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Q-Eye
Operating Instructions
EN
System extension
[
42,0426,0112,EN 009-20052020
2
Dear reader,
Introduction Thank you for the trust you have placed in our company and congratulations on buying this
high-quality Fronius product. These instructions will help you familiarise yourself with the
product. Reading the instructions carefully will enable you to learn about the many different
features it has to offer. This will allow you to make full use of its advantages.
Please also note the safety rules to ensure greater safety when using the product. Careful
handling of the product will repay you with years of safe and reliable operation. These are
essential prerequisites for excellent results.
EN
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4
Contents
Safety rules ................................................................................................................................................ 7
Explanation of safety notices ................................................................................................................ 7
General ................................................................................................................................................. 7
Proper use ............................................................................................................................................ 7
Environmental conditions...................................................................................................................... 8
Obligations of the operator.................................................................................................................... 8
Obligations of personnel ....................................................................................................................... 8
Mains connection .................................................................................................................................. 8
Protecting yourself and others .............................................................................................................. 9
Danger from toxic gases and vapours .................................................................................................. 9
Danger from flying sparks ..................................................................................................................... 10
Risks from mains current and welding current...................................................................................... 10
Meandering welding currents................................................................................................................ 11
EMC Device Classifications .................................................................................................................. 12
EMC measures ..................................................................................................................................... 12
EMF measures...................................................................................................................................... 13
Specific hazards.................................................................................................................................... 13
Requirement for the shielding gas ........................................................................................................ 14
Danger from shielding gas cylinders..................................................................................................... 14
Safety measures at the installation location and during transport ........................................................ 15
Safety measures in normal operation ................................................................................................... 15
Commissioning, maintenance and repair.............................................................................................. 16
Safety inspection................................................................................................................................... 16
Disposal ................................................................................................................................................ 16
Safety symbols...................................................................................................................................... 17
Data protection...................................................................................................................................... 17
Copyright............................................................................................................................................... 17
General information ................................................................................................................................... 18
Principle ................................................................................................................................................ 18
Benefits ................................................................................................................................................. 18
Device concept ..................................................................................................................................... 18
Application areas and intended purpose............................................................................................... 20
Scope of supply .................................................................................................................................... 21
Options.................................................................................................................................................. 21
The following components are required but are not included in the scope of supply ........................... 22
Warning notices on the device.............................................................................................................. 22
Control elements and connections............................................................................................................. 23
General ................................................................................................................................................. 23
Power supply ........................................................................................................................................ 23
Camera unit .......................................................................................................................................... 24
Before commissioning................................................................................................................................ 26
Setup regulations .................................................................................................................................. 26
Mains connection .................................................................................................................................. 26
Compressed air supply .............................................................................................................................. 27
Compressed air supply ......................................................................................................................... 27
Mounting the camera unit .......................................................................................................................... 28
Overview of available mounting devices............................................................................................... 28
Mount/replace welding torch clamp ...................................................................................................... 28
Mounting the Q-Eye bracket ................................................................................................................. 29
Mounting the camera unit ..................................................................................................................... 29
Mounting and connecting the power supply............................................................................................... 31
Setup regulations .................................................................................................................................. 31
Mounting the power supply horizontally................................................................................................ 31
Mounting the power supply vertically .................................................................................................... 31
Connecting control lines to the power supply ....................................................................................... 32
Connecting and routing the hosepack ....................................................................................................... 33
Connect the hosepack to the power supply and the compressed air supply........................................ 33
Protective tube for compressed air hose .............................................................................................. 33
Connecting the hosepack to the camera unit........................................................................................ 34
Positioning the protective tube for the compressed air hose ................................................................ 34
EN
5
Routing the hosepack ........................................................................................................................... 35
Connecting the interface ............................................................................................................................ 36
Connecting the digital RS232 I/O module............................................................................................. 36
Activating visualisation of the power source data ...................................................................................... 37
RCU 5000i ............................................................................................................................................ 37
Setting up the PC....................................................................................................................................... 38
General ................................................................................................................................................. 38
System requirements ............................................................................................................................ 38
Installing the driver for the camera........................................................................................................ 38
Port 15010 ............................................................................................................................................ 40
Installing the Q-Eye server/client .......................................................................................................... 41
Q-Eye software .......................................................................................................................................... 43
Starting Q-Eye ...................................................................................................................................... 43
Overview ............................................................................................................................................... 44
Rotate the view ..................................................................................................................................... 44
Scaling .................................................................................................................................................. 44
Play/stop ............................................................................................................................................... 45
Information ............................................................................................................................................ 45
Open welding recording ........................................................................................................................ 45
Manually save the welding recordings .................................................................................................. 45
Automatically save welding recording................................................................................................... 45
Visualisation of the power source parameters ...................................................................................... 45
Zoom function ....................................................................................................................................... 46
Representation of the recording time.................................................................................................... 46
IP address for server............................................................................................................................. 47
Camera settings.................................................................................................................................... 47
Camera control ..................................................................................................................................... 48
Setting up a network connection................................................................................................................ 50
Local client/server operation on a PC ................................................................................................... 50
Client/server operation on two PCs via direct Ethernet connection...................................................... 50
Client/server operation on two PCs via a network ................................................................................ 51
Adjusting the camera image ...................................................................................................................... 52
Setting the camera focus ...................................................................................................................... 52
Optical filters .............................................................................................................................................. 53
Filter types and use............................................................................................................................... 53
Inserting the optical filter in the camera unit ......................................................................................... 53
Care, maintenance and disposal ............................................................................................................... 55
General ................................................................................................................................................. 55
Every start-up........................................................................................................................................ 55
If necessary........................................................................................................................................... 55
Disposal ................................................................................................................................................ 57
Troubleshooting ......................................................................................................................................... 58
General ................................................................................................................................................. 58
Troubleshooting .................................................................................................................................... 58
Technical data............................................................................................................................................ 62
Camera unit .......................................................................................................................................... 62
Power supply ........................................................................................................................................ 62
6
Safety rules
EN
Explanation of
safety notices
DANGER!
Indicates immediate danger.
► If not avoided, death or serious injury will result.
WARNING!
Indicates a potentially hazardous situation.
► If not avoided, death or serious injury may result.
CAUTION!
Indicates a situation where damage or injury could occur.
► If not avoided, minor injury and/or damage to property may result.
NOTE!
Indicates a risk of flawed results and possible damage to the equipment.
General The device is manufactured using state-of-the-art technology and according to recognised
safety standards. If used incorrectly or misused, however, it can cause:
- injury or death to the operator or a third party,
- damage to the device and other material assets belonging to the operating company,
- inefficient operation of the device.
All persons involved in commissioning, operating, maintaining and servicing the device
must:
- be suitably qualified,
- have sufficient knowledge of welding and
- read and follow these operating instructions carefully.
The operating instructions must always be at hand wherever the device is being used. In
addition to the operating instructions, attention must also be paid to any generally applicable and local regulations regarding accident prevention and environmental protection.
All safety and danger notices on the device
- must be in a legible state,
- must not be damaged,
- must not be removed,
- must not be covered, pasted or painted over.
For the location of the safety and danger notices on the device, refer to the section headed
"General" in the operating instructions for the device.
Before switching on the device, rectify any faults that could compromise safety.
This is for your personal safety!
Proper use The device is to be used exclusively for its intended purpose.
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The device is intended solely for the welding processes specified on the rating plate.
Any use above and beyond this purpose is deemed improper. The manufacturer shall not
be held liable for any damage arising from such usage.
Proper use includes:
- carefully reading and following all the instructions given in the operating instructions
- studying and obeying all safety and danger notices carefully
- performing all stipulated inspection and maintenance work.
Never use the device for the following purposes:
- Thawing out pipes
- Charging batteries
- Starting engines
The device is designed for use in industry and the workshop. The manufacturer accepts
no responsibility for any damage caused through use in a domestic setting.
The manufacturer likewise accepts no liability for inadequate or incorrect results.
Environmental
conditions
Obligations of the
operator
Operation or storage of the device outside the stipulated area will be deemed as not in accordance with the intended purpose. The manufacturer shall not be held liable for any damage arising from such usage.
Ambient temperature range:
- during operation: -10 °C to + 40 °C (14 °F to 104 °F)
- during transport and storage: -20 °C to +55 °C (-4 °F to 131 °F)
Relative humidity:
- up to 50% at 40 °C (104 °F)
- up to 90% at 20 °C (68 °F)
The surrounding air must be free from dust, acids, corrosive gases or substances, etc.
Can be used at altitudes of up to 2000 m (6561 ft. 8.16 in.)
The operator must only allow persons to work with the device who:
- are familiar with the fundamental instructions regarding safety at work and accident
prevention and have been instructed in how to use the device
- have read and understood these operating instructions, especially the section "safety
rules", and have confirmed as much with their signatures
- are trained to produce the required results.
Checks must be carried out at regular intervals to ensure that operators are working in a
safety-conscious manner.
Obligations of
personnel
Mains connection Devices with a higher rating may affect the energy quality of the mains due to their current
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Before using the device, all persons instructed to do so undertake:
- to observe the basic instructions regarding safety at work and accident prevention
- to read these operating instructions, especially the "Safety rules" section and sign to
confirm that they have understood them and will follow them.
Before leaving the workplace, ensure that people or property cannot come to any harm in
your absence.
consumption.
This may affect a number device types in terms of:
- Connection restrictions
- Criteria with regard to the maximum permissible mains impedance
- Criteria with regard to the minimum short-circuit power requirement
*)
at the interface with the public grid
*)
*)
see "Technical data"
In this case, the plant operator or the person using the device should check whether the
device may be connected, where appropriate by discussing the matter with the power supply company.
IMPORTANT! Ensure that the mains connection is earthed properly
EN
Protecting yourself and others
Anyone working with the device exposes themselves to numerous risks, e.g.
- flying sparks and hot pieces of metal
- Arc radiation, which can damage eyes and skin
- Hazardous electromagnetic fields, which can endanger the lives of those using cardiac pacemakers
- Risk of electrocution from mains current and welding current
- Greater noise pollution
- Harmful welding fumes and gases
Suitable protective clothing must be worn when working with the device. The protective
clothing must have the following properties:
- Flame-resistant
- Insulating and dry
- Covers the whole body, is undamaged and in good condition
- Safety helmet
- Trousers with no turn-ups
Protective clothing refers to a variety of different items. Operators should:
- Protect eyes and face from UV rays, heat and sparks using a protective visor and regulation filter
- Wear regulation protective goggles with side protection behind the protective visor
- Wear stout footwear that provides insulation even in wet conditions
- Protect the hands with suitable gloves (electrically insulated and providing protection
against heat)
- Wear ear protection to reduce the harmful effects of noise and to prevent injury
Danger from toxic
gases and vapours
Keep all persons, especially children, out of the working area while any devices are in operation or welding is in progress. If, however, there are people in the vicinity:
- Make them aware of all the dangers (risk of dazzling by the arc, injury from flying
sparks, harmful welding fumes, noise, possible risks from mains current and welding
current, etc.)
- Provide suitable protective equipment
- Alternatively, erect suitable safety screens/curtains.
The fumes produced during welding contain harmful gases and vapours.
Welding fumes contain substances that cause cancer, as stated in Monograph 118 of the
International Agency for Research on Cancer.
Use at-source extraction and a room extraction system.
If necessary, use a welding torch with an integrated extraction device.
Keep your face away from welding fumes and gases.
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Fumes and hazardous gases
- must not be breathed in
- must be extracted from the working area using appropriate methods.
Ensure an adequate supply of fresh air. Ensure that there is a ventilation rate of at least
20 m³ per hour at all times.
Otherwise, a welding helmet with an air supply must be worn.
If there is any doubt about whether the extraction capacity is sufficient, the measured toxic
emission values should be compared with the permissible limit values.
The following components are responsible, amongst other things, for the degree of toxicity
of welding fumes:
- Metals used for the workpiece
- Electrodes
- Coatings
- Cleaners, degreasers, etc.
- Welding process used
The relevant material safety data sheets and manufacturer's specifications for the listed
components should therefore be studied carefully.
Recommendations for trade fair scenarios, risk management measures and for identifying
working conditions can be found on the European Welding Association website under
Health & Safety (https://european-welding.org).
Danger from flying sparks
Flammable vapours (e.g. solvent fumes) should be kept away from the arc's radiation area.
Close the shielding gas cylinder valve or main gas supply if no welding is taking place.
Flying sparks may cause fires or explosions.
Never weld close to flammable materials.
Flammable materials must be at least 11 metres (36 ft. 1.07 in.) away from the arc, or al-
ternatively covered with an approved cover.
A suitable, tested fire extinguisher must be available and ready for use.
Sparks and pieces of hot metal may also get into adjacent areas through small gaps or
openings. Take appropriate precautions to prevent any danger of injury or fire.
Welding must not be performed in areas that are subject to fire or explosion or near sealed
tanks, vessels or pipes unless these have been prepared in accordance with the relevant
national and international standards.
Do not carry out welding on containers that are being or have been used to store gases,
propellants, mineral oils or similar products. Residues pose an explosive hazard.
Risks from mains
current and welding current
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An electric shock is potentially life threatening and can be fatal.
Do not touch live parts either inside or outside the device.
During MIG/MAG welding and TIG welding, the welding wire, the wirespool, the feed rollers
and all pieces of metal that are in contact with the welding wire are live.
Always set the wirefeeder up on a sufficiently insulated surface or use a suitable, insulated
wirefeeder holder.
Make sure that you and others are protected with an adequately insulated, dry base or cover for the earth or ground potential. This base or cover must extend over the entire area
between the body and the earth or ground potential.
All cables and leads must be secured, undamaged, insulated and adequately dimensioned. Replace loose connections and scorched, damaged, or inadequately dimensioned
cables and leads immediately.
Use the handle to ensure the power connections are tight before every use.
In the case of power cables with a bayonet connector, rotate the power cable around the
longitudinal axis by at least 180° and pretension.
Do not wrap cables or leads around the body or parts of the body.
The electrode (rod electrode, tungsten electrode, welding wire, etc.) must
- never be immersed in liquid for cooling
- Never touch the electrode when the power source is switched on.
Double the open circuit voltage of a power source can occur between the welding electrodes of two power sources. Touching the potentials of both electrodes at the same time
may be fatal under certain circumstances.
Arrange for the mains cable to be checked regularly by a qualified electrician to ensure the
ground conductor is functioning properly.
Protection class I devices require a mains supply with ground conductor and a connector
system with ground conductor contact for proper operation.
EN
Meandering welding currents
Operation of the device on a mains supply without ground conductor and on a socket without ground conductor contact is only permitted if all national regulations for protective separation are observed.
Otherwise, this is considered gross negligence. The manufacturer shall not be held liable
for any damage arising from such usage.
If necessary, provide adequate earthing for the workpiece.
Switch off unused devices.
Wear a safety harness if working at height.
Before working on the device, switch it off and pull out the mains plug.
Attach a clearly legible and easy-to-understand warning sign to the device to prevent any-
one from plugging the mains plug back in and switching it on again.
After opening the device:
- Discharge all live components
- Ensure that all components in the device are de-energised.
If work on live parts is required, appoint a second person to switch off the main switch at
the right moment.
If the following instructions are ignored, meandering welding currents can develop with the
following consequences:
- Fire hazard
- Overheating of parts connected to the workpiece
- Irreparable damage to ground conductors
- Damage to device and other electrical equipment
Ensure that the workpiece is held securely by the workpiece clamp.
Attach the workpiece clamp as close as possible to the area that is to be welded.
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Position the device with sufficient insulation against electrically conductive environments,
e.g. Insulation against conductive floor or insulation to conductive racks.
If distribution boards, twin-head mounts, etc., are being used, note the following: The electrode of the welding torch / electrode holder that is not used is also live. Make sure that the
welding torch / electrode holder that is not used is kept sufficiently insulated.
In the case of automated MIG/MAG applications, ensure that only an insulated wire electrode is routed from the welding wire drum, large wirefeeder spool or wirespool to the wirefeeder.
EMC Device Classifications
EMC measures In certain cases, even though a device complies with the standard limit values for emis-
Devices in emission class A:
- Are only designed for use in industrial settings
- Can cause line-bound and radiated interference in other areas
Devices in emission class B:
- Satisfy the emissions criteria for residential and industrial areas. This is also true for
residential areas in which the energy is supplied from the public low-voltage mains.
EMC device classification as per the rating plate or technical data.
sions, it may affect the application area for which it was designed (e.g. when there is sensitive equipment at the same location, or if the site where the device is installed is close to
either radio or television receivers).
If this is the case, then the operator is obliged to take appropriate action to rectify the situation.
Check and evaluate the immunity to interference of nearby devices according to national
and international regulations. Examples of equipment that may be susceptible to interference from the device include:
- Safety devices
- Power, signal and data transfer lines
- IT and telecommunications devices
- Measuring and calibrating devices
Supporting measures for avoidance of EMC problems:
1. Mains supply
- If electromagnetic interference arises despite correct mains connection, addition-
al measures are necessary (e.g. use a suitable line filter).
2. Welding power leads
- must be kept as short as possible
- must run close together (to avoid EMF problems)
- must be kept well apart from other leads
3. Equipotential bonding
4. Earthing of the workpiece
- If necessary, establish an earth connection using suitable capacitors.
5. Shielding, if necessary
- Shield off other nearby devices
- Shield off entire welding installation
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EMF measures Electromagnetic fields may pose as yet unknown risks to health:
- effects on the health of others in the vicinity, e.g. wearers of pacemakers and hearing
aids
- wearers of pacemakers must seek advice from their doctor before approaching the device or any welding that is in progress
- for safety reasons, keep distances between the welding cables and the welder's head/
torso as large as possible
- do not carry welding cables and hosepacks over the shoulders or wind them around
any part of the body
Specific hazards Risk of damage to eyesight. Never look directly into the camera's flash bulb.
Keep hands, hair, clothing and tools away from moving parts. For example:
- Fans
- Cogs
- Rollers
- Shafts
- Wirespools and welding wires
Do not reach into the rotating cogs of the wire drive or into rotating drive components.
Covers and side panels may only be opened/removed while maintenance or repair work is
being carried out.
EN
During operation
- Ensure that all covers are closed and all side panels are fitted properly.
- Keep all covers and side panels closed.
The welding wire emerging from the welding torch poses a high risk of injury (piercing of
the hand, injuries to the face and eyes, etc.). Always keep the torch well away from the
body (devices with a wire-feed unit).
Never touch the workpiece during or after welding - risk of burns.
Slag can jump off cooling workpieces. The specified protective equipment must therefore
also be worn when reworking workpieces, and steps must be taken to ensure that other
people are also adequately protected.
Welding torches and other parts with a high operating temperature must be allowed to cool
down before handling.
Special provisions apply in areas at risk of fire or explosion - observe relevant
national and international regulations.
Power sources that are to be used in areas with increased electric risk (e.g. near boilers)
must carry the "Safety" sign. However, the power source must not be located in such areas.
Risk of scalding from escaping coolant. Switch off cooling unit before disconnecting coolant flow or return lines.
13
Use only suitable load-carrying equipment supplied by the manufacturer when transporting
devices by crane.
- Hook chains and/or ropes onto all suspension points provided on the load-carrying
equipment.
- Chains and ropes must be at the smallest angle possible to the vertical.
- Remove gas cylinder and wire-feed unit (MIG/MAG and TIG devices).
If the wire-feed unit is attached to a crane holder during welding, always use a suitable,
insulated wire-feed unit holder (MIG/MAG and TIG devices).
If the device has a carrying strap or handle, this is intended solely for carrying by hand. The
carrying strap is not to be used if transporting with a crane, forklift or other mechanical
hoist.
All lifting accessories (straps, handles, chains, etc.) used in connection with the device or
its components must be tested regularly (e.g. for mechanical damage, corrosion or changes caused by other environmental factors).
The testing interval and scope of testing must comply with applicable national standards
and directives as a minimum.
Odourless and colourless shielding gas may escape unnoticed if an adapter is used for the
shielding gas connection. Prior to assembly, seal the device-side thread of the adapter for
the shielding gas connection using suitable Teflon tape.
Requirement for
the shielding gas
Danger from
shielding gas cylinders
Especially with ring lines, contaminated shielding gas can cause damage to equipment and
reduce welding quality.
Meet the following requirements regarding shielding gas quality:
- Solid particle size < 40 µm
- Pressure condensation point < -20 °C
- Max. oil content < 25 mg/m³
Use filters if necessary.
Shielding gas cylinders contain gas under pressure and can explode if damaged. As the
shielding gas cylinders are part of the welding equipment, they must be handled with the
greatest of care.
Protect shielding gas cylinders containing compressed gas from excessive heat, mechanical impact, slag, naked flames, sparks and arcs.
Mount the shielding gas cylinders vertically and secure according to instructions to prevent
them falling over.
Keep the shielding gas cylinders well away from any welding or other electrical circuits.
Never hang a welding torch on a shielding gas cylinder.
Never touch a shielding gas cylinder with an electrode.
14
Risk of explosion - never attempt to weld a pressurised shielding gas cylinder.
Only use shielding gas cylinders suitable for the application in hand, along with the correct
and appropriate accessories (regulator, hoses and fittings). Only use shielding gas cylinders and accessories that are in good condition.
Turn your face to one side when opening the valve of a shielding gas cylinder.
Close the shielding gas cylinder valve if no welding is taking place.
Safety measures
at the installation
location and during transport
If the shielding gas cylinder is not connected, leave the valve cap in place on the cylinder.
EN
The manufacturer's instructions must be observed as well as applicable national and international regulations for shielding gas cylinders and accessories.
A device toppling over could easily kill someone. Place the device on a solid, level surface
such that it remains stable
- The maximum permissible tilt angle is 10°.
Special regulations apply in rooms at risk of fire or explosion
- Observe relevant national and international regulations.
Use internal directives and checks to ensure that the workplace environment is always
clean and clearly laid out.
Only set up and operate the device in accordance with the degree of protection shown on
the rating plate.
When setting up the device, ensure there is an all-round clearance of 0.5 m (1 ft. 7.69 in.)
to ensure that cooling air can flow in and out freely.
When transporting the device, observe the relevant national and local guidelines and accident prevention regulations. This applies especially to guidelines regarding the risks arising during transport.
Safety measures
in normal operation
Do not lift or transport operational devices. Switch off devices before transport or lifting.
Before transporting the device, allow coolant to drain completely and detach the following
components:
- Wirefeeder
- Wirespool
- Shielding gas cylinder
After transporting the device, the device must be visually inspected for damage before
commissioning. Any damage must be repaired by trained service technicians before commissioning the device.
Only operate the device when all safety devices are fully functional. If the safety devices
are not fully functional, there is a risk of
- injury or death to the operator or a third party
- damage to the device and other material assets belonging to the operator
- inefficient operation of the device
Any safety devices that are not functioning properly must be repaired before switching on
the device.
Never bypass or disable safety devices.
Before switching on the device, ensure that no one is likely to be endangered.
Check the device at least once a week for obvious damage and proper functioning of safety
devices.
Always fasten the shielding gas cylinder securely and remove it beforehand if the device
is to be transported by crane.
Only the manufacturer's original coolant is suitable for use with our devices due to its properties (electrical conductibility, anti-freeze agent, material compatibility, flammability, etc.).
15
Only use suitable original coolant from the manufacturer.
Do not mix the manufacturer's original coolant with other coolants.
Only connect the manufacturer's system components to the cooling circuit.
The manufacturer accepts no liability for damage resulting from use of other system com-
ponents or a different coolant. In addition, all warranty claims will be forfeited.
Cooling Liquid FCL 10/20 does not ignite. The ethanol-based coolant can ignite under cer-
tain conditions. Transport the coolant only in its original, sealed containers and keep well
away from any sources of ignition.
Used coolant must be disposed of properly in accordance with the relevant national and
international regulations. The coolant safety data sheet may be obtained from your service
centre or downloaded from the manufacturer's website.
Check the coolant level before starting to weld, while the system is still cool.
Commissioning,
maintenance and
repair
Safety inspection The manufacturer recommends that a safety inspection of the device is performed at least
It is impossible to guarantee that bought-in parts are designed and manufactured to meet
the demands made of them, or that they satisfy safety requirements.
- Use only original spare and wearing parts (also applies to standard parts).
- Do not carry out any modifications, alterations, etc. to the device without the manufacturer's consent.
- Components that are not in perfect condition must be replaced immediately.
- When ordering, please give the exact designation and part number as shown in the
spare parts list, as well as the serial number of your device.
The housing screws provide the ground conductor connection for earthing the housing
parts.
Only use original housing screws in the correct number and tightened to the specified
torque.
once every 12 months.
The manufacturer recommends that the power source be calibrated during the same 12month period.
A safety inspection should be carried out by a qualified electrician
- after any changes are made
- after any additional parts are installed, or after any conversions
- after repair, care and maintenance has been carried out
- at least every twelve months.
For safety inspections, follow the appropriate national and international standards and directives.
Further details on safety inspection and calibration can be obtained from your service centre. They will provide you on request with any documents you may require.
Disposal Do not dispose of this device with normal domestic waste! To comply with the European
Directive on Waste Electrical and Electronic Equipment and its implementation as national
law, electrical equipment that has reached the end of its life must be collected separately
and returned to an approved recycling facility. Any device that you no longer require must
either be returned to your dealer or given to one of the approved collection and recycling
facilities in your area. Ignoring this European Directive may have potentially adverse affects on the environment and your health!
16
Safety symbols Devices with the CE mark satisfy the essential requirements of the low-voltage and elec-
tromagnetic compatibility directives (e.g. relevant product standards of the EN 60 974 series).
Fronius International GmbH hereby declares that the device is compliant with Directive
2014/53/EU. The full text on the EU Declaration of Conformity can be found at the following
address: http://www.fronius.com
Devices marked with the CSA test mark satisfy the requirements of the relevant standards
for Canada and the USA.
Data protection The user is responsible for the safekeeping of any changes made to the factory settings.
The manufacturer accepts no liability for any deleted personal settings.
Copyright Copyright of these operating instructions remains with the manufacturer.
The text and illustrations are all technically correct at the time of printing. We reserve the
right to make changes. The contents of the operating instructions shall not provide the basis for any claims whatsoever on the part of the purchaser. If you have any suggestions for
improvement, or can point out any mistakes that you have found in the instructions, we will
be most grateful for your comments.
EN
17
General information
Lieferumfang
scope of supply
vom Anwender
from user
data
Luft
air
LocalNet
RS232
serial
Netzteil
power supply
Kamera + Beleuchtung
camera + lighting
Schlauchpaket
hose package
digital I/O module
supply
data
Versorgung
Steuerung
SPS
control
Principle Q-Eye is a camera-based monitoring system for automated arc welding processes. During
the welding process it records the weld pool, the solidification process and the completed
weld seam. It allows the welding process to be monitored from a distance, e.g. from a control station. It is also possible to save and retrieve recording sequences as files. The welding current, welding voltage and wire feed speed data can also be viewed through a data
connection to the power source.
Benefits - Traceability of the current welding process outside a welding cell, remote from the
welding process
- High-contrast and detailed images of the creation of the weld seam
- Camera, high-performance lighting and control integrated in a compact camera unit
- Easy access to the welding torch as the entire length of the welding torch neck is kept
clear; the camera unit is at a distance of approx. 25 cm from the Tool Center Point
(TCP)
- Exploits the arc-shielding effect of the welding torch gas nozzle
- Combined cooling and cleaning concept for camera optics and lighting system
- Robust, electrically and thermally insulated camera unit housing
- Suitable for use in high-temperature areas, even short-term exposure up to 80 °C
Device concept Camera, high-performance flash bulb, and a control unit for camera and flash synchroni-
sation are combined in a compact and robust camera unit. The camera unit features easily
replaceable, transparent protective glass for the camera lens and flash bulb, as well as air
cooling for the internal components. The compressed air required for the air cooling also
flows over the protective glass and is effective in keeping these free of smoke and deposits.
The camera unit is connected to the power supply and the compressed air supply via a
dedicated hosepack.
Depending on environmental conditions a standard office PC or industrial PC is connected
to the power supply. The power supply provides the flash bulb with the high voltage required. The data line from the camera to the PC runs through the hosepack and power supply. The client/server architecture of the Q-Eye software supports remote transfer to
another PC, where the welding recording can be viewed.
18
The client software retrieves the data from the server software. The client software can be
installed on the same PC as the server software. The client software can likewise be installed on any PC that is connected to the server PC via Ethernet.
If the power source is connected via the optional RS232/LocalNet converter, it is possible
to control the welding recording using the power source signals. This ensures that welding
recording only takes place during the welding process.
- The welding recording is started and stopped automatically via the power source signals when the arc is ignited and extinguished respectively
- When archiving welding recordings, only data that is directly related to the welding
process is collated
- The power source parameters for the welding current, voltage and wire feed speed
can be viewed underneath the welding recording in the form of a synchronous graph
and also as real-time values
EN
If there is no connection to the power source, the welding recording is started and stopped
via the supplied digital RS232 I/O module.
- The 24 V DC control signal from an external control (system, robot, PLC, etc.) starts
and stops the welding recording.
- The 24 V DC control signal is directed to the digital RS232 I/O module.
- The lines for the 24 V and GND voltage of the control signal are connected to the digital I/O module, which is connected in turn to the PC (server) via an RS232 cable.
- The visualisation is limited to the welding recording, additional parameters specific to
the power source are not displayed.
When using the RS232/LocalNet converter, simultaneous use of the digital RS232 I/O
module is recommended. This allows the recording to be controlled independently, e.g.
when the arc is started and stopped frequently (interval welding), which prevents a number
of short recording sequences from being created.
In the case of a Twin process with two power sources and two arcs, two RS232/LocalNet
converters are required in order to display the power source parameters for both arcs. The
following screenshot shows the power source parameter dual view for a Twin process.
19
Application areas
and intended purpose
WARNING!
Operating the equipment incorrectly or shoddy workmanship can cause serious injury and damage.
The following documents must be completely read and understood before commissioning:
► these operating instructions
► the operating instructions of the power source in use
► the operating instructions of all other system components
► especially the safety rules in the above mentioned documents
The device is intended exclusively for process monitoring within the following permissible
application areas and environments. Any use above and beyond this purpose is deemed
improper. The manufacturer shall not be held liable for any damage arising from such usage.
The device is designed for use in industry and the workshop. The manufacturer accepts
no responsibility for any damage caused through use in a domestic setting.
Permissible, typical application areas and environments are:
- Automated welding systems:
robot welding systems
linear welding systems
gantry welding systems
high performance welding applications
- Production halls
- Heavy steel construction, with the following conditions:
deposits
radiation
heat: short-term exposure of the camera to temperatures up to 80 °C
- Adjustment for automated systems
- Protection of personnel: remote monitoring due to welding process conditions, such
as heat, dust, radiation, smoke, robot movement, etc.
20
Utilisation in accordance with the intended purpose also comprises:
- complying with all the instructions in the operating instructions
- of Q-Eye
- of the power source in use
- of all other system components
- performing all stipulated inspection and servicing work
Utilisation not in accordance with the intended purpose comprises:
- use of unsuitable hardware and software for the PC(s) to be used
- unsuitable compressed air supply or insufficient cool, pure compressed air (the exact
specification can be found in the "Compressed air supply" chapter.)
- if there is no LocalNet connection between the power source and the server PC: provision of an unsuitable external signal for controlling the recording
- incorrect mounting and alignment of the camera unit: the camera lens must not point
directly at the arc; it must be appropriately shielded by the gas nozzle or through use
of suitable additional devices.
- direct reflection of a laser beam in the camera lens: if a laser is used in the monitored
welding process, this must not be reflected in the camera lens (for example by the
workpiece surface), as this would destroy the camera sensor.
Scope of supply System is supplied with:
- Camera unit including
- mounting bracket
- software
- transparent protective glass for the flash bulb and camera
- Power supply
- for supplying the flash bulb
- for transferring the camera data to the PC
- Digital RS232 I/O module
- for starting and stopping the welding recording via a 24 V control signal from an
external control.
- a data cable is provided for connecting the I/O module to the PC using the Q-Eye
software.
- hosepack, routes the following lines:
- high voltage lines for the flash bulb
- data line for the camera
- compressed air line, outer diameter 4 mm
EN
Options Depending on the type of application for Q-Eye, the following options may be required:
- clamp for the welding torch
- CMT
- Robacta
- Robacta Drive
- Q-Eye audio installation kit
- LocalNet/RS232 converter
- for the power source data connection for automatic starting and stopping of the
welding recording, synchronised with the igniting and extinguishing of the arc.
- for transferring the power source data: welding current, welding voltage and wire-
feed speed.
- LocalNet passive distributor
- for connecting the RS232/LocalNet converter if there are no free LocalNet con-
nection sockets on the power source.
21
The following
(1) (2)
components are
required but are
not included in
the scope of supply
The following components are also required in addition to the Q-Eye scope of supply and
the application-specific options:
- PC or PCs
- PC or industrial PC with suitable protection, depending on the environmental con-
ditions.
- More detailed information can be found in the "System requirements" section of
the "Commissioning" chapter.
- Compressed air supply according to the "Commissioning" chapter.
Warning notices
on the device
There are warning notices and safety symbols on the power supply. These warning notices
and safety symbols must not be removed or painted over. They warn against operating the
equipment incorrectly, as this may result in serious injury and damage.
WARNING!
An electric shock can be fatal.
Switch off the power supply before working on the hosepack or power supply.
No. Element
(1) Electric shock warning
(2) Rating plate
22
Control elements and connections
X1 X2 X3 X4
CAM1 CAM2 PC
EN
General
Power supply
NOTE!
As a result of software updates, you may find that your device has certain functions
that are not described in these operating instructions, or vice versa.
Certain illustrations may also differ slightly from the actual controls on your device. However, these controls function in exactly the same way.
No. Function
X1 X1: Connection socket for 600 V DC supply
supply for flash bulb, hosepack
X2 X2: 4-pin Molex Mini-Fit socket
input for relay control via 3.3 - 5 V TTL signal or alternative 24 V DC signal,
switches X3, e.g. for control of a solenoid valve
X3 X3: 2-pin Molex Mini-Fit socket
switched 24 V output, relay output controlled by X2
X4 X4: 2-pin Molex Micro-Fit socket
permanent 24 V output, supply for the digital I/O module
CAM1 USB-A port
for camera, hosepack
CAM2 USB-A port
for additional camera, hosepack
PC USB-B port
for PC
23
Camera unit
(1) (2)(3) (4) (5)
(1)
(3)
(4)
(5)
(2)
No. Function
(1) Fuse slow-blow 0.63 A
for 24 V output
(2) LED overtemperature - red
Lights up if the power supply overheats
LED overtemperature goes off: power supply is ready for use again
(3) LED power supply - green
Lights up when the power supply is connected to the mains
(4) Fuse slow-blow 6.3 A
Fuse protection for mains connection 110 V AC - 230 V AC
(5) Mains connection
Permissible input voltage range: 110 V AC - 230 V AC
No. Function
(1) Camera protective glass
with clear, circular area
24
(2) Flash bulb protective glass
textured throughout
(3) X1: 600 V supply connection socket
High-voltage supply flash bulb, hosepack
(4) Compressed air connection
Hosepack, outer diameter 4 mm
(5) Data cable connection socket
Hosepack
EN
25
Before commissioning
Setup regulations
If one of these devices topples over or falls it could cause serious or even fatal injury.
Make sure that all components are installed and secured correctly.
The system installer is responsible for the installation of Q-Eye monitoring system
components.
Ensure that:
► all connections are connected properly
► all screw fastenings are securely fixed
The manufacturer shall not be liable for any damage caused as a result of incorrect assembly of the monitoring system.
Mains connection The devices are designed to run at the mains voltage specified on the rating plate. The fuse
protection required for the mains cable can be found in the "Technical data" section. If there
is no mains cable or mains plug on your device, fit one that conforms to national standards.
WARNING!
NOTE!
NOTE!
An inadequately dimensioned electrical installation can cause serious damage.
The mains cable and its fuse must be dimensioned to suit the local power supply. The technical data shown on the rating plate applies.
26
Compressed air supply
EN
Compressed air
supply
The compressed air is used to cool the camera unit and to clean the protective glass for
the camera lens and flash bulb. The flow rate for the compressed air must correspond to
the following table, according to the number of images taken per second (frames per second - fps) and the ambient temperature:
Image/s Ambient temperature
fps = frames per
second
10 fps 20 l/min 20 l/min 25 l/min 30 l/min
15 fps 30 l/min 35 l/min 40 l/min 45 l/min
20 fps 40 l/min 45 l/min 50 l/min -
The values stated apply to a duty cycle of 100%.
A flow sensor is recommended to ensure sufficient cooling and cleaning under all operating
conditions. The flow rate can be set precisely according to the table using a flow sensor
and a pressure regulator.
NOTE!
Insufficient filtering of the compressed air supply can cause serious contamination
and damage within the camera unit.
up to 25 °C 40 °C 60 °C 80 °C
short-term exposure
The compressed air must be free of oil and water, corresponding to filter stages up to 0.01
µm.
Additional requirements for the compressed air supply:
- connection for the compressed air line with outer diameter of 4 mm near to the power
supply on the rear end of the hosepack
- pressure: maximum 10 bar
- All details apply to a compressed air temperature of up to 25°C
27
Mounting the camera unit
1
Overview of available mounting devices
Depending on the welding torch, the following mounting devices are available for supporting both the welding torch and the camera unit on the collision box. The additional mounting devices, as detailed in the sections "Mounting the Q-Eye bracket“ and "Mounting the
camera unit", are the same for all welding torches.
standard mounting bracket for Binzel clamp mounting bracket for Binzel or for Dinse
Mount/replace
welding torch
clamp
28
Mounting bracket CMT 22° or CMT 36°
Replace the existing mounting device
for the welding torch on the collision
box
– with a suitable mounting device as
listed in the section "Overview of
available mounting devices“.
Mounting the Q-
(1)(2) (3) (4) (5)
1
2
(6)
3
(7)
4
Eye bracket
Insert spacer with pin (1) in either hole
(3) or (5) depending on the required
position.
Align the threaded holes (2) and (4).
Secure the spacer using the M6 x 35
mm screw (6).
– Tighten the screw (6) to a torque
of 6 Nm.
EN
Mounting the
camera unit
(7) (8)
Secure the bracket for the camera unit to the threaded hole of the spacer (8) with the
M8 x 20 mm screw (7).
– Select the hole for the camera unit on the bracket according to the required posi-
tion.
– Turn the bracket to the required position before tightening.
– Tighten the screw (7) to a torque of 18.5 Nm.
NOTE!
Risk of irreparable damage to the camera sensor.
If a laser is used in the monitored welding process, this must not be reflected in the camera
lens, for example by the workpiece surface.
The camera lens must not point directly at the arc; it must be appropriately shielded by the
gas nozzle or via suitable additional devices.
29
(1)
1
2
Attach the camera unit to the bracket
using two M5 x 12 mm screws (1).
– Select the threaded holes for the
camera unit according to the required position.
– Tighten the screws (1) to a torque
of 4.5 Nm.
(1)
If necessary, readjust the position of
the camera unit.
– The positioning should be carried
out as shown.
– The camera should show the re-
quired image area, without reflections or glare due to flash or the
arc.
– If the welding process allows, ad-
justing the tilt angle of the welding
torch may help.
- If adjusting the orientation does not work, suitable shields must be used to block the
interfering light sources.
30
Mounting and connecting the power supply
(1) (3) (2)(3)(2)
1
2
3
1
EN
Setup regulations
Mounting the
power supply
horizontally
NOTE!
Mounting the power supply in an unsuitable environment can lead to serious damage.
Mount the power supply, according to its design, in a suitable or suitably protected environment according to protection class IP20.
The power supply can be mounted horizontally or vertically on the wall or floor. Detailed
information can be found in the following sections.
Screws for mounting the power supply on
the floor or wall are not included in the scope of supply.
Use two screws (2) to attach the mounting bracket (1) to the housing.
Attach the mounting bracket to the opposite housing side in the same way.
Attach the power supply on the mounting bracket to the wall or floor using
four screws (3).
Mounting the
power supply vertically
Screws for mounting the power supply on
the floor or wall are not included in the scope of supply.
Use four screws (2) to attach two
mounting brackets (1) to the housing.
(2)(1) (2) (2)(1)(2)
31
Attach the power supply on the moun-
(3)
(3)
(3)
(3)
2
X2 X3 PC X4
1
2
3
4
ting bracket to the wall or floor using
four screws (3).
Connecting control lines to the
power supply
Plug the 4-pin Molex Mini-Fit plug for
relay control into X2
Plug the 2-pin Molex Mini-Fit plug for
24 V relay control into X3
Plug the USB-B plug for the PC into the
PC port
Plug the 2-pin Molex Micro-Fit plug for
the 24 V supply of the digital I/O module into X4
32
Connecting and routing the hosepack
(1)
1
(2)
(3) (4)
(5)
3
(1)
(2)
EN
Connect the
hosepack to the
power supply and
the compressed
air supply
Fit the strain-relief device to the power
supply with a screw (1).
Secure the hosepack (2) with strain-relief device.
2
Connect the plug (3) for the flash bulb supply into connection socket X1.
- Position the plug (3) as shown in the figure on the right.
- Secure the plug (3) using a union nut.
Connect the plug (4) for the camera to one of the two CAM connection sockets.
4
Connect the hose (5) to the compressed air supply.
5
- A detailed specification for the compressed air supply can be found in the "Com-
pressed air supply" chapter.
Protective tube
for compressed
air hose
The protective tube (1) protects the exposed area of the compressed air hose (2) from the
damaging UV rays of the welding process. The protective tube (1) can be delivered preassembled on the compressed air hose (2) (as shown in the left figure) or separately (see
right figure).
(1) (2)
If the compressed air hose (2) is not delivered with the protective tube (1) already fitted:
Fit the protective hose (1) on the compressed air hose (2) as per the figure on the left
1
33
Connecting the
(1)
(2)
(3)
1
(1)
(2)
hosepack to the
camera unit
The positioning of the protective tube (1) when connecting the hosepack to the camera unit
is explained in the "Positioning the protective tube for the compressed air hose" section.
Connect the data cable (1) to the connection socket
- Connect and secure the push-pull plug as shown in the right-hand figure.
Push the compressed air hose (2) into the socket
2
- Ensure that the hose is secure.
- To release the hose press the blue ring as far as it will go.
Connect the plug (3) for the flash bulb supply into the connection socket and secure
3
with a union nut.
- Proceed as explained in "Connecting the hosepack to the power supply"
Positioning the
protective tube
for the compressed air hose
Slide the protective hose (1) completely onto the compressed air hose (2) as per the
1
figure on the right
(1)
34
Routing the hose-
1
pack
NOTE!
EN
Risk of damage.
Fasten the hosepack in such a way that it
cannot be damaged, kinked or subjected to
tensile stress.
Fasten the hosepack to the torch hosepack.
35
Connecting the interface
(2)(1)
(3)
(4)(5)
1
2
3
PC
24 V DCRS 232
Digitales I/O-Modul RS232
digital I/O module RS232
Netzteil Q-Eye
power supply Q-Eye
SPS Steuerung
SPC control
Signal 24 V
Connecting the
digital RS232 I/O
module
Connect the lines (1) and (2) from the
power source for the permanent 24 V
DC supply to the Ub+ and Ub- connections.
For the digital 24 V DC signal, which is used
to start and stop recording, e.g. from a PLC
or robot control:
connect lines (3) and (4) to the I0- and
I0+ connections.
The inputs are electrically isolated by
means of optical couplers.
Connect the RS232 plug (5) from the
PC.
36
Activating visualisation of the power source data
1
RCU 5000i The RCU 5000i remote control unit is required when using an RS232/LocalNet converter
to view the welding voltage and welding current data obtained from the power source. Proceed as follows with the RCU 5000i remote control unit:
In the "Documentation" menu, set the "Documentation" and "Job documentation"
menu items to "On".
Set the "Every nth seam" to "1" and "Every n seconds" to "0.1 s"
2
Further information can be found in the RCU 5000i operating instructions, chapter "Establishing basic settings for the documentation".
If an RCU 5000i is not available, the welding current, voltage and wire feed speed cannot
be viewed. However it is possible to define when the recording starts and stops
- provided a LocalNet connection to the power source is available
- via the welding start signal of the power source
EN
37
Setting up the PC
1
4
General The Q-Eye software consists of client and server. The client supports remote transfer to
another PC, where the welding recording can be viewed. The client software, which calls
the data from the server, can be installed on the server computer or on any computer that
is connected to the server via Ethernet.
System requirements
To successfully install and use Q-Eye, the following requirements must be met for the PC
and the software that is already installed:
- the PC must be located at the end of the hosepack or right next to the power supply
- depending on the environmental conditions, a PC or industrial PC (IPC) with appropriate protection is required
- a monitor, keyboard and mouse are also required for the initial setup of the server PC
- PC must not be more than 3-4 years old
- Processor: Intel Pentium DualCore
- RAM: 2 GB
- Hard disk: HDD, more than 100 GB for optimum local storage capacity
- LAN: 1 x 100 MBit, or ideally: Gigabit-LAN 1000 MBit
- Interfaces:
USB2.0: 4x (high speed)
(recommended: Intel ICH 8, Intel ICH 9 or Intel ICH 10 chipset)
(an Intel CR, Intel 5 series or Intel 3400 chipset may cause problems)
RS232: 1x
RS232 for twin welding processes: 2x
(use of a USB/RS232 converter or USB/Ethernet is possible, e.g. for the digital I/O
module)
Ethernet: in case of LocalNet connection of the power source via Ethernet
Software requirements for the PC:
- Windows XP, at least SP2, or Windows 7
both with deactivated firewall (port 15010 must be open)
- DotNet Framework 4.0
Installing the driver for the camera
38
32-bit or 64-bit systems have their own drivers. The camera driver must use the same number of bits as the PC operating system.
Place the CD in the CD-ROM drive
Start Windows Explorer
2
Open the drive directory for the CD-ROM
3
Open the file "uEyeBatchinstall.exe" in folder "Software/driver" according to whether
a 32-bit or 64-bit operating system is being used
The following dialog box appears:
Select "2 - Install the uEye USB driver" by entering "2" and pressing the "Enter" key
5
6
As soon as a text line appears indicating the process is complete:
Confirm the message by pressing the "Enter" key
Connect the camera to the relevant USB port
7
The software will automatically detect the camera.
EN
The "Found New Hardware Wizard" dialog box opens:
Select "No, not this time"
8
Click "Next>"
9
The dialog box changes to:
39
Select "Install the software automatically (Recommended)"
13
14
15
16
10
Click "Next>"
11
The following dialog box only appears when a CD-ROM is inserted:
Depending on whether the installation is being carried out from the CD-ROM drive or from
the hard disk:
Select one of the two options
12
Click "Next>"
The "Completing the Found New Hardware Wizard" dialog box appears:
Click "Finish" to complete the installation
The installation steps described above are repeated in essentially the same way.
Carry out and complete the installation as described above
If a camera is connected to another USB port, the installation steps described above are
repeated in essentially the same way.
Port 15010
40
Carry out and complete the installation as described above
IMPORTANT!
The Q-Eye server uses port 15010.
This must not be blocked or locked. No other programs may use port 15010.
Installing the Q-
3
Eye server/client
A sample installation is described that is essentially the same for both the Q-Eye server
and client.
Place the CD in the CD-ROM drive
1
Start Windows Explorer
2
Open the drive for the CD-ROM
Double-click on "Q-Eye Server.x.xx.msi" or "Q-Eye Client x.xx.msi" (x.xx = version
4
number) to start the installation
The "Q-Eye Server" or "Q-Eye Client" dialog box appears:
EN
Click "Next>"
5
The dialog box shows the "Folder" section:
Under "Folder", either leave the default installation path or use the "Browse..." button
6
to select a specific installation path
Click "Next>"
7
The "Confirm installation" dialog box appears:
41
Click "Next" to start the installation
8
9
The "Installation complete" dialog box appears:
Click "Close" to finish the installation
Once the installation has completed successfully, restart the PC
10
42
Q-Eye software
1
EN
Starting Q-Eye
After successful installation you can find the
- "Q-Eye Server" software in the "Startup" menu
- "Q-Eye Client" software in the start menu under "Programs", under "Fronius
Product Group"
Q-Eye Server:
"Q-Eye Server" starts automatically when the PC is started. If the "Q-Eye Server" is closed
and then needs to be restarted, proceed as follows:
Double click on "Q-Eye Server" in the "Startup" menu.
1
The Q-Eye server does not have a visible interface. The symbol shown here appears in the task bar to indicate that Q-Eye Server is open.
Q-Eye Client:
Double-click "Q-Eye Client" in the start
menu under "Fronius Product Group".
A dialog box appears, which is empty apart from the buttons down the sides.
43
Overview The dialog box opened previously contains the following buttons and areas. A detailed ex-
(5)
(6)
(7)
(10)
(9)
(8)
(4)
(3)
(2)
(1)
(14)
(13)
(12)
(11)
planation of the associated functions is given in the following sections.
No. Function
(1) Rotate the view
Rotate the view
(2) Scaling
(3) Play/stop
(4) Information
(5) Open welding recording
(6) Manually save the welding recordings
(7) Automatically save welding recording
(8) Representation of the power source parameters
(9) Zoom function - zoom in
(10) Zoom function - zoom out
(11) Representation of the recording time
(12) IP address for server
(13) Camera settings
(14) Settings for camera control
Each click of the "rotate" (1) button rotates the camera image 90° clockwise. You
can set a preferred view by repeatedly clicking the button (1).
Scaling
44
Click this button (2) once to activate the scaling. This allows you to optimally adjust
the camera image both for the large and small dialog box. The correct aspect ratio
of the camera image is maintained. Click this button (2) again to deactivate the scaling function.
Play/stop
1
If a recording is open, it can be played back using the "play/stop" button (3). During
playback, the sequence plays in a loop until the "play/stop" (3) button is clicked
again.
EN
Information
Open welding recording
Manually save the
welding recordings
The "Information" (4) button displays general information, such as the Q-Eye software version.
Q-Eye's proprietary data format for welding recordings is "qed". In addition to the
image recording by the Q-Eye camera, the qed files contain optional information on
the power source parameters: welding current, voltage and wire feed speed.
Click "Open" (5).
Select the required file in the standard selection window.
2
The computer loads the data into the main memory. Depending on the file size, this
may take a few moments.
This button (6) allows you to manually save the current welding recording. Click the
button (6) to open a dialog box, where you can select the required storage location.
Automatically
save welding recording
Visualisation of
the power source
parameters
This button (7) allows you to automatically save the current welding recording.
Clicking on the button (7) turns it orange. At the same time a dialog box opens,
where you can select the required storage location.
Any welding recording currently taking place is immediately and automatically
saved to the specified storage location. Clicking the button (7) again deactivates the
automatic save function and the button (7) returns to its original colour.
If the power source was connected to the PC when creating the welding recording, a graph
of the power source parameters is displayed. The graph is displayed underneath the camera recording in the dialog box and shows the following values plotted against time:
- Welding current I (A) - red
- Welding voltage U (V) - blue
- Wire feed speed V
(m/min) - green
d
During playback, movement of the vertical red line is synchronised with the welding recording. To obtain a quick overview of a sequence or select a specific position, the red line can
be moved by clicking and dragging.
45
To the right of the graph are the real-time values for welding current, voltage and wire feed
1
speed. If required, use the check boxes to hide individual parameters.
Zoom function
The "zoom in" (9) and "zoom out" (10) buttons allow you to enlarge or shrink a section of the graph for the welding current, voltage and wire feed speed power source
parameters.
Zoom into the graph:
Click the "zoom in" (9) button.
Draw a zoom area on the graph.
2
When you zoom, a horizontal slider (15) appears underneath the diagram. This allows you to navigate within the entire welding recording even when zoomed in.
To return to the original view:
Click the "zoom out" (10) button.
3
Representation of
the recording
time
(9)
(10)
(15)
Clicking on the "Frame" check box displays a graph with points along the time axis. Each
point represents a camera image transmission time point.
Next to the "Frame" check box the current number of images since the start of recording is
displayed, e.g. 142.
The "Frame time" is displayed underneath this. This shows the current elapsed time since
the start of recording in seconds, e.g. 14.22.
46
IP address for
(12)
1
2
3
server
Click the "Server" button (12) to open
the "Server Address" dialog box.
Enter the IP address for the Q-Eye server in the relevant field.
- e.g."192.168.0.1" or "localhost"
Click the "OK" button.
EN
Camera settings
Click the "Camera" button to open the "CameraSetupDialog" dialog box for the
1
camera settings.
rate
(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
(9)
(10)
The "CameraSetupDialog" dialog box contains the following settings and information:
No. Function
(1) Camera
Serial number of the connected camera
(2) Pixel clock [MHz]
The internal clock frequency of the camera (27 MHz)
If you experience any transmission problems, reduce the frequency to 20 MHz
(3) Exposure [ms]
Exposure time
Set this as low as possible to prevent distracting reflections and other light effects
(4) Gain
Intensification factor for brightness
Disadvantages of setting this too high: increased noise, less contrast in bright are-
as
If you wish to set a value for "Gain" (4), always select the "Gain boost" (5) check
box first
47
(5) Gain boost
2
(1)
(2)
(3)
(4)
Increases the sensitivity of the camera sensor
(6) Rotation
Basic setting for image rotation in degrees
(7) Target frame rate [FPS]
Frame rate in frames per second (FPS)
Factory setting: 10, can be adjusted up to 20
(8) Actual frame rate
Current actual frame rate in frames per second (FPS)
The actual value (8) displayed must correspond to the "Target Frame Rate" set val-
ue (7).
(9) Flash count
Counts the total number of images (flashes).
This value relates to each camera individually. If several cameras are present, the
flashes are counted separately for each camera.
(10) Enable audio
Only available in connection with the optional audio recording equipment (Q-Eye
Audio installation kit)
Camera control
The sound is only transmitted live, audio sequences cannot be recorded.
To save any changes:
Click the "Save" button.
Click the "Control" button to open the "Camera control" dialog box.
1
The "Camera control" dialog box allows you to make the following settings:
48
No. Function
(1) Start/Stop
Digital I/O:
when controlling recording using a digital I/O module via a 24 V DC signal from the
robot or other external control
LocalNet:
when controlling recording and transferring the power source data using a RS232/
LocalNet converter
(2) Seam Number
It is possible to start and stop the recording according to the relevant weld seam
number, provided that the part number and weld seam number are known and the
recording is controlled via LocalNet.
You can enter several weld seams by separating the numbers with commas.
If left blank, all available weld seams are recorded.
(3) Digital I/O
In the case of recording control via digital I/O module
COM Port:
Select the COM port in use, e.g. "COM1"
EN
Input:
Select the input in use on the I/O module, e.g. "I0" for Input 0
(4) LocalNet
In the case of recording control via RS232/LocalNet converter or via Ethernet
Enable Master:
recording controlled via the master or leading power source
Enable slave - only for 2 wire processes:
the welding current, voltage and wire feed speed power source data are also re-
corded via the slave or trailing power source
UDP - for data transfer via a network:
enter the network address
RS232 - for data transfer via a RS232 COM port:
enter the RS232 COM port in use
To save any changes:
click the "OK" button.
2
49
Setting up a network connection
(1)
1
2
3
1
Local client/server operation on a
PC
Client/server operation on two
PCs via direct
Ethernet connection
Click the "Server" button (1) to open
the "Server Address" dialog box.
Enter "localhost" in the relevant field.
Click the "OK" button.
In order to set up a data connection for two PCs via a dedicated network cable, set up
a network connection in Windows.
The procedure for entering the static IP address depends on the operating system.
Example:
- PC for Q-Eye Server: IP = 192.168.0.1
- PC for Q-Eye Client: IP = 192.168.0.2
Open the "Server Address" dialog box as described in the previous section "Local cli-
2
ent/server operation on a PC".
50
Enter the IP address for the server in the relevant field.
1
3
Click the "OK" button.
4
EN
Client/server operation on two
PCs via a network
Depending on the available network, contact the system administrator responsible for
setting up client/server operation.
Normally a client communicates with the server. If another client attempts to access the
server at the same time, this second client will receive a message with the IP address of
the first authorised client PC.
Another PC can only access the Q-Eye server once the Q-Eye client is no longer accessing
it.
51
Adjusting the camera image
(1)
(2)
1
(3)
Setting the camera focus
Unscrew the M4 x 4 mm grub screw (2)
from the threaded hole (1) on the camera unit using a size 2 Allen key.
NOTE!
If, in the process described below, the now exposed grub screw (3) is turned too
many times in one direction, it may disengage from the camera lens gearing.
In such cases the focus can no longer be set without disassembling the camera unit. In the
right-hand figures below, part of the housing interior is shown to illustrate this situation.
► Do not turn the grub screw (3) more than 50 times in one direction
(3)
Use a size 3 ball head Allen key to turn the grub screw (3) until the camera is sharply
2
focused on the required area of the workpiece.
If 50 turns in one direction does not improve the image sharpness:
- turn the grub screw (3) by approx. 50 turns in the reverse direction and then reverse
the direction again and turn it a maximum of 50 times
- if this does not improve the image sharpness or results in disengagement of the grub
screw (3), contact After-Sales Service
Use a size 2 Allen key to replace and tighten the M4 x 4 mm grub screw (2) that was
3
removed previously.
52
Optical filters
(1) (2) (3)
(1)
open
(2)
1
EN
Filter types and
use
Three different optical filters are available for use in case of glare or strong reflections during recording.
No. Function
(1) Filter ND = 0.3 *
mild filtering effect
(2) Filter ND = 0.5 *
medium filtering effect
(3) Filter ND = 1 *
heavy filtering effect
* ND = Neutral Density - grey filter
The figure to the left shows a recording with strong glare without an optical filter, in comparison the figure on the right shows the same recording using an optical filter.
Inserting the optical filter in the
camera unit
Grasp the protective glass (1) by the grip (2) using standard combination pliers, turn
anti-clockwise and remove from the camera unit
53
Remove the aperture (3) from the ca-
(3)
(4)
2
(5)
(3)
3
(3)
(4)
4
(1)
mera lens (4)
Insert the optical filter (5) into the aperture (3)
Place the aperture (3) on the camera
lens (4)
(2)
close
Grasp the protective glass (1) by the grip (2) using standard combination pliers, insert
5
it into the camera unit and turn it clockwise as far as it will go
54
Care, maintenance and disposal
2
5
(1)
close open
1
General Under normal operating conditions, Q-Eye requires only minimum care and maintenance.
However, it is vital to observe some important points to ensure the system remains in a
usable condition for many years.
WARNING!
Machines that start up automatically can cause serious injury and damage.
In addition to these operating instructions, the safety rules issued by the manufacturer of
the robot and welding systems must also be observed. For your personal safety, ensure
that all protective measures have been taken and will remain in place for the duration of
your stay within the working area of the robot.
EN
Every start-up check the camera and lighting protective glass for contamination and damage
If necessary Protective glass
1
check the camera unit and connections for damage
check the power supply and connections for damage
3
check the hosepack and connections for damage
4
check the compressed air supply, lines and connections for damage
If the protective glass becomes contaminated and the compressed air cleaner cannot remove the dirt, clean the protective glass with a cloth. If this does not remove the contamination, replace the protective glass.
- Protective glass with clear circular area for camera
- Protective glass textured throughout for lighting
To replace the protective glass, proceed as follows:
grasp existing protective glass by the grip (1) using standard combination pliers, turn
anti-clockwise and remove.
insert the new protective glass in the empty hole and turn clockwise as far as it will go.
2
Filter grille on the power supply
55
If dirt accumulates on the power supply's filter grille, clean it with compressed air. It is not
(1) (1)(2)
1
usually necessary to remove the grille. The figure shows the filter grille before and after
cleaning.
If cleaning with compressed air does not work, replace the filter grille as follows:
Remove four screws (1)
Remove the retaining plate (2) and the filter grille
2
Fit the new filter grille (3) and retaining plate (2) with the four screws (1)
3
56
EN
(1)
(1)
Disposal Dispose of in accordance with the applicable national and local regulations.
(1)
(1)
(3)
(2)
57
Troubleshooting
General
WARNING!
Work that is carried out incorrectly may result in serious injury or damage to property.
► Only trained and qualified personnel may install, operate or perform troubleshooting
work on the device.
WARNING!
An electric shock can be fatal.
Before opening the device
► Turn the mains switch to the "O" position
► Unplug the machine from the mains
► Prevent it from being switched on again
► Using a suitable measuring instrument, check to make sure that electrically charged
components (e.g. capacitors) have discharged
WARNING!
An inadequate ground conductor connection can cause serious injury or damage.
The housing screws provide a suitable ground conductor connection for earthing the housing.
► The housing screws must not be replaced by any other screws without a reliable
ground conductor connection.
Troubleshooting
Blurry welding recording
Poor contrast, no detail
Cause: the camera's protective glass (with clear circular area) is contaminated,
smeared or heavily scratched
Remedy: clean or, if necessary, replace the camera's protective glass (with clear circu-
lar area), as per the "Care, maintenance and disposal" chapter
Cause: focus incorrectly set
Remedy: calibrate the focus using the adjusting screw in the camera unit, as per the
"Commissioning - adjusting the camera image" chapter.
Cause: contaminated or smeared lens caused by operation without protective glass
Remedy: remove the aperture cap from the lens and clean the lens with a clean fabric
cloth. Replace the aperture cap and protective glass (with clear, circular area).
58
Welding recording is too dark
Poorly lit recording
Cause: unsuitable positioning of the camera unit in relation to the welding surface
Remedy: change the mounting position of the camera unit or adjust the tilt angle in re-
lation to the welding torch. change the tilt angle of the welding torch, if the process allows.
Cause: the protective glass for the camera or flash bulb is contaminated or dis-
coloured
Remedy: clean the protective glass or, if necessary, replace it
Cause: faulty flash bulb or decreasing power
Remedy: Contact After-Sales Service
Cause: wrong optical filter inserted
Remedy: remove the optical filter, if necessary replace with an optical filter with a more
mild filtering effect
WARNING!
An electric shock can be fatal.
Switch off the power supply before working on the hosepack or power supply.
EN
Cause: supply voltage from the power supply too low
Remedy: check the hosepack supply lines for damage, replace the hosepack if there is
any obvious damage. If the hose pack is OK, replace the power supply.
Welding recording is too bright
A large part of the image is overexposed.
Cause: unsuitable positioning of the camera unit in relation to highly-reflective surfac-
es
Remedy: change the mounting position of the camera. Adjust the tilt angle in relation to
the welding torch. Change the tilt angle of the welding torch, if the process allows.
Cause: arc shines directly into the camera
Remedy: adjust the position of the camera unit in relation to the welding torch. Use suit-
able shields to block the arc rays.
Cause: the protective glass (textured throughout) for the flash bulb is missing
Remedy: insert protective glass for the flash bulb
Cause: missing aperture cap on the camera lens
Remedy: place aperture cap with 1.6 mm hole on the lens, to do this you need to re-
move the camera's protective glass (with clear, circular area).
Welding recording is not saved
Cause: automatic save is deactivated
Remedy: activate automatic save and select storage location (folder)
Cause: full hard disk
Remedy: delete any recordings that are no longer required
59
No flash during recording
Images almost black
Cause: 230 V power supply not connected
Remedy: check the connections on the camera unit and power supply
Cause: high-voltage line of the hosepack is not connected
Remedy: check the connections on the camera unit and power supply and connect if
necessary
Cause: insufficient cooling of the power supply, the power supply switches off due to
overtemperature - red LED lights up
Remedy: check the filter grille on the power supply, replace depending on level of con-
tamination
Cause: the ambient temperature is permanently too high, the power supply switches
off due to overtemperature
Remedy: ensure that the ambient temperature does not permanently exceed 40 °C and
provide adequate supply of fresh air and cooling air
Cause: faulty camera unit/flash bulb
Remedy: contact After-Sales Service for repair/replacement
Flash fails
Images are black
Cause: Flash unit has overheated - insufficient cooling/cooling break down
Remedy: check cooling power. Ensure compressed air supply provides sufficient cool-
ing.
Camera unit only flashes 1-2 times and logs off from the PC
Cause: defective/damaged data cable screening (EMC problem)
Remedy: replace the hosepack
camera unit flashes, but no image appears on the PC
Cause: USB host controller on the PC cannot process the data quickly enough - this
may happen, for example, with the Intel (CR) 5 series / 3400 USB controllers
Remedy: reduce the camera frame rate - note: the lower the frame rate, the higher the
minimum exposure time, which can quickly lead to overexposure during welding
Target frame rate (FPS) is not reached
Cause: insufficient support for USB2.0 connection on the PC
Remedy: change the USB2.0 connection on the PC, check whether the PC fulfils the
minimum requirements
60
Cause: defective/damaged data cable screening
Remedy: replace the hosepack
No welding recording on the monitor
The Q-Eye software does not detect the camera unit
Cause: data cable not connected
Remedy: check and connect all connections
Cause: power supply not connected
Remedy: connect the power supply and check whether the green power supply LED is
lit
Cause: camera is not detected or not correctly detected by the PC
Remedy: install the driver as detailed in chapter "Setting up the PC", section "Installing
the driver for the camera".
Cause: camera is not detected by the PC - faulty or damaged data cable
Remedy: replace the hosepack
Cause: camera is not detected by the Q-Eye software
Remedy: if the data cable is connected to another USB port on the power supply or PC
(Q-Eye Server), then reinstallation of the driver is recommended, as detailed
in the chapter "Setting up the PC", section "Installing the driver for the camera".
EN
Cause: no control signal for recording start
Remedy: check the connection and setting for the I/O module or the LocalNet connec-
tion, as detailed in the "Commissioning" chapter.
Cause: no 24 V DC supply voltage for the digital I/O module
Remedy: check/replace the fuse for the 24 V DV output on the power supply
Cause: no connection to the Q-Eye server (offline)
Remedy: restart the Q-Eye server and then the Q-Eye client; in the case of network op-
eration: check the network connection
Cause: software crash/hanging (Q-Eye Client, Q-Eye Server, LocalNet Server, Dot-
NetFramework, camera driver, etc.)
Remedy: restart the PC, contact After-Sales Service if this does not solve the problem
Cause: Faulty camera
Remedy: contact After-Sales Service for repair/replacement
No recording
No or impaired communication between the PC and the power source or control for the digital I/O
Cause: no control signal for recording start
Remedy: check the connection and setting for the I/O module or the LocalNet connec-
tion
Q-Eye Client does not start or crashes immediately
Cause: installed driver version does not use the same number of bits (32 or 64) as the
PC operating system
Remedy: install driver version that uses the same number of bits (32 or 64) as the PC
operating system
61
Technical data
Camera unit
Power supply
High-voltage input 560 V DC
max. 180 W
Interface USB2.0
Frame rate/image rate up to 20 fps (frames per second)
10 fps is default
Resolution 752 x 480 dpi
Image detail at a distance of 25 cm: 100 x 80 mm
Operating hours 2500 - 3000 h
drop in flash bulb power after approx. 10
Connections data cable, high-voltage supply and compressed air line
Wearing parts protective glass, change rate depends on operating conditions
and welding process
Mark of conformity CE
Degree of protection IP 20
Dimensions 180 x 160 x 50 mm
Weight 1 kg (1.2 kg with bracket)
Mains voltage 110 V AC (US) - 230 V AC
Power consumption max. 200 W
idle shutdown, when no device is connected
Fuse protection 110 - 230 V AC6.3 A slow-blow
8
flashes
High-voltage output 560 V DC
max. 180 W
Control voltage output 24 V DC
max. 18 W
Fuse protection 24 V DC 0.63 A slow-blow
Marks of conformity CE
Degree of protection IP 20
Dimensions 300 x 215 x 80 mm
Weight 3 kg
62
EN
63
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Froniusstraße 1
A-4643 Pettenbach
AUSTRIA
contact@fronius.com
www.fronius.com
Under www.fronius.com/contact you will find the addresses
of all Fronius Sales & Service Partners and locations.
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