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Horizontal Mounting Seven Parameter Electronic Phase Shift Weld Control
Resistance Welding Machines
CS-6 2.7
Rev. F
PO Box 3153 Bethlehem, PA 18017 484-898-0257 [email protected]
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Notes to the Manual
Software 2.7 Release F
Manual Purpose
Purpose of this manual is to provide a basic consultant book for the staff involved in resistance welding technology and being familiar with the machine on which the control is installed.
Remark: All of our equipment is subject to continuous development; therefore we must reserve the right of construction changes to the Hardware-Software of the unit and of changes in this manual without notice or obligation.
This manual includes the information necessary for the correct operation of the electronic control and for its ordinary servicing in order to prevent incorrect use and for the safety of the people involved in its operation. Any other type of service is not allowed without having contacted first our Servicing department – [email protected] The supplied information has no intent to replace, integrate or change any rules, regulations, law by decree, directive or special laws in force in the Country where the installation takes place. The suggestions are given to the staff involved in the installation and servicing assuming that these personnel is expert and pre pared to face any problem of servicing. For any clarification or information not included in this manual, please do not hesitate to contact us.
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Table of Contents
1. Safety ............................................................................................................................ 4
2. Precautionary Labeling ............................................................................................... 7
3. Sw Rel. 2.7 Descriptions: ............................................................................................ 9
4. Warranty Description ................................................................................................ 10
5. System Parameters setting: ..................................................................................... 11
6. Edit of welding cycle Programs Parameters and associated LEDs: ..................... 12
7. LED, description of associated functions, inputs, outputs, weld yes, weld no, and
check faults ............................................................................................................... 13
8. CS-6 Operation: ......................................................................................................... 13
9. Summary Table Settings ........................................................................................... 14
10. Description of “OPERATING MODE” parameter in the CS-6 unit ......................... 15
11. MODE = 0 independent operation AUX waiting ...................................................... 16
12. MODE = 1 immediate operation no waiting AUX .................................................... 17
13. MODE = 2 Simultaneous operation with the previous. ........................................... 17
14. MODE = 3 electric cascade with simultaneous opening ........................................ 18
15. MODE = 4 electric cascade with independent opening .......................................... 19
16. MODE = 5 pneumatic cascade no overlap ............................................................... 20
17. MODE = 6 pneumatic cascade with overlap ............................................................ 21
18. MODE = 7 unit disabled............................................................................................. 22
19. Connection Diagram Fig. 1 ....................................................................................... 24
20. Mechanical dimensions ............................................................................................ 25
21. Drilling template ........................................................................................................ 26
22. Product disposal at the end of its life ...................................................................... 27
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1. SAFETY
READ THIS MANUAL COMPLETELY BEFORE ATTEMPTING TO
INSTALL OR OPERATE THIS CONTROL.
STORE THIS TECHNICAL INFORMATION IN A PLACE TO WHICH ALL USERS HAVE ACCESS AT ANY TIME!
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NORMAL USE
This manual contains all information concerning normal use of the RWC, llc. CS-290P Weld
Control. Together with designated welding hardware, the CS-290P Weld Control is intended to be
used for RESISTANCE WELDING. It is not intended for any other use.
RETROFITS AND MODIFICATIONS BY USER
QUALIFIED PERSONNEL This manual is designed for welding technicians and engineering personnel with knowledge of installation and safety standards of electrical and automation technology. Specific knowledge of hardware and software components of EN6041 and related welding hardware is required. This manual must be read and understood by qualified personnel.
CARDIAC PACEMAKERS
CAUTION
The use of this control for purposes other than intended use may result in injury to user or others or damage to equipment.
This control should only be used for its intended purpose!
WARNING
Retrofits or modifications may have negative effects on the safety of unit! Consequences could include death, personal injury, or damage to property and loss of warranty. Please contact factory prior to retrofits or modifications to the EN6041 using third-party equipment. This is the only way to determine whether these parts can be used with this control.
WARNING
Due to strong magnetic fields arising from resistance welding, the function of cardiac pacemakers may be disturbed. This may cause death or considerable health damages to persons concerned! These persons should avoid the welding system.
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EXPLANATION OF ADVISORY NOTATIONS Throughout this manual, advisory notations are included to inform the user of certain circumstances
which need to be emphasized. The hierarchy of these advisory notations is as follows:
1. DANGER
2. WARNING
3. CAUTION
4. NOTICE
DANGER
The signal word DANGER is used to call attention to immediate or imminent hazards which if not avoided will result in immediate, serious, or personal injury or loss of life. Examples are: exposed high voltage; exposed fan blades.
WARNING
The signal word WARNING is used to call attention to potential hazards which could result in personal injury or loss of life. Examples are: not using proper personal protection; removal of guards.
CAUTION
The signal word CAUTION is used to call attention to hazards which could result in non-life threatening personal injury or damage to equipment. CAUTION may also be used to alert against unsafe practices.
NOTICE
The term NOTICE is used for making recommendations on use, supplementary information, or helpful suggestions. Non-compliance with these recommendations may result in damage to control, welding machine, or workpiece.
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2. PRECAUTIONARY LABELING
RWC, LLC. follows the practices of the
RWMA for precautionary labeling. See
RWMA Bulletins #1 and #5 for a complete
description. Observe the WARNING,
DANGER, and CAUTION labels affixed to
control to maintain safe operation.
FOR SERVICE CONTACT Placed on control to inform the user how to obtain service information.
– FLASH HAZARD WARNING Placed on items that should not be disassembled or remanufactured by non-qualified personnel – items such as circuit breakers and contactors that require expertise of original manufacturer when repairs are required; although these devices look simple in design, improper reassembly could result in dangerous conditions.
HAZARDOUS VOLTAGE
DANGER
Placed on interior of control to advise weld control may be powered by more than one source.
HAZARDOUS VOLTAGE WARNING
Placed on exterior of control to advise weld control may be powered by more than one source.
VOLTAGE/FLASH HAZARD DANGER
Placed on interior of control to advise to remove power before changing fuses.
NOTICE
FOR SERVICE ON THIS CONTROL
Contact your Machine Dealer or:
Resistance Welding Controls, LLC
PO Box 3153
Bethlehem, PA 18017.
484.898.0257 [email protected]
8
WATER HOSE BURST HAZARD Placed on exterior of control. Hoses on direct water-cooled
contactors connect points of differential voltage; water in hoses will allow some magnitude of current to conduct through them; if there is no water flow and power is left on, water will ionize and deteriorate interior of hose, resulting in hose bursting. NOTE: 1200 amp Contactor is indirectly water- cooled and should not have voltages on water-cooling connections. Label is sometimes used on indirectly water-cooled contactors because operators cannot tell if
contactor is directly or indirectly water-cooled. Also the “Water Off–Power Off/Power On–Water On” recommendation is used generically whether the contactor is directly or indirectly water-cooled.
HAZARDOUS VOLTAGE GND/PE DANGER Placed on interior of control at GROUND connection to advise control must be grounded and this is the point.
PINCH POINTS CAUTION
Placed on interior of control near points where wires can be pinched to advise pinching of wires can cause control
damage
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3. Sw Rel. 2.7 Descriptions:
General
• Automatic Compensation of the network voltage fluctuation.
• EMERGENCY Input for cutting power to the control and valves.
• Two cycle start inputs for execution of two separate programs 1 and 2, in association with the same valve or a different one.
• Short circuit protected output for solenoid valve or end cycle signal, output for synchronous ignition of the SCR.
• Manage dual weld heads, or dual weld head schedule.
• Selectable times in ½ cycles steps up to 10 and complete cycle steps over 10.
• Direct set of welding/non-welding by keys "+" and "-".
• Malfunctions Control.
• Outputs voltage 24 V D.C. 5W max, the outputs is protected from the short circuit.
• Supply voltage can be set to 230 or 440 V +/- 20%.
• Automatic detection of the supply frequency: 50/60 Hz.
Program Parameters:
• Squeeze adjusting time from 0 to 99 Cycles.
• Slope up adjusting time from 0 to 20 Cycles.
• Adjustment of two- weld stroke, one of which is settable in preheating or post heating and the other as welding, from 1/2 to 99 cycles or continuous welding (function co.) with interruption by separate inlet.
• Welding pulse setting from 1 to 9.
• Cold time setting from 0 to 99 Cycles.
• Hold time setting from 1/2 to 99 Cycles.
• Off Time setting from 0 to 99 Cycles.
• Program cycle Repeat Setting.
System Parameters:
• Setting the aperture of the first half cycle of welding.
• Set of 16 tables of COS (φ).
• Setting time auxiliary heat before or after welding.
• Set for simultaneous or cascade.
• Setting of the trigger point for the end weld signal before or after hold time.
• Set function for Rocker Welder.
• Set the machine for double weld heads/point with or without overlap.
• Association Start of cycle 1 to program 1 and start cycle 2 to program 2 at one valve or two.
WARNING
THE STANDARD CERTIFICATION FOR THE SAFETY DEVICE “DUAL PALM CONTROL” IF REQUIRED FOR A MACHINE IS CUSTOMER DETERMINED SINCE IT DEPENDS ON LOCAL SAFETY REQUIREMENTS AND THE SAFETY STUDY PERFORMED BY THE CUSTOMER FOR THE SPECIFIC
APPLICATION.
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THREE YEAR LIMITED WARRANTY
Important: Please read carefully. Our warranty statement provides critical information regarding your RWC weld control and subsequent service policy.
Resistance Welding Controls, LLC., warrants that all RWC control panels, EXCEPT Mid-frequency Inverter controls, silicon controlled rectifiers (SCRs), insulated gate bipolar transistors (IGBTs), SCR and IGBT assemblies, circuit breakers, and electro-mechanical contactors, are free of manufacturing defects for a period of THREE YEARS from the date of original purchase and, in the event of a manufacturing defect, RWC will repair or replace, at its discretion, the defective part without any cost for parts or labor. All silicon controlled rectifiers, SCR assemblies, IGBT assemblies, circuit breakers, and electro-mechanical contactors in RWC control panels are covered by a limited warranty from the original manufacturer. If these parts fail because of a manufacturing defect, they will not be repaired or replaced by RWC, but will be returned by RWC to the original manufacturer in accordance with said manufacturer’s warranty.
EXCLUSIONS: This warranty does not cover damage by accident or misuse, unauthorized repair or modification to any control assembly by the customer. Important Note: The warranty period is considered from date of shipment and is tracked by serial number code.
USE OF OUT OF WARRANTY REPAIR SERVICE: To obtain service for any printed circuit board assembly or welding control after the warranty period, send the assembly or control, prepaid, to RWC Controls, LLC., and RWC will repair the printed circuit board assembly or control and return it to you without further warranty. Additional service charges will be invoiced at time of shipment. Needed info is on a label that looks like this.
For questions regarding the function of your machine, please call: RWC, LLC 484-898-0257 8:00 am – 5:30pm Ask for our service department.
INTELLECTUAL PROPERTY NOTICE
The information contained in this manual is intellectual property SAFCO SYSTEMS and is copyright protected. The possession of this information gives no transfer right to competitors.
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5. System Parameters setting: With the CS-6 in "ready" mode, LED N° 7 green is on, it is possible to access the system parameters. The procedure for accessing the parameter is as follows:
1) Hold down the arrow key "←" press the "+" button. This will light up all LEDs except the N° 8, which represents the parameter in the first half-period modification or welding. Using the "+" and "-" it is adjustable from 20 degrees to 90 degrees, the default value is 87 degrees, Parameter Name=”FHLF”.
2) Pressing the arrow key "→" turns off the LED N° 9 and N° 8 lights up, you can set
one of the 16 tables dependent on the power factor of the machine for optimal adjustment of the current, the table below shows the openings for each table, the default value is 7, Parameter Name=“TABL”.
Cosine Table @50Hz
Power Factor ON Delay Table N°
Cosfi Electric Degree Milliseconds Setting Value 0,482 61,20 3,40 15 0,522 58,50 3,25 14 0,562 55,80 3,10 13 0,600 53,10 2,95 12 0,637 50,40 2,80 11 0,673 47,70 2,65 10 0,707 45,00 2,50 9 0,740 42,30 2,35 8 0,770 39,60 2,20 7 0,799 36,90 2,05 6 0,827 34,20 1,90 5 0,853 31,50 1,75 4 0,876 28,80 1,60 3 0,898 26,10 1,45 2 0,917 23,40 1,30 1 0,930 20,70 1,15 0
3) Set the desired table of power factor, you move with the arrow key "→" will light the LED N° 10 to set the use of the auxiliary hot time 1, before or after the hot time (weld) 2. Value to "0" before weld (default), the value to "1" after weld, parameter name = "HOT_POS".
4) Pressing the arrow key "→" will light the WORK MODE parameter LED N°11, for this
setting refer to the specific section 7, set it to the default value = 0 if you want this setting for a single job: the WORK_MODE is considered to "0" for the conditions Set, and Double Head, parameter name="WORK_MODE". Verify JP5.
5) Pressing the arrow "→" will light the LED N°12 to change the point of activation of
WARNING
BOFORE POWERING UNIT UP TO SET THE SYSTEM PARAMETERS YOU MUST VERIFY THE VOLTAGE SETTING ON VOLTAGE CHAGEOVER JUMPER LOCATED NEAR J1. THIS IS SHOWN IN
BETTER DETAIL IN CONNECTION DIAGRAM IN FIGURE 1 ON PAGE 24
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the end of the cycle, after the off time to 0, before the hold time to 1, parameter name=”FC_MODE”.
6) Press the arrow "→" will light the LED N°13 the voltage compensation 0 = off, 1 =
on Parameter name=“LCMP”.
7) Press the arrow "→" you can change the mode for a foot rocker “Pivoting” mode. 0 is the default, 1 for a foot rocker.By pressing the arrow "→" passed to the LEDs N°15 to introduce the operation of two welding programs, programs 1 and 2, combined with the early cycles 1 and 2 with the same pilot valve EV1, the parameter set to 1, or execution of two welding programs, 1 and 2 and control two different valves, parameter set 2, parameter name= "SET", check JP5.
8) By pressing the arrow "→" to switch to LED N°16 and you can enter the operating
Double head with combination of valve 1 to program 1 and valve 2 to program 2. Functionality double spot (DSPT) without overlap, parameter set to "1", features double spot (DSPT) with overlapping, parameter set to "2", parameter name "DPT", check JP5.
9) Again pressing the arrow "→" key to exit the setup menu to return to ready mode, LED
N° 7 on. See section 9 for the summary table of the range of allowed values and configurations.
6. Edit of welding cycle Programs Parameters and associated LEDs:
Via the arrow "←" and "→" key, you can select the program parameters set in the welding cycle to change, the corresponding LED is lit, the change is made possible using the "+" and "-" keys,
Follow the description of the parameters and their limits. When ready, LED N°7 is on, pressing the arrow "→" the display (20) flashes now using the "+" and "-" you can set the program to run or modify (1-16), you will have to return to “ready” for the proper execution pushing “←” or enter in edit pushing “→”. LED N° 8 Squeeze: waiting time for the electrodes to close and develop necessary pressure before welding, if the sub parameter "Pivoting" is set to 0, after this time the valve will remain in latching and if the pressure contact is closed, starts the welding cycle. The range is from 0 to 99 cycles of which the first 10 in half-cycles. Led N° 9 Up-Slope: rise time of the percent current set value. The values range from 0, no slope up no present, up to 20 cycles. LEDs N ° 10&12 of the times hot 1 and 2: times during which there is the supply of current, these are set from 1/2 to 99 cycles. The first 10 cycles can be set in ½ cycles, over the value of 99 has the view of the passage to the continuous weld "Co" only for the weld time 2, welding, the interruption of the welding is done via the input end of welding "FCW", if the weld time 1 auxiliary is set to 0, it is disabled. LEDs N ° 11&13 currents of weld cycles 1 and 2: Set the output current during the warm cycles 1 and 2 can be set from 10% to 99%. LED N° 14 Cold Time: cold time during the pulse function of the welding current, if the value associated with the pulse is greater than 1; time is adjustable from 1 to 99 cycles, It is used as cold time between auxiliary, weld time and weld when pulsing. LED N° 15 Pulse: represents the number of pulses of the welding cycle, time and current,
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to perform, with values ranging from 1 to 9 pulses. LED N° 16 Hold Time: Time during which, at the end of welding, the valve of the electrodes is closed, the range is from 1 to 99 cycles, the first 10 can be set to half cycle. LED N° 17 Off Time: time during which, at the end of Hold time. The valve of the electrodes remains open. The range is from 0 to 99 cycles, the first 10 can be set to half cycle. LED N° 18 Single cycle or repeated: If set to 1, enables you to repeat the entire cycle of welding, to 0 if the welding cycle is single.
7. LEDS, description of associated functions, inputs, outputs,
weld yes, weld no, and check faults
LED N° 1 Line: when lit it indicates the presence of the power supply or, if it is off, it indicates the absence of power. Check the power supply, the voltage Change Bridge, or fuse located in the positions shown in Figure 1. LED N° 2 Start 1: lit when the input "start cycle 1" is closed (the welding cycle at the closure of the inputs at the beginning of the cycle that is in ready and in EDIT). If the LED remains off after the activation of the same, check the wiring and the contact of the start cycle, if it is a closed cycle the power on or after CS-6 shows the removal message Start cycle "IC". LED N° 3 Start 2: lit when the input "start cycle 2" is closed (the welding cycle by the closure of the inputs at the beginning of the cycle that is in Ready and in EDIT); If the LED remains off to the activation of the same check the wiring and the contact of the start cycle, if it is a closed cycle the power on or after CS-6 shows the removal message Start cycle "IC". LED N° 4 pressure contact: when on indicates input of "pressure contact" closed (the welding cycle continues after the time of squeeze if this input is closed, the end of the squeeze time of the CS-6 shows the message "CP" and waits if it is not closed). If the LED is off, check the wiring and the contact. LED N° 5 End continues weld (CO) lit when the input to the "End of continuous weld" is closed (the cycle of continuous welding is interrupted in the presence of this input). If the LED is off, check the wiring and the contact. LED N° 6 solenoid and or end of cycle: lit when the output valve 1 or 2 is active, in case of failure to verify the presence of voltage across the valve during power of the LED, the outputs are protected against short circuit which also may not be a short to activate the completion. LED N° 19 Weld YES, Weld NO: with the LED N° 7 lit, unit ready, you can enable the supply of the current during the welding cycle or disable the pilot of the power unit to run cycles without currents. To do this, simply press the "+" and the LED lights will drive in welds, and with the "-" button, the LED turns off and the unit does not weld.
8. CS-6 Operation:
Turning on the CS-6 displays the version of the software installed. Verification will be performed for the main frequency displaying the value, the error message "Fr" is a possible instability of the network and the values 50 to 60 are an indication of proper reading. Check for input cycle start and there are requests for removal by the "IC" message on the display. That view is also presented at the end of the cycle if they are not removed the start cycle.
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If the pressure contact is not closed after the time of the squeeze CS-6 stops waiting for the closing and displays the "CP" message on the screen. After performing the setting of system parameters and program, as described above, the unit can be used to begin working. Note that you can run the cycle with both the CS-6 in ready, LED N° 7 on, that during the editing of the parameters at the end of the cycle, and starting was during the editing control. The parameters in editing will not show the number of cycles made on the display.
9. Summary Table Settings
WARNING
In the use of the second output as the valve, you must provide the setting of
jumper "JP5", by 1-2 (END CYCLE) TO 2-3 (OUT VALVE)
During the execution of the program in EDIT, the modus "WORK MODE",
"SET" and "DPT" are inactive, you can test only the current program, which
are active both IC1and IC2 on the same program!
.
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10. Description of “OPERATING MODE” parameter in the CS-6 unit
The feature of the CS-6 is it can be used in combination with other controls of the same
type for sequences of operation (cascade / simultaneous).
The parameter (11) WORK_MODE allows you to program the operating mode of inter
linked with other controls through control signals.
If the control is used alone, i.e. not connected to another unit of the same type, the
parameter “WORK_MODE” must always set to 0. The mode of operation from 1 to 7 is
used every time the control is linked with other controls.
FUNCTIONAL MODES AND DESCRIPTIONS: 0 = Independent operation 1 = Immediate 2 = Simultaneous 3 = Electric cascade with simultaneous electrodes 4 = Electric cascade with independent electrode openings 5 = Pneumatic cascade with no overlap 6 = Pneumatic cascade 7 = Unit disabled
When control units are connected to each other, as in the interconnection scheme below,
for the welding sequence the units are synchronized with the inputs SYNC and AUX.
All controls have the cycle start signals connected in parallel.
The SYNC input is connected to the previous control to EV1 output.
The AUX input is connected to the end cycle (FC/END) of the previous unit.
For modes 1 to 7, the parameter setting the parameter of the end cycle mode (12) must be set to "1".
AUX input is reported as CP input in the Operating manual.
STAR T 2 STAR T 2 STAR T 2 SYN C (EN D-W )
EV1 7 6
SYN C (EN D- W )
EV1 7 6
SYN C (EN D- W )
EV1 7
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11. MODE = 0 independent operation AUX waiting
This mode is used in the case to a single pair to electrodes, i.e. when the control is not
used in combination with another CS-6.
In this case, the CS-6 functions as a normal control with all options enabled.
In this mode, and only in this mode, the control can work in auto-repeat by setting the
parameter to 1 SINGLE/REPEAT (18).
DESCRIPTION OF I/O SERVICE SIGNAL:
The beginning of the cycle is determined by the presence of start signals 1 or 2.
If the AUX input is not present, after the squeeze, the control waits for this input. The
self-restraint of the valve occurs after the arrival of the AUX signal and before welding.
SYNC input is not used.
The end cycle signal is activated at the end of welding time, before hold time, if the
parameter “end cycle type” (12) is set to 1 or after off time if this parameter is set to 0, and
it is switched off when you release the cycle start signal or after 0.5 seconds if the cycle
start signals are no longer present.
The output remains active during the hold time if this parameter (12) is set to 1.
In the figure are shown the signals in the case of repeated cycle in MODE= 0
NOTICE The following pages describe the various modes of operation.
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12. MODE = 1 immediate operation no waiting AUX
In this mode, the CS-6 is used in combination with other CS-6.
The beginning of the cycle is determined by the presence of start signals of 1 or 2 without
waiting for the other welding units.
The control works in simple mode without the repeat cycle function.
DESCRIPTION OF I/O SERVICE SIGNALS:
The beginning of the cycle is determined by the presence of start signals of 1 or 2.
The input signals SYNC and AUX are not used, their activation has no effect.
The end cycle signal is activated at the end of welding time, before hold time and switch off
when you release the cycle start signal or after 0.5 seconds if the start signals are not
present.
The end cycle output remains active during the hold time.
13. MODE = 2 Simultaneous operation with the previous
In this mode, the CS-6 is used in combination with other CS-6. In this mode, the machine starts the cycle after squeeze of the previous machine. The cycle occurs simultaneously with the previous. Welding may or may not be simultaneous but the closure of the electrodes is at the same time
(it depends on the parameter squeeze time).
The control works in simple mode without the repeat cycle function.
The first unit of the chain must be set to 1 independent. In this mode, the previous unit
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cannot be set in MODE = 7 otherwise it will block the next CS-6
DESCRIPTION OF I/O SERVICE SIGNALS:
The beginning of the cycle is determined by the presence of start signals of 1 or 2 and the
synchronization signal SYNC.
The AUX input is irrelevant.
The end cycle signal is activated at the end of welding time, before hold time and switched off
when you release the cycle start signal.
The output remains active during hold time.
14. MODE = 3 electric cascade with simultaneous opening
In this mode, the CS-6 is used in combination with other CS-6.
This approach aims to obtain a welding sequence called “Electrical cascade."
All the machines tighten the welding electrode at the same time, welding in sequence, one
after another without overloading the power line.
The electrodes remain closed until the cycle start signal is activated.
The first control of the chain must have the AUX place to + 24V.
In this mode, the units should all be set in MODE = 3 otherwise you will have no
simultaneous reopening of the electrodes.
DESCRIPTION OF I/O SERVICE SIGNALS:
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The beginning of the cycle is determined by the presence of start signals of 1 or 2 and AUX,
which is activated by the previous group. This determines the cycle time of the machine
between the squeeze and welding. When the previous unit has completed it activates AUX
to the next CS-6 giving consent to be welded to the next machine.
The electrodes are opened when all the machines are welded and remove the start cycle signal. The SYNC input is not used. The end cycle signal is activated at the end of welding time, before hold time, and turns off when you release the start cycle signal. The output remains active during the hold time. If there is a next unit, the end cycle signal will drive the AUX of the next CS-6.
15. MODE = 4 electric cascade with independent opening
In this mode, the CS-6 is used in combination with another CS-6.
In this mode, all the machines close the welding electrodes at the same time and welding is
performed in sequence, avoiding the overhead electrical line.
Each machine will open regardless of the electrodes in accordance with the parameters set for each control. The first control of the chain must have the AUX place to +24V The control works in simple mode without the repeat cycle function.
DESCRIPTION OF I/O SERVICE SIGNALS:
The beginning of the cycle is determined by the presence of start signals of 1 or 2 and
'AUX’, which is activated by the previous group. This determines the cycle time of the
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machine between the squeeze and welding.
When the previous unit has completed, the next activates the AUX giving consent to weld to
the next machine.
After welding and the holding time, the CS-6 continues and opens the electrodes
independently of each unit.
The end cycle signal is activated at the end of welding time, before hold time, and turns it off
when you release the signal to start the cycle.
The output remains active during the hold time.
If there is a next unit, the end cycle signal will drive the AUX of the CS-6 next.
16. MODE = 5 pneumatic cascade no overlap
In this mode, the CS-6 is used in combination with other CS-6.
The purpose to this mode is that the welding machines conduct the welding sequence. Each machine cycle starts only after the previous one has finished the welding and hold time and has initiated the opening of the electrodes.
If a unit is deactivated MODE = 7, the following units do not continue with the weld.
To correct this problem, the following control can be programmed to MODE = 6 (PNEUMATIC
CASCADE WITH OVERLAP) or MODE = 4 (ELECTRIC CASCADE WITH INDIPENDENT
ELECTRODES OPENING), obviously this control will run the welding cycle as programmed.
In this mode, the AUX input is not tested (block before welding, after squeeze waiting
electrodes closed).
If you must use this function (for example, when you have a foot pedal in two stages), you
can set the first control in MODE = 4 (ELECTRIC CASCADE WITH INDEPENDENT
ELECTRODES OPENING).
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The control works in simple mode with the repeat cycle function.
DESCRIPTION OF I/O SERVICE SIGNALS:
The beginning of the cycle is determined by the presence of start signals of 1 or 2 and the
presence of the signal SYNC to "1" and then "0 ". The SYNC signal indicates the status of the
valve of the previous group. If it turns off the valve for open the electrodes the control starts
the welding cycle.
The AUX is not used, and its activation has no effect.
The cycle end signal is activated over the welding time and turns off when you release the
start cycle signals.
The output remains active during the hold time.
17. MODE = 6 pneumatic cascade with overlap
In this mode, the CS-6 is used in combination with another CS-6.
The purpose to this mode is for the welding machines to conduct the welding sequence; each
machine cycle starts only after the previous one has finished the welding, but before the
opening of the electrodes. So, acting for the duration of hold time, the electrodes can be
closed before the previous unit opens preventing the piece from moving.
In this mode, the AUX input is tested (block prior to welding after squeeze waiting electrodes closure).
If you must use this function (for example, when you have a foot pedal in two stages), can
be achieved by setting the first control in mode 4 (ELCTRIC CASCADE WITH
INDIPENDENT ELECTRODES OPENING).
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The control works in simple mode without the repeat cycle function.
DESCRIPTION OF I/O SERVICE SIGNALS:
The beginning of the cycle is determined by two conditions: the presence of the cycle start
signal and no AUX signal.
At welding start the AUX signal of the next unit is disabled by the previous, when the previous
unit turns off the solenoid valve to open the electrodes the next unit starts the his welding
cycle.
The SYNC signal is not used, and its activation has no effect.
The end cycle signal is activated over the welding time and turns off when you release start
cycle signals. The output remains active during the hold time.
18. MODE = 7 unit disabled
In this mode, the control is disabled. The control does not close the electrodes and does not
weld, but allows the operation of machines that follow.
START and AUX signals are not involved for the operation of the other unit.
The signal SYNC to the next control is not fired (no EV1 out), which is why if the pneumatic
cascade is performed without overlapping (MODE = 5) the sequence is interrupted.
To avoid the problem, the unit can be programmed in MODE = 6 (PNEUMATIC CASCADE
WITH OVERLAP) or MODE = 4 (ELECTRIC CASCADE WITH INDEPENDENT
ELECTRODES OPENING).
The welding cycle time remains as programmed.
Page | 23
WARNING
This Weld Control does not support Dual Palm Button Initiation. A Third Party
device compliant with local codes is needed to be connected to the pressure switch or foot switch input for safety.
Page | 24
CAMBIO TENSION VOLTAGE CHANGEOVER
R S R S
19. Connection Diagram Fig. 1
TRS
80m
m
90m
m
DANGER
ENSURE POWER IS OFF WHILE WIRING
Line Voltage is present when power is on.
WARNING
Observe connections KG SCR that otherwise burns resistance 5W mounted
on ignition board SM297.
Page | 25
20. Mechanical dimensions
Page | 26
21 Drilling template
80.0
74.0
Page | 27
23. 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 its life, it must not be disposed of 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 to the environment and human health resulting from
improper disposal, and also allows you to recover recyclable materials from which the
product is made.
The equipment cannot be disposed of as municipal waste.
Refusal to properly dispose of equipment can result in a fine.
The equipment 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, may be
harmful and/or dangerous to the environment and human health.
The symbol of the crossed-out wheeled bin indicates that the equipment cannot be
thrown in the trash, and must be disposed of properly.
