Operating instructions

Welding data documentation software

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QDOC 9000 V2.0

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General information

CautionRead the operating instructions! The operating instructions provide an introduction to the safe handling of the products.

Read the operating instructions of all system components!•Observe accident prevention regulations!•Observe country-specific regulations!•Have confirmed by signature if necessary.•

NoteIn case of questions on installation, commissioning, operation, peculiarities at the operating site and the intended purpose, contact your sales partner or our customer service at +49 2680 181-0. A list of authorized sales partners can be found at www.ewm-group.com.

The liability in connection with the operation of this system is expressly limited to the operation of the system. Any other liability of any kind is expressly excluded. This disclaimer is recognized upon the commissioning of the system by the user. Both compliance with these instructions and the conditions and methods of installation, operation, use and maintenance of the machine cannot be monitored by the manufacturer. Improper installation can cause damage to property and endanger people as a result. For this reason, we accept no responsibility whatsoever for losses, damages or costs which arise due to faulty installation, improper operation and incorrect use and maintenance or which are related in any way.

© EWM HIGHTEC WELDING GmbH, Dr. Günter-Henle-Straße 8, D-56271 Mündersbach, Germany The copyright for this document remains with the manufacturer. Written permission is required for partial or total reprinting. We reserve the right to make technical changes.

1 Table of contents

Table of contents

Back to contents

1 Table of contents 1

2 Safety notes 3

2.1 Information on using these operating instructions 3

2.2 For your safety 4

3 Intended use 5

3.1 Area of application 5

4 Getting started 6

4.1 Functionality and cabling 6

4.2 Installation 6

4.2.1 System requirements 6

4.2.2 Installing the software 6

4.2.2.1 Microsoft .NET 2.0 Framework 6

4.2.2.2 General information 7

4.3 After the installation 9

4.4 Functionalities 10

4.5 Start of measuring readiness - recording function 11

5 Evaluating recordings 12

5.1 Selecting data 13

5.2 Configuring the display 14

5.3 Filtering data 15

5.4 Exporting and loading data 16

5.5 Deleting results 17

5.6 Log with welding history 17

5.7 Overlapping curves display 18

5.8 Inserting 18

5.9 Consumption values 19

5.10 Statistics 20

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Table of contents

Back to contents

6 Welding Procedure Qualification Record (WPQR) 21

7 Additional functions 27

7.1 Creating backups with the data manager 27

7.2 Troubleshooting 28

7.2.1 USB test program 28

7.2.2 EWM USB manager 29

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2

2.1

Safety notes

Information on using these operating instructions

Safety notes Information on using these operating instructions

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DANGERWork or operating processes which must be complied with precisely to avoid imminently hazardous situations which will result in death or serious injury.

The title of the safety note contains the "DANGER" signal word and a general warning symbol. •In addition, the danger is pointed out with a pictogram at the side. •

WARNINGWork and operating processes which must be complied with precisely to avoid hazardous situations which could result in death or serious injury.

The title of the safety note contains the "WARNING" signal word and a general warning symbol. •In addition, the danger is pointed out with a pictogram at the side. •

CAUTIONWork and operating processes which must be complied with precisely to avoid hazardous situations which could result in minor or moderate injury.

The title of the safety note contains the "CAUTION" signal word and a general warning symbol. •The danger is pointed out with a pictogram at the side. •

CAUTIONWork and operating processes which must be complied with precisely to avoid damaging or destruction of the product.

The title of the safety note contains the "CAUTION" signal word and no general warning symbol. •The danger is pointed out with a pictogram at the side.•

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2.2 For your safety

Safety notes For your safety

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NOTE Technical peculiarities to be observed by the user.

The title of the safety note contains the "NOTE" signal word and no general warning symbol.•Notes are pointed out with a pictogram at the side.•

WARNINGValidity of the document! This document is only valid in combination with the operating instructions of the power source used (welding machine)!

Read the operating instructions, especially the safety notes of the power source (welding machine)!

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NOTE Detailed, additional welding safety notes can be found in the operating instructions of the welding

machine. You can also find a list of the currently valid standards and regulations there. You should be familiar with the basic functions of the operating system and a computer and should

have experience using software.

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3

3.1

Intended use

Area of application

Intended use Area of application Back to contents

This software was created using state-of-the-art technology and in accordance with the applicable laws and standards. It is to be used only as intended.

WARNING

Danger due to improper use! The machine was manufactured using state-of-the-art technology and in accordance with the applicable laws and standards. Improper use can cause damage to people, animals and property. EWM accepts no liability for damages resulting from improper use!

The machine may only be used as intended and by trained, professional personnel! •Do not modify or convert the machine in any unintended way! •

This software was developed for data exchange with welding machines of the Tetrix, alpha Q and Phoenix series. Basic functions:

Recording and documentation of welding data in an SQL database, e.g. current, voltage, welding time, etc. •Printing out welding data and creating a WPQR •Data management •

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4

4.1

4.2

4.2.1

4.2.2

4.2.2.1

Getting started

Functionality and cabling

Installation

System requirements

Installing the software

Microsoft .NET 2.0 Framework

Getting started Functionality and cabling

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The QDOC 9000 V2.0 software records welding data from a power source via a data interface.•The software always shows the current measurement values (recording monitor).•The recorded welding data are saved in a database.•Each QDOC 9000 V2.0 set includes a software package on a CD-ROM to install a "workstation" version of the software on any computer (WIN XP or later). In addition, the set includes a PCINT X10 V2.0 and a SECINT X10 USB, a serial cable to connect the computer to PCINT X10 V2.0 and a 7-pole system bus cable. The end of the cable with the blue cable binder is to be plugged into the PCINT X10 V2.0. The PCINT X10 V2.0 is connected to the Phoenix, Tetrix or alpha Q welding machine with a 7-pole system bus cable.

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Windows 7, Windows Vista, Windows XP SP2•.NET Framework 2.0 installed (will also be installed if necessary)•Intel Pentium (or similar) CPU with at least 1.7 GHz•At least 512 MB RAM•At least 300 MB available hard disk space•CD-ROM drive for software installation•Available USB 1.1 or USB 2.0 connection to connect the welding machine•

NOTE .NET Framework is a product enhancement for Windows operating systems from Microsoft and is

absolutely required for operation of the QDOC 9000 V2.0 software.

Questions on this enhancement should be sent to the originator (Microsoft).•Should .NET Framework 2.0 not yet be installed on your computer, it will be installed by the program as well.

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4.2.2.2 General information

Getting started Installation

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NOTE Close any other programs which are open before proceeding with the installation.

In principle, it is sufficient to follow the instructions of the installation wizard and confirm the default settings.

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Experienced users can customize the default settings according to their needs.•

Start your computer and wait until Windows has loaded fully.•Place the software CD into your CD or DVD drive.•The installation starts automatically after a few seconds.•

NOTE Should the "automatic start" Windows options be disabled for the CD or DVD drive, start the

installation by running the "setup.exe" program in the root directory of the CD or DVD

Select the language for the QDOC 9000 V2.0 software in the drop-down field on the left-hand side of the window. The selection also determines the language used during installation. Confirm by clicking the "OK" button on the right-hand side of the window.

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Getting started Installation

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You can change the installation folder of the software by entering it manually in the editing field or by clicking the "Browse" button. Then click "Continue" to continue the installation.

During the initial installation, the USB driver component has to be selected if no other EWM software with this option has been installed yet.

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4.3 After the installation

Getting started After the installation Back to contents

Before confirming, you have to connect SECINT X10 USB provided for the QDOC to the system. Confirm with "Yes" to configure the interface.

NOTE If SECINT X10 USB has been used for EWM software already installed on the PC, it can no longer

be used after the QDOC configuration is complete

Af ter the installation a folder called QDOC 9000 V2.0 should be displayed on the desktop. It contains the following:

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4.4 Functionalities

Getting started Functionalities

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The following functionalities are available: Recording program Registration, display function

Results database All welding data recordings are saved in this database.If it is located:on the local computer (no network solution)

the data is organized in a ring buffer via the database limiter. This limits the data quantity and deletes the oldest recordings.

on another computer (with network solutions)

If the results database is located on a data server, the cache is used for intermediate data storage if the database cannot be used for saving.

Evaluation program This program accesses the results database and is used to visualize the welding results. The result data are divided into separate records for each recording (or line in the table view) and the progression of the welding parameters (curves). Saving the curves is optional, i.e., welding curves do not need to be saved for each recording (reduces the recording volume).

Internal services (programs running automatically in the background) handle the communication between the programs. You can add comments to the recorded data either specified before the welding process or entered afterwards. They include:

Designation Any desired text Identifier Any desired term can be entered after welding, userOrder Orders are records for describing orders which are created and then selected

by the operator during production conversion.

The data storage is fundamentally revision- and manipulation-proof. All welding results are displayed with the orders etc. which were available at the time of production. Subsequent changing of the results is not possible.

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Getting started Start of measuring readiness - recording function

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4.5 Start of measuring readiness - recording function

The recording function is the central monitor of the system. It displays all process conditions online, i.e. the average values of the welding parameters for the current welding job. Operation of the recording module is fully automatic and does not require additional user action. Monitoring and recording of the measurement data begins after welding starts.

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5 Evaluating recordings

Evaluating recordings

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The data is recorded and evaluated simultaneously.

The program accesses a database and creates queries which are current when the program is started. Since new data are continuously being recorded in the database while production is in progress, you can view a current list by clicking the Update button. The New counter periodically indicates the number of newly entered records.

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5.1 Selecting data

Evaluating recordings Selecting data

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The table first lists all recordings in the default data directory or the last used directory. With the Data ⁄ Directory button you can open another directory containing valid data. The validity of a database is checked and indicated using icons.

Directory The selection is made in a directory tree; only local directories can be

selected. Using the client/server database, access to other servers/computers is only possible via their DNS or IP address.

Alias Directory paths, servers or other machines (e.g. on the network) can be saved as an alias and are thus easier to access.

Archive In the case of a network version with network operating software, all known archive directories created directly by the archive manager are listed.

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5.2 Configuring the display

Evaluating recordings Configuring the display

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You can adjust the table to suit your needs, i.e. you can select the columns to be displayed and define their sequence. The Configuration button opens the configuration screen. The Fields to be displayed window lists the current columns of the table.

Right/Left buttons - to remove/add columns•Up/Down to set the position of the selected column•Settings for ascending or descending order of the recordings, based on a defined number of columns. We recommend displaying the date first and then the time in descending order, so you get an up-to-date overview of the welding data at all times.

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You can also define individual "logos" and factory designations for printing.

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5.3 Filtering data

Evaluating recordings Filtering data

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With the Filter button you can limit the query quantity according to certain criteria. Only the currently displayed (i.e. configured) columns are filtered.

You can, for example, define a date filter if you wish to view welding data for one day only. You can also filter by time, to view the data of one shift only.

To activate the filter, you have to select the respective element (ticked) in the filter selection and the filter option itself (Filter ticked in the list view).

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5.4 Exporting and loading data

Evaluating recordings Exporting and loading data

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To select data click Select all or, if you wish to select only some data, use [CTRL] + the left mouse button.

Open the Export selection window via Data. The following export options are available:

Export HKS The selected records are exported from the database into a file named by you in a directory of your choice (e.g. USB stick). You can re-import the data unchanged via the Load button. This function ensures a simple selective way to evaluate welding results again in the same form at another location. All data are always exported combined into one record (average values and curves).

Export (curves) A selected record is exported as a CSV file (comma separated values), which can be read by Excel (from Microsoft Inc.) or another program. Thus all chronological signal sample values of this recording can be accessed.

Export (results) All selected records with the (configured) columns visible in the table are exported as a CSV file which can be read by Excel (from Microsoft Inc.) or another program. Thus you can create your own evaluation tables or logs.

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5.5

5.6

Deleting results

Log with welding history

Evaluating recordings Deleting results

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To select data click Select all or, if you wish to select only some data, use [CTRL] + the left mouse button. You can the delete these records using the Delete button.

Open the Export selection window via Data. The following export options are available:

Selecting Curves or double-clicking with the mouse will display the welding data history.

The curves of the measured process parameters are displayed individually and can be shown or hidden.•You can show additional curves simply by using the navigation buttons.•With the zooming function you can analyze the curves in more detail (zoom in - left mouse button from top left to bottom right; re-zoom in reverse order)

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Using the Measure button you can display two pointers which can be moved with the mouse. The bottom section of the window shows a table with the measurement values and their difference, which are determined at the position of the pointer. In the case of a measured welding speed or a speed calculated from the entered seam length (see inputs), the position in relation to the seam is also calculated at the pointer positions. It it possible to zoom between the pointers.

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5.7

5.8

Overlapping curves display

Inserting

Evaluating recordings Overlapping curves display

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Using this display, you can view up to 50 welds in their chronological progression as curve sets.

You can select the displayed parameters individually. The bottom table lists the displayed welds. If you select an entry in the table, it is highlighted in color in the curve set. This display is especially suitable for optimizations and troubleshooting.

Via the clipboard you can use this view e.g. in a report.

Using this function, you can add further details to the result data. This will apply to all selected records.

Name Adding comments to mark welding results, e.g. poor seam result, etc. Using the filter function you can then in turn make a selection based on these names.

Seam length When entering the seam length, the welding speed is calculated automatically (calculated welding speed). If the output and energy are determined in the machine based on the welding process, the energy input per unit length is also calculated.

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5.9 Consumption values

Evaluating recordings Consumption values Back to contents

When selecting this function via the Results ⁄ Consumption values button, a total line is displayed on the bottom section of the table. Calculation is carried out for all selected records if the following parameters were recorded:

Number of seams•Wire consumption•Gas consumption•Energy•Welding duration•Seam length•

Calculations can be made using these parameters.

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5.10 Statistics

Evaluating recordings Statistics

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Using the Results/Statistics button you can generate a statistical summary of all values displayed (filtered) in the table. The C1-C8 options select the channel over which a statistic is to be generated, e.g. current or voltage.

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6 Welding Procedure Qualification Record (WPQR)

Welding Procedure Qualification Record (WPQR)

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Using the WPQR function, the recorded welding data can be supplemented with additional information.

The WPQR is an informal function only and not to be seen as an alternative to a WPS system.

To access the WPQR, you first have to select a seam in the evaluation module and then click the WPQR button. The following window then opens:

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Welding Procedure Qualification Record (WPQR)

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The WPQR is divided into five subject areas:

General informationHere you can save general data, such as the WPQR number, manufacturer, customer, author, welder, etc. You can save additional comments under "Additional information". You can create any desired logo to be used to print the WPQR using the Load image button. With the PDF file button, you can save a WPS as a PDF file. Use the Job file button to save a PC300.NET database (*JXT file) to document the welding parameters which were used for welding. With the Print button, you can print the WPQR. The bottom section shows the the previously selected seams. Usually only one seam should be displayed here.

You can apply one WPQR to multiple selected seams. For this purpose, you have to select them in the evaluation module. In the WPQR section you can select the seam whose information you wish to add to all others in the bottom field. Automatic, continuous addition of predefined WPQRs during operation is not possible.

NOTE When selecting multiple records to edit WPQR data, special care

is required to prevent undesired overwriting of data.

Application example 1: Adjusting the WPQR data of a single record. Select only this individual record and edit it in the WPQR module. These data are applied when the window is closed.

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Application example 2: Information that has already been created for a record shall be applied to multiple records. Select all records including the one which already contains data (block marked in blue). Then open the WPQR screen. Select only the record whose information you wish to apply in the selection list in the bottom section. Closing the window with "OK" will copy these data to all records.

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Welding Procedure Qualification Record (WPQR)

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Joint type and seam typeHere you can save information on the seam, such as the welding joint, seam type, groove preparation, geometric form, position, etc. When doing so, note that selecting a specific seam type requires the logical selection of a specific groove preparation. This is taken into account by the logic of the WPQR in that only certain selections of various fields are possible. Note the following chain of causation: seam type = groove preparation = geometric form = position

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Welding Procedure Qualification Record (WPQR)

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Production parametersOn this dialog the user can set the production parameters of the seam, such as the welding process method, pass type, specifications on the welding joint, seam guidance, current type and set point values.

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Welding Procedure Qualification Record (WPQR)

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Welding consumables – GasesOn this dialog you can save your welding consumables, shielding gases and gas backing settings.

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Welding Procedure Qualification Record (WPQR)

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EquipmentOn this dialog, the WPQR author can save information on the welding torch, cooling, torch position, electrode, operating mode, welding type, job number, program number and ignition.

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7

7.1

Additional functions

Creating backups with the data manager

Additional functions Creating backups with the data manager

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With the data manager, you can manage the generated measurement data. You can copy, move, delete, export and import data.

The data manager is divided into a top and bottom section. Whichever section is active (top section in the figure) functions as the source directory, and the inactive section (bottom section in the figure) functions as the destination directory.

Top section:

• shows all available records in the source directory .• Records sorted by day

Bottom section

• destination directory, in which the selected records will be copied or moved.

The source and destination directories can be set as desired. Aliases (see "Evaluating") or directories can be used. (To open the window, tick Directory.) You can also create new directories or delete selected directories.

NOTE Using Delete directory can also accidentally delete system folders of the operating system or required

directories of the QDOC 9000 V2.0 system!

Select individual day data by clicking them with the mouse; you can select multiple records using [Ctrl] + mouse button.

Copying, moving and deleting records: You can copy or move selected day data by copying or moving them from the source directory to the destination directory.

Moving the data will delete it from the source directory. With the Delete button you will delete selected data in the source directory permanently.

With the Export function you can export data to a USB stick, and with Import you can read them in on another machine.

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7.2

7.2.1

Troubleshooting

USB test program

Additional functions Troubleshooting

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To test whether data communication is possible, the USB test program can be started. Next, select the required USB serial converter. Clicking the Config button allows you to set the required baud rate of 19200. With the Start button, communication between the computer and machine is started. Stop terminates communication.

If communication is successful, the data packets will look similar to this:

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7.2.2 EWM USB manager

Additional functions Troubleshooting

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With the USB manager you can easily configure SECINT X10 USB for either QDOC 9000 V2.0 or any other EWM program, such as PC300.NET. With the USB manager, the virtual COM port of SECINT X10 USB can be read in case of a non-QDOC 9000 V2.0 configuration and the code of SECINT X10 USB. In addition, you can see the type of software for which SECINT X10 USB is configured.

Configured for QDOC 9000 V2.0:

Configured for PC300.NET or other EWM software:

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