A new dimension in Welding technology

QINEO® CHAMP

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A giant leap for welding technology.

CHAMP

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We, Messrs. Carl Cloos Schweisstechnik GmbH in Haiger, are one of the pioneers of modern welding technology and are still today one of the international market leaders. We have united our two core businesses, arc welding and robot technology, under one roof and can offer our customers economic and technically high-quality solutions from a single source.

About 700 employees develop and manufacture the CLOOS product range – from QINEO® welding power sources up to turnkey QIROX® robot systems and automated systems supplied specifically for our customers’ individual require-ments. The highly efficient product range of MIG/MAG and TIG welding machines and the robot system technology can be found in complex production lines and cost-effective compact welding cells used in the core markets automotive, mechanical engineering as well as commercial vehicles.

With a large range of proven and innova-tive welding processes, we at CLOOS can offer solutions for the future providing maximum efficiency and productiv-ity with regard to automated welding. Products and processes are tested in our technology centre under practical conditions. All necessary processes meet the quality management system DIN EN ISO 9001.

We operate in the German market with more than 20 representatives. There are also more than 40 sales and service centres in our worldwide organisation.

QINEO® CHAMP is another innovation from CLOOS which will set the standards for future welding. The latest develop-ments in the QINEO® product range can be found at www.qineo.de

The new generation of welding power sources for manual and automated applications.

QINEO® are the high-quality welding power sources by CLOOS which have been developed specifically for commercial and

industrial welding purposes. They meet every demand of manual and automated welding. Moreover the modular QINEO®

system allows individual solutions which can be adapted to your specific production requirements and objectives. From

capacity class to special equipment, each QINEO® is customized and supplemented by a comprehensive accessories pro-

gram and matching services. With highest availability, shortest delivery times and best quality QINEO® welding power

sources offer you considerable economical advantages.

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Quantum leap in high-tech welding

QINEO® CHAMP

Efficient, precise, versatile – this high-tech equipment meets the highest demands. In every performance category and under complex performance conditions.

No matter whether it is for 350, 450 or 600 amps, every QINEO® CHAMP machine can offer many different welding processes for a variety of possible applications, materials and plate thicknesses. Increased flexibility thanks to the free adjustment of characteristic curves, excellent welding properties, low-cost operation – the QI-NEO® CHAMP incorporates all these capabilities into one state-of-the-art solution for a new dimension in welding technology.

The advantages of QINEO® CHAMP in overview

Utmost Flexibility Free adjustment of the characteristic curves and control parameters in a single parameter mode

Excellent process qualityHigh-tech for excellent welding results

Simple and intuitiveClear control panel with extensive functions

Low operating costsEnergy saving standby mode

Stable functionInfluences from outside circuits are compensated for

CompatibleSecure communication with weld-ing robots via standardised field bus systems

Vari DriveMakes possible Cold Weld processes for coated materials and almost spatter-free welding

Cold WeldLow energy welding of thin materials, low spatter operation and best gap bridging ability

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Configuration example

QINEO® CHAMP 600

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Applications All steel and aluminium materials Automated welding

Advantages Extremely high weld speed and depo-

sition rate Excellent weld seam quality and

minimum risk of pore formation Minimum heat input Optimum arc control

Process diversity in perfection

Cold Weld

Applications Thin plates Steel, chrome-nickel, aluminium,

cu-based materials Manual and automated welding

Advantages Very high weld speed and deposition

rate Good gap bridging ability Perfect weld seams Lowest component distortion

Vari Drive

Applications Thin plates Coated materials, steel, chrome-nickel,

aluminium, cu-based materials Joining of a material mix (steel/alu-

minium) Automated welding

Advantages Highest weld speed and deposition

rate Good gap bridging ability Perfect weld seams Lowest component distortion

With the Cold Weld process an alternating current produces a very special pulse form, which brings about an extremely low heat input. Due to this type of ‘cold’ arc weld-ing the welding process can be optimally controlled. The material is only subjected to minimum heat and the original material properties remain to a large extent un-changed. This enables an excellent weld quality to be achieved with gut gap briding and increased weld speed. The Cold Weld process is mainly used with thin to medium sized plate thicknesses.

Tandem Weld

For tandem welding two separately fed welding wires with separated potentials are fed together in a melt pool. Thanks to the consequent separation of the two power circuits, the welding arc can be fully controlled. The major advantages of the Tandem Weld process are extremely high efficiency, minimum heat input, excellent weld seam quality and extraordinarily high deposition rate.

Processes

Outstanding features of the QINEO® CHAMP are its superior arc ignition behaviour, uniformity, stability and excellent welding results. The many welding processes al-low highly flexible application possibilities with a variety of materials. Clean Start, the ignition routine patented by CLOOS, ensures reliable and low spatter arc ignition with all processes.

Vari Drive is an option for the Cold Weld process and, in case of automated welding, leads to a further increase of weld speed with excellent weld seam quality. Intentionally toler-ated short circuits are dissolved spatter-free and enable an extremely short and stable pulsed arc. Vari Drive also ensures the highest process security when welding coated thin plates from aluminium to zinc.

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Control Weld

Vari Weld

Applications Steel, aluminium, chrome-nickel materials MIG brazing of surface-coated or

high-strength thin steel plates Manual and automated welding

Advantages Optimum weld pool control Very low spatter drop transfer Completely stable arc conditions even

under varying external influences

The Control Weld Process supplies a uniform arc which is particularly advantageous when welding thin steel. The classic industries are automotive construction, elec-tronics, vehicle construction, heating technology, white goods and furniture. This process can also be used for reliable repair welding throughout all industry sectors and allows for welding under pure CO

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The Vari Weld process creates an extremely low spatter pulsed arc. Its special strengths are the welding of aluminium and MIG brazing where due to the low temperature the base material remains metallurgically unaffected and the corrosion protection is maintained. This process offers completely stable arc conditions and an outstanding controllable weld pool even under varying external influences. The Vari Weld process can therefore be seen in all industrial sectors.

Speed Weld

Applications Medium and thick materials Mainly automated welding

Advantages Good penetration depths at high

weld speeds Perfect side wall joints High-quality weld seams

The Speed Weld process is most suitable for joining components of medium to thick wall thicknesses. Good penetration depths and perfect side wall joints at high weld speeds are achieved by means of a focused pulsed arc with a medium to high deposition rate. The Speed Weld process is used in all areas of industrial production.

Applications Thin plate Welding under pure CO

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Manual and automated welding, repair welding

MIG brazing

Advantages Uniform arc Low heat input Good gap bridging ability

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The Rapid Weld process provides advantages wherever high deposition rates and optimum penetration depths at high process speed are required. It is particularly suited for manual and automated applications in sectors such as the construction machine industry, shipbuilding, railway and container construction.

Rapid Weld

Duo Pulse

Applications All materials to be welded Manual and automated welding

Advantages High-quality visible welds with a

uniformly rippled weld seam surface, less rework

Optimum gap bridging Selective control of the heat input

The Duo Pulse process creates outstanding weld surfaces and ensures a reliable weld seam quality. The change of heat input in the arc results in a uniformly rippled weld seam surface which means that rework on visible welds is minimised. The furniture and electrical industrial sectors, and aviation, automotive and motorcycle industries are all suitable application areas.

Processes

Applications Medium and thick materials Manual and automated welding

Advantages Fast wire feed for high process speeds Deep penetration with high deposition

rates Penetration profile can be regulated

All processes in one brochure

As a system supplier CLOOS have not specialised in just one welding process but have developed welding power sources which offer all processes currently in use. Each process has its special advantages and application area, but also certain technical restrictions which are explained in our special brochure ”Welding“, which can be downloaded or ordered under

www.cloos.de

Welding

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Modular design

Weld your way.

The configuration possibilities of the QINEO® CHAMP are as flexible as the welding applications are versatile. This is guaranteed by the modular product concept. From capacity class to additional equipment, each individual QINEO® CHAMP is manu-factured specifically. Moreover all components, such as the inverter with wide-area input, the compact wire drive with dynamic reverse behaviour and the torch with optimum gas coverage, are customised in the cost-efficient series production.

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Capacity classes

350Ampere

450Ampere

600Ampere

Full capacity for each application

Thin or thick plate: there is a QINEO® CHAMP with the appropriate capacity class for every requirement. In total there are 3 capacity classes: the 350 Amp power source is designed for welding thin plate, the 600 Amp QINEO® CHAMP is used when welding thick plate. The QINEO® CHAMP with 450 Amp is suitable for a variety of applications with different plate thicknesses. With this choice you can achieve optimum welding results for all material thicknesses.

Configuration example

QINEO® CHAMP 600

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Weld penetration geometry

Drop removal characteristics

Arc dynamics

Arc form

Start and end crater behavior

Perfect synergy programs for all process variants

Synergy

The possibilites for defining individual parameters are determined by the process used.

Multi-switch RPU Remote Programming Unit

The RPU control unit can be supplied in two versions for use on automated systems with several power sources in one application. It can either be operated with a single power source or alternatively as a multi-switch unit. With multi-switch it is possible to control up to eight QINEO® AUTOMOTIVE power sources from a single unit. Protected by a robust housing, the RPU can be taken directly to the processing location to carry out adjustments and programming procedures. During produc-tion the RPU is located where it can be clearly seen and provides information on the current parameters of the welding process being used.

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QINEO® control module PREMIUM

Sophisticated automation

With the PREMIUM operating module the QINEO® CHAMP has a wide range of functions and is intended for the highest level of automated welding tasks. Its operation is simple and intuitive thanks to an LCD display with clearly arranged function keys. All welding tasks are supported in an ideal manner.

One operation for 1000 jobs

The operating module has a JOB func-tion which enables up to 999 jobs to be archived and retrieved. LEDs display the adjustable parameters and makes them easier to store. Graded user rights can also be set up which ensure that certain defined welding parameters can only be changed by authorised personnel.

Individual characteristic curvesSpecial materials require individual synergy programs. These can be generated and stored as character-istic curves on any QINEO® CHAMP. Programming is carried out directly from the operating panel without any auxiliary resources.

External circuit compensationIn order to assist in the achievement of excellent welding results in the most difficult operating conditions, QINEO® CHAMP can carry out an automatic external circuit compen-sation.

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User administrationThe user administration of the oper-ating module enables access rights to be defined on several levels. Authori-sation to carry out programming is determined by individual passwords. The data sets are therefore protected from unauthorised access.

Optional weld data monitoring On the QINEO® CHAMP all weld-ing parameters are monitored and archived to ensure constant weld seam quantity. The weld data moni-toring system, which can be fully programmed via the display, has a learning mode and several individu-ally adjustable monitoring channels. The limit values and the response when exceeding or falling below thresholds can be programmed by the user. It is therefore possible to choose between two responses: a warning or interruption of the process. All results can be saved in a log book.

Standby function The standby function of the QI-NEO® CHAMP offers low operation costs and high efficiency. As soon as welding starts and the data en-tered by the operator remain fixed for a predefined period of time, an automatic switch to energy saving standby mode takes place; reducing the power consumption to less than 10 Watts. When starting a new ap-plication, the fast availability of the equipment is guaranteed.

Teach pendant On CLOOS QIROX® welding robots operation can be displayed on the teach pendant. This improves the ease of operation and efficiency – particu-larly where the welding requirements often change. All functions can be controlled via the teach pendant. This also includes the selection of different power sources connected to the robot and the control of different welding processes.

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Accessories

Single-source supply

QINEO® CHAMP offers the best conditions for use in rough workshop environment: Every component is manufactured from high-quality materials and tested in order to guarantee a long service life and high efficiency.

Sensors ensure quality

In order to ensure the highest quality welding results in automated processes, a tactile gas nozzle sensor and an adap-tive arc sensor from the QIROX® range are available. Additional information is provided in the brochure “QIROX® Sensors”.

External wire drive QINEO® WIRE DRIVE AUTOMATION

Compact design, low weight: The external wire drive has been developed specially for fully automated welding devices. It can be easily mounted on a robot arm and integrated in the QIROX® robot mechanics. A high-performance roller drive with a powerful motor ensures a slip and abraison free wire delivery.

Duo Drive

The CLOOS Duo Drive is an additional external wire drive, which is used directly on the welding torch in order to achieve optimum welding results. The perfect coordination of the wire drives ensures a uniform feed of the wires with optimum speed.

Wide range of welding torches

The CLOOS welding torches are as ver-satile as the welding power sources. We produce gas and water cooled welding torches for each capacity class and for every manual welding requirement and develop special welding torches in all geometries.

RPU remote control with multi-switch

The PREMIUM operating module on the QINEO® CHAMP can also be supplied with an RPU (Remote Programming Unit) remote control. It is very user-friendly – particularly when the power source and the welding location are a distance apart.

Plug & weld components

In order to ensure the highest quality welding results in automated processes, a tactile gas nozzle sensor and an adap-tive arc sensor from the QIROX® range are available. Additional information is provided in the brochure “QIROX® Sensors”.

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External cooling module

The QINEO® CHAMP can be delivered with an external cooling module as an option. Advantage efficiency: Depend-ing on the configuration, one cooling module is sufficient for the operation of two or more welding power sources.

Spare parts and special equipment

All QINEO® welding power sources can be supplied wth sets of wheels or feet. In addition wire coils, filters, housing elements and connection hoses are part of the range of accessories as well as special equipment such as arc sensors and gas nozzle sensors.

Mechanical cleaning of the welding torches

With the help of the cutting device con-tamination inside the welding torches is removed by two rotating knives. The gas shroud is then injected with a releasing agent to prevent adhesion of weld spatter and to facilitate the next cleaning process-es. The result: Higher system productivity and constantly high weld quality.

For applications with QIROX® robots, QINEO® CHAMP has a high-capacity VBC (Variable Bus Connection) interface which enables the power source to be control-led via the robot. Modules for commonly used equipment from other manufactur-ers make the QINEO® CHAMP very flexible to use.

ProfibusBus module for coupling to a Profibus (Process Field Bus) system. It is integrated in the power source and can be configured via the operating panel.

Secure interfaces

Industrial EthernetWith the help of the industrial Ethernet, it is possible to connect to the available LAN devices, which are necessary for the management and control of the production processes.

DeviceNetThis is a field bus based on CAN; it is common mainly in the USA and Asia. Maximum 64 network nodes per field bus segment. The node addresses can be set up by means of rotary switches or DIP switches on the device.

ProfiNetProfinet uses TCP/IP and IT standards; it has a real-time Ethernet capability and allows the inte-gration of field bus systems. The Profinet concept has a modular design so that the user can select the functionality.

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Welding machines

Weld current 20 A - 350 A 20 A - 450 A 20 A - 600 A

Weld current at 60 % duty cycle 350 A / 31,5 V 450 A / 36,5 V 600 A / 44 V

Weld current at 100 % duty cycle 270 A / 27,5 V 350 A / 31,5 V 500 A / 39 V

Open-circuit voltage 75 V 75 V 88 V

Mains voltage 400 V / 50 Hz / 3-phase 400 V / 50 Hz / 3-phase 400 V / 50 Hz / 3-phase

Special voltages 380 V, 415 V, 440 V, 480 V, 500 V 380 V, 415 V, 440 V, 480 V, 500 V 380 V, 415 V, 440 V, 480 V, 500 V

Connection cable 4 x 4 mm2 4 x 6 mm2 4 x 10 mm2

Main protection 25 A 32 A 50 A

Type of protection IP 23 IP 23 IP 23

Insulation class F F F

Type of cooling F F F

Dimensions L/B/H (without wire drive) 1226 x 630 x 741 mm 1226 x 630 x 741 mm 1226 x 630 x 741 mm

Weight (without wire drive) 191 kg 204 kg 244 kg

Dimensions L/B/H compact machine 1226 x 630 x 942 mm 1226 x 630 x 942 mm 1226 x 630 x 942 mm

Weight compact machine 193 kg 206 kg 246 kg

Maximum track width approx. 552 mm approx. 552 mm approx. 552 mm

QINEO®

CHAMP 350

QINEO®

CHAMP 450

QINEO®

CHAMP 600

Wire drive speed max. 30 m / min max. 30 m / min

Dimensions L/W/H 285 / 220 / 215 mm 285 / 220 / 215 mm

Weight 7,5 kg 7,5 kg

Wire diameter 0,8.. 2,0 mm 0,8.. 2,0 mm

QINEO®

WIRE DRIVE AUTOMATION

QINEO®

WIRE DRIVE AUTOMATION

Wire drive units

Technical Data

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Service

Always at your service

Our Service-Hotline is free of charge and in the case of emergencies is available for you even after office hours. We can offer a 24-hour service without additional costs. Even in the case of welding machines, operating modules and accessories which have been in use for more than 20 years we have the expertise to answer all your questions.

Service-Hotline +49 (0) 27 73 85-132

Active worldwide

There are more than 40 sales and service centres in our worldwide CLOOS organisa-tion, which are at your disposal for sales and service. In addition, our experienced service team in Haiger can be called at any time for any technical problems. In this way we can ensure effective help on site if breakdowns occur.

Long service life guaranteed

With maintenance and inspection at regular intervals the technical availabil-ity of a CLOOS system is nearly 100 %. But if faults do occur, we can minimise downtime by means of a quick repair. This is ensured by well-equipped spare parts stores and a computer-controlled logistic system

Additional information regarding QIROX® the system for automatic welding and cutting can be obtained at www.qirox.de

www.qineo.de

Carl Cloos Schweisstechnik GmbH

Industriestrasse

D-35708 Haiger, Germany

Phone +49 (0)2773 85-0

Fax +49 (0)2773 85-275

E-mail info@cloos.de

QIN

EO23

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