Summary of Contents for Proteus WeldSaver III WS2G11
- Page 1 Proteus Industries Inc. A third generation of excellence in coolant control for robotic welding systems WS2G11 WS2G30 Installation and Operating Instructions...
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Page 2: Table Of Contents
Fax: (248) 299-0528 Proteus Industries Inc. Information in this document was correct at the time of printing; however, specifications are subject to change as Proteus Industries’ 340 Pioneer Way, Mountain View, CA 94041 continuous improvement processes establish new capabilities. Tel: (650) 964-4163 Fax: (650) 965-0304 www.proteusind.com... -
Page 3: Contacts & Cautions
Purpose 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- cific to these WeldSaver versions. If you are attempting to install a different version of the WeldSaver, you may need wiring and connection information specific to that version. -
Page 4: What It Is & What It Does
Section 2 : What It Is & What It Does 24 VDC DeviceNet® Connection Connection Check Valve Solenoid Valve Bypass Knob Keypad Solenoid Valve Flow & Status Display Model Number Serial Number Manufacture Date Status Indicating LEDs Setup Keys DeviceNet Controls Control Keys &... - Page 5 Section 2 : What It Is & What It Does The Proteus WS2G WeldSaver is a unique water control unit with several advanced capabilities: It’s a Flow Meter The large, bright LED display shows the actual flow rate through the system in LPM (Liters Per Minute) or indicates the flow rate relative to a user-selected Alarm Flow Rate.
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Page 6: How It Works
Section 3 : How It Works 1. Flow Sensing & Measurement Supply Rotor A sensitive and rugged flow 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. -
Page 7: Installation & Testing
Section 4 : Installation & Testing 4.1 Mechanical Installation & Water Connections Tools required: • Adjustable wrenches • Pipe wrenches • Teflon-based pipe sealant • Mounting bolts x 4 to fit #8-32 mounting holes Or M5 x 12 mm screws for units fitted with a mounting bracket Mechanical Installation Refer to Figure 3 on Page 23 for dimensions and fastening locations. - Page 8 Section 4 : Installation & Testing Refer to Figure 2 below to identify the water connection ports. Supply Return To Robot From Robot Figure 2: Plumbing connection locations of the WS2G WeldSaver Make plumbing connections to the Supply, Return, To-Robot and From-Robot connection ports on the WeldSaver using the appropriate pipe fittings and sealing washers.
- Page 9 Section 4 : Installation & Testing Depress the solenoid valve bypass knob and turn it 90° clockwise to a vertical position to enable flow. NOTE The WS2G WeldSaver is equipped with a solenoid valve featuring a manual bypass function. Solenoid Valve Bypass Knob...
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Page 10: Electrical & Devicenet® Connections
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 certified DC power supplies only. Aux Power (XE) DeviceNet Setup Menu Proteus Industries Inc. - Page 11 Section 4 : Installation & Testing Checking DeviceNet Functionality ACTION rESUlT 1. Turn power ON to the DeviceNet bus. NET = Off The MOD status LED will be grEEN. grEEN MOD = The NET status LED will flash momentarily until the DeviceNet Master allocation sequence has completed, after which the LED will stop flashing and remain solid grEEN.
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Page 12: Three Functionality Tests
Section 4 : Installation & Testing 4.3 Three Functionality Tests To ensure that the WeldSaver is functioning correctly, check the Valve Shut-Off function, the Bypass function and the Cap Off Detection function as described below. Operational Keys desired function Action Status lEd restore to Normal Status lEd... - Page 13 Section 4 : Installation & Testing Test the bypass Function ACTION rESUlT STATUS lEd Leak Detection function is turned OFF. 1. Press the key. The ByPASS status LED will be yEllOw. yEllOw Leak Detection function is turned ON. 2. Press the key again.
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Page 14: Selecting Control Parameter Values
Section 5 : Selecting Control Parameter Values STEpS fOr SElECTINg CONTrOl pArAmETEr vAlUES 1. enter SeTuP Mode Press the key to enter SeTuP mode. 2. Select the Parameter to adjust Press the key to move DOWN the stack to the parameter you wish to adjust. Press the key to move UP the stack to the parameter you wish to adjust. - Page 15 Section 5 : Selecting Control Parameter Values Parameter Values for the WS2G11 WeldSaver STaCK PreSeT CONTrOL ParaMeTer DeSCrIPTION & NOTeS SyMbOL VaLue alarm Flow Trip Point This is the lowest flow rate at which the welding system should be operated. Coolant flow lower than this rate does not provide sufficient cooling 1.5 LPM Range...
- Page 16 Section 5 : Selecting Control Parameter Values Parameter Values for the WS2G30 WeldSaver STaCK PreSeT CONTrOL ParaMeTer DeSCrIPTION & NOTeS SyMbOL VaLue alarm Flow Trip Point This is the lowest flow rate at which the welding system should be operated. Coolant flow lower than this rate does not provide sufficient cooling 7.6 LPM Range...
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Page 17: Troubleshooting
Section 6 : Troubleshooting 6.1 Status Faults STATUS kEypAd INdICATION STATUS: Ok TO wEld NOrMaL OPeraTING CONDITION grEEN grEEN NET = FLOW OK = grEEN MOD = Flow rate of 12.9 is shown for example only. STATUS: NOT Ok NeT STaTuS errOr NOT a WeldSaver error Check all network connections NET = Off... -
Page 18: Operating Faults
Section 6 : Troubleshooting 6.2 Operating Faults fAUlT kEypAd INdICATION lO flO fAUlT lO flO ERROR MESSAGE Flow is less than alarm flow rate setting Check Alarm flow rate setting. Correct If necessary. If Alarm flow rate setting is OK, increase flow rate if possible. - Page 19 Section 6 : Troubleshooting 6.2 Operating Faults (Continued) fAUlT kEypAd INdICATION JAmmEd rOTOr fAUlT CAp Off ERROR MESSAGE rotors are jammed or rotating too slowly because of fouling Clean or replace rotors. NOTE Flow rate indication is always 0.0 in the event of a Jammed Rotor Fault.
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Page 20: Weldsaver Faults
Section 6 : Troubleshooting 6.3 WeldSaver Faults prOblEm : wEldSAvEr dOES NOT dETECT CAp Off CONdITION unit is in byPaSS mode Press the key to return to normal operation. Leak response setting is TOO SLOW Enter setup mode and select the function. - Page 21 Section 6 : Troubleshooting 6.3 WeldSaver Faults (Continued) prOblEm: wEldSAvEr dOES NOT ShUT Off wATEr flOw Solenoid valve manual override is engaged Turn solenoid valve manual bypass knob 90° counterclockwise to disengage (See Page 9). Solenoid valve pilot flow is blocked Clean or replace solenoid valve.
- Page 22 Section 6 : Troubleshooting 6.3 WeldSaver Faults (Continued) prOblEm: fAlSE CAp Off EvENTS OCCUr wITh rEgUlArITy rotors are fouled Clean or replace rotors. prOblEm: NO wATEr flOw IS prESENT flOw rATE INdICATION dISplAyS 0.00 vAlvE STATUS lEd IS Valve is CLOSeD Press the key to open the valve.
- Page 23 Section 7 : Dimensional Drawings Front View rear View right Side View Figure 3: Dimensions of the WS2G WeldSaver...