exchange Current, while the end of the cycle is determined by the removal of the signal Pb Com or Pb A IC = START WELD CYCLE NIC = NO START WELD CYCLE

Source Program Inputs Pb Com + Pb A or PEDAL1

Inputs Pb Com + Pb B or PEDAL2

Inputs Pb Com+Pb C

INTERNAL EXTERNAL SEQUENTIAL BusRam BusPrg

START IC 1 NIC NIC

Set START IC 1 START IC 2 NIC

Source Program .

Inputs Pb Com+Pb A

Inputs Pb Com +Pb B

Inputs Pb Com +Pb C

INTERNAL EXTERNAL BusPrg BusRam

If are not present Pb B and Pb C: IC with welding current 1

If is preset Pb B and not Pb C IC with welding current 2

If is present Pb C IC with welding current 3

NIC NIC

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5.2. Selection of Running Programs

Source selection of programs is done by pressing the key on the front panel; the key

must first be enabled via the parameter " SRC-PRG KEY EN " site in the parameters of the

system. The program in use will depend on the source defined, which will be chosen from External, "Ext": The program is defined by the group of inputs. If the selection is set to external programs, this will be done through the inputs "PROG 1-2-4-8-16-32" as the corresponding binary code, program 0 in the program 63, for a total of 64 programs held in non-volatile system memory. The assertion of the inputs should be made 50 mS before the command to start the cycle. The number of the selected program is shown on the display. Preset , "Set": Active mode only in spot, the program is defined in the Settings menu by the beginning of the cycle between inputs 1 and 2 with a program from 0 to 63.. Internal, "Int": Program is defined in the main window "RUN" and is unique. Sequential, "Seq.": Active mode only in spot, the program number is incremented every cycle starting in sequential mode from the pre-set start value to the final pre-set value. The values are set in the menu System Parameters. BusRam: In this mode, the welding parameters are set up and run to and from the ram area of the Field bus, if present. BusPrg: In this mode, the welding parameters are retrieved and executed by the Fieldbus, if any, by setting the bit "Pg 1-2-4-8-16-32" as a corresponding binary code, program to program 0 63 for a total of 64 programs held in non volatile memory system, see user fieldbus.

5.3. Pre stroke function The function allows solenoid (EV6) switch on switch off the through the assertion of entry

Pb Com + Pb D or PED PRE-STROKE (to +24VP) for all time set in "Pre Stroke Time"

site in the system parameters, if the input is removed before the expiry of that time, the electromagnetic valve is turned off immediately. Deactivation of the solenoid is asserting STOKE PRE-entry and it is immediate. The ready output is on until the beginning of the cycle. This function is active until the command is in a state of "Ready!" or "Waiting for IC."; It is not active during the cycle.

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Enabling the valve, the operating cycle starts, and the access to edit is denied, The output stage is energized, ready to supply the valves, do not put hands or limbs between the welding electrodes .

5.4. External input weld currents enable. This input allows the enabling / disabling of weld current in welding and in all hot cycles. Enabling or disabling, is displayed on the display of the CS-NET in the settings area in RUN mode.

This input is compared "logical" with the input given by the key on the front panel and the parameter "current" of the program selected If the current is switch off from the external, is shown NO (Ex).on the display. If disabled from program NO (Pg). If disabled from internal key NO (In). If not used, this input must be connected to +24 V

5.5. Inputs Protection To ensure safety and operational quality, the CS-NET oversees internal and external temperatures of the welding system. The temperature of the transformer / diode uses a separate input; this input can be even connected to the series of air and water sensors (pressure and flow meter). If you don’t want to monitor this input, you must connect it to +24 VP; THE MANUFACTURER SUGGESTS USING THE PROTECTION INPUT FOR PRESERVING THE MACHINE EQUIPMENT FUNCTIONALITY.

5.5.1 Over temperature of the transformer / diode (Thermostat) This input is normally connected to a closed contact coming from the thermostat located on the welding transformer. In the case of thermostat opening due to high temperature, the unit reports the alarm on the display in the State / Function area. This alarm is shown in the table of alarm and warning messages. In case of alarm the unit will enter in "Not Ready" mode with the output READY off. On restore of normal operating condition, the alarm is automatically removed. In spot mode, if the alarm should occur during the welding cycle, this will not be considered until the hold time. In Seam mode, if the alarm should occur during the welding cycle, the current would be interrupted.

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5.6. Control inputs

5.6.1 Emergency This input must be connected to an emergency stop button, normally closed. The opening of this input causes an immediate exit from the machine’s cycle, and the immediate removal of all outputs by removing the power from the output stage. For this function a purely electric circuit separate from the control logic was made (FAIL SAFE). The emergency is reported on the display in the State / Function area. The presence of the emergency status makes impossible to start any cycle.

5.6.2 Pressure switch The input is always checked before or after squeeze time, based upon its setting that can be done in the EDIT settings menu. The cycle comes into latching after the detection of the pressure switch (connection to +24VP) and it follows its settings. If not used, the input shall be connected to +24VP. In seam mode CP allows to wait for the motor start, before starting the welding, is also used to monitor the error condition by any inverter drive motor, if during the cycle this input goes off, the current would be inhibited; the display shows the waiting starting engine.

5.6.3 Current probe To this input can be connected a Rogowski coil current transducer, for a simple measuring and visualizing or as a feedback to adjusting the current; when Rogowski is active, the CS-NET performs a continuous monitoring and adjustment of the transducer, if during the operations that component should be shorted or open the CS-NET reports the error by blocking the cycle. In alternative you can use a current transformer CT. The choice between the two types of transducer is made by setting a specific parameter in the system parameters; it also determines the choose of , primary or secondary current measuring..

5.6.4 Voltage probe When the unit is set to work in PK, EK or AD modes is necessary to connect this input through a twisted / shielded cable directly to the tips, and it is necessary to set the

parameter “VE Input” to YES in system parameters, Pay attention at the exact polarity

connections..

5.6.5 Reset alarms In RUN mode, using this input, you can quit the error and turn off the output "OUT OF RANGE", generated by the condition of out of tolerances and if the welding quality control test function enabled. Moreover, the input, if the function counting point is enabled, the inlet quits the alarm “maximum points reached”, and resets to zero the counter welding spots counter.

The errors reported is cleared out through this input as alternative to the key on the front panel of CS-NET/T

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5.6.6 Reset steps In RUN mode, using this input, you can reset the count of steps, and quit the alarm, switching off the output "END STEPS" related to the selected program. That affects the pairs of electrodes that did generate the alarm.

5.7. Control outputs

5.7.1 Main Solenoid valves (EV 1,2,3,4) Outputs are active at +24VP with load current up to 200mA, protected against short circuits, used for driving the pistons closing the electrodes. Outlets can be independently associated with pre squeeze piston or with squeeze piston. The association can be done in edit menu by mean of a program parameter. In Seam mode the valves are associated to squeeze piston and Roller motor drive.

5.7.2 Forge solenoid valves and Roll motor (EV 5) This active output to +24 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 "analog" is able to provide a DC voltage variable from 0V (0%) to 9.9V (99%) in the case of full scale at 10V. Using a scale parameter in the menu system parameters, you can set the output voltage up to 99%, from 5 to 10V. In spot mode the output is set to the value entered in the running program for each program parameters setting. In Seam mode, the value is kept constant throughout the program running, until the program changes.

5.8. Signalling outputs There are seven signals outputs described below.

5.8.1 Ready This active output to +24VP, with load current up to 200mA, protected from short circuit. When active indicates the CS-NET is ready to execute the machine cycle (RUN). It is turned off in case of errors or alarms, or when the key is in edit position.

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5.8.2 End cycle This output signals the end of the welding cycle. It is a normally open relay contact, with the closing time adjustment using the correspondent parameter in system parameters. It closes according to the setting of its parameter.

5.8.3 Antii-tiedown Normally closed contact relay it opens with the first cycle with the presence of current, and it is deactivated when the cycle reach the hold time. This output has the function of interlock with other welding systems.

5.8.4 End current increase (END STEPS) This active output to +24VP, with load current up to 200mA, protected from short circuit. When active indicates the end of the current increment steps, used to compensate the wear of electrodes pairs.

5.8.5 Delta TS This active output to +24VP, with load current up to 200mA, protected from short circuit. When active indicates hot cycles are in progress.

5.8.6 Out of range This active output 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. When activated, indicates that during the hot cycle times, the CS-NET will supply the firing unit to start SCR to supply current to the transformer.

6. Communications

6.1. Connecting a printer CS-NET can be connected to a printer with a serial communication interface. The connection is done via a serial cable, as shown in Annex , connected to the socket 9-pin connector present on the CS-NET/L when configured in RS232 mode. It is possible to set the communications port unit in the menu of communications. To use the printer you must set the port as to be used for printing (PRN.) in the parameter "Ser.Direct."

6.2. Connecting a personal computer The CS-NET can be connect to a PC to via the serial RS-232C. The connection can be done via a serial cable, as shown in Annex , connected to the socket 9-pin connector present on the CS-NET/L. You can set the communications port unit in the menu of communications.

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Finally, set the serial port to the PC in the parameter "Ser.Direct."

6.3. Connecting to a network The CS-NET can be connected to a network using the RS-485, CS-NET is a slave node. The connection can be done via a serial cable, as shown in Annex , 9 pin connector located on the present on the CS-NET/L. 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-NET/L, you can operate the unit into a field bus with the complete visibility.

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7. Control mode and features Using the parameters of the program you can choose six modes of regulation.

7.1. Duty rate D‰ In D‰ mode the drive of transformer primary is in proportion to Duty set in the parameters for the hot cycles, and is fixed. 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. If you connect the ring Rogowski or CT, you can read on the display the RMS value of the main welding current and of the pre-and post-welding current. In any case, no current regulation is done, so the current will vary with changes of the physical parameters of the machine.

7.2. Duty rate compensated primary voltage V‰ In V‰ mode the drive of the transformer primary is made in duty-percentage as set in the program parameters for the hot cycles, and varies to maintain a constant voltage at the 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 Rogowski coil or CT, you read on the display the RMS value of the main welding current and of the pre-and post-welding current. In any case, the current adjustment is not done, so the current will vary with changes of the physical parameters of the machine.

7.3. Constant current IK In IK mode, the drive of the transformer primary is made by adjusting the duty so that the circulating current in the secondary circuit, detected by Rogowski coil, secondary control, or CT, primary control, is constant and it matches the set in KA in the program parameters for the hot cycles, the adjustment is made every ms to override changes due to fluctuations in line voltage, changes of resistance of the piece etc… This mode does not work without the calibration of the machine (transformer - plant) for each pair of electrodes-transformer used. The Rogowski coil is always necessary to get the reaction voltage from the secondary or CT to get it from primary.

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7.4. Welding mode "advanced"

7.4.1 Tips connections to CS-NET/L The methods are based on advanced welding a good understanding of what happens during welding, thus requiring the connection of the probe voltage at the tips. In addition to wire cable to the acquire power connector X3, you must set the parameter "VE Input" in the menu "System Parameters” to “YES”. Insert in parallel to the voltage leads, close to the input connector, a 100 ohm resistor 1W, this to increase the noise immunity of the voltage signal. Use, double-shielded cable as Lapp Kable ART.0032302

7.4.2 Tips for the voltage acquisition The voltage measurement is very delicate, because, unlike the current is influenced by the measuring point and is very sensitive to electrical noise in the system. Keep in mind that when you move the point of withdrawal in the relief of power, energy and strength change significantly, necessitating a new parameterization of the weld. is therefore necessary to define a stable point of measurement on the machine, and do not change after defining the parameters of the ways, PK EK or AD. Pay attention to the polarity of connection to the connector. Adopt shielded cables and, if possible, entwined, the shield must be connected only by the CS-NET 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 CS-NET 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 the same time, the best measure would be the point of the electrodes near the welding point. Since the two requirements conflict, it is necessary to reach a compromise. In general, we recommend:

• In most cases [cf. Fig1], it is preferable to take the voltage of the electrodes where the arms

are divided. This helps to avoid having cables in the space of the piece, you can avoid subjecting the cable to continuous mechanical stress and you have a minimum area between the two conductors. In some special cases (for example, micro-welding) may be interesting to bring the sampling point near the electrodes. In this case, if you always keep in mind that the two wires must be as close together as possible (preferably twisted), and then there are problems of mechanical interference with the machine part to be welded.

• It is advisable to separate the wires, both “+” and “-“, and move route them connected to the arms of the electrodes, because in general this area between the two cables is too big.

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7.5. Constant power, PK, introduction

In constant power mode, the voltage and the current at the tips are measured , and eventually corrected , every period, to keep their product constant depending on the fluctuation of line voltage. If the secondary resistance will decrease the current will be increased and vice versa, if the secondary resistance will increase the current is decremented. In this mode, the parameter "VE input" of voltage probe presence should be set to "YES" and as with IK mode the calibration of machine is required. The installation of the Rogowski coil, and of the voltage sensor at the tips are required.

The mode is active only in spot-weld cycles.

7.5.1 Constant power, PK, operative notes

1. After 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 your system into the PK and change the welding program:

a. Fix the parameter "current limit" in this way the output current will not exceed the level specified in any case even if is not reached the required power

b. Fix the desired power level

The welding at constant power, keeps constant the power over time, and therefore the heat provided. The current trend therefore varies depending on the resistance, in particular, you can expect a lower level of current at the beginning (when the resistance is higher) and higher at the end, after the formation of the core

When the CS-NET works in PK, all distribution of the program are adjusted in power and is available the same cycle program cases IK, V‰ and D‰.

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7.6. Constant energy, EK, introduction In Constant energy mode instead of the current parameter 1 will appear as energy parameter where it sets the energy required for the welding in progress; the time parameter 1 takes the meaning of the welding time maximum after which the power supply will stop, reporting the anomaly. In EK the CS-NET constantly adjusts the current to keep the product VxIxT constant within the set time limits. To work that way you will need to carry out a weld test in IK for the correct setting of this mode

In this mode, the parameter " VE input " of voltage probe presence should be set to

"YES" and as with IK mode the calibration of machine is required The installation of the Rogowski coil, and of the voltage sensor at the tips are required.

This mode is available only in spot cycles.

7.6.1 Constant Energy, EK, operative notes EK mode is a special case of control IK, in which the delivery time is defined by the CS-NET itself (within limits) depending on the parameters of energy.

1 Defining an optimal operating condition by working in IK mode, preferably without the use of pulses, repetition. In particular, it is 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

3 Bring the program EK mode:

a. Fix the amount of energy required on hot cycle, a weld 1 and weld 2, Pre and Post heating continue to be performed in IK mode

b. Set the parameters "T. x Welding Min" and "Welding x T. Max" to the minimum and maximum time desired for welding, on hot times, 1 and 2 (if used). In particular, as the maximum time it is suggested to set a value greater than that found in welding IK, then the algorithm to leave the task to stop welding

Welding now stops automatically when the power required output is reached. The CS-NET shows the time actually spent in welding, highlighting where it reached the level of energy required or, conversely, when the weld is the minimum time period, although it had already been achieved energy set. For the next development, remember that: The change in the current set point, with the same energy required, reduce the

energy release time The times of the initial slope-up and masking, change the window measure and then

read the amount of energy. Therefore requires a new verification in IK mode. Any repositioning of the probe voltage can significantly change the energy values,

and request a new set-up parameters.

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7.7. Adaptive, AD, introduction In AD mode, after having marked a weld "Good" in IK mode, you can set the maximum welding time allowed (the welding time 1) and the minimum time; then you set a percentage of resistance decrease after the maximum value reached at which the welding will stop. The concept of this adaptive control is to monitor the resistance of the point during the warm up to a maximum and then detect a reduction percentage of the resistance. The welding time never is less than the minimum and never exceeds the maximum value. In this mode, the parameter "VE input" of voltage probe presence should be set to "YES" and as with IK mode the calibration of machine is required The installation of the Rogowski coil and the voltage sensor at the tips are required.

This mode is available only in spot cycles.

7.7.1 Adaptive, AD, operative notes The adaptive mode is a special case of control IK, where the use is stopped when the resistance has dropped about a percentage set 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 leave to the algorithm the task to stop welding.

b. Set a level of resistance fall of start (eg 7%) c. Run the tests.

3. Any hold after the resistance drop can be introduced, using the hot time during the welding,

the system automatically stops supply of hot time 1 when it detects a loss of resistance equal to set the core building. It may be necessary to reduce the current demand, and increasing the times of

welding, to simplify the identification of the instant collapse of the resistance. Experiment with different levels of % drop, in order to make the process repeatable NOTE: Since the drop of the resistance phenomenon is an event quite variable and influenced by several factors (eg, dirt sheets, projection equipment, ...) algorithm with the AD welding time can vary from point to point, significantly . This is normal behavior. It is suggested, however, accurately checking the stability of the process, and the quality of a large sample of welds the same as validation.

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8. Messaging and display Below, we report the display window, in the "RUN" on the display of the CS-NET/T, mode spot and seam, and associated sub windows. Dispaly windows in spot mode

Prog.:00 Int. Mode:IK Spot N° 0

Curr.:NO(Ex/Pg/In) TIME 1 : 0.0~ Alarm:NO IRMS 1 : 0.00KA

Rept.:NO TIME 2 : 0.0~ Puls.:1 / 1 IRMS 2 : 0.00KA

Status/Function:

CS-NET READY!

Display windows in Seam mode

Prog.:00 Int. Mode:D‰ Spot N° 0

Curr.:NO(Ex/Pg/In) TIME : 0.0~

Alarm:NO PAUSE : 0.0~ IRMS : 0.00KA

Status/Function:

CS-NET READY!

Sub windows Settings area In this part of the window you can find the following information: The number of program to run (00-63), the source of the program (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-NET, "Ready!" or "Not Ready." During the welding cycle it displays the functions performed; in the line below the alarm and warning messages. Operating mode area In this part of the window you can find the following information: Setting associated with the program running, one of the six operating modes at points: D‰, V‰ IK, PK, EK, AD, and three Seam: D‰, V‰ IK. Spot counter area Here is shown the number of welds made up to a maximum of 65,000 points, it is increased only by the current is set to "YES". The count is resettable in sub window dedicated to it. WARNING: This counter has no inherence with the auto-step counter, so a reset does not reset cycle increase current.

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8.1. Main measures window and sub windows The main window displays the measures of the last welding performed. In Seam mode instead , one of three running welding, or other way at the end of the cycle, the last executed. First Windows in spot with VE=NO

TIME 1 0.0~ IRMS 1 0.00KA

TIME 2 0.0~ IRMS 2 0.00KA

First window in spot with VE=YES

Time 1 0.0~ IRMS 1 0.00KA

Tips 0.00V

Res. 0.00uΩ

In Seam mode, there is only one combination:

TIME 0.0~

PAUSE 0.0~ IRMS 0.00KA

8.2. Sub windows measures in different modes of work By pressing the arrow key →DX, you can access the sub windows display, alternative to that of the main measures of the weld and through the ←SX-arrow key to came back to the main window measure.

Sub windows, only in spot:

Weld 1:

TIME 0.0~ IRMS 0.00KA

ENERGY 0J

POWER 0.00KW

Pushing

Weld 2:


ENERGY 0J

POWER 0.00KW

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Pushing

Pre Heating:


POWER 0.00KW

Pushing

Temper:


POWER 0.00KW

Pushing

Degrees:

Deg PreHeating 0°

Deg weld 1 0°

Deg Weld 2 0°

Deg Temper 0°

Sub Windows always present of Auto-Step:

This sub window is used to display the percentage increases in current, carried out during the welding, to offset the natural wear of the tips. They are, in addition, display the number of welding related to the increases. You can reset the increments, starting from the initial current set, to do this simply highlight the '"NO", after selecting the pair of electrodes in use, with "up" or "down " placed on the line "Inc. Clear "and press the" + "(get a"yes' "). It is reminds that at the end of the scheduled increases, the CS-l highlights the achievement, with the message of the end steps out and activating the "End steps"

Auto-Step:

Electrodes 1

Clear Inc. NO

Actual Spots 0

Actual Inc.(%) 0.0

Sub windows always present count setting of welds.

Counter:

Preset 1

Enable NO

Reset NO

It is possible to stop the CS-NET in a state of "not ready" after a pre-set number of welds. To enable the counting in the sub window counter, proceed as follows:

• 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

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• 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 line "ENABLE" NO • Set to YES with key confirmation "+".

Going back to the main window the count is set and enabled. During the work cycles, the weld counter is incremented. At the comparison of the number of welds with the value set for comparison, the CS-NET stops showing the alert "number of welds achieved" and entering to "NOT READY! ", the output" Ready "goes off. The reset of the alarm of the counter can be made in the sub-window of the setting counter, resetting the count or disabling it; zeroing in the main window can be performed by pressing the "+" key , from remote , the reset can be performed via the 'input "Reset alarms". Sub window always display the current request from the external or bus.

Ext/Bus Set:

V‰, 0‰ IK 0.0KA

Window present if Measure are enabled, it display Measure from CAN Bus card.

CAN Measure 1

Actual Pos. 0.0mm

Act.Press. 0.0ba

Act.Force 0dN

Window present if Measure are enabled, it display Measure from CAN Bus card.

CAN Measure 2

Cl.Pos.El. 0.0mm

Final Pos. 0.0mm

Weld Press. 0.0ba

Weld Force 0dN

Welding current window SEAM

Shows the average values of three current in KA, the program runs in Seam welding

Currents:

IRMS 1 0.00KA

IRMS 2 0.00KA

IRMS 3 0.00KA

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Sub window of Use Deg.or SEAM Weld

Degrees:

Deg weld 1 0°

Deg weld 2 0°

Deg weld 3 0°

Sub window, reading CS-NET parameters

This window displays: the value of % grid voltage V, the temperature of the radiator, and the maximum primary supplied current.

Stato:.

Grid V.% : 0%

Grid Freq.: 00.0Hz

IPrim : 0.0A

Sub window of SW CS-NET/T and CS-NET/L (Terminal and Power) This window displays: the software versions the terminal and power units

SW.Vers.:

SW T 2.10.000000

SW L 2.10.300419

Machine ID 000

Sub window of graphics set

Graphic:

Measure: Isec

Decim(x): 1

From this window you can define the settings of the chart, the graphics area is activated by scrolling with the DX arrow on the next screen. The measured value can be chosen from:

* only if secondary voltage reading is 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.

Isec performance of the secondary current (measured by Rogowski, if available, or primary sensor)

D% SCR open rate performance

Vsec* Secondary voltage performance

Pow* Power output performance

Res* Resistance performance

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After a new approach is necessary to initiate a new point to refresh the graphic screen. The graphics window is automatically scaling according to the values obtained. It 'be careful when comparing the graphs together, the possibility that the screen has been scaled vertically so different between the two acquisitions. It will be possible to read the graph:

the unit of time, displayed as Period / div, which is derived from the frequency of the system and the decimation value chosen;

the unit of value shown (KA, V,%, etc..), Scaled so as to ensure a meaningful display the acquired waveform. The full scale value displayed in the graph represents the maximum allowed in this moment for the y-axis

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8.3. Selection mode, of the program to execute.

Through continuous press of the button , on the front panel is possible to switch, in rotation, the source of program selection, the key must first be enabled via the parameter

“Src-pr key en” site in the system parameters

The commutations, each time, are as follows: Prog.:XX Ext. = Program number selected from external binary inputs .

Prog.:XX Set. = This function is enable only in spot cycle, the program is join to start

cycle IC1 and IC2, configured in edit, in the settings menu. Prog.:XX Seq. = Set the sequential reading of the program, starting from the first

program selected and incrementing each cycle start until you reach

the last one, and then cycling again from first to last. Prog.:XX Int. = Manual Setup from the internal to the first press, with XX flashing is

possible, using the "+" and "-" set the desired program, the second pressing, XX stops flashing, the program is set and ready to be execute

Prog.:XX BusRam = The parameters of the welding program are written by the PLC in

the ram dedicated to the field bus.

Prog.:XX BusPrg = The parameters of the welding program are referred by PLC in the

ram-bit input dedicated to the field bus, see field bus manual.

XX it is variable from 00 to 63

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8.4. Control function of the welded spot In mode D‰, V‰, IK PK and EK you can set the parameter "Control Mode" to YES, It runs the limits check, in spot mode and in Seam mode. In the welding program, you must enable the control function and set correctly the following parameters: Initial Blanking

Limit XXX Max

Limit XXX Min

These parameters allow you to set limit values on current measurements of power and energy in the hot cycles.

Spot mode limit check: It runs at the end of set Cycles of welding, and monitors the average of measurements taken, by setting the parameter N ° bad spot, other than zero; overcoming a number of consecutive welds out of tolerances, the CS-NET is blocked in "NOT READY!" condition, displaying alarm, It waits to be reset from the lock condition.

Seam mode limit check: It runs on the average current, measured during the welding time, set for each current, the control is carried out through the duration of continuous welding, by setting the parameter N ° bad spot, other than zero, overcoming a number of consecutive welds out of tolerances , the CS-NET is blocked in "NOT READY!" condition, displaying alarm, is expected to reset the lock condition. 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.

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9. Alarms and warnings During operation, the system performs a continuous diagnostic monitoring of its state, if anomalies occur, it alerts the operator. The anomalies are of two types: ALARM and WARNING. The first one are critical situations, which do not allow the system to work (eg the demand for welding at constant current with the Rogowski band opened (or not enabled) or that might compromise the safety function (failures, malfunctions). In this case, the system prevents new start disabling the ready until the anomaly is resolved. The second category is records that do not necessarily require the interruption of activities, but that it should be brought to the attention of the operator. In both cases, the terminal sends a message to the operator. Pressing the "+" key allows to confirm the reading of the message, and to restore the functioning of the system, however: It is necessary to find out the cause of malfunction and to be sure that the conditions that generated 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.

10. Alarms & warnings list

N° Cod. Description Alarm /

Warning

Alarm

Lock

GENERAL SYSTEM MESSAGES

1 1 ERROR! Crc eeprom CS-NET/P Data in non-volatile memory CS-I / P corrupt.

Alarm YES

2 3 ERROR! Communication with CS-NET/P The CS-NET / T cannot communicate with the

CS-I / P or there are continuous connection

errors / communication, check connectors and

cables between the inverter and the display.

Alarm No

3 3 ERROR! Serial Line ERROR RS422 serial communication line

between CS-NET / T and CS-NET / P, check

connectors and cables between the inverter and

the display.

Warning No

4 4 WARNING! BUS not connected During operation, with fieldbus and watchdog

function of bus, has not been updated the

control bits.

May indicate a problem with the connection of

the fieldbus or in interaction with PLC control.

Refer to the manuals of communication via the

fieldbus.

Alarm YES

5 5 Push “+” = Init vars o”-“= Skip is required to reset the parameters in EEPROM

minimum values default: by pressing the "+"

button to initialize them, by pressing the "-"

button will leave the current values

Warning YES

90 of 111


6 6 Wait, Parameters Loading The message is displayed for a short period,

initializing parameters, in case it is confirmed

that the default setting of the EEPROM.

Warning YES

7 7 ERROR! 24VP I/O Lack of voltage 24V I / O: connect properly

(possibly with jumpers) section IO (see chapter

"Commissioning").

Alarm YES

8 8 ERROR! Outlet short It 'has detected a short circuit on the lines of

the outputs; eliminate the cause of short circuit

and reset the system.

Alarm YES

9 1

0

ERROR! Control Mode not allowed ERROR management system software, report

what happened to the manufacturer. Alarm YES

10 1

1

ERROR! Internal RT CONTROL Alarm YES

11 1

2

!! EMERGENCY !! Emergency button pressed (open contact). The

system is placed in security (IO disabled, IGBT

stops, sw control pause) until the button is

pressed.

Alarm YES

12 1

7

b

WARNING! CAN-bus Communication Lost! If enabled measurement indicates the lack of

communication with the card SM300EXP5 via

Can Bus, check the connection or correct

wiring

Warning NO

START WELD MESSAGES

13 1

8

ERROR! Rogowski not initialized The request for current arrogation occurred

before initialization of the Rogowski: from

when the unit, up to 3 seconds are necessary

for the proper activation and calibration of the

read circuit Rogowski.

Alarm YES

14 1

9

ERROR! Rogowski Internal Circuit The readout circuit Rogowski found ineligible

values if the alarm persists or occurs

frequently, it is possible that there is a

malfunction in the electronics of the

acquisition.

Alarm YES

15 2

0

ERROR! Rogowski open or short Resistance detected at the ring Rogowski

outside the permissible range: Make sure that

the ring is in good condition and properly

connected, and that there are no cracks or

breaks in the connecting cables.

Alarm YES

16 2

1

ERROR! Current Feedback required Has been required welding mode that requires

feedback current activated (Rogowski or CT).

Enable current measurement machine

calibration menu.

Alarm YES

17 ERROR! Transformer ratio necessary You tried to perform a weld with reading

primary current (CT), but without setting the

turns ratio of the transformer. Define the

parameter from the Calibrate menu and try

again

Alarm YES

18 2

5

WARNING! Vsec input (VE)required to YES In PW, EK, AD is necessary to activate the

input voltage. Connect the terminals correctly to

measure and enable the parameter "VE input"

from the "System Parameters"

Alarm

YES

91 of 111


MESSAGES DURING WELD CYCLE

19 2

7

ERROR! Time out Rogowski Integration Saturation of the integrator circuit of the

Rogowski: welding too long (60s).

In the case of pulsed operation or rollers, may

indicate that the pause time between the pulses

is not sufficient to download the measuring

circuit.

Alarm YES*

20 3

0

ERROR! Tips voltage reading During a welding voltage measurement tips

active, was detected outside a limit value or

zero. Check the connection.

Alarm YES

21 3

6

WARNING! Limit Max/Min. Stop! has reached the set number of consecutive

welding parameter out of bounds. Check the

cause before continuing to weld.

Alarm YES

22 3

7

WARNING! Reached N Spot max you have reached the limit set by parameter

count welds. After the reset, you can continue

to weld.

Warning YES

23 3

8

WARNING! Pair(1/2/3/4) N max steps was reached the maximum number of steps of

the pair of electrodes in use. Reset the step

counter (front panel or from a dedicated input)

to resume welding.

Warning YES

24 3

9

WARNING! SCR OR Transf. Overheating Thermal alarm from external bimetal place on

the transformer / SCR connected externally by

the user

Alarm YES**

25 4

4

WARNING! Remove Start Cycle Presence of inputs cycle start still active after

the completion of the current point, with

"repeat cycle" is not active, or the transition

from RUN to EDIT (display).

Warning YES

26 4

5

WARNING Waiting rollers motor start [mode SEAM] At the start, indicates that the

cycle is awaiting the start of the engine; during

welding, report the removal of the current

anomaly in the driving of the motor

Warning No

27 4

6

ERROR! Open Electrodes Attempt welding electrodes are not closed on

the workpiece. Make sure there are no

abnormalities of behavior of transformer,

electrodes and electrical connections.

Since this report is subject to "false positives",

you can disable it from the system parameters.

Alarm YES

28 4

6

b

Elect. Close Pos. not in Tolerance! After closing the control electrodes with the

measure set in the running program is not in

tolerance

Alarm YES

29 4

6

c

Current Cut Pos. not Reach! After starting welding is welded to the set time

without reaching the cut measure current Alarm YES

30 4

6

d

End Pos. Elect. not in Tolerance! At the end of maintaining the measurement

made is not in tolerance with the one set in the

running program

Alarm YES

31 4

6

Pressure/Force Measure not in tolerance After the closing of the electrodes, the control

with the measurement set in the program, in

execution, it is not within tolerance

Alarm YES

92 of 111


e

32 4

6

f

Resistance Measure not in Tolerance! After welding, there has been a strength of the

welded spot, out of tolerance Alarm YES

CONTROL MESSAGES DURING CURRENT EROGATION

33 4

7

WARNING! Current out of range, low The current reading was outside the

permissible minimum current value (20% of

the set point), in the ways IK / PK / EK

Alarm YES

34 4

8

WARNING! Current out of range, high The current reading was outside the maximum

permitted current value (160% of the set point),

in the ways IK / PK / EK

Alarm YES

35 4

9

WARNING! Limit max current you have exceeded the Maximum Current

Limit set in the program. Make sure that the

tolerances are compatible with the application,

and that you have correctly set the time on the

masking measure.

Warning No

36 5

0

WARNING! Limit min current you have exceeded the limit set in the

Minimum current program. Make sure that the

tolerances are compatible with the application,

and that you have correctly set the time on the

masking measure.

Warning No

CONTROL MESSAGES ON ADVANCED WELD MODES

37 5

2

WARNING! Limit max power [PK mode] has been exceeded Limit Maximum

Power set in the parameters of the program. Warning No

38 5

3

WARNING! Limit min power [PK mode] has been exceeded limit exceeded

Minimum Power set in the parameters of the

program.

Warning No

39 5

4

WARNING! EK T. Max reached [EK mode] has not been reached in the energy

required set time. Warning No

40 5

5

WARNING! EK not reached T. Min [EK mode] The 'Energy set in the program is

reached before the minimum time set. Warning No

41 5

6

WARNING! AD fail T. Min [AD mode] During the heat cycle, has been

read a change in the gradient in a resistive time

below the threshold set time, doing a suspect

abnormality welding.

Warning No

42 WARNING! AD fail T. Max [AD mode] During the heat cycle, has been

read a change in the gradient in a resistive time

over the threshold set time, doing a suspect

abnormality welding.

* These alarms immediately interrupt the current erogation.

** These reports are automatically disabled.

93 of 111


PAGE INTENTIONALLY LEFT BLANK

94 of 111


PAGE INTENTIONALLY LEFT BLANK

95 of 111


11. Expansions, Interfaces, Software Options

11.1. Parallel interface module Compact Com SM300CC This module assembled in its seats in the CS-NET / P, allows the support of communication modules HMS Compact Commission for the interface to the fieldbus such as: Profibus-DeviceNet-CANopen-CC/Link-Modbus/RTU-Profinet/IO-EtherNet/IP-EtherCAT-Modbus/TCP

11.2. 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.

11.3. PC adapter module from RS232 to RS485 The module converts the serial interface RS232 to a personal computer, a network interface 485, to allow the management of CS-NET on a network (Safco Systems proprietary protocol, similar to the mod-bus).

11.4. PC program A PC software is available operating in Windows 98, Windows XP operating systems To manage CS-NET in a network with RS485 or RS232 point to point. Details about the features are provided in the specific manual. The main screen is shown in the window below:

96 of 111


12. Technical Data

12.1. Electrical characteristics power, inputs and outputs.

12.1.3 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

Current +24VP - 180 mA

Insulation 250 VAC functional

SIGNAL OUT

MIN MAX

Maximum Range -0,3 V 26 V

Condition 0 -0,3 V 1,5 V

Condition 1 23 V 27 V

Current each out - 500 mA

Outputs total current - 850 mA


Type Contacts NA, NC

MIN MAX

Voltage on contacts 3 V 48 VAC / 48VDC

Power 30 VA

Switch current 1 A


Maximum cable section 1 mm²

Table 1 Digital Signals

12.1.4 Analog signals IN – OUT

Rogowski (input)

Secondary current Range Ring Gain

150mV/KA @ 50Hz

±100 KA

MIN MAX

Frequency 10 Hz 5000 Hz


VSEC (input)

MIN MAX


Frequency 0 5000 Hz

Proportional Valve (output)

Type Voltage Output

MIN MAX

Maximum Range 0 10

Maximum voltage fault 12 V

Current 80 mA

Table 2 Analog signals

97 of 111


12.1.6 Mechanical and environmental

Framework Aluzinc

Protection degree IP20

Overall external dimensions 270 × 146 × 60 mm

Weight 2 kg

Air temperature 0 ÷ 40 °C

RH 90 % no condensing

Table 3 - Mechanical and environmental

12.1.7 SCR Cooling Water; flow min. 4 l/min; T water 20 ÷ 40 °C

Table 1 – Cooling

PH 7,0 ÷ 9,0

Hardness G.F. < 10

Maximum chlorine content 20 PPM

Maximum content of sulphate 100 PPM

Maximum nitrate content 10 PPM

Maximum solids content 200 PPM

Maximum content of calcium carbonate 50 PPM

Resistivity at 25 °C > 5 kΩ·m

Table 2 - Properties Water Cooling

98 of 111


12.2. CS-NET/T mechanical dimension

118m m

57m m

244m m

226m m

(max depth)

45m m

(pod measure)

212mm x 116mm

Ø 7

99 of 111


12.3. CS-NET/L mechanical dimension

100 of 111


13. Attachments

13.1. Connections schematics Rev.0 (Annex A)

COLLEGAMENTI EST ERNIEXTERNAL CONNECT IONS

CONT R.

DATA

CS-NET

OUT-2

IN-1

OUT-1

IN-2

220mm x 200mm

H1

R

G1

G2

K2K1

O U TW ATER

J POWER

TO CS- I / T

DOCUMENTO RISERVATO - 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

DIST RIBUZ.

+24V P

+PROP.

CAN-BUS GND

CAN H

GND P

CAN L

-VALVE

0V

+24VVALVESUPPLY

DIS.

VIS.

MALERS 422

DATA DIS. VIS.

+24V P

+24V P

GND P

GND P

N.C.

RXD

RXD

TXD

TXD

8

9

6

7

5

2

3

1

4

G. M.

1

OUT-2

FEMALERS 232 /RS 485

GND (+5V)

RESERVED

GND P

TX/RX A

TX/RX B

TXD

N.C.

N.C.

RXD

2

8

9

6

5

7

3

4

1

5

X 1

4

1

1

6

X 2

1

OUT-1

IN-1

1

1

1IN-2

ROGOWSKI

ELETTRONICA INDUSTRIALE

[email protected]

www.safcosys.it

segue F.

F.

X 3

1

POWERSUPPLY

S

T

R

1 11

J POWER

I / O CARD

INW ATER

TRS

S

R E S IS TE N ZAR E S IS TO R

T ERM OS T A T OT HE RM OST AT

W05-SM274-R

CE 17642 B

s egue F.14-1-13

9

1

ANTICONCOMITANCE N.C. 2


END CYCLE N.O. 2

+24V P

END CYCLE N.O. 1

OUT OF RANGE

END STEPS

GND P

CURRENT-ON

10

1

12

PRE-STROKE EV 6

GND P

DTS

READY

FORGE EV 5

EV 1

EV 2

EV 3

EV 4

GND P

RESET STEPS

+24V P

CURRENT ON/OFF

RESET ALARM

P -SW

1

12

PB A

PB C

PB PRE-STROKE (PB D)

PB B

PED PRE-STROKE (PED D)

PEDAL 2

PB COM

EMERGENCY

+24V P

+24V P

PEDAL 1

PROG 04

PROG 08

PROG 32

PROG 16

F.

TO CONNECTJ2 SM274

1

1

PROG 01

PROG 02

+24V P

THERMOSTAT

10

9

4

6

7

8

5

3

2

1 2 3 4 5 6

6

S T087

440V

J 2

CAM B IO T E NS IONECHA NGE T E NS ION

6

0V 400V

21 3 4 5

S M 274GK

KG

J 120V0V1

TH ER MO STAT TR AFO( IF N O T I/O C AR D )

SHORT SCR INPUT-JUMPER IF NOT USED+24V P

AUX PWR INPUT

WITH I/O CARD FUNCTION= SHORT SCRNOT I/O CARD FUNCTION= EMERGENCY

NOT E:

REV.

SAFCO

CE 17642 B

101 of 111


13.2. Connections schematics Rev.0 without I/0 Card (Annex B)

COLLEGAMENT I EST ERNIEXT ERNAL CONNECT IONS

CONT R.

DAT A

CS-NET

220mm

H1

R

G1

G2

K2K1

W 05-SM274-R -AL

U S C ITA A C Q U AO U T W A TE R

GND (+5V)

RESERVED

GND P

+24V P

+24V P

GND P

N.C.

TXD

TXD

RXD

RXD

TX/RX B

N.C.

N.C.

GND P

RXD

TXD

TX/RX A







DESCRIZIONEREV.

DIST RIBUZ.

TO C S- I / T

PROP.

VALVE

VALVESUPPLY

+

-

0V

+24V

DIS.

VIS.DAT A DIS. VIS.

6

9

7

8

5

3

4

2

1

MAL ER S 42 2

G. M.

FEMALER S 23 2 /R S 4 8 5

4

6

9

7

8

5

3

2

1

4

6

1

X 2

X 3

1

J POWER

10

9

4

6

7

8

5

3

SAFCO


info@

safcosys.it

www.safcosys.it

ROGOWS K I

CE 17642 B

segue F.

F.

50H zS

1 1

T

P O W E R S U P P LY400 /440 V

R

1 1

2

E N R A TA A C Q U AIN W A TE R

S

TRS

10mm


10mm

ø 6.5

T E R M OS T A T OT HE RM OS T A T

CE 17642 B

WITH I/O CARD FUNCTION= S HORT S CRNOT I/O CARD FUNCTION= E ME RGENCY

s e gu e F.14-1-13

S HORT S CR INP UT-JUMP E R IF NOT US E D

A UX P WR INPUT

NOT E :

+24V P

F.

CA M B I O T E NS I ONECHA NGE T E NS I ON

200mm

TO CONNECTJ2 SM274

TH ER M O STAT TR AFO( IF N O T I/O C AR D )

1 2 3 4 5 6

J 1

S T087

440 V

6

S M 274

20V

GK

0V 400 V

6

KG

0V1

21 3 4 5

J 2

102 of 111


13.3. Connections schematics Rev. A with I/O Card (Annex C)







DIST RIBUZ.

REV.


SAFCO

CE 17642 B

PROG 02

CS-NET


10

9

1

1

12

1

12

DAT ADESCRIZIONE

+24V P

+24V P

GND P

GND P

TO CS-I / T N.C. 5

8

9

6

7

TXD 4

RXD

RXD

TXD

2

3

1

DIS.

VIS.VIS.DIS.

G . M .

OUT-2

MALERS 422

OUT-2

1

5

4

1

1

6

GND (+5V)

RESERVED

GND P

TX/RX B

TX/RX A

2

N.C.

N.C.

RXD

8

9

6

5

7

3

4

TXD

1

+24V P

+PROP.

CAN-BUS GND

CAN H

GND P

CAN L

-VALVE

0V

+24VVALVESUPPLY

OUT-1FEMALE

RS 232 /RS 485

1

OUT-1

IN-2

IN-1

X 1

X 2

1

1IN-2

IN-1

1

J POWER

GND P

CE 17642 BCONT R.

DAT A s egue F.05-06-14



END CYCLE N.O. 2

+24V P

END CYCLE N.O. 1

CURRENT-ON

OUT OF RANGE

END STEPS

GND P

F.

PB PRE-STROKE (PB D)

PRE-STROKE EV 6

DTS

READY

FORGE EV 5

EV 1

EV 2

EV 3

EV 4

GND P

RESET STEPS

+24V P

CURRENT ON/OFF

RESET ALARM

P -SW

PED PRE-STROKE (PED D)

PB A

PB C

PB B

PEDAL 2

PB COM

EMERGENCY

+24V P

+24V P

PEDAL 1

PROG 32

PROG 16

PROG 08

PROG 04

1

220mm x 200mm

[email protected]

www.safcosys.it

H1

R

G1

G2

K2

K1

S

1

ROGOWSKI

POWERSUPPLY

S

T

R

J POWER

X 3

1 11

I / O C AR D

8

7

9

10

11

12

13

14

5

6

INW ATER

T RS

O U TW ATER

4

1

2

3

segue F.

F.


T E RM OST AT OT HERM OS T AT

W05-SM274-R

SH O R T SC R IN PU T - J U MPER IF N O T U SED

WITH I/O CARD FUNCTION= SHORT SCRNOT I/O CARD FUNCTION= EMERGENCY

PROG 01

+24V P

THERMOSTAT

AU X O U TPU T+24V P

GNDP

+24V P

C .T. IMPU T

AU X PW R IN PU T

TO CONNECTJ2 SM2741 2 3 4 5 6

TH ER MO STAT TR AFO( IF N O T I/O C AR D )

NOT E:

S T087

J 2

621 3 4 5

440V

CA M B IO T ENS IONECHANGE T ENS ION

0V 400V

1

6

S M 274GK

KG

J 120V0V

103 of 111


13.4. Connections schematics Rev. A without I/O Card (Annex D)

4 WITH I/O CARD FUNCTION= SHORT SCRNOT I/O CARD FUNCTION= EMERGENCY

NOT E:

COLLEGAMENTI ESTERNIEXTERNAL CONNECTIONS

G . M .







TO CS-I / T

DESCRIZIONE

DISTRIBUZ.

REV.

DIS.

VIS.VIS.DATA DIS.

MALERS 422

N.C. 5

+24V P

+24V P

GND P

GND P

8

9

6

7

TXD 4

RXD

RXD

TXD

2

3

1

PROP.

VALVE

+24VVALVESUPPLY

+

-

0V

FEMALERS 232/RS 485

2

GND (+5V)

RESERVED

GND P

TX/RX B

N.C.

N.C.

RXD

8

9

6

5

7

3

4

TXD

TX/RX A 1

X 2

4

1

6

1

s egue F.

CS-NETCONTR.

DATA 05-06-14

CE 17642 B

F.

SH O R T SC R IN PU T - J U MPER IF N O T U SED

AU X O U TPU T

AU X PW R IN PU T

C .T. IMPU TJ POWER

8

7

9

10

11

12

13

14

5

6

+24V P

GNDP

+24V P

W05-SM274-R

[email protected]

www.safcosys.it


SAFCO

S

ROGOWSKI

X 3

1 1

POWERSUPPLY

S

T

R

segue F.

CE 17642 B

F.


H1

R

G1

G2

K2

K1

TO CONNECTJ2 SM274

TH ER MO STAT TR AFO

6

1 1

2

3

1 2 3 4 5

O U TW ATER

INW ATER

T RS

S T087

6

440V

CA M B IO T ENSIONECHANGE T ENSION

21 3 4 5

0V 400V

J 2

220mm x 200mm

T E RM OS T AT OT HERM OST A T

1

6

S M 274GK

KG

J 120V0V

104 of 111


13.5. Module can bus expansion valve with proportional feedback, linear transducer and pressure sensor Rev.A (annex E)

BOX DIN RAIL - CUSTODIA A GUIDA DINMEASURES - MISURE

138mm x 78mmSM300_EXP5

Potenziometro lineareLinear potentiometer1K÷5K LIN 0,1%

0÷250mm

Cella di carico 0÷10V oSensore di pressione 0÷10V

Load cell 0÷10V orPressure sensor 0÷10V







DESCRIZIONE

DIST RIBUZ.

REV.

DIS.

V IS .DIS .DAT A VIS.

PROP.VALVE

VALVESUPPLY

+

-

+24V

0V

J PROP

21 3

GND

+24V

1

+

4

GND

s e g u e F.


SM300_EXP5G. M.

19-11-09

300EXP5.SKD

REV. A

CONT R.

DAT A

CE 17643 B

F.

1

1 2 3 4 5

GND

AN 0

+5V

AN1

GND

J AN_IN

J CAN 2

CAN H

CAN L

+24V P

GND P

CAN H

SAFCO in

[email protected]

www.safcosys.it


J 24V_OUT

+24V

1

+24V

1

CAN L

GND

+24V

GND

CAN L

GNDP

GNDP

CAN H

J 24V_IN J CAN 1

1 22

1

1 2

1

3

1

GND

CE 17643 B

segue F.

F.

GNDP

(AUX) INP 1

(AUX) INP 2

(AUX) OUT 1

(AUX) INP 3

+24V

J IN_OUT

1 2 3 4 5 6

1

U

+

-

FCZERO CILINDROZERO CYLINDER

GND

5 +24V P

CS-IJ CAN

1

2

3

4

GND P

CAN H

GND P

CAN L

105 of 111


13.6. Serial connection cable for personal computer (Annex F)

Warning: for connection to CS-NET/L RS232 to personal computer or printer, use cable as

shown follow. Never connect pins 1, 4, 6, 7, 8, 9

To CS-NET

Front view

TO CS-NET

MALE SUB-D 9 PIN

TO PC

FEMALE SUB-D 9 PIN

Back view

To PC

8

86 7

1 2 3

6 7

1 2 3

9

4 5

9

4 5

106 of 111


13.7. Network cable RS-232 TO RS-485 (Annex G)

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 ConverterRS-232 TO RS-485

MODEL 2089PATTON

XMT

G

107 of 111


13.8. Network cable USB TO RS-485 (Annex H)

The interface converter is an optional accessory

M

3

COD.688257

RS 485

USB / RS 485

F

F

12

108 of 111


13.9. Spot cycle timing diagram (Annex I)

CU

RR

DO

WN

SL

OP

E

*= At the call of the program is set to the first pressure from P1-2-3-4-5, not set to 0, so if 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 The exchange of the pressure from phase to phase takes place in the previous half period exchange with a time of adjustment of the voltage of 5ms.

109 of 111


13.10. Seam cycle timing diagram (Annex J)

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

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13.11. Product disposal at the end of its life

In accordance with European Directive 2003/92/EC on waste electrical and electronic equipment (WEEE) at the end of his life, the product must not be disposed with municipal waste, but must be delivered to dealers who provide this service or at the appropriate places for collection by the local authorities. The separate collection 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 to municipal collection points or platforms authorized; equipment contains substances which, when released into the environment due to improper use or improper disposal may be harmful and / or Dangerous to the very environment and human health; the symbol of the crossed-out wheeled bin indicates that the equipment can not be thrown in the trash, but started a collection.

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AC Control For Resistance Welding Machine CS-NET … Operating Manual ENG R.2... · AC Control For Resistance Welding Operating Manual ... (EV 1,2,3,4) ... 12.1.7 SCR Cooling