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Cloos NexT 452 AC, Руководство по эксплуатации

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8.3.1 QWD-M4 .............................................................................................................. 183

8.3.2 

QWD-P5 / QWD-M5 ........................................................................................ 184

8.4 

Inserting the welding wire .......................................................................... 185

8.4.1 QWD-M4 .............................................................................................................. 185

8.4.2 

QWD-P5 / QWD-M5 ........................................................................................ 186

8.5 

Adjustment of the pressure clamps ........................................................ 187

9. Maintenance ...............................................................................................

188

10. 

Error list ........................................................................................................

189

11. 

Disposal and Recycling ..............................................................................

190

Block 6a Error messages 

191

1. 

Error messages ............................................................................................

192

Block 6b General maintenance instructions

 207

1. 

Maintenance and Care ..............................................................................

208

1.1 

Regular testing .................................................................................................. 209

1.2 

Semi-annual testing ....................................................................................... 210

1.3 

Annual testing ................................................................................................... 210

1.4 

Special testing ................................................................................................... 211

1.4.1 

Optional filter mat in the cooling unit ................................................... 211

1.4.2 

Lifting eyes at the wire drive unit ............................................................. 211

1.4.3 

Electrolytic capacitors of the transistor cascades ............................. 211

Block 7 Automation 

213

1. Interfaces .....................................................................................................

214

1.1 

QOMI Module (Open Machine Interface) .............................................. 214

1.2 

Profibus Module (Process Field Bus) ........................................................ 214

1.3 

ProfiNet Module ............................................................................................... 215

1.4 

DeviceNet Module ........................................................................................... 215

1.5 

Ethernet-IP Module ......................................................................................... 215

2. 

QIROX Technology Interface (QTI) ............................................................

216

2.1 

Software compatibility .................................................................................. 216

2.2 

Assignment of protocol type for Tandem operation ........................ 216

2.3 

Additional welding processes protocol type 2 .................................... 216

2.4 

Control of communication between welding power source and 
robot ...................................................................................................................... 216

3. 

Basic configuration Operating mode "Tandem" ..................................

217

3.1 

Connection diagram ....................................................................................... 217

3.2 Conditions ........................................................................................................... 217
3.3 Pre-adjustments ............................................................................................... 218

3.3.1 

QIROX robots ...................................................................................................... 218

3.3.2 

QINEO welding power sources .................................................................. 218

3.4 

Job programming QINEO welding power sources ............................ 220

3.4.1 

Select operating mode "Tandem" ............................................................. 220

3.4.2 

Adjustment of the synergy variant .......................................................... 222

3.4.3 

"Active QWD" setting ...................................................................................... 223

4. 

Pulse synchronisation ...............................................................................

226

4.1 Configuration .................................................................................................... 226

4.1.1 

Synchronisation mode ................................................................................... 227

4.1.2 

Phase shift ........................................................................................................... 228

5. 

Job allocation ..............................................................................................

230

Содержание NexT 452 AC

Страница 1: ...Master Premium AC DC OPERATING INSTRUCTIONS QINEO NexT En This is a translation of the original operating instructions BA QN NX 04 20 Rev 3 41 Keep for future use...

Страница 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...

Страница 3: ...he 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 authoris...

Страница 4: ......

Страница 5: ...24 4 Environmental circumstances 25 4 1 Storage 25 4 2 Transport 26 5 Qualification of users 26 Block 2 Basic information Qineo NexT 27 1 Power source views 28 2 Product description 30 3 Transport 30...

Страница 6: ...lse parameters in the Expert Mode 54 6 8 Main Programming Active QWD 55 6 9 Main Programming Welding circuit from x 02 55 7 MAIN Measured values 55 7 1 Operating data 56 7 1 1 Data set switching 1 2 5...

Страница 7: ...e unit QWD B 97 10 7 Diagnostics Cooling module 97 10 7 1 Diagnostics cooling module LED 98 10 8 Diagnostics Robot 99 11 MAIN 2 Language 100 12 MAIN 2 Data backup 101 12 1 Data backup Job 101 12 1 1 S...

Страница 8: ...onal parameters of operating mode Spot Welding Interval 126 4 2 6 Parameter setting ranges optional 126 4 3 Save and load job 128 4 3 1 Quick memory access 128 4 3 2 Storage management 129 5 Configura...

Страница 9: ...INEO Wire Drive M4 169 3 1 Connection overview M4 170 4 QINEO Wire Drive M5 171 4 1 Connection overview M5 172 4 2 Connection instructions cable assembly 173 4 2 1 Preparations on QWD M5 173 4 2 2 Att...

Страница 10: ...pen Machine Interface 214 1 2 Profibus Module Process Field Bus 214 1 3 ProfiNet Module 215 1 4 DeviceNet Module 215 1 5 Ethernet IP Module 215 2 QIROX Technology Interface QTI 216 2 1 Software compat...

Страница 11: ...11 Block 1 Operational Safety...

Страница 12: ...r sources 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 conformit...

Страница 13: ...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 even death DANGER Describes an...

Страница 14: ...s have to be considered Safety 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...

Страница 15: ...th arc welding systems in the environment of the power source the feed lines and the torch However the safety values for persons with active implants cardiac pacemakers defibrillators and similar migh...

Страница 16: ...ly network It is difficult to guarantee electromagnetic compatibility for class A machines due to conducted emissions and radiated interferences in these areas 3 3 3 Radiation Ultraviolet and infrared...

Страница 17: ...y regulations 3 3 5 Fire prevention explosion Remove all flammable materials around the welding place or cover these with a non flammable or at least hardly combustible material Hot slag or spatter mi...

Страница 18: ...sioned The negative cable earth cable and the positive cable are locked by turning to the right Loose plugs affect the arc and thus the welding behaviour of the power source to a considerable extent...

Страница 19: ...3 grey N Earth conductor blue PE Protective conductor green yellow The terminal voltage of the power source can be up to 113 V DC or 48 V AC Although the power source is marked S for welding in enviro...

Страница 20: ...ection In the case of improper mains connection of the machine severe shock currents may arise In connection with the welding power source the protective conductor may be destroyed by faulty mass conn...

Страница 21: ...ring welding They may cause the following Overheating of components which are connected to the workpiece Fire risk Destruction of protective conductors Danger to life The two following figures show an...

Страница 22: ...the mains cable 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 curre...

Страница 23: ...e opened or removed during mainte nance or repair works Make sure that during operation all covers and side panels are closed and duly assembled by means of toothed conical spring washers earthing Bef...

Страница 24: ...e cooling circuit and damage the coolant pump The manufacturer is not liable for such damages Pay attention to the following notes when opening the cooling circuit Bring the welding torch and the torc...

Страница 25: ...y the manufacturer Please observe the national and international standards and regulations regarding the safety check The mounting area should be free of dust and aggressive agents The ground should b...

Страница 26: ...xis see label For the transport of the machine it is important to adhere to the valid national and regional guidelines and safety regulations in force Only persons who have been trained and instructed...

Страница 27: ...27 Block 2 Basic information Qineo NexT...

Страница 28: ...Power source views 1 2 5 4 3 Figure 6 Front view QINEO NexT left and QINEO NexT AC right 1 Main switch 2 Status LED welding power source 3 Status LED cooling unit 4 Level indicator 5 Coolant filler n...

Страница 29: ...et X77 8 USB 9 External VBC interface X70 10 Pulse synchronisation and Tandem connection X32 11 Connection external wire drive 12 Mains connection 13 Welding current positive cable 14 Welding current...

Страница 30: ...the MoTion Weld pro cess and are used for welding thin medium and thick sheets 3 12 mm Materials to be welded are Quality steel CrNi steel aluminium AlMg AlSi AlMn and copper based materials CuSi AlB...

Страница 31: ...key press This enables you to set the exact gas quantity by means of a gas control cone If the button is pressed for more than 0 5 s the function is only active as long as the button is pressed For s...

Страница 32: ...led in the cooling system after having connected the welding torch Always use a coolant approved by CLOOS It is not allowed to use chlorinat ed or mineral water because of its electrical conductivity...

Страница 33: ...of used electric and electronic units with the unsorted municipal solid waste They have to be collected separately The symbol Dustbin on wheels indicates the necessity of waste separation In Germany o...

Страница 34: ...ry V 36 5 36 5 I1 60 primary A 30 5 32 5 S1 60 primary kVA 21 1 22 5 Data 100 duty cycle I2 100 secondary A 350 350 U2 100 secondary V 31 5 31 5 I1 100 primary A 22 22 6 S1 100 primary kVA 14 8 15 7 M...

Страница 35: ...8 6 4 MAIN Programming Setting ranges 49 6 4 1 Input of setting ranges 49 6 4 2 Prerequisite to use the setting ranges 50 6 4 3 Deactivating the setting ranges 51 6 5 MAIN Programming Tandem 52 6 6 MA...

Страница 36: ...tics Process control Data set info 89 10 5 Diagnostics Power unit 90 10 5 1 Diagnostics Power unit Mains 90 10 5 1 1 Diagnostics Power unit Mains Measured values 91 10 5 2 Diagnostics Power unit Tempe...

Страница 37: ...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 job job sel...

Страница 38: ...dataset Material Fe CrNi1 4316 AlSi AlMg AlMg4 5 Mn CuSi CuAl Fe Basis Fe Rut Fe Met Wire 0 8 0 9 1 0 1 2 1 4 1 6 2 0 2 4 mm Gas 82 argon 18 CO2 91 argon 4 O2 5 CO2 92 argon 8 CO2 90 argon 10 CO2 95 a...

Страница 39: ...oid valve closes after expiration of the gas post flow time 3 2 4 cycle Operating mode 4 cycle is provided for longer manual welds 1st cycle Press torch trigger Solenoid valve for shielding gas opens...

Страница 40: ...on on the torch You can find additional information in the chapter 6 2 Parameters in the operating mode Super 4 cycle on page 47 3rd cycle Press torch trigger again The end crater program is executed...

Страница 41: ...lled pulsed arc The welding settings are chosen in such a way that a hard and stable pulsed arc arises The welding current depends on the distance between torch and workpiece Arc seam tracking is poss...

Страница 42: ...f the control processor This enables exceptionally low spatter welding of thin sheets in the range of approx 0 5 mm 3 0 mm The AC part is set by means of the rotary knob 2 see Figure 9 This pulsed arc...

Страница 43: ...am ics and Fine adjustment Arc length CleanStart is always active 5 MAIN Function The display field is highlighted yellow if one function is active 5 1 DuoPulse If the function is active a second weld...

Страница 44: ...when the wire is fed further For the Wire forward function on the torch cable assembly the wire speed from the above menu always applies Wire monitoring in the MCU is taken into account here 5 5 Wire...

Страница 45: ...c curve is not changed It can always be reset to the original state display 0 In programming mode the following display concept applies Yellow time Green m min step size Red power In the programming m...

Страница 46: ...6 1 Parameters in the operating modes 2 cycle and 4 cycle Function Correction value Gas pre flow Off 99 Inching in 99 Start program time Off 99 Start program power 99 Upslope Off 99 Main power Absolu...

Страница 47: ...param eters The power continuation is ensured by shortly pressing the torch trigger 0 5 s Use the function Step modulation to determine the step width of the increase or the reduction of the wire spe...

Страница 48: ...value between 99 and 99 The appropriate absolute value changes as well 6 3 Parameters in operating mode Spot Welding Interval If the operating mode Spot welding is active you have to enter the values...

Страница 49: ...ser management see section 9 4 Access rights on page 70 6 4 1 Input of setting ranges In order to be able to input the setting ranges you have to log on as Con figurator MAIN 2 Log on The setting rang...

Страница 50: ...quisite to use 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 operatin...

Страница 51: ...82 Argon 18 Co2 0 0 Zugangsverwaltung Optionen Bedienlevel Automatik Schweissen freigeben Job aufrufen freigeben Handrad Leist Fein freigeben Job speichern sperren Figure 17 Config Access management...

Страница 52: ...ower sources type QINEO NexT Master The Expert Mode is an alternative operating possibility to the synergy mode The Expert Mode requires a fundamental knowledge of the pulsed arc welding process and i...

Страница 53: ...parameters use the MAIN or Esc buttons with active Expert Mode You are now in the MAIN menu Always use rotary knob 1 to set the wire speed Use rotary knob 2 to set the most important electrical parame...

Страница 54: ...4 DuoPulse parameters in the Expert Mode DuoPulse is not an independent pulsed arc welding process but only a changing between two parameter settings If the Expert Mode function is active the DuoPuls...

Страница 55: ...er source has recognised more than one QWD When a QWD is activated wire is fed from the torch in the case of a weld ing start There is a risk of Injury by the sharp wire tip Electric shock when touchi...

Страница 56: ...e adjustment speed x10 x100 x1000 Meaningful operating data can only be collected in conjunction with the optional SD sensor in the wire drive The operating data can be displayed on the operating modu...

Страница 57: ...ary to increase the seam counter by one Display Messwerte Betriebsdaten Puls 4 Takt V 0 A 1 2 mm Fe 82 Argon 18 Co2 0 0 B E T R I E B S D A T E N Summenz hler Betriebszeit 12 47 Std Verbrauchsdaten ab...

Страница 58: ...igure 27 Display Messwerte Verbrauchskosten x 11 Puls 4 Takt V 0 A 1 2 mm Fe 82 Argon 18 Co2 0 0 B E T R I E B S D A T E N Summenz hler Betriebszeit 12 47 Std Kosten ab Reset 1 Schweissn hte 0 Verbrau...

Страница 59: ...to be expected Since this is a calculated value the real welding current may differ from the pre announcement The display Vset shows the welding voltage to be expected Since this value has been calcu...

Страница 60: ...Co2 0 0 Wasser ber wachung Kompen sation Benutzer verwaltung Ethernet Uhr Prozess ber wachung Display Konfig V 10 Figure 29 Config menu Figure 30 Config General menu Display Konfig Allgemein ab V2 Nex...

Страница 61: ...et the speed of the parameter change released by the torch trigger The adjustment is between 1 10 The correction value is 100 ms each Step width Using this function you set the size of the parameter c...

Страница 62: ...parameters Arc length Power and Dynamics External process selection is ignored in connection with QTI Designation Function Off If two different processes are executed at the same time with a Tandem t...

Страница 63: ...available with AC welding power sources Designation Function Standard Positive pole on welding torch Negative pole on welding torch Recommended when changing to a TIG welding torch or when using spec...

Страница 64: ...ettings Sense technology On Off Mode On or Off Sense technology Differential voltage Difference 0 0 V 40 0 V If the adjusted voltage is exceeded the error message Err 25 Sense voltage exceeded appears...

Страница 65: ...ction is configured in this menu refer to Figure 34 During threading the wire feed speed is continuously increased In a period of 20 seconds it increases from 0m min to the maximum value Figure 33 Con...

Страница 66: ...eneral Options The welding power source is equipped with an option chip Each time when being switched on the processor of the welding power source de tects the activated software options in the option...

Страница 67: ...ct 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 code appea...

Страница 68: ...e coolant can be 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...

Страница 69: ...s the workpiece during the measure ment The measurement process is started on the operating module by means of the rotary knob and is also possible from the torch trigger Proceed as follows in order t...

Страница 70: ...Access to the preset values is blocked The user with Automatic operating level does not need an access code Programmer The user with the Programmer operating level can call and look at the individual...

Страница 71: ...ned time to the Operating level when switching on You can select between Off and Log out after 1 to 30 min Access management Option In this menu the following access rights can be set for the Automati...

Страница 72: ...rce or the operating module must dispose of a PAK port The PAK is connected to the PAK port of the welding power source and the user profile is loaded The user is automatically logged on to the weldin...

Страница 73: ...999 which are stored in the welding power source Allowed jobs default The user can only call and use the allowed jobs It is possible to specify defined parameter limits setting ranges within a job fo...

Страница 74: ...save jobs after login with your password or PAK Call job Designation Function Enable You can call jobs without login Lock You can only call jobs after login with your password or PAK Rotary knob In th...

Страница 75: ...ser Push rotary knob 3 to select a free storage space in the user overview and to save all relevant user data in the Config Edit user menu INFO Puls 4 Takt V 0 A 1 2 mm Fe 82 Argon 18 Co2 0 0 Konfig B...

Страница 76: ...t configurator locked appears This prevents the last authorised user from being deleted unintentionally 9 4 2 3 Config User management User overview PAK A PAK can only save one user profile If you sav...

Страница 77: ...the desired position for entering numbers The selected number field is highlighted in white You can select a number between 000 and 255 by means of rotary knob 3 Use one of the arrow keys to move to...

Страница 78: ...ernal The error message is reset by an external signal OMI or bus system Ignition control If there is no signal Arc existing within 5 seconds after the command Start welding the error message Err 24 A...

Страница 79: ...an active job and the next job this is detected and the system will jump back to the job with the position xx1 Example Active job 44 next job 48 job continuation to storage space 41 Terminal process v...

Страница 80: ...cs The diagnostics menu provides the following submenus Display Konfig Allgemein 3 ab V10 Puls 4 Takt V 0 A 1 2 mm Fe 82 Argon 18 Co2 0 0 Konfig Allgemein 3 Potistellbereich WIG Min A 0 Max A 0 Figure...

Страница 81: ...no Docu no For an error entry the error number and for a documen tation entry the documentation number that identifies the entry Error text Docu text The text belonging to the respective error number...

Страница 82: ...Diagnostics System logbook Logbook selection The number of entries indicates the number of logbooks 10 3 Diagnostics Control Software version corresponds to Diagnostics Software version Mod ules NexT...

Страница 83: ...utputs during Automatic mode Diagnose Ethernet 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 000 000 000 000...

Страница 84: ...CollectWarningGr1 CollectWarningGr2 WarningWire Warn ingCurrent WarningVoltage WarningGas WarnMotCurrCK WarnMotCur rCDD WarnWeldTime WarningRes 1 WarningRes 2 SDAbort Sd ready Select signals Use rota...

Страница 85: ...tus bits of the inputs and outputs of the VBC module Via the menu item Module Reset you reset the IP address and the subnet mask of the VBC module to 000 000 000 000 Diagnose VBC NexT V x 4 Diagnose V...

Страница 86: ...e functionality of the LED by moving the middle rotary knob to mode Diag nostics The parameters can now be changed The LED adapts to the changed values Diagnose Led Diagnose Led Mode Frequenz 0 1 Hz T...

Страница 87: ...responds to DSP software see Diagnostics Soft ware version Modules QN DSP D I A G N O S E Tandem Puls 4 Takt V 0 A 1 2 mm Fe 82 Argon 18 Co2 0 0 Gar tekonfiguration Tandem Funktion Aus Tandem Status T...

Страница 88: ...Puls 4 Takt V 0 A 1 2 mm Fe 82 Argon 18 Co2 0 0 Synchronisation Modus Taktgeber Frequenz 200 Hz Phasenverschiebung 50 Taktgeber aktiv Synchronisation aktiv Figure 65 Diagnostics Process control Pulse...

Страница 89: ...g power source To load further data sets into the welding power source read the chapter 12 MAIN 2 Data backup on page 101 Diagnose Aktuelle Kennlinie St tzpunkte 10 Draht Min 3 5 m min Draht Max 12 0...

Страница 90: ...the welding power source of the connected mains supply Diagnose Leistungsteil Inverter Stromnetz Abgleich Temperatur L fter Led Typ Inverter DC Leistung 450 A Software Version 01 03 00 PLD Version 01...

Страница 91: ...spannung L1 L2 4 8 V Netzspannung L2 L3 5 0 V Netzspannung L3 L1 5 0 V Netzfrequenz 0 00 Hz Phase L1 2 L2 3 0 Grad Phase L2 3 L3 1 0 Grad Diagnose Messwerte Figure 71 Diagnostics Power unit Mains Meas...

Страница 92: ...rieb Sollwert Strom Sollwert Spannung 0 0 V AC Polung Frequenz AC Frequenz 20 Hz Spannungsabsenkung Aus Leistung Aus Diagnose Inverter V 2 03 xxx Figure 74 Diagnostics Power unit Inverter in operation...

Страница 93: ...iagnose L fter L fter Modus AC L fter Modus 0 Aus Betrieb L fter Inverter Modus Sollwert Drehzahl Istwert 0 U min berwachung L fter AC Modul Modus Sollwert Drehzahl Istwert 0 U min berwachung 0 Betrie...

Страница 94: ...le rotary knob The parameters can now be changed The LED adapts to the changed values Diagnose Led Diagnose Led Mode Frequenz 0 1 Hz Tastverh ltnis 100 Rot 10 Gr n 0 Blau 0 Diagnose Figure 78 Diagnost...

Страница 95: ...purposes During this process the other nodes along the wire section remain inactive Before starting with diagnosis ensure that either no wire is inserted or the pressure rollers are open Otherwise err...

Страница 96: ...onal options that might be enabled If the signal state is 1 On the corresponding box is highlight ed in yellow This menu is also displayed as a submenu for the QWD A Ventile Tasten Optionen Diagnose Q...

Страница 97: ...h water sensors The pump and fan can be started or stopped in diagnostics mode using the function Pump fan mode Diagnose QWD B Puls 4 Takt V 0 A 1 2 mm Fe 82 Argon 18 Co2 0 0 Typ QN WD B1_1 Software V...

Страница 98: ...ddle rotary knob The parameters can now be changed The LED adapts to the changed values Diagnose Led Diagnose Led Mode Frequenz 0 1 Hz Tastverh ltnis 100 Rot 10 Gr n 0 Blau 0 Diagnose Figure 86 Diagno...

Страница 99: ...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 digital Number of the digital wel...

Страница 100: ...ard slot underneath 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 s...

Страница 101: ...o called jobs can be written from the welding power source to the storage medium or from the storage medium to the job memory of the welding power source INFO Datensicherung Qineo NexT V1 03 31 Job D...

Страница 102: ...quentially Use the function from Job to select the beginning of the block e g Job 1 The display shows Block Start and the selected job number in yellow Now select the end of the block by means of the...

Страница 103: ...oad button The jobs are saved in the job memory of the welding power source Datensicherung JOB Qineo NexT V1 03 xx Laden Von Datei Auswahl Bis Datei Details Alle ausw hlen Memory Card Job Puls 4 Takt...

Страница 104: ...e the files to the storage medium After a successful saving the cor responding configuration file is marked with a green tick If a file was skipped a white line appears at the respective position If a...

Страница 105: ...7 Data backup Load config from storage medium menu 12 3 Data backup Synergy Datensicherung Synergie Qineo NexT V1 03 xx Lade von USB Speichern Speichere auf USB Laden Datensicherung Synergie Puls 4 Ta...

Страница 106: ...tion The current operating level is shown in the upper part of the display You can now enter your personal access code in the lower part of the dis play The access code is activated by pressing rotary...

Страница 107: ...of rotary knob 3 The Job name function takes you to the Text input menu 10 10 L schen Job Name Job speichern V 2 03 xx 1 2 3 4 5 6 7 8 9 1 Figure 100 Save job menu Figure 101 Text input menu ABC abc...

Страница 108: ...e required 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...

Страница 109: ...he 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 you want to activate another job tap the job button again You are no...

Страница 110: ...110 Job mode...

Страница 111: ...iagnostics Power unit LED 119 3 5 3 Diagnostics Cooling module 119 3 5 4 Diagnostics Process control 119 3 6 Functions Information 119 3 7 Functions Loading Saving 120 4 Operation 121 4 1 Operating co...

Страница 112: ...135 5 3 4 Job continuation 135 5 4 Config General 2 136 5 4 1 Wire speed in 136 5 4 2 V display shows 136 5 4 3 Gas flow min max 136 5 4 4 TIG pot setting range min max 136 5 5 Compensation of the ex...

Страница 113: ...ment or dynamics VNominal in Syn Off mode lock unlock 8 12 9 10 11 13 14 15 Figure 102 Display 15 Position Designation Function 8 Welding process Display active process 9 Operating mode Display active...

Страница 114: ...n the characteristic curve The arc becomes softer and wider The arc becomes concentrated and smaller During the normal MAG process the shape of the arc is influenced in the dynamic range In the Rapid...

Страница 115: ...ee MIG MAG welding process with synergy function It offers a stable metal transfer from short arc to spray arc Rapid Weld modified Control Weld This is a modified Control Weld welding process A very c...

Страница 116: ...able for high welding speeds and is ideal for joining sheet metal parts from 0 1 5 mm The welding current depends on the distance be tween torch and workpiece Arc seam tracking is pos sible in connect...

Страница 117: ...arance of the weld seam surface is formed by the defined change of parameters During root welding defined cool down times are reached depending on the setting If the DuoPulse function is activated the...

Страница 118: ...at regular intervals as the storage space is limited Using the QDM software there are two options Via the backup functions or the management functions The system logbooks are allocated to a certain we...

Страница 119: ...the fan which is in the power unit is indicated AC Fan If an AC power unit is installed a separate fan diagnostics is displayed 3 5 2 6 Diagnostics Power unit LED In this menu you test the functionali...

Страница 120: ...is saved on the external storage medium The DSA function saves the data set number of the characteristic curve data set in the Synergie syn file on the external storage medium Load characteristic curv...

Страница 121: ...e is applied on wire electrode Wire drive unit starts with reduced speed inching in Arc ignites welding current flows Wire drive unit switches to the preset speed 2nd cycle Release torch trigger Wire...

Страница 122: ...ecuted with the adjusted parameters and then switches via a programmable time function Upslope to the main program 3rd cycle Press and hold torch trigger Change from main program to the end program vi...

Страница 123: ...ap torch trigger Depending on the configuration of the Step modulation and Num ber of steps parameters the power and wire feed speed are increased or reduced with each press of the button on the torch...

Страница 124: ...s These default values can be adjusted in the secondary parameters menu 4 2 1 Adjusting secondary parameters 1 Press the menu button 2 Use the left rotary knob to select the menu for the secondary par...

Страница 125: ...e rotary knob and confirm by pressing the knob 4 2 3 Parameters of operating modes 2 cycle and 4 cycle Gas pre flow duration Correction value Off 99 Inching in Correction value 99 Start time duration...

Страница 126: ...essed for the increase or reduction When the maximum number of steps is reached the power is changed in the opposite direction each time the button is pressed 4 2 5 Additional parameters of operating...

Страница 127: ...f the function Power is enabled in addition the setting ranges for start main and end crater power are also active All other adjustment parameters are blocked Blue bars at the bottom of the main displ...

Страница 128: ...a welding circuit is car ried out in the configuration menu under menu item Compensation see chapter 5 5 Compensation of the external welding circuit on page 136 4 3 Save and load job Individual user...

Страница 129: ...tart screen press the menu button 2 Turn the rotary knob to select a storage space 3 Press the left rotary knob for approx 4 seconds until the selected field turns yellow and DEL appears Deactivate ac...

Страница 130: ...g the knob A list of the storage spaces will appear 2 Select an empty storage space using the rotary knob and confirm your selection by pressing the knob An input mask appears The following functions...

Страница 131: ...tivate an active job keep the job button pressed until the storage management appears 2 Using the rotary knob select the Job off menu and confirm the selection by pressing the knob The storage managem...

Страница 132: ...e card slot above the operating module 2 Select a storage space to be assigned a language The following functions appear Activate Load Delete Cancel If a language is already assigned to this storage s...

Страница 133: ...st have the following dimensions Width 479 pixels Height 167 pixels 5 2 2 2 cycle start and end crater program For welding application it is rarely necessary to use the start and end crater programs e...

Страница 134: ...into consideration when switching the process 5 2 6 Reset to factory setting Press and hold the knob to reset the settings When resetting to the factory settings all configuration points are reset to...

Страница 135: ...he torch trigger The adjustment is between 1 20 The correction value is 0 1 m min each for the Power and 1 each for the Fine and Dynamic parameters 5 3 3 Cooling water pump If an external cooling is c...

Страница 136: ...e welding power source To validate the welding power source the terminal voltage must be set here Otherwise the voltage display will be incorrect 5 4 3 Gas flow min max Herewith you determine the mini...

Страница 137: ...ng current is fed in Measurement is finished after approx 1 second If it was successful the measured values are automatically displayed So they can be compared with already stored values 5 Repeat the...

Страница 138: ...in case of a trou ble signal The monitoring is configured as follows Function Description Off Reset on Start The error message is reset at the next Welding start signal Reset from ex ternal Reset of e...

Страница 139: ...efine how long a threshold value is exceeded in seconds until an error message is triggered For example 1 5 2 seconds 5 8 Sense technology This function is only effective in the Control Weld MAG norma...

Страница 140: ...e wire drive unit nearest to the wire storage to be the signal transmitter QWD contact sensor ring sensor 2 Welding power source waits for the selected sensor signal from QWD A QWDBx_1 contact sensor...

Страница 141: ...t The access management differentiates between two operating levels Blocked Enabled Use this menu to configure which functions are available for the user in blocked status and whether an access code m...

Страница 142: ...rights to certain functions adjustments and welding parameters are enabled or blocked and saved in a user profile via the user management If a user logs in who is unknown to the welding power source...

Страница 143: ...e welding power source After login Welding is only enabled after login at the welding power source Job range enable Allowed jobs The user has only access to the job range defined in the user profile A...

Страница 144: ...emory spaces jobs is enabled Save Job Save S1 S5 Locked The storage on quick memory spaces jobs is blocked Allowed The storage on quick memory spaces jobs is enabled If the option Job memory MasterPlu...

Страница 145: ...characters an allowed job range of at least 1 to max 994 jobs a defined operating level 6 Give the user profile a name 7 Specify a password The password must be unique It must not be used for another...

Страница 146: ...corresponding PAK port The requested user profile is now transferred to the PAK 5 11 PC adaptation A connection between the welding power source and the software QDM can be established using the Ethe...

Страница 147: ...by means of the rotary knob 5 15 Off Re start In this menu you can switch off or restart the welding power source via the operating module 1 Use the rotary knob to select a corresponding function for...

Страница 148: ...148...

Страница 149: ...149 Block 4 Additional information...

Страница 150: ...Figure 108 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...

Страница 151: ...the configuration menu of the welding power source to determine which of the setting parameters shall be changed in which step width and speed by means of the additional buttons For more information...

Страница 152: ...3 SD ber 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 112 Menu 3 SD module 3 1 Monitoring channels...

Страница 153: ...at 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 frictio...

Страница 154: ...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 control...

Страница 155: ...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 LowByte and HighByte and is preset from 0 to 10...

Страница 156: ...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...

Страница 157: ...g 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 the mid...

Страница 158: ...er Set value The value specifies the expected actual 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 o...

Страница 159: ...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...

Страница 160: ...A 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...

Страница 161: ...tails 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 mi...

Страница 162: ...ing 3 Select and confirm a monitoring 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...

Страница 163: ...ions oder Fehler Eintrag in 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 be...

Страница 164: ...164 SD module...

Страница 165: ...s on QWD M5 174 5 QINEO Wire Drive A4 175 5 1 Structure and function A4 176 6 QINEO Wire Drive AR4 177 6 1 Connection overview AR4 178 7 Function 179 7 1 Button Gas manually 179 7 1 1 Adjustment of th...

Страница 166: ...tions Wire feed unit QN WF 22 QN WF 32 QN WF 64 Transport and storage 30 C 60 C 20 C 85 C 20 C 50 C Relative air humidity up to 90 at 20 C up to 50 at 40 C 20 80 1 4 Compatibility list Information on...

Страница 167: ...vers The wire coil must be secured on the wire coil holder with the locking head to prevent it falling off Options Remote control connection Protective shield Flow meter EURO connection Can be used on...

Страница 168: ...cable assembly connection 2 Torch cooling flow 3 Torch cooling return 4 Welding current connection 5 Quick coupling cooling return 6 Quick coupling cooling flow 7 Quick coupling gas 8 Socket to contr...

Страница 169: ...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...

Страница 170: ...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...

Страница 171: ...ousing body by means of solid hinges For safety reasons the cover is equipped with a spring damper It is suitable for industrial use Options Flow meter EURO DINSE connection Carriage Remote control co...

Страница 172: ...4 5 Optional connector sockets RC ECO MHW xxx TQ MHW xxx Master RC ECO RC Master RPU RC Plus MHW xxx Premium 6 Socket for optional SZ connec tion 7 Wire inlet wire drum 8 Opening for VSP connecting ca...

Страница 173: ...Connection instructions cable assembly Follow the steps below to connect the CMW CMG cable assembly 4 2 1 Preparations on QWD M5 5 7 2 6 3 Hex key 6 AF 4 Open ended wrench 14 AF 8 Star screwdriver 25...

Страница 174: ...mp screw to adjust the braking force of the wire coil holder so that it does not run when the motor brakes and no wire windings fall off the coil possibly resulting in kinking or short circuits If the...

Страница 175: ...QINEO Wire Drive A was specially developed for industrial robot appli cations Options EURO DINSE connection Weld data monitoring CLOOS Duo Drive CDD Wire end control Installation kit A4 MoTion CLOOS M...

Страница 176: ...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...

Страница 177: ...t of industrial robots This ensures an optimum welding wire feed especially in the field of hollow shaft robots Despite the comprehensive equipment with different sensors for weld data monitoring it i...

Страница 178: ...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...

Страница 179: ...This function enables the exact adjustment of the gas flow rate by means of a gas measuring tube 7 1 1 Adjustment of the gas flow rate Designation Function Gas measuring tube Measurement of the gas e...

Страница 180: ...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...

Страница 181: ...g loose 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 8 1 2 Risks due to electrical hazards Risk of...

Страница 182: ...gas flow to the litre scale of the pressure 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 wi...

Страница 183: ...use 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 fro...

Страница 184: ...184 General commissioning 8 3 2 QWD P5 QWD M5 The illustrations may differ from the original INFO 4 3 2 1...

Страница 185: ...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 To obtain a perfect welding...

Страница 186: ...186 General commissioning 8 4 2 QWD P5 QWD M5 The illustrations may differ from the original INFO The wire inlet must not touch the wire drive roller INFO...

Страница 187: ...d away from the body Risk of electric shock If unrestricted access to the live single parts of the QINEO Wire Drive is possible all persons must exercise caution to prevent electric shock or risks of...

Страница 188: ...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...

Страница 189: ...nt 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...

Страница 190: ...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...

Страница 191: ...191 Block 6a Error messages...

Страница 192: ...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 Bus...

Страница 193: ...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 Service 8 Error during trans...

Страница 194: ...re version remote control out of date Software update required Software update Service 44 Software version VBC DeviceNet out of date Software update required Software update Service 45 VBC DeviceNet m...

Страница 195: ...date Software update required Software update Service 61 Software version QWD1 out of date Software update required Software update Service 62 Software version QWD2 out of date Software update require...

Страница 196: ...carrier Service 189 No enable from control computer Time of initialisation in control computer exceeded 25 seconds Switch machine Off and On Check software for compatibility Service 190 Transmission...

Страница 197: ...Switch machine Off and On Check cable connections Service 245 Please switch back on If values in the configuration have been changed that require a restart Perform a restart 250 QWD1 No controller dat...

Страница 198: ...ed Preset rotation speed not reached Encoder signals faulty motor movement Check motor movement Check wire feed distance Check encoder Fuse 42V supply faulty Power supply board Service 262 CDD1 Desire...

Страница 199: ...the other Software update may be required Service 272 Error in file format Faulty file Use correct file format Service 274 QWD1 Overcurrent Overload results in increased current load of the drive uni...

Страница 200: ...or when importing data in option chip Enter new option chip code Use new option chip Service 316 Wrong option chip Option chip is not recognised Use new option chip Service 317 Wrong activation code W...

Страница 201: ...g and connections Service 504 Error fan AC module Fan failed Check plug and connections Service 505 Mains Phase failure Uneven voltage due to phase failure Service 506 Mains Undervoltage Mains voltage...

Страница 202: ...lass Unknown power class Service 534 Error when loading the alignment values The set values do not match the checksum Service 535 Error inverter PLD Only for CW processes Error during re ignition afte...

Страница 203: ...B stick not found Data carrier missing faulty Check data carrier Insert data carrier again Service 621 Internal USB stick is write protected Data carrier faulty Check data carrier Insert data carrier...

Страница 204: ...V1 00 00 Check software version Software update Service 705 QWD B3 1 failed Connection to the module interrupted during operation Switch machine Off and On Check plug and connections Service 706 Softw...

Страница 205: ...failed Connection to the module interrupted during operation Switch machine Off and On Check plug and connections Service 755 CMD2 failed Connection to the module interrupted during operation Switch m...

Страница 206: ...lty motor movement Check motor movement Check wire feed distance Check encoder Fuse 42V supply faulty Power supply board Service 765 Speed error CMD4 Preset rotation speed not reached Encoder signals...

Страница 207: ...207 Block 6b General maintenance instructions...

Страница 208: ...208 1 Maintenance and Care 1 7 4 5 2 3 8 10 Optional external cooling unit 10 9 Optional lifting eyes 3 11...

Страница 209: ...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...

Страница 210: ...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...

Страница 211: ...he filter mat If the filter mat is very dirty change it Only use original CLOOS parts 1 4 2 Lifting eyes at the wire drive unit Check the lifting eyes for damages once a month If they are damaged chan...

Страница 212: ...212...

Страница 213: ...213 Block 7 Automation...

Страница 214: ...r or connection to special purpose welding systems Field buses are industrial communication systems using different me dia such as copper cables fibre optic cables LWL and radio wireless By means of a...

Страница 215: ...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...

Страница 216: ...ion It must be observed that in Tandem 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...

Страница 217: ...or example with a robot The second welding 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 th...

Страница 218: ...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...

Страница 219: ...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...

Страница 220: ...ion Welding power sources with protocol type 2 support additional welding processes such as Tandem f f see 2 3 Additional welding processes protocol type 2 on page 216 INFO INFO Synergie Betr Verfahre...

Страница 221: ...slave welds Both gas valves open only the slave arc is monitored the two welding power sources are monitored S torch single wire torch T torch Tandem torch In the Tandem operating mode the S Pulse and...

Страница 222: ...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...

Страница 223: ...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...

Страница 224: ...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...

Страница 225: ...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...

Страница 226: ...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...

Страница 227: ...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...

Страница 228: ...lf of the pulse frequency Pulse receiver alternating The welding power source executes the pulse with a time delay before or after the pulse of the pulse generator The offset depends on the set phase...

Страница 229: ...ly 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 adjustment the time delayed sync...

Страница 230: ...synchronisation is used in connection with two or more in dividual processes a corresponding job has to be called in the welding power sources The following scenarios can be realised using the exampl...

Страница 231: ...ection job selection must remain identical in the robot controller Job number Wire in front Wire in the back Operating mode Tandem Seam tracking signal Synergy variant Pulse synchronisation Process Ma...

Страница 232: ...232...

Страница 233: ...233...

Страница 234: ...www qineo de...

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