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CTR12000 Car-O-Liner

Group

41644, EN - rev. 2, 2012-09

General information on troubleshooting and remedy actions.

Only qualified electricians are allowed to open up power source and mains
plug.

ATTENTION!

Prior to any work on open power source, disconnect the

machine from the mains and discharge the intermediate circuit.

Fault

Possible cause

Solution

Workpieces stick to the electrodes.

Excessive welding current.

Reduce welding power.

Unsuitable electrode caps.

Use correct caps.

Insufficient electrode pressure.

Increase contact pressure.

Poor welding spot.

Insufficient welding current, welding time and/or
energy applied.

Increase welding current and/or time,
create special program with suitably
adapted parameters, if necessary.

Electrode pressure is too high.

Reduce contact pressure.

Electrodes are in poor condition, diameter is too
large.

Clean electrodes, reshape and restore
correct dimensions, replace electrode
caps, if necessary.

Wrong program has been selected.

Correct selection.

Wrong adjustment of total material thickness.

Correct adjustment.

Poor sheet position, not close-lying.

Correct

Welding spatter

Color or dirt between the sheets.

Clean.

Poor contact between the workpieces or
between the workpiece and the electrode

Increase electrode pressure.

Excessive welding current, welding time and/or
energy applied.

Reduce welding current, energy and/or
time, create special program with suitably
adapted parameters, if need be.

Current slope-up time is too short.

Increase slope-up time.

Electrode diameter is too large, worn electrode. Clean electrodes, reshape and restore

correct dimensions, replace electrode
caps, if necessary.

Insufficient electrode pressure.

Increase electrode pressure.

Burnt spots or spots with craters or
imprints.

Excessive welding current, welding time and/or
energy applied.

Reduce welding current, energy and/or
time, create special program with suitably
adapted parameters, if need be.

Insufficient electrode pressure.

Increase electrode pressure.

Deformed electrode caps.

Clean electrodes, reshape and restore
correct dimensions, replace electrode
caps, if necessary.

Poor sheet position, not close-lying.

Correct.

DANGER

Содержание CTR12000

Страница 1: ... 41644 rev 2 2012 10 EN CTR12000 Part 2 Welding menus and settings Instruction Manual ORIGINAL ...

Страница 2: ...la tions The equipment has not been altered or rebuilt without approval from Car O Liner AB Genuine Car O Liner AB spare parts are used in any repairs Operation and maintenance has been carried out according to the instructions in this manual All claims on warranty must verify that the fault has occurred within the guarantee period plus that the unit has been used within its operating range as sta...

Страница 3: ...9001 2008 and ISO 14001 2004 accredited organisation Below an example of how the EC Declaration of Conformity for the CTR12000 is outlined A signed and dated copy of the EC Declaration of Conformity including serial number is included in the documentation for the CTR12000 Please contact your distributor if you need a new copy of the Declaration of Conformity ...

Страница 4: ...Semi automatic ELMA QS 22 3 2 1 Pre Spot Operation program 26 3 2 2 Optional settings 27 3 3 Manual STANDARD conventional resistance spot welding 28 3 3 1 Using edge welding caps 29 3 4 Multi function welding gun optional tool SINGLE 30 3 5 Special automaker programs 32 3 6 Further adjustments 34 3 6 1 Description of settings in the ELMA QS mode 34 3 6 2 Welding process segments in ELMA QS mode 35...

Страница 5: ...ser unique operating convenience You may easily switch between different programs for different and also very demanding welding tasks and with the same convenience you may also adapt the pro grammed combination of parameters to special requirements 1 1 1 Display 1 The machine has a liquid crystal display LCD For detailed information on the different screens such as for the different welding progra...

Страница 6: ...lso use the rotary encoder to call these functions 1 1 4 Rotary encoder 4 The rotary encoder can be used to select all the welding functions being available For this purpose turn the rotary encoder until the desired function is displayed in a gray field Then press the switch for activating the corre sponding function or the selection menu windows based Depending on the menu the ESCAPE button at th...

Страница 7: ...r if the LED indicator QS Yellow and or QS Red lights up too QS RED YELLOW Indicates that the spot weld is faulty that there is a problem of insulation and that the welding operation has been interrupted during the preheating phase 1 1 6 USB Device 11 The USB Device offers most simple data transfer between operator and ma chine The data is downloaded on or uploaded from a USB Stick See chapter 3 8...

Страница 8: ...pot welding error 15 Indicates faulty spot weld welding could not perform because of full or part insulation or welding time outside the QS limits Reset button Q For error acknowledgement 1 1 8 Selector switch for Welding power I kA 18 The potentiometer Power I kA has two functions 1 In Manual STANDARD welding mode conventional spot welding the welding current is adjusted by means of the potentiom...

Страница 9: ... 2012 09 9 1 1 9 Selector switch Time t s 19 While in the STANDARD welding mode conventional spot welding this potentiometer is used to preset the welding time on a scale in t s For all the other operating modes this potentiometer has no function ...

Страница 10: ... program BASIC C gun C 80 arm electrode CAP 13 mm and welding operation AUTOMATIC The integrated welding programs that are stored in the physical welding da tabase have write protection They can however be used to create personal ized welding program see 3 7 while being in the EDIT mode Additionally you may create personalized welding programs to be saved as follows Up to 99 synergic user programs...

Страница 11: ...on the screen 2 3 Operating mode AUTO Running mode The AUTO mode allows welding programs to be selected via synergic se lection parameters welding process task selection and tong This operating mode does not allow program modification but the selection of invariable programs or while in the ELMA QS mode to adapt the total plate thickness and thus the synergic background parameters to the welding t...

Страница 12: ...2 41644 EN rev 2 2012 09 If you are interested in the Expert operating mode please contact your local Car O Liner distributor which will be pleased to offer you instructions and if necessary more detailed information about this mode ...

Страница 13: ...ed sheet metal By pressing the gun trigger and closing the tong a complex measuring system starts its work It is able to collect the total thickness of the material which should be welded and with the start of the current flow it recognises if there is a normal or high strength steel between the electrode caps within some milliseconds For that the machine controls the welding process fully automat...

Страница 14: ...c welding process you have to do the following adjustment 1 Choose CHECK EL in the task menu 2 Choose the connected tong and electrode arm The following adjustments are possible 3 Choose electrode cap Attention C 40 is not used in VISION VISION EDcoat mode Standard version VW version BMW version ...

Страница 15: ...use otherwise the puls sonar system which is integrated in the tong could not collect the total thickness of the material and the right parameters that are needed are locked If the EDIT key is on EDIT an error message red fault light would also be shown which has to be quitted by the user Attention Always use new or clean electrode caps when making CHECK EL ...

Страница 16: ...yed with the LED s of the QS traffic light and the LED s tool and electrode in the lower control panel If the machine has performed the CHECK EL successfully change the adjustment to menu task WELDING Now the machine is ready to start welding By pressing the soft key F5 you change to display mode ...

Страница 17: ...displays the signal spot error red error code 16 Partwise isolation the welding current do not flow the direct way from the electrode through the metal sheets but a detour Then a preheating is acti vated automatically which heat the metal sheets and through maceration or evaporation burns through the glue or varnish rest at the spot area The term of that phase the yellow light keeps lighting If th...

Страница 18: ...welding following signals could appear a green code 10 the resistance is between the reference resistance and the presetted maximum resistance b green after yellow code 11 resistance is higher than the presetted maximum resistance If the resistance by reaching the target energy lower than the reference resistance there is a bypass on the workpiece and the virtual machine calculates the seize of th...

Страница 19: ...rror 16 F16 Total Isolation Error 17 F17 Measured value out of Tolerance Error 18 F18 Key switch on EDIT Setting Error 19 F19 Starting energy too low Error 20 F20 Start button not activated Error 21 F21 Test cycles not successfull Error 22 F22 Critical time reached Error 23 F23 Sheet thickness lower 0 1 mm Error 24 F24 No valid Check values Error 25 F25 No Isolation breakthrough after Pre heating ...

Страница 20: ...a usual current time control are displayed with a yellow light during the pro cess After the process stops the yellow light is replaced usually by the green light if the CTR12000 control system finish the process successfully Intermediate messages yellow could appear if e g to breakthrough a part wise isolation or the resistance characteristic is higher than generally ex pected Attention Exceeding...

Страница 21: ...leaking water is collected e g with a drapery Please also pay attention with the arm connection surface At the connection surface up to 12 000 A could be transferred Any impurities on the connection surface should be removed with a fine sandpaper to prevent any interference in the current flow ...

Страница 22: ...ashing on the lower control panel the current tong needs to be calibrated This calibration is necessary for pre cisely determining the process impedance during the welding process and for checking the tool tong used After you have selected CHECK EL from the menu Tasks and gun set up press the start button to initiate calibration DO NOT FORGET that the calibration must be made with clean copper bri...

Страница 23: ...y phase has been ini tiated for the primary fuse After the recovery time has expired the LED goes automatically out and the restart of the machine is released This proce dure prevents in a reliable way any overheating of the mains fuse and the mains supply connection cable After successful current tong calibration select WELDING from the Tasks menu The key operated switch must be in position AUTO ...

Страница 24: ...welding current energy and pressure in the back ground The value set with the second potentiometer Time t s is not con sidered with this procedure For positioning the welding tong on the work piece the tong may be opened and closed without current by pressing and releasing the start trigger up to and from the first action point please refer also to part 1 of the operating manual Setting up the wel...

Страница 25: ...time limit had been reached Welding operation is interrupted and stopped if the energy applied after half welding time is only half the set point QS YELLOW Indicates during welding operation that the program is branching into the preheating segment QS YELLOW RED Although the program has branched into the segment PREHEATING weld ing operation has not been successfully completed Possible causes insu...

Страница 26: ...nd Tool light up as soon as this maximum number has been achieved or the LED Electrode lights up and any further welding operation is blocked to allow inspection and if necessary replacement of the electrode caps Such inspection and replacement is only possible while the power source is OFF and consequently the error message will be reset only after the power source has been switched off and on Af...

Страница 27: ...ey END further optional settings can be performed The screen indicates besides the selection menu whether the selected combination can be welded by displaying the accord ingly defined program or the BASIC PROGRAM If more than one pro gram is available the selection arrow appears on the screen Several selectable programs are displayed according to the following priority scheme 1 JOB 2 X programs cu...

Страница 28: ...conventional resistance spot welding Welding current and time are adjusted afterwards exclusively by means of the two po tentiometers Power l kA and Time t s on the corresponding scale ob serving plate thickness and material For recommended welding values see table on page 31 see also decal on the front cover Experienced values serve as setting parameters Attention C 40 is available only in STANDA...

Страница 29: ...ending on sheet thickness Attention If the welding spots are placed on the edge of the heat moulded metal sheets see picture above the metal sheets joints will be altered by the increased temperature which will affect collision characteristics in a negative way To avoid this the welding spots must be placed as far inward as possible With edge welding caps the OEM repair manual demands for the a me...

Страница 30: ...iven below We recommend checking individual settings by doing welding trials on test material before welding on vehicles We recommend checking individual settings by doing welding trials on test material before welding on vehicles The Single side gun adapter for the C X Gun should be clamped between the electrodes of the gun by pressing the gun trigger once with the polarity as guided on the adapt...

Страница 31: ...on gun is exclusively designed for repair work on car bodies Since the gun is not water cooled an overheat protection device thermostat has been fitted that is triggered at thermal overload and prevents the machine from being restarted The cooling down phase following such overheating can last up to 20 minutes until the machine restart is released C tong Multi function gun ...

Страница 32: ...t operation from the menu Welding process The following screen is then displayed The different special automaker programs can be selected from the field to the right of the parameter PROGRAM and generally run under Welding These kinds of program are not freely adjustable like the ELMA QS They in fact are a set of precisely defined parameters for one special welding task ...

Страница 33: ...t welding procedure ELMA QS When the impurities is too thick the welder will not allow welding For this reason it is recommended to use Pre Spot Operation PSO This operation will eliminate all impurities such as ED coat dirt thin bond ing thin rust etc The program to be selected for the different welding tasks is determined by the automaker and given in his parameter documentation for car repair z...

Страница 34: ...1 Description of settings in the ELMA QS mode The menu item FURTHER ADJUSTMENTS contains the sub menus to the individual program segments The sub menus allow the following parameters and synergic parameters see also chapter Editing synergic characteristics to be adjusted Menu 1 Menu 2 ...

Страница 35: ...lding process segments in ELMA QS mode The welding process is divided into individual segments that are displayed on the screen The figure below shows their chronology during welding op eration 3 6 3 Welding process segments in the VISION mode Time t TEST PRE PULSE ...

Страница 36: ...tant for current slope up and time constant for current slope down A Point is defined as the synergic parameters that are regis tered and saved for one power value Up to 20 points can be saved without prescribed order for creating a characteristic The computer computes and indicates the intermediate values between two points from a line equation The parameters of a characteristic for those power v...

Страница 37: ...ss the fol lowing screens will appear Synergic characteristics for the most common welding jobs have already been drawn up and memorized by the manufacturer If need be they can be adapted to customer s requirements Any modification of data fields synergy or other parameters made in the EDIT mode is marked with and displayed between two asterisks and stored in the computer s buffer memory Modified ...

Страница 38: ...ady saved data from being overwritten To this purpose activate the window RENAME The following alphanumerical field opens up and allows you to enterer the new name In this mask you may activate different fields to produce the following ef fects STORE New synergic parameters are saved and already memorized pa rameters are overwritten To save a program just click the symbol on the left side of the i...

Страница 39: ... required Depending on the automatically collected total thickness of the material the database provides 35 physical parameters for each welding process which are controlled by the control system Virtual Machine The characteristic curves which are generated by the virtual generator effect a drastic compensation of splatters also with a combination of long electrode arms with a lower electrode forc...

Страница 40: ...nergy required After that save this working point as a job named from J01 to J99 If required the welding pa rameters of a saved job can always be corrected in the EDIT mode and working points can even be completely deleted or overwritten Welding machines disposing of suitable optional interfaces can be used for welding operation via remote control unit or with welding robots If such an automatic w...

Страница 41: ... a window opens up and shows the existing programs that can be selected The window looks like below Use the cursor to select the corresponding programs manually In case of external program selection via remote control or robot interface select in the menu SELECTION the item JOB The screen changes as follows By calling JOB in the AUTO mode you can activate the remote control or robot interface and ...

Страница 42: ... field To give you an example how the screen could look like Now activate the DISPLAY mode Soft key DISPLAY Use the potentiometer Power l kA to adjust the desired total material thickness and perform a test weld Optimize the welding parameters in the menu FURTHER ADJUST MENTS key lock switch in position EDIT and save the optimum value as working point e g J01 COMPONENT A The maximum number of avai...

Страница 43: ...e to modify and re modify one parameter You may correct the welding power of a job at any time The same goes for the synergic and remaining parameters to be approached by the field FUR THER ADJUSTMENTS of the corresponding table The operations and displays when creating and saving jobs mostly corre spond to those performed and appearing when editing synergic characteris tics Therefore no details a...

Страница 44: ... welding program visualization Installation of updates Updates of the plug weld data base for welding parameters Installation of special welding software new materials new processes Backup of QS data only available for machines with QS system How to use the USB Device Normal welding operations generally do not require the USB drive If you wish to use the USB device nevertheless proceed as follows ...

Страница 45: ...en DELETE welding programs Attention The use of this function is only possible in EDIT mode It is necessary that an USB key is in the USB device After you have pressed the soft key F2 under the MEMORY field and have selected the menu PRINT the following screen is displayed The window that pops up and program stack ACTION gives access to the function DELETE ...

Страница 46: ...elding programs with the modi fied parameters to an USB stick If you want to store your individual pro grams choose UserDB SpotQS logfile export To copy the SpotQS logfile you have to insert the USB Stick to the USB Drive of the machine Choose SpotQS logfile export to transfer the QS da ta to the USB stick Please also read the additional instruction manual Ana lysing Spot QS datasheets ...

Страница 47: ...es of program editing but only qualified users that have been trained by Car O Liner should make use of them For this reason the access to the EXPERT mode is protected by a password You will receive this password after you have been given special instruction or training by our service staff Having entered the password and accessed the expert mode you can change the password if you like If so selec...

Страница 48: ... and time Move the cursor onto the corresponding field or use the rotary encoder ERROR LOG Activate the field ERROR LOG to display a possible fault If no error malfunction occurred the mask NO PENDING ERROR appears Oth erwise the corresponding fault is displayed on the screen SYSTEM RESET Activate the field SYSTEM RESET to initiate system reset i e the micro processors are re started and the syste...

Страница 49: ...er section error Switch power source OFF ON Delivered compressed air is not sufficient Check compressed air supply pressure adjusted at the pressure reducer 3 bars hose connections Switch power source OFF ON Mains fuse is triggered during welding Wrong mains fuses Clean the metal from any rust color etc To confirm the message press any key to return to the chosen program welding The message locks ...

Страница 50: ...welded and or the electrodes Remove insulation layer if necessary create special program with suitably adapted parameters Sheets are not close lying Increase electrode squeeze pressure The transition resistance of the sheets to be welded does not correspond to the value preset in the welding program Repeat the spot if necessary create special program with suitably adapted parameters Welding time i...

Страница 51: ...orrect selection Wrong adjustment of total material thickness Correct adjustment Poor sheet position not close lying Correct Welding spatter Color or dirt between the sheets Clean Poor contact between the workpieces or between the workpiece and the electrode Increase electrode pressure Excessive welding current welding time and or energy applied Reduce welding current energy and or time create spe...

Страница 52: ...Car O Liner Group AB CTR12000 52 41644 EN rev 2 2012 09 ...

Страница 53: ... and Service Over 55 000 Car O Liner Collision Repair Systems are in use worldwide Car O Liner runs operations of its own in Scandinavia USA UK France Germany Singapore India and China and sells through local distributors in more than 60 countries Car O Liner products are well known for their high quality advanced technology and ergonomic design Telephone 46 227 412 00 www car o liner com info car...

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