Car-O-Liner CTR12000 Manuale utente
(41644, rev 2) 2012-10, EN
CTR12000
Part 2 - Welding menus and settings
Instruction Manual
(ORIGINAL)
Car-O-Liner Group AB CTR12000
241644, EN - rev. 2, 2012-09
Foreword
The Spot Welder CTR12000 is used by body shops
to duplicate the welding procedure used by the car
manufacturers. All other use of the equipment, or
use that is contrary to the instructions in this manu-
al, can cause personal injury and/or machine dam-
age. Pictures in this manual, where nothing else is
mentioned, and the term “the welder” concerns all
welders.
Car-O-Liner AB can in no way be held responsible
for intentional or unintentional damage, and conse-
quent unlimited loss of profit, loss of income, loss
of business opportunity, loss of use or other similar
nuisance, irrespective of how this has arisen, that
originates from incorrect use of this equipment or
its use in a manner not intended.
Warranty
Car-O-Liner AB offers a two-year guarantee from
the date of delivery. This guarantee covers material
defects and assumes normal care and maintenance.
Wearing parts are excluded from these terms of
warranty. The warranty does not cover normal wear
and tear or damage caused by third persons, by
improper handling or by manipulation by third per-
sons. Normal wear and tear, mechanical damage or
defects resulting from improper handling are ex-
pressly excluded from this warranty.
The guarantee assumes that:
The equipment is correctly installed and in-
spected in accordance with current local regula-
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
stated in the specifications. All claims must include
the product type and article number. This data is
stamped on the name plate.
Note
This instruction manual provides advice as well as
instructions for installation, operation, maintenance
and troubleshooting.
IMPORTANT! Read this manual
carefully to become familiar with the proper
operation of the welder. Do not neglect to
do this as improper handling may result in
personal injury and damage to the
equipment.
The drawings in this manual are intended only to be
illustrative and do not necessarily show the design
of the equipment available on the market at any
given time. The equipment is intended for use in
accordance with current trade practice and
appropriate safety regulations. The equipment
illustrated in the manual may be changed without
prior notice.
The contents in this publication can be changed
without prior notice.
This publication contains information that is
protected by copyright laws. No part of this
publication may be reproduced, stored in a system
for information retrieval or be transmitted in any
form, in any manner, without Car-O-Liner AB’s
written consent.
Copyright © Car-O-Liner AB, 2009
CTR12000 Car-O-Liner Group AB
41644, EN - rev. 2, 2012-09 3
Conformity with directives and standards
The CTR12000 is manufactured by Car-O-Liner AB, which is an ISO 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.
Car-O-Liner Group AB CTR12000
441644, EN - rev. 2, 2012-09
Contents
1
Operation.........................................................................5
1.1General .................................................................................................5
1.1.1Display (1)..............................................................................5
1.1.2Key-operated switch (2).........................................................6
1.1.3Soft keys (3)...........................................................................6
1.1.4Rotary encoder (4).................................................................6
1.1.5LED indicators (5-10).............................................................6
1.1.6USB- Device (11)...................................................................7
1.1.7LED indicators (12-15) / Reset button Q ...............................7
1.1.8Selector switch for “Welding power“ I/kA (18) .......................8
1.1.9Selector switch “Time“ t/s (19)...............................................9
2
Welding menus..............................................................10
2.1General ...............................................................................................10
2.2Starting the welding machine..............................................................11
2.3Operating mode “AUTO“ (Running mode)..........................................11
2.4Operating mode “EDIT“ (Modification mode)......................................11
2.5Operating mode “Expert“ ....................................................................11
3
Welding processes .......................................................13
3.1Fully automatic: VISION / VISION ED COAT .....................................13
3.2Semi automatic: ELMA-QS .................................................................22
3.2.1Pre Spot Operation program ...............................................26
3.2.2Optional settings..................................................................27
3.3Manual: STANDARD (conventional resistance spot welding) ............28
3.3.1Using edge welding caps.....................................................29
3.4Multi-function welding gun (optional tool): SINGLE ............................30
3.5Special automaker programs ..............................................................32
3.6Further adjustments ............................................................................34
3.6.1Description of settings in the "ELMA QS" mode..................34
3.6.2Welding process segments in ELMA-QS mode ..................35
3.6.3Welding process segments in the "VISION" mode..............35
3.6.4Editing synergy characteristics in the "ELMA QS" mode ....36
Definition of “welding power characteristics“ ......................................36
3.6.5Editing synergy characteristics in the "VISION" mode
Definition of “welding power characteristics" ......................................39
3.7Options................................................................................................40
3.7.1General ................................................................................40
3.7.2Working with “Jobs” .............................................................41
3.8USB- Drive ..........................................................................................44
3.9Welding program management...........................................................45
3.10Machine shut-down.............................................................................48
4
Troubleshooting............................................................49
CTR12000 Car-O-Liner Group AB
41644, EN - rev. 2, 2012-09 5
1 Operation
1.1 General
Your welding machine offers multiple functions and a large range of differ-
ent settings though the number of control elements is quite reduced. This
“economy of switches“ results from the high-tech microprocessor control
system.
The most important control element – the rotary encoder – is located on the
power source’s control panel. Together with the large, easy-to-read display,
this switch offers to the user 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 programs, see chapter
2 Welding menus.
5
–
10. LED indicators
1. Display
3. Soft keys
11. USB Device
12-15. LED indicators /
Reset button Q (also
being incorporated in the
welding tong’s handle)
18. Power I/kA
potentiometer
19. Time t/s
potentiometer
4. Rotar
y
encode
r
2. Key operated switch
AUTO/EDIT
Car-O-Liner Group AB CTR12000
641644, EN - rev. 2, 2012-09
1.1.2 Key-operated switch (2)
The key lock switch allows access and selection of the operating modes
“AUTO“(Automatic operation) and “EDIT“(Edit//Program). The standard
mode for welding operation is “AUTO”.
Service menus are only accessible while the key lock switch is in position
“EDIT“. Pull out the key to prevent any manipulation by unauthorized per-
sons and keep it in a safe and accessible place.
1.1.3 Soft keys (3)
The soft keys (membrane switches) are used for selecting the functions that
are indicated in the lower display bar – exactly above the corresponding soft
key. You can also 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 the bottom right of the dis-
play) or the term “ESCAPE” appears. Select the ESCAPE button or the
ESCAPE function, if you do not wish to make a choice. All the settings
made before in the menu concerned are cancelled and the original values are
maintained.
1.1.5 LED indicators (5-10)
(5) YELLOW: Indicates that the welder is ready for operation
(6) GREEN: Indicates that welding operation is being performed
(7) RED: Indicates pending malfunction
CTR12000 Car-O-Liner Group AB
41644, EN - rev. 2, 2012-09 7
(8) QS-RED: Indicates that spot weld is faulty or not weldable, or faulty
current tong calibration or that the tong used is not suitable.
(9) QS-YELLOW: Indicates heating phase for preparing the spot weld or
warning limit for current tong calibration.
(10) QS-GREEN: Indicates that spot weld and/or current tong calibration
has been okay. Indicates alarm limit or current tong calibration error, 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 “USB drive” for information on use.
Additional control elements are located on the lower control panel of the
power source.
1.1.7 LED indicators (12-15) / Reset button Q
NOTE! Also being incorporated in the handle of the welding tong.
12
13
14
15
Car-O-Liner Group AB CTR12000
841644, EN - rev. 2, 2012-09
LED for “Tool” (12)
Indicates incorrect calibration of the current tong or that the tong is not suit-
able, or – the LED’s Tool and Electrode being flashing – that calibration of
the current tong is necessary
LED for “Electrode” (13)
Indicates that electrodes need to be checked (limit of the spot counter has
been reached). With flashing LED: see above.
LED for “Fuse” (14)
Indicates that the start of the welding operation has been suppressed during
the recovery time of the primary fuse.
LED for “Spot 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
potentiometer “Power” l/kA on a scale in kA.
2. While in the Semi Automatic ELMA-QS mode (ELMA spot
welding with QS supervision), the potentiometer “Power“ is used
to preset the total material thickness on the large display
(independent of the scale) with all the relevant welding parameters
being adjusted automatically in the background (synergy table).
CTR12000 Car-O-Liner Group AB
41644, EN - rev. 2, 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.
Car-O-Liner Group AB CTR12000
10 41644, EN - rev. 2, 2012-09
2 Welding menus
2.1 General
Basic screen
Programs, selection menus and parameters are selected from and displayed
on the basic screen. Display button (F5) is used to indicate and display pro-
grams, set points and actual values.
Display screen
The example above shows the following setting:
Welding task: CHECK-EL, Welding process:VISION, welding 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: X01 - X99
Up to 99 JOBS: J01 - J99 (see 2.10.2)
You may modify or overwrite synergic user programs (X01 - X99) as often
as you like.
Optional
program
VAS 6755.
Optional
program
BMW. Choose with soft key F5.
Altri manuali per CTR12000
1
Indice
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