Proteus WeldSaver III WS2G11 User manual

A third generation of excellence in coolant

control for robotic welding systems

WS2G11 WS2G30

Installation and Operating Instructions

Proteus Industries Inc.

Technical Support

Proteus Industries Inc.

340 Pioneer Way

Mountain View, CA 94041

Tel: (650) 964-4163

Fax: (650) 965-0304

E-mail: weldsaver@proteusind.com

In the Detroit, MI area, local support is available from:

MJM Sales, Inc.

2660 Auburn Road, Suite 300

Auburn Hills, MI 48326

Tel: (248) 299-0525

Fax: (248) 299-0528

Table of Contents

Section Description Page

1 Contacts & Cautions 3

2 What It Is & What It Does 4

3 How It Works 6

4 Installation & Testing 7

4.1 Mechanical Installation & Water Connections 7

4.2 Electrical & DeviceNet® Connections 10

4.3 Three Functionality Tests 12

5 Selecting Control Parameter Values 14

6 Troubleshooting 17

6.1 Status Faults 17

6.2 Operating Faults 18

6.3 WeldSaver Faults 20

7 Dimensional Drawings 23

WS2GUM Rev 001 04/2008

Information in this document was correct at the time of printing;

however, specications are subject to change as Proteus Industries’

continuous improvement processes establish new capabilities.

Proteus Industries Inc.

340 Pioneer Way, Mountain View, CA 94041

Tel: (650) 964-4163 Fax: (650) 965-0304

www.proteusind.com sales@proteusind.com

Section 1 : Contacts & Cautions

NOTE

Product warranty does NOT cover the repair of installation errors.

Proteus WeldSavers are manufactured by ISO 9001 registered processes and are

warranted to be free from defects in material and workmanship for 2 years from the

date of shipment. The full text of this limited warranty is accessible on the Proteus

Industries website at www.proteusind.com/warranty/.

The cost of cleaning ow sensors, recalibration or repair of mechanical damage in-

curred during installation of the product are NOT covered by the warranty.

A Purchase Order will be required to allow recovery of such service costs.

Throughout this manual, NOTE, CAUTION and WARNING statements are used to highlight important opera-

tional and safety information.

Important Safety Information

Taking proper precautions to avoid damage to the WeldSaver during installation helps ensure consistent, error-

free operation, which lowers costs and assists on-time completion of contracted work.

The safety-related statements inserted in these instructions provide an alert to installers and operators to take

sensible steps to allow the WeldSaver to operate correctly the rst time and every time.

NOTE

NOTE statements provide details that are important to the

successful understanding and application of the system.

CAUTION!

CAUTION statements identify conditions or practices that

could result in damage to equipment or other property.

WARNING!

WARNING statements identify conditions or practices that

could result in personal injury or loss of life.

This manual has been created to assist the installation, functional testing and operation of the WS2G11 and

WS2G30 versions of the Proteus WeldSaver™. Dimensional drawings and water and power connections are spe-

cic to these WeldSaver versions.

If you are attempting to install a dierent version of the WeldSaver, you may need wiring and connection

information specic to that version. Please contact WeldSaver Technical Support for assistance.

Purpose

Section 2 : What It Is & What It Does

Solenoid Valve

Bypass Knob

Keypad

Solenoid Valve

Check Valve

DeviceNet®

Connection

24 VDC

Connection

Figure 1: Overview of functional components and keypad of the WS2G WeldSaver

Flow & Status Display

Status Indicating

LEDs

Setup Keys

Control KeysDeviceNet Controls

& Status Panel

Model Number

Serial Number

Manufacture Date

Section 2 : What It Is & What It Does

The Proteus WS2G WeldSaver is a unique water control unit with several advanced capabilities:

The large, bright LED display shows the actual ow rate

through the system in LPM (Liters Per Minute) or indicates

the ow rate relative to a user-selected Alarm Flow Rate.

Water ow to the weld cell can be turned ON and OFF us-

ing the keypad or remotely from the weld controller.

When the solenoid valve is OPEN, water is owing and the

VALVE status LED is OFF.

When the solenoid valve is CLOSED, water is not owing

and the VALVE status LED is RED.

When the ow to the weld cell is greater than the Alarm

Flow Rate, the FLOW OK status LED is GREEN.

When the ow to the weld cell is less than the Alarm Flow

Rate, the FLOW OK status LED is OFF and the FAULT status

LED is RED.

The LO FLO fault message is displayed and the weld con-

troller is instructed to stop the weld program.

In the event of a weld cap loss, the leak is detected and

water ow is shut o in less than 1 second.

The CAP OFF fault message is displayed and the weld con-

troller is instructed to stop the weld program.

The FAULT and VALVE status LEDs are RED.

It’s a Flow Meter

It’s an ON/OFF Flow Valve

It’s a Flow Monitor

It’s a Very Fast Leak Detector

Section 3 : How It Works

A sensitive and rugged ow sensor is located in both the

supply and return coolant lines.

A six-spoke rotor is mounted on a stainless steel shaft in

the cylindrical turbine chamber. Coolant enters the tur-

bine chamber through a precision-drilled orice, causing

the rotor to spin at a rate that is directly proportional to the

linear velocity of the liquid passing through the chamber.

Magnets located at the end of the rotor spokes turn ON

and OFF a Hall Eect sensor located outside the turbine

chamber. The frequency output of the Hall Eect sensor is

measured by a microcomputer that calculates the ow rate

of the liquid.

1. Flow Sensing & Measurement

The measured inlet ow rate is compared with the Fault (OK to Weld) and Alarm ow rates as selected by the

operator.

When the measured ow rate is greater than the Fault ow rate, the microcomputer sends the digital mes-

sages DiG1WS_OktoWeld and DiG1WS_MinFlow to the weld controller.

When the measured ow rate is greater than the Alarm ow rate, but less than the Fault ow rate, the micro-

computer sends only the digital message DiG1WS_OktoWeld to the weld controller.

When the measured ow rate is less than the Alarm ow rate, the microcomputer stops sending the digital

message DiG1WS_OktoWeld.

The weld controller makes decisions aecting weld operations based on the ow status reported by the

WeldSaver.

2. Flow Comparison

The WeldSaver’s microcomputer uses a patented algorithm to continuously monitor the output frequencies

of both the supply and return ow sensors. This algorithm is able to detect a loss of a weld cap or other cata-

strophic loss of ow continuity in less than 0.3 seconds.

When a cap loss event is detected, the microcomputer shuts o water ow in both the inlet and return lines

and sends the digital message DiG1WS_CapLoss to the weld controller.

The weld controller makes a decision to shut down weld operations.

3. Cap Loss Detection

Supply

Hall-Eect

Sensor

Rotor

Magnet

Section 4 : Installation & Testing

4.1 Mechanical Installation & Water Connections

Adjustable wrenches

Pipe wrenches

Teon-based pipe sealant

Mounting bolts x 4 to t #8-32 mounting holes

OR M5 x 12 mm screws for units tted with a mounting bracket

•

Tools required:

Refer to Figure 3 on Page 23 for dimensions and fastening locations.1.

Mechanical Installation

Flush the inlet piping.1.

Flushing, Making & Testing Water Connections

CAUTION!

Flush contaminants and other accumulated construction debris from the up-

stream water pipe BEFORE connecting the WeldSaver.

Failure to ush coolant lines may result in the fouling of the WeldSaver’s supply

ow sensor and clogging of smaller orices in the robot supply lines, manifolds

and the weld gun.

CAUTION!

Flush contaminants and other debris from water lines connecting the robot,

manifold, transformer, SCR and any other water-cooled components BEFORE

connecting them to the WeldSaver.

Failure to ush these lines may result in the fouling of the WeldSaver’s return

ow sensor and clogging of smaller orices in the robot supply lines, manifold,

transformer, SCR, weld gun and any other water-cooled components.

Lubricate threads

Use a lubricating and non-hardening pipe sealant such as Teon paste on all pipe threads. This material

will lubricate G ¾ straight-threaded ttings to simply their installation.

CAUTION!

Do NOT allow excess pipe sealant to enter the ow sensors!

Excess material may foul the sensors and cause clogging of smaller orices in the

robot’s supply lines, manifold, transformer, SCR, weld gun and any other water-

cooled components.

Section 4 : Installation & Testing

Refer to Figure 2 below to identify the water connection ports.3.

Make plumbing connections to the Supply, Return, To-Robot and From-Robot connection ports on the

WeldSaver using the appropriate pipe ttings and sealing washers.

NOTE

The WS2G WeldSaver requires G ¾ metric plumbing connections.

Figure 2: Plumbing connection locations of the WS2G WeldSaver

Supply

Return

To Robot

From Robot

CAUTION!

Ensure that the correct hoses have been connected to the To-Robot and From-

Robot connections.

Check hose labels or trace water ow to conrm that the WeldSaver is connected

to include the water circuit cooling the weld gun.

If the hose connections are not correct, the WeldSaver may NOT be able to detect

the loss of a weld cap.

Adjust pipe connections as required for proper alignment of the WeldSaver.5.

Section 4 : Installation & Testing

Turn water ON slowly.7.

WARNING!

The WeldSaver body is NOT insulated!

When using the WeldSaver with hot liquids, use proper personal protective

equipment.

Depress the solenoid valve bypass knob and turn it 90° clockwise to a vertical position to enable ow.6.

NOTE

The WS2G WeldSaver is equipped with a solenoid valve featuring a manual bypass

function.

The solenoid valve is functional when the slot in the

knob is in a HORIZONTAL position.

During normal operation, the solenoid valve enables

the control of ow through the system, either locally

using the WeldSaver keypad or remotely from the

weld controller.

The solenoid valve can be bypassed by depressing

the knob and turning it 90° clockwise to a vertical

position.

In the manual override state, water can ow through

the system to allow leak testing without engaging

24 VDC electrical power.

Solenoid

Valve

Bypass

Knob

Check for leaks at all connections to the WeldSaver.

Eliminate all leaks before proceeding.

Turn the solenoid valve bypass knob 90° counterclockwise and return it to a horizontal position for nor-

mal operation.

10.

NOTE

If the solenoid valve manual bypass knob is left in a vertical position, the valve will

NOT function when power to the WeldSaver is turned on.

Section 4 : Installation & Testing

Refer to Figure 3 above to identify the 24 VDC power interface connections.

Conrm that the auxiliary power cable has 24 VDC present between pins 2 and 3.

4.2 Electrical & DeviceNet® Connections

Connecting 24 VDC Auxiliary Power

Proteus Industries Inc.

340 Pioneer Way

Mountain View, CA 94041

(650) 964-4163

www.proteusind.com

Made in USA

Foreign and domestic

components

1 3

2 4

3 1

Aux Power (XE) DeviceNet Setup Menu

MALE

FEMALE

1 - Spare

2 - 24 VDC

3 - 0 VDC

4 - Spare

MALE

FEMALE

1 - Drain

2 - V+

3 - V-

4 - CAN_H

5 - CAN_L

Alarm (minimal)

Fault (adequate)

Response time

Stabilization delay

Startup leak

Display options

Restore default

CAUTION!

Connect the interface cables to the weld controller and the 24 VDC power source

BEFORE connecting them to the WeldSaver.

Connect the auxiliary power cable to the 4-pin connector on top of the WeldSaver body.3.

NOTE

The WS2G WeldSaver must be connected to 24 VDC auxiliary power, DeviceNet 24

VDC power and a functional DeviceNet controller to perform correctly.

Proteus highly recommends connecting the WeldSaver to certied DC power

supplies only.

Figure 3: Wiring and electrical connection diagrams for the WS2G WeldSaver

Refer to Figure 1 on page 4 to identify the DeviceNet power interface locations.

Refer to Figure 3 above to identify the DeviceNet power interface connections.

Conrm that the DeviceNet cable has 24 VDC present between pins 2 and 3.

Connect the DeviceNet cable to the bus leading to the weld controller.

Connect the DeviceNet cable to the 5-pin connector on top of the WeldSaver body.

Connecting the DeviceNet Interface Cable

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