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31

1

Connection wire drive

2

Ethernet

3

Welding current bushing

4

Connection designations, see 
chapter 2.

5

ext. Cooling, optional

6

Tandem, optional

7

Coolant supply and return

8

Mains connection

9

Seam tracking

10

Maintenance access Pump

11

Coolant drain cock

12

Inspection window coolant

13

Coolant filler neck

1

2

3

4

5

6

7

8

9

10

11

12

13

Figure 7.  Rear view QINEO Champ Pro

Summary of Contents for QINEO

Page 1: ...En This is a translation of the original operating instructions WP L 02 19 Rev 1 1 Keep for future use OPERATING INSTRUCTIONS QINEO CHAMP Pro...

Page 2: ...Carl Cloos Schweisstechnik GmbH Carl Cloos Strasse 1 35708 Haiger GERMANY Telephone 49 0 2773 85 0 Telefax 49 0 2773 85 275 E mail info cloos de www cloos de...

Page 3: ...in the directives applied is verified with conformance to the following standards and regulations Major conversions and add ons which are not carried out by the manufacturer or the manufacturer s auth...

Page 4: ......

Page 5: ...5 Qualification of users 28 Block 2 Basic information Qineo Champ Pro 29 1 Connection overview welding power source 30 2 Connection overview optional interfaces 32 3 Connection overview QWD M4 33 4 Co...

Page 6: ...Expert Mode 66 8 MAIN Measured values 67 8 1 Operating data 67 8 1 1 Data set switching 1 2 68 8 1 2 Seam counter Setup 69 8 1 3 Consumption costs 70 9 MAIN Display 70 10 MAIN 2 Config Configuration...

Page 7: ...rite an existing job 107 15 3 Copy a job 107 15 4 Activate job 108 Block 4 Additional information 109 1 RC Plus Remote Control 110 2 MHW 405 TQ 2 button torch 111 3 SD module 112 3 1 Monitoring channe...

Page 8: ...1 1 2 Semi annual testing 162 1 3 Annual testing 162 1 4 Special testing 163 1 4 1 Optional filter mat in the cooling unit 163 1 4 2 Crane suspensions at the wire drive unit 163 1 4 3 Electrolytic cap...

Page 9: ...amming QINEO welding power sources 172 3 4 1 Select operating mode Tandem 172 3 4 2 Adjustment of the synergy variant 174 3 4 3 Active QWD setting 175 4 Pulse synchronisation 178 4 1 Configuration 178...

Page 10: ......

Page 11: ...11 Operational safety Block 1 Operational Safety...

Page 12: ...urces and the accessories in the QINEO series have been developed designed and manufactured according to the generally accepted safety regulations This is confirmed by the declaration of conformity an...

Page 13: ...y damage CAUTION Describes a probably dangerous situation which may result in minor injury or damage to property WARNING Describes a probably dangerous situation which may result in severe injury or e...

Page 14: ...y regulations BGV D1 Safety regulations BGV A3 National and regional fire protection rules Works on supply voltage repairs and maintenance must be carried out by qualified personnel only electricians...

Page 15: ...helmet and gloves as well as solid well insulated work shoes should be worn 3 3 1 Danger due to electromagnetic fields EMF According to the Accident Prevention Regulations BGV B11 Electro magnetic fi...

Page 16: ...quirements in industrial and residential areas including residential areas connected to the public low voltage supply network Class A machines are not intended for use in residential areas where elect...

Page 17: ...pplying parts in regular intervals Use fume extraction systems Pay attention to the national and regional safety regulations 3 3 5 Fire prevention explosion Remove all flammable materials around the w...

Page 18: ...l information An electric shock can prove fatal Basically every electric shock is extremely dangerous Do not touch live parts within or outside the power source During MIG MAG welding the welding wire...

Page 19: ...f the cover or side panel The cross section of the connection cable must be adequate The machine must be connected to a three phase four wire system with earth conductor and operated Connection to ung...

Page 20: ...ns voltage 400V Only the welding torch and wire drive unit may be installed and operated in such places Depending on the process used it may happen that there is an addition of the two open circuit vo...

Page 21: ...s The functioning of the protective conductors the supply network and machine cables must be checked before commissioning and in regular intervals by a skilled electrician It is regarded as gross negl...

Page 22: ...y welding currents see Figure 4 and Figure 5 1 Welding power source 2 Workpiece 3 Welding table earth connected The welding current flows via the protective conductor of the welding power source if th...

Page 23: ...and in the building installation are hereby destroyed If possible use a potential compensating line with a high cross section Please observe the following points to prevent stray currents Fasten work...

Page 24: ...be opened or removed during maintenance or repair works Make sure that during operation all covers and side panels are closed and duly assembled by means of toothed coni cal spring washers earthing Be...

Page 25: ...ix the original coolant with other coolants to prevent a chemical reaction which could clog the cooling circuit and damage the coolant pump The manufacturer is not liable for such damages Pay attentio...

Page 26: ...air filter mats if environmental conditions with increased fuses aerosols metal dust etc are concerned The user must regularly check the degree of soiling of the filter mat Dirty filters must be repl...

Page 27: ...machine should be stored in a dry and clean room The ambient temperatures must not exceed 200 C and 450 C In case of a longer storage the machine should be covered with a suitable foil In principle t...

Page 28: ...er is not liable for damage to property or persons caused by unqualified personnel The copyright law for the safety regulations and the operating instruction manual remains with the manufacturer Text...

Page 29: ...29 Block 2 Basic information Qineo Champ Pro...

Page 30: ...CHAMP Pro 30 1 Power switch 2 Operating module 3 Connection socket Negative cable Figure 6 Front view QINEO Champ Pro 1 2 3 1 Connection overview welding power source...

Page 31: ...ns see chapter 2 5 ext Cooling optional 6 Tandem optional 7 Coolant supply and return 8 Mains connection 9 Seam tracking 10 Maintenance access Pump 11 Coolant drain cock 12 Inspection window coolant 1...

Page 32: ...eriphery CAN X7 Seam tracking X33 Gas nozzle sensor X34 OMI X70 Tandem Pulse synchronisation X32 Qineo Pulse Pro Qineo Champ Pro Standby for external cooling X40 DeviceNet X74 ProfiBus X72 ProfiNet X7...

Page 33: ...ule 9 6 8 5 7 4 3 2 1 10 16 13 12 18 17 15 14 8 7 6 5 4 2 1 3 1 Torch cable assembly connec tion here EURO connection 2 Blow out connection for EURO connection 3 Torch trigger connection for SZ connec...

Page 34: ...cylinder support for standard gas cylinders The connections for the torch cable assembly are located at the front of the QWDM or QWDA wire drive unit A liquid cooling for the torches is standard in t...

Page 35: ...erating module This function enables to generate a 2nd parameter set Then it is possible to constantly change between the two parameter sets with a defined frequency It is possible to correct the arc...

Page 36: ...such as MIG MAG welding machine possibly cable assembly with wire drive unit MIG MAG welding torch shielding gas cylinder and reducing valve have to be assembled In the case of welding machines with...

Page 37: ...ds on the process and material and ranges between 8 and 16 l min If the Qineo Champ Pro is connected to a central gas supply system closed circular pipeline the reducing insert bore hole 0 6 mm in the...

Page 38: ...essure unit as is necessary for the relevant wire type and size The adjustment is reproducible The pressure roller clips arms swing out for threading the wire or exchanging the wire drive rollers Both...

Page 39: ...hoses are filled when the pump runs When using very long cable assemblies the resulting loss of water in the storage tank must be replenished Please note the maximum coolant quantity level The cover...

Page 40: ...lected separately The symbol Dustbin on wheels indicates the necessity of waste separation In Germany old appliances from private households can be handed in free of charge at the local collection poi...

Page 41: ...A 450 600 U2 60 secondary V 36 5 44 I1 60 primary A 33 1 53 9 S1 60 primary kVA 22 4 36 3 Data 100 duty cycle I2 100 secondary A 350 465 U2 100 secondary V 31 5 37 5 I1 100 primary A 22 4 34 5 S1 100...

Page 42: ...CHAMP Pro 42...

Page 43: ...4 7 MAIN Progr Programming 55 7 1 Parameters in the operating modes 2 cycle and 4 cycle 57 7 2 Parameters in the operating mode Super 4 cycle 57 7 3 Parameters in operating mode Spot Welding Interval...

Page 44: ...8 Config Clock 91 10 9 Config Process monitoring 92 11 MAIN 2 Diagnostics 93 11 1 Diagnostics Cooling 94 11 2 Diagnostics Software versions 94 11 3 Diagnostics I 0 Inputs and Outputs 95 11 4 Diagnost...

Page 45: ...ide enables simple operation even when programming extensive welding tasks Item Description 1 Function keys F1 F8 2 Colour LCD display 3 LED arc start 4 Rotary knob 1 power wire speed 5 Keys Esc MAIN...

Page 46: ...er The wire speed is increased the arc becomes shorter Definition Dynamics By turning the rotary knob 2 the operator can influence the shape of the arc In the positive setting range the arc becomes co...

Page 47: ...e provides the following operating modes 2 cycle 4 cycle Super 4 cycle Spot welding Interval External 4 1 2 cycle Operating mode 2 cycle is provided for short manual welds 1st cycle Press torch trigge...

Page 48: ...flows Wire drive unit switches to the preset wire speed 2nd cycle Release torch trigger Execution of start program and upslope if required Welding process continues with the adjusted main parameters...

Page 49: ...h cycle Release torch trigger again Change from main parameter to the end parameter via a time func tion Downslope the end parameter time is executed Wire drive unit stops Welding voltage is switched...

Page 50: ...to select the welding current The displays for wire diameter and material thickness are masked out 5 3 Speed Pulse In the SpeedPulse mode the regulator settings are chosen in such a way that a hard an...

Page 51: ...and the negative share of the alter nating current All other parameter settings required are done by means of the control processor This enables MIG MAG pulse welding of thin sheets in the range of a...

Page 52: ...ry deep penetration The following characteristic curves are available as Rapid Weld variant Normal Fe 92 Ar 8 CO2 wire 1 0 mm Normal Fe 92 Ar 8 CO2 wire 1 4 mm Normal Fe 82 Ar 18 CO2 wire 0 8 mm Norma...

Page 53: ...Mode single parameter mode on page 64 6 2 CleanStart Clean Start is a special ignition routine which ensures a reliable and low spatter arc ignition The complete ignition routine runs in the milliseco...

Page 54: ...gas valve is switched on manually The function is activated deactivated by a short key press If the button is pressed for more than 0 5 s the function is only active as long as the but ton is pressed...

Page 55: ...llow time Green m min step size Red power In the programming mode you can access the next or previous parameter by shortly tapping on the arrow buttons A graphic display is integrated for better orien...

Page 56: ...lue with the corresponding physical size is shown in a separate line see example Figure 12 When times are corrected yellow LED an OFF is displayed after 99 The function e g Start program is switched o...

Page 57: ...entered in addition 7 2 Parameters in the operating mode Super 4 cycle Function Correction value Gas pre flow Off 99 Inching in 99 Start program time Off 99 tor Start program power 99 Upslope Off 99...

Page 58: ...alue a second weld parameter can be generated which is higher or lower than the basic value By means of a defined frequency there is a switch over between the two parameter sets The appearance of the...

Page 59: ...Interval time Absolute value 0 99 9 sec Display only if the function is active A Spot welding time between 0 99 9 s can be selected with rotary knob 3 By tipping the arrow button on the right you can...

Page 60: ...or end crater power The Setting range function appears see Figure 16 Synergie Betr Verfahren Funktion M A I N Progr Messwerte Anzeige Puls 4 Takt Dyn 8 5m min 2 4 V 0 A 1 2 mm Fe 82 Argon 18 Co2 0 0...

Page 61: ...the setting ranges As soon as setting ranges are configured they are available for the Pro grammer or Automatic operating levels Activating the setting ranges for the Automatic operating level To use...

Page 62: ...on 18 Co2 0 0 Zugangsverwaltung Optionen Bedienlevel Automatik Schweissen freigeben Job aufrufen freigeben Handrad Leist Fein freigeben Job speichern sperren Figure 18 Config Access management Options...

Page 63: ...uring the Tandem op erating mode see section Basic configuration Operating mode Tandem on page 169 If the Expert Mode function is active the function is under MAIN Pro gramming 2 7 6 MAIN Programming...

Page 64: ...been transferred to the Expert Mode If there is a change between Synergy mode and Expert Mode the changed parameters are retained in the respective mode The secondary parameters are set by means of r...

Page 65: ...eters MAG Normal Pulse S Pulse Time duration x x x Upslope x x x Wire speed Downslope x x x Gas pre flow x x x Gas post flow x x x Inching in x x x Ignition mode x x x Voltage x Choke x Burnback x x x...

Page 66: ...hown in the display In the position Wire the 2nd parameter set is generated only by modifying the wire speed DP frequency The selected frequency is used to switch between the selected original paramet...

Page 67: ...lues for wire weight wire costs gas costs and energy costs must be entered in the Cost rates menu item The numerical values are selected by means of rotary knob 3 By pressing the rotary knob 3 you can...

Page 68: ...mm 6 2 g 1 2 mm 8 9 g 1 6 mm 15 8 g Aluminium solid wire 1 m 1 0 mm 2 1 g 1 2 mm 3 1 g 1 6 mm 5 4 g CuSi solid wire 1 m 1 0 mm 6 7 g 1 2 mm 9 6 g 1 6 mm 17 1 g Steel flux cored wire 1 m Metal powder 1...

Page 69: ...r Betriebszeit 12 47 Std Verbrauchsdaten ab Reset 1 Schweissn hte 0 Verbrauch Kosten Datensatz umschalt 1 2 Kosten s tze Schweisszeit 10 17 Std Aktuelle Naht 12 4 Sek Schweisszeit 0 0 Sek Draht 0 00 m...

Page 70: ...basis of the wire speed value The Sheet thickness display shows the possible sheet thickness to be welded It can only be used as a rough reference to determine the cor rect parameters The sheet thickn...

Page 71: ...0 C Start Blechdicke 8 5 mm ASet 230 A VSet 27 9 V Synergie Betr Verfahren Funktion M A I N Progr Messwerte Anzeige Puls 4 Takt Dyn 8 5m min 2 4 V 0 A 1 2 mm Fe 82 Argon 18 Co2 0 0 C Start Blechdicke...

Page 72: ...Power Fine arc length Dynamics and Job can be activated and varied by the torch triggers during the welding process Except for the Job setting parameter the interval and step size can be adjusted on...

Page 73: ...to the external cooling Function Description Automatic Depending on the thermal load the calculator of the welding power source controls the running time of the cooling pump and the fan On As soon as...

Page 74: ...ng torch equipped with a potentiometer can achieve in the TIG welding process 10 3 1 Config General Basic settings Display Konfig Allgemein 3 ab V10 Puls 4 Takt V 0 A 1 2 mm Fe 82 Argon 18 Co2 0 0 Kon...

Page 75: ...process selection Name Function Off If two different processes are executed at the same time with a Tandem torch If variants of synergy characteristic curves are used If a correction value for Upslop...

Page 76: ...After the Reset the text will be highlighted yellow 10 3 1 1 Config General Basic settings Tandem Define in this menu item whether the welding power source shall be Mas ter or Slave during Tandem ope...

Page 77: ...os Arcette 2 Binzel PP 401D TBI PPP 7G 7W Dinse DIX MPZ 304 Not defined Blocked drives will be displayed in red in the selection These drives may be activated optionally Puls 4 Takt V 0 A 1 2 mm Fe 82...

Page 78: ...on the processor of the welding power source de tects the activated software options in the option chip e g Release Pulse ExpertMode Operating data Push Pull systems etc see Figure 36 If you intend t...

Page 79: ...n is correct the newly activated option is listed in the Activated options overview If an error occurred during the transmission or input of the activation code the error message 317 Wrong activation...

Page 80: ...monitored The limit value is set in C The limit value should not exceed 60 C The start delay allows a trouble free recording of the measured values In addition an error must exist for a certain error...

Page 81: ...etting is 13 m Total cable length The cable lengths of the connection cable assembly minus line earth and torch cable assembly are added and entered as numerical value Based on the cable length the we...

Page 82: ...Enable measurement The controller changes to the measurement mode 3 Place the torch head firmly on the workpiece The current tip must touch the workpiece 4 Press the torch trigger or select the menu i...

Page 83: ...this management system Use the arrow symbols to switch between the individual menu items The access management of the welding power source has 3 operating levels Automatic Programmer and Configurator...

Page 84: ...t ic Programmer and Configurator The access options are described at the beginning of this paragraph Automatic log off of configurator To protect the welding power source against unauthorised access y...

Page 85: ...password by calling the CLOOS Service Hotline You can now enter again the code num ber 10 6 2 Config User management and PAK option The access rights for certain functions adjustments and welding para...

Page 86: ...allowed to log in at the weld ing power source Information of unknown users are saved at the welding power source Not allowed Only users who are listed in the configuration of the welding power source...

Page 87: ...f password via keyboard In this menu item you can select the following functions Name Function Allowed default The manual input of a 6 digit code number at the welding power source is allowed Not allo...

Page 88: ...rs 10 6 2 2 Config User management User overview You can only do changes in the Config User management User overview menu if you are logged in at the welding power source with the Configurator operati...

Page 89: ...3 2 Press the Delete user function This is done without any further query If the last user with operating level Configurator is deleted the error message Last configurator locked appears This prevent...

Page 90: ...tion MAIN If a PAK is assigned to a user the user can log on to the welding power source with the PAK Only the functions which are released for this user are available INFO Figure 47 PAK Programming P...

Page 91: ...r an exact data recording during weld data monitoring the exact time and the correct data are important You can enter this data in the Config Clock menu Use the arrow symbols to switch between the ind...

Page 92: ...he error message Err 24 Arc failure ignition phase will appear on the display You have the following options Off When the ignition control is off wire feed will continue in case of a trouble signal Re...

Page 93: ...g power source Display of Tandem state and Tandem configuration Display of the configuration of pulsed arc synchronisation Display of the entries in the system logbook Display of the robot communicati...

Page 94: ...nternal or external cooling is ac tive 11 2 Diagnostics Software versions In the Software versions menu the design of the welding power source the power class and the data set number are displayed The...

Page 95: ...StoreYes CurrentYes EndWeldVolt SystemFault TempFault CollectFault ReadyforWeld ProcessActive Watershortage Waterflow GasNozzContact SD CollectFault CollectFault Gr 1 Collect Fault Gr 2 WireFailure Cu...

Page 96: ...ual input of sig nals can be activated The signal state can be switched on or off by using the On or Off function If the input or output is active the box is shown red framed Pressing the Normal funct...

Page 97: ...E A Modul Reset Station Name Status Info QINEO EIN Ausgangsbytes Modul Typ ProfiNet IO 2 Status XXX Firmware V0 00 00 IP Adresse 000 000 000 000 Subnetzmaske 000 000 000 000 Eingang XXX Ausgang XXX F...

Page 98: ...e welding power source D I A G N O S E PC Anpassung Puls 4 Takt V 0 A 1 2 mm Fe 82 Argon 18 Co2 0 0 Ethernet Steuerung MAC Adresse 00 00 00 00 00 00 IP Adresse 000 000 000 000 Subnetzmaske 000 000 000...

Page 99: ...ontains the following information Time stamp The time stamp of the logbook entry At this time the welding power source saved the entry in the logbook User The user who was active when the entry was sa...

Page 100: ...archived or are copied again later into the data management of the application The date for every logbook is indicated in the menu Diagnostics System logbook Logbook selection The number of entries i...

Page 101: ...rve selection gas kind of wire etc This counter is off during job mode Commands Special commands determine the protocol version switch etc Connections Number of the connection attempts VBC command dig...

Page 102: ...he card slot below rotary knob 3 Press the function Read from card All language files on the SD memory card are displayed Select the required language file by means of rotary knob 3 and confirm the se...

Page 103: ...n by pressing rotary knob 3 Enter function The job will be saved on the SD memory card Save several jobs Use the function from Job to select the beginning of the block e g Job 1 The display shows Bloc...

Page 104: ...unctions Syn Card After activating the function the current characteristic curve is saved on the SD memory card DSA Card After activating the function the current data set number is saved on the SD me...

Page 105: ...access code in the lower part of the dis play The access code is activated by pressing rotary knob 3 After 5 unsuccessful attempts to enter the password an 8 digit code num ber appears below the Acce...

Page 106: ...ss 5 Geh use Nr 495868 6 No Name 7 8 9 10 No Name Job 10 Job 10 Job 100 Job 100 Job L schen Job Name J O B S P E I C H E R N Normal 4 Takt V 0 A 1 2 mm Fe 82 Argon 18 Co2 0 0 1 CLOOS Innovation 2 Quer...

Page 107: ...character in the character table Shortly press rotary knob 3 to transfer the character to the upper line Once you have selected all characters confirm your selection with the Enter function The job is...

Page 108: ...knob 3 Press the job button again or the rotary knob 3 to activate the selected job The LED on the job button lights up The job number and job name are displayed in the lower part of the MAIN menu If...

Page 109: ...109 Block 4 Additional information...

Page 110: ...l Figure 68 RC Plus 1 2 7 8 5 3 6 4 1 Quick save memory keys 1 4 2 Multi functional key hold value display selection actual value display 3 Selection key Processes 4 Selection key Operating modes 5 Jo...

Page 111: ...ion menu of the welding power source to determine which of the following parameters shall be changed in which step width and speed by means of the remote control Power Fine adjustment ArcLength Dynami...

Page 112: ...wachung M A I N 3 Puls 4 Takt V 0 A 1 2 mm Fe 82 Argon 18 Co2 0 0 SD ber wachung M A I N 3 Puls 4 Takt V 0 A 1 2 mm Fe 82 Argon 18 Co2 0 0 Figure 70 Menu 3 SD module 3 1 Monitoring channels Anzeige So...

Page 113: ...n that the QWD feed capacity is too high if the measured value is below the set value So the CDD ROB wire drive unit slows down It may be an indication that the QWD feed capacity is too low or the fri...

Page 114: ...sensor signal Ignition After the start command given by the robot or the peripheral equipment PLC the signal Arc on must be transmitted within the selected ignition time from the power source controll...

Page 115: ...ule OMI module Profi Bus Profi Net Device Net A bus system Profi Bus Profi Net Device Net is necessary to transmit digital data to the reserve channels of the SD module The value range is divided into...

Page 116: ...es Load Default values of an SD configuration Enter a component name Reset the seam counter to 0 Or change the value of the seam counter via the middle rotary knob manually You can enter a 20 digit na...

Page 117: ...toring channels can be combined in groups Thus it is possible to allocate different priorities to the individual monitoring channels Turn the middle rotary knob to select a monitoring channel Press th...

Page 118: ...ner Set value The set value indicates the default value Warning range The value e g 5 A indicates the section from the warning range to the limit range where a warning message is displayed in the oper...

Page 119: ...12 Zeit 7 8 Sec Drahtvorschub 11 4 m min Strom 255 A Spannung 35 V Gas 14 8 l min Motorstrom QWD 1 5 A Logbuch Auswahl Keine Fehler Puls 4 Takt V 0 A 1 2 mm Fe 82 Argon 18 Co2 0 0 Puls 4 Takt V 0 A 1...

Page 120: ...1 2 mm Fe 82 Argon 18 Co2 0 0 13 12 2010 L O G B U C H Uhrzeit 10 35 47 5 11 Bauteil Unterbodengruppe Naht 12 Job 10 ohne Pulse Zeit 7 8 Sec Drahtvorschub 11 4 m min Strom 255 A Spannung 35 V Gas 14...

Page 121: ...s Normal 4 Takt V 0 A 1 2 mm Fe 82 Argon 18 Co2 0 0 13 12 2010 F E H L E R Uhrzeit 10 35 47 1 2 Bauteil Unterbodengruppe Naht 12 Zeitpkt 4 8 Sec Dauer 1 8 Sec Drahtvorschub Grenzwert Max 12 4 m min Gr...

Page 122: ...onitoring channel using the middle rotary knob The submenu SD data opens 4 Turn the middle rotary knob to allocate a group to the monitoring channel 5 Use the arrow keys to select the individual param...

Page 123: ...das aktuelle SD Logbuch Start Schwei prozess blaue LED leuchtet Einschleichen Liste 1 Zeit Achse berwachung SD Schwei zeit berwach Startverz gerung Schwei parameter Z nd berwachung Schwei parameter Dr...

Page 124: ...124 SD module...

Page 125: ...Gas manually 133 5 1 1 Adjustment of the gas flow rate 133 5 2 Button Wire forward or Wire backward 134 6 Commissioning 135 6 1 Safety instructions for commissioning 135 6 1 1 Risks due to mechanical...

Page 126: ...up to 50 at 40 C Information on spare parts and consumables as well as circuit diagrams of the individual wire drives and wire feed units can be found in the spare parts documentation for the QINEO w...

Page 127: ...files to stiffen the housing The interior of the wire drive unit is accessible via a stable cover which is fastened on the housing body by means of solid hinges For safety reasons the cover is equippe...

Page 128: ...ssembly connection 2 Torch cooling flow 3 Torch cooling return 4 Wire inlet 5 Welding current connection 6 Quick coupling cooling return 7 Quick coupling cooling flow 8 Quick coupling gas 9 Socket to...

Page 129: ...he QINEO Wire Drive A was specially developed for industrial robot ap plications Options EURO DINSE connection Weld data monitoring CLOOS Duo Drive CDD Wire end control Installation kit A4 CLOOS MoTio...

Page 130: ...ard 9 Button Wire backward 10 Cooling water connection red 11 Cooling water connection blue 12 Power connection 13 Cooling water connection blue 14 QN WF 22 HD 15 Cooling water connection red 16 Gas c...

Page 131: ...mounting on or at the shoulder joint of industrial robots This ensures an optimum welding wire feed especially in the field of hollow shaft robots Despite the comprehensive equipment with different se...

Page 132: ...ection 6 Connection for collision protec tion gas nozzle sensor etc 7 Connection nipple blow out optional 8 Torch cooling flow 9 Torch cooling return 10 Wire inlet 11 Connection nipple blow out 12 Coo...

Page 133: ...This function enables the exact adjustment of the gas flow rate by means of a gas measuring tube 5 1 1 Adjustment of the gas flow rate Designation Function Gas measuring tube Measurement of the gas e...

Page 134: ...tons is pressed the wire feed motor switches on and accelerates from 1 m min to 7 m min in 3 seconds The welding wire is fed forward or backward The buttons are located on the inside or front of the w...

Page 135: ...ose hair can be caught by the drive rollers and cause severe injuries Wear fitted work clothing Do not wear jewellery Pull your hair back when working 6 1 2 Risks due to electrical hazards Risk of ele...

Page 136: ...ssure reducer on the gas cylinder In the case that a company is working with a central gas supply inlet pres sure 6 8bar the welding torch will not be provided with a sufficient gas quantity Therefore...

Page 137: ...se stab injuries on hand eyes or the face During the wire feeding you should always keep the welding torch in a position turned away from the body Please take care that the current tip is removed from...

Page 138: ...138 Commissioning 6 7 8 5...

Page 139: ...welding torch in a position turned away from the body Please take care that the current tip is removed from the torch Isolate the welding power source from the power supply before you start the change...

Page 140: ...140 Commissioning 7 5 6 The wire inlet must not touch the wire drive roller INFO...

Page 141: ...he wire feeding you should always keep the welding torch in a position turned away from the body Risk of electric shock If unrestricted access to the live single parts of the QINEO Wire Drive is possi...

Page 142: ...or defects which may lead to a hazard Prior to each start of the QINEO Wire drive please check The correct mounting of the current tip The correct mounting of the gas nozzle The screw connection of th...

Page 143: ...t at the pressure clamps Drive rollers worn Correct the pressure adjustment Change the drive rollers Undesired continuous wire feed or gas escape Button is possibly stuck because of dirt or deposits C...

Page 144: ...lin de Make sure to provide for safe and environmentally sound disposal of consumables and operational materials According to European directives Directive 2002 96 EC of the European Parliament and Co...

Page 145: ...145 Block 6a Error messages...

Page 146: ...0 0 C Start Blechdicke 8 5 mm ASet 230 A VSet 27 9 V Synergie Betr Verfahren Funktion M A I N Progr Messwerte Anzeige Puls 4 Takt V 0 A 1 2 mm Fe 82 Argon 18 Co2 0 0 F E H L E R 1 Fehlermeldung CAN Bu...

Page 147: ...Off and On Check cable connections Service 7 Error when loading the version data Operating module cannot call up the information of the control Switch machine Off and On Check cable connections Servic...

Page 148: ...nitoring check water flow rate Check limit values Refill coolant if required Ventilate pump Check cooling circuit Service 22 High water temperature Optional machine equipment Water temperature higher...

Page 149: ...4 Excess temperature water pump Ambient temperature too high or pump runs without coolant or coolant circuit is interrupted possibly pump faulty Let the machine cool down Check cooling circuit Refill...

Page 150: ...tion between control and ProfiNet module faulty Switch machine Off and On Check plug and connections ProfiNet Service 50 VBC Profibus failed Communication between control and ProfiNet module faulty Sw...

Page 151: ...are update Service 67 Software version IO module 1 out of date Software update required Software update Service 68 Software version IO module 2 out of date Software update required Software update Ser...

Page 152: ...up the information of the control Switch machine Off and On Check cable connections Service 189 No enable from control computer Time of initialisation in control computer exceeded 25 seconds Switch m...

Page 153: ...or connected Check plug and connections Check SD module Service 207 Sector size in data flash exceeded File size exceeded File not compatible with software Service 210 SD module Job not available Job...

Page 154: ...feed distance Check encoder Fuse 42V supply faulty Power supply board Service 259 QWD2 Desired rotation speed not reached Preset rotation speed not reached Encoder signals faulty motor movement Check...

Page 155: ...distance Check CDD cable connections Check encoder Fuse 42V supply faulty Power supply board Service 266 System External RAM memory error RAM chip on control board missing or faulty Service 267 Invali...

Page 156: ...Service 283 Tandem Slave failed No connection could be established to the Slave for 2 seconds Check Tandem connection cable Check Slave Service 284 Tandem System not ready Slave does not send any sign...

Page 157: ...of user data sets is reached No further user data sets will be created from a PAK Remove unused user data sets 600 Emergency stop 601 Safety stop 700 Software version QWD B1 1 out of date Software out...

Page 158: ...are version Software update Service 711 QWD B2 2 failed 712 Software version QWD B3 2 out of date Software out of date minimum V1 00 00 Check software version Software update Service 713 QWD B3 2 fail...

Page 159: ...159 Block 6b General maintenance instructions...

Page 160: ...160 1 Maintenance and Care 1 7 6 4 5 2 3 8 11 9 10 Optional external cooling unit 10 Optional crane suspension 3...

Page 161: ...ozzle base gas distributor current tip and gas nozzle Clean current tip and gas nozzle from dirt Damages and intact insulation of the torch neck of the manual welding torch Contact a qualified electri...

Page 162: ...e mentioned testing instructions the corresponding state laws regulations have to be met Control Remedy Weekly 2 The perfect function of the operating interface signal and control LEDs Contact a quali...

Page 163: ...r mat If the filter mat is very dirty change it Only use original CLOOS parts 1 4 2 Crane suspensions at the wire drive unit Check the crane suspensions for damages once a month If they are damaged ch...

Page 164: ...164...

Page 165: ...165 Block 7 Automation...

Page 166: ...d buses are industrial communication systems using different me dia such as copper cables fibre optic cables LWL and radio wireless By means of a bi serial transmission they are able to manage the con...

Page 167: ...es for the supply of the DeviceNet bus participants with 24 Volt operating voltage The bus participants can be supplied with power by bus or an external source The maximum length of the DeviceNet cabl...

Page 168: ...andem operation welding power sources with the protocol type 1 only support the Tandem process Tandem job selection Welding power sources with protocol type 2 support additional welding processes such...

Page 169: ...ding power source is configured as Slave and is only connected with the Master welding power source 3 2 Conditions All welding power sources involved fulfilled the following conditions PREMIUM operati...

Page 170: ...k side Arc adaptation 1 always master welding power source length correction more wire shorter arc Arc adaptation 2 always slave welding power source length correction more wire shorter arc Dynamics 1...

Page 171: ...the robot shall only set the job number but no other parameters 2 If the robot shall set the two parameters Arc length and Power 3 If the robot shall set the three parameters Arc length Power and Dyna...

Page 172: ...Tandem process INFO Synergie Betr Verfahren Funktion M A I N Program mieren Messwerte Anzeige Puls 4 Takt Dyn 8 5m min 2 4 V 0 A 1 2 mm Fe 82 Argon 18 Co2 0 0 C Start Blechdicke 8 5 mm ASet 230 A VSe...

Page 173: ...slave welds Both gas valves open only the slave arc is monitored the two welding power sources are moni tored S torch single wire torch T torch Tandem torch In the Tandem operating mode the S Pulse an...

Page 174: ...combinations please contact CLOOS department for Application Engineering The single wire process variants are named Standard It is recommended to adjust the option Tandem following in the slave weldi...

Page 175: ...tandard MIG MAG torch As an example the Tandem torch is connected to QWD1 and a single wire torch to QWD2 With a corresponding torch changing system you can automatically change between the torches Pr...

Page 176: ...Argon 18 Co2 0 0 P R O G R A M M I E R E N Startleistung Dyn 6 0 m min 0 6 2 Stell bereich Tandem Aktiver QWD Expert Mode Impuls Sync Puls 4 Takt V 0 A 1 2 mm Fe 82 Argon 18 Co2 0 0 Programmieren Akt...

Page 177: ...determine which QWD is actuated by the welding power source Name Function QWD number 1 4 The welding power source activates QWD1 4 for welding Puls 4 Takt V 0 A 1 2 mm Fe 82 Argon 18 Co2 0 0 Programm...

Page 178: ...s always corresponds to the own pulse time of the machine set by the synergy characteristic curve Every welding power source can set the frequency as pulse generator or as pulse receiver synchronise t...

Page 179: ...power source is available for synchronisation Pulse receiver The welding power source executes its pulses at the configured time depending on the pulse generator Asynchronous The allocation of pulse g...

Page 180: ...f of the pulse frequency Pulse receiver alternating The welding power source executes the pulse temporarily offset before or after the pulse of the pulse generator The offset depends on the set phase...

Page 181: ...ase shift of 50 Alternately synchronised pulse mode has a mostly positive influence on the process stability Pulse generator f1 Pulse receiver f2 alternating b2 Alternating 1 2 f1 f2 With this adjustm...

Page 182: ...synchronisation is used in connection with two or more individual processes a corresponding job has to be called in the weld ing power sources The following scenarios can be realised using the exampl...

Page 183: ...nd and the program selection job selection must remain identical in the robot controller Job number Wire in front Wire in the back Operating mode Tandem Seam track ing signal Synergy variant Pulse syn...

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