- CRS Industrial Power Equipment

CRS_Inverters_for_Welding_ENG_20101008
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1| 7
INVERTERS FOR WELDING
Introduction
Easy to integrate into automated processes, these
inverter power supplies can control the energy for the
welding process with almost any kind of required pulse
shape. The main voltage is first rectified and then
passed through a controlled rectifier inverter and a
transformer to provide direct voltage. Feedback results
of the primary and secondary voltage and current are
provided, thus permitting perfect process control.
In addition to output current, cycle rate is also an important process-determining parameter when selecting an
inverter. The higher the cycle rate, the more effectively
the device delivers pulses with high edge steepness and
optimum control performance.
As output increases, these requirements become less
important, allowing lower frequencies to be used.
They also feature high-performance and easy-to-use
software to carry out complex control functions.
Our software has been developed with real processes in
mind and offers a range of powerful tools:
> Current control
> Voltage control
> Power control
> Limitation of control values
> Creation of controlled advanced pulses
> Part conditioning
> Weld to electrode displacement
> Data recording for process analysis
CRS_Inverters_for_Welding_ENG_20101008
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2| 7
INVERTERS FOR WELDING
HSW Mini
The Hot Spot Welding mini is a complete system enclosed in
one unit (430 x 420 x 150 mm) for resistor welding applications.
It is composed of:
> Primary inverter
> High frequency transformer
> Power diodes
> Shunt
> Control Processing Unit with RS232 serial line
> Operator control panel with 1 line by 16 characters display
> Main switch
Controlled via RS232 serial line by a PC/PLC or CRS remote
control unit (Part Number: REM305 or REM306).
HSW Mini Specifications
Max welding output voltage (Max load)
Max output current (Peak value )
Instant power
Continuous duty cycle
Short term (10 cycles) duty cycle
Peak primary current required
Minimum primary current requirement
Adjustment precision (In line conforming with EN50160)
Number of welding profile phases
Max time for each phase
Number of transformers incorporated in ferrite E70
Working frequency on the primary stage
Working temperature
Interface RS232
Short circuit protection
Overheating protection
Phase loss detection
Graphic memorization A + V real time
Mains voltage
Mains frequency
Cos §
Unit of
Measurement
Volt
Ampere
W
%
%
A/ac
A/ac
%
each
Ms
each
kHz
°C
Vac
Hz
CW-AH01
Air – 2500A
7.5V / 7%
CW-WH01
Water – 2500A
7.5V / 10%
7.5
2500
18750
7
15
54
25
2
3
2000
2
15
30
Present
Present
Automlimit
Present
Present
400
50 - 60
1
7.5
2500
18750
10
15
54
16
2
3
2000
1
15
40
Present
Present
Autolimit
Present
Present
400
50 - 60
1
CRS_Inverters_for_Welding_ENG_20101008
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3| 7
INVERTERS FOR WELDING
HSW Power Module
The power module for Hot Spot Welding (HSW) applications is a
device operating with a PWM technique at 50kHz equipped with a
parallel type interface hardware (20 pole bus with flat cable). This
interface facilitates the parallel interconnection of more than one
power module.
Power modules can be integrated in automated welding systems.
Required in addition to the power module:
> Control Processing Unit (Part Number: CPU063)
CPU card that interconnects with the power modules via 20 pole
bus. It is equipped with RS232 serial communication line to
connect either a PC/PLC or a CRS remote control unit (REM).
> Auxiliary transformer card (Part Number: MIN001)
Power suply of the CPU card.
> Remote Control Unit (Part Number: REM305 or REM306)
Remote control unit with operator control panel.
> Flat cable - from CPU to MOD (Part Number: CBF105 or
CBF106)
Standard 20 pole flat cable to connect power module to CPU card.
> Flat cable - from MOD right to MOD left (Part Number:
CBF103)
Standard 20 pole flat cable to connect both sides of the power
module. Not needed in case of using only half power module.
> RS232 cable - CPU to REM
Standard cable for RS232 serial communication line to connect
CPU card to REM.
HSW Power Module Specifications
Max welding output voltage (Max load)
Max output current (Peak value )
Instant power
Continuous duty cycle
Short term (10 cycles) duty cycle
Peak primary current required
Minimum primary current requirement
Adjustment precision (In line conforming with EN50160)
Number of welding profile phases
Max time for each phase
Number of transformers incorporated in ferrite E70
Working frequency on the primary stage
Working temperature
Interface RS232
Short circuit protection
Overheating protection
Phase loss detection
Graphic memorization A + V real time
Mains voltage
Mains frequency
Cos §
Optional:
> Operator panel kit (Part Number: OPP001)
Front display card used for configuration set-up and
check. If installed, debug jumper of the CPU card must
be turned ON.
> Flat cable - from CPU to OPP (Part Number: CBF201)
Standard 34 pole flat cable to connect CPU card to
operator panel.
Unit of
Measurement
Volt
Ampere
W
%
%
A/ac
A/ac
%
each
Ms
each
kHz
°C
Vac
Hz
CRS_Inverters_for_Welding_ENG_20101008
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CWM-A02
Air
2500A
7.5V / 7%
CWM-W03
Water
2500A
7.5V / 10%
CWM-W01
Water
5000A
7.5V / 5%
7.5
2500
18750
7
15
54
25
2
3
2000
2
15
30
Present
Autolimit
Present
Present
Present
400
50 - 60
1
7.5
2500
18750
10
15
65
16
2
3
2000
1
15
NA
Present
Autolimit
Present
Present
Present
400
50 - 60
1
7.5
5000
37500
5
10
130
110
2
3
2000
2
15
NA
Present
Autolimit
Present
Present
Present
400
50 - 60
1
4| 7
INVERTERS FOR WELDING
HSW Block Diagram (1 Power Module)
CBF103
Main power input
3 x 400VAC
R
S
T
R
S
T
+
Left
side
Main power input
3 x 400VAC
Cable provided with MIN001
-
Right
side
R
S
T
1 2 3 4 5 6 7 8 9 10 11 12
CBF105 or CBF106
Power
module
-
MIN001
Main power input
3 x 400VAC
CPU063
1 2 3 4 5 6 7 8 9 10 11 12
CN2
CN3
CN4
CN5
2 3 7 CN1
+
OPP001
CBF201
RS232 serial cable
3 2 7
CN5
REM
DC power
output
Power input: 24Vdc
CN1
1 2
HSW Block Diagram (2 Power Modules)
CBF103
Main power input
3 x 400VAC
R
S
T
R
S
T
Power
module
No. 1
+
Left
side
MIN001
Main power input
3 x 400VAC
R
S
T
1 2 3 4 5 6 7 8 9 10 11 12
Cable provided with MIN001
CBF105 or CBF106
-
CPU063
1 2 3 4 5 6 7 8 9 10 11 12
CN2
CN3
CN4
CN5
2 3 7 CN1
+
Right
side
REM
DC power
output
Power input: 24Vdc
Right
side
+
-
+
-
Power
module
No. 2
R
S
T
CBF105 or CBF106
R
S
T
Main power input
3 x 400VAC
CBF201
RS232 serial cable
3 2 7
CN5
Left
side
Main power input
3 x 400VAC
Main power input
3 x 400VAC
CBF103
CRS_Inverters_for_Welding_ENG_20101008
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CN1
1 2
OPP001
5| 7
INVERTERS FOR WELDING
AWS Mini
The Arc Welding System mini is a 100V/50A continuous current mode
switching power generator with an embedded header driver. Included
with the machine is one ignition coil to be placed near the target. The
machine can drive up to two ignition coils.
The most important and unique characteristic of this machine is that it
allows the welding to take place without any added material (tin or
brazing alloys); instead, the welding takes place due to the fusion of
the parts.
This method is an improvement versus the conventional tin immersion method in that it works without mechanically touching the
parts being welded and thus avoiding any mechanical stress or disturbance. More over, since the welding process takes less than
50ms, the thermal stress is reduced to an area of 1mm2.
AWS mini is enclosed in a case and is controlled by a microprocessor to permit the connectivity with robotized systems to obtain
perfect synchronization for highly automated welding systems.
AWS mini also monitors every single welding (shot) by storing in the local memory the waveform profile of current and voltage and
is communicated via the serial port to the host system to be analyzed.
The most popular applications for this technology are:
> Relay terminals
> Solenoid terminals
> Lamps terminal
> Thermocouple
Controlled via RS232 serial line by a PC/PLC or CRS remote control unit (Part Number: REM305 or REM306)
AWS Mini Specifications
Max welding output voltage (Max load)
Max output current (Peak value )
Continuous duty cycle
Short term (10 cycles) duty cycle
Minimum primary current requirement
Adjustment precision (In line conforming with EN50160)
Max number of heads
Number of welding profile phases
Max time for each phase
Working frequency on the primary stage
Working temperature
Interface RS232
Short circuit protection
Overheating protection
Graphic memorization A + V real time
Mains voltage
Mains frequency
Cos §
Unit of
Measurement
CWA-A01
Air - 50A
100V / 50%
Volt
Ampere
%
%
A/ac
%
each
each
Ms
kHz
°C
Vac
Hz
100
50
50
100
16
2
2
3
999
25
40
Present
Autolimit
Present
Present
400
50 - 60
1
The welding process is as follows:
> One cathode tungsten (negative polarity) is placed at 0.6mm from the target.
> The target to be welded is connected to the anode (ground).
> The machine through the control of the embedded header driver brings up the voltage to 15000V and ionizes the gas (air or inert
gas) between anode and cathode.
> When the spark is started the power supply generator drives the current to generate and maintain the plasma arc according with
the time and current parameters set in the memory.
CRS_Inverters_for_Welding_ENG_20101008
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6| 7
INVERTERS FOR WELDING
CPU Software List
Software
Rev
Product
HSW
ASW
Description
Comm. Protocols
CRS ASCII
Modbus-RTU
Q63HSW3C
1:01
Software driven by CRS remote control unit (REM) via CRS ASCII
protocol.
Q63HSWKI
1:01
Software driven by an external PC or PLC connected through RS232
communication port via CRS ASCII protocol. It is able to record
current and voltage values every 1ms and transmit the recorded
data to the PC or PLC for a real welding waveform graphic display or
analysis at the end of the welding operations.
Q63HSWMB
1:01
Software driven by an external PC or PLC connected through RS232
communication port via Modbus-RTU protocol. It is able to record
current and voltage values every 1ms and transmit the recorded
data to the PC or PLC for a real welding waveform graphic display or
analysis at the end of the welding operations.
Q63AWSKI
1:01
Software driven by an external PC or PLC connected through RS232
communication port via CRS ASCII protocol. It is able to record
current and voltage values every 1ms and transmit the recorded
data to the PC or PLC for a real welding waveform graphic display or
analysis at the end of the welding operations.
Q63AWSMB
1:01
Software driven by an external PC or PLC connected through RS232
communication port via Modbus-RTU protocol. It is able to record
current and voltage values every 1ms and transmit the recorded
data to the PC or PLC for a real welding waveform graphic display or
analysis at the end of the welding operations. An emergency input
from a N.C. external contact is provided for emergency Power Off of
the AWS inverter.
CRS_Inverters_for_Welding_ENG_20101008
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7| 7
INVERTERS FOR WELDING
Remote Control Unit (REM)
Technical Specifications
Supply voltage
Power consumption
24Vdc
0.75A max
INPUT
The remote control unit (REM) is an electronic card that communicates with the Q500 rectifier, up to 100 meters away, via serial
communications (through CRS-ASCII or Modbus-RTU protocol)
or analogue control.
It is a versatile unit with a simple and functional operating
interface which enables to control the external hardware of the
welding system (pedal, approach contact, etc.) and lead in the
meantime the power inverter. It can be easily installed on a
synoptic lectern and it is custom-programmed upon request.
INCLUDED:
> A mounting frame or a plastic case
> An operator control panel which includes:
- 8 keys
- 8 LED indicators
- 4 lines by 16 characters display
Specification
Part Number
With plastic case (240 x 190 x 90mm)
With mounting frame
REM306
REM305
Number of digital/analogue input lines
Number of digital input lines
Analogue entry level
Steps
Low logic entry level (digital mode)
4
6
0 - 10V
1024
5V
DIGITAL OUTPUTS
Number of digital outputs
Contact’s max current with resistive load
Contact’s max voltage rating
8
0.1A
48Vac
ANALOGUE OUTPUTS
Number of analogue outputs
2
Analogue outputs level
0 - 10V
256
Steps
WELDING PRE-PROGRAMMED FUNCTIONS
Approach SQD
1/100s
Approach SQZ
1/100s
Phases (weld1)
See data (WPH)
Preservation time
1/100s
Acceptability for voltage and current
0 - 100%
DEFINITION OF THE WELDING PHASE (WPH)
Ramp (slope)
0 - 255ms
Current value
0 - Base scale A
Sampling value
0 - 15V
Time
0 - 255ms
WAVEFORM PROGRAMMING
Binary or keyboard selection
COMMUNICATION PORTS
Number
Type
2
N.01 RS232 + N.01 RS485
REM Software Available
Software
Rev
Product
Description
R30HSW3C
1:02
HSW
Up to 32 different welding waveforms (max 3 phases each) can be saved . The software also
handles all the required HSW system input/output signals. Connection to the HSW machine is
through the RS232 serial connection working at 19200 bauds.
R30HSWCC
1:01
HSW
Special software for a machine working in a system with a load cell. Up to 25 different welding
waveforms (max 3 phases each) can be saved. The software also handles all the required HSW
system input/output digital and analogue signals for measuring crushing forces
(Newton/meter). Connection to the HSW machine is through the RS232 serial connection
working at 19200 bauds.
R30AWSMB
1:01
AWS
Standard software which handles all required arc welding system (AWS) input/output digital
and analogue signals.
CRS_Inverters_for_Welding_ENG_20101008
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Haicang District
Xiamen, Fujian
PRC 361022
ITALY
Via Scagnello 26
23885 Calco (Lecco)
Italy
MEXICO
Calle 23 No. 311
Fracc. Itzincab
Mérida, Yucatán
México 97392
Ph: +86 (592) 310 2555
Ph. ext: 8832
Fax: +86 (592) 651 8101
Ph: +39 (039) 991 0999
Ph. ext: 2103
Fax: +39 (039) 927 4399
Ph: +52 (999) 930 0270
Ph. ext: 1814
Fax: +52 (999) 930 0293
chinasales@crspower.com
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