With Vortex Flow Sensing

TECHNICAL REFERENCE MANUAL

DEVICENET MODELS
CONTENTS

1 Overview
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Important Safety Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Technical Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

2 Features and Functions

What It Is and What It Does. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Flow Sensing and Measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Flow Comparison . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Cap-Loss Detection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Functional Components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Keypad . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Key Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Optional Solenoid Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

3 Specifications and Performance

Performance Characteristics. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Wetted Materials. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Compliance and Certifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
FCC Part 15 Notice . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

4 Installation and setup

Tools Required. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Pneumatic Connections. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Plumbing Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Electrical Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
DeviceNet Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
DeviceNet Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Input/Output Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Electronic Data Sheet (EDS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

5 Functional Testing
Power and DeviceNet Connectivity. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Flow Detection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Valve Shut-Off. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Bypass Mode. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Cap-Off Detection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

6 Parameter Setup
WeldSaver Control Parameters. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Setup Menu and Factory Default Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Adjusting Control Parameter Values. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

7 Status Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

8 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

i
1 OVERVIEW

Introduction
This document provides comprehensive technical information about the Proteus WeldSaver™ coolant flow controller and
leak detector featuring a DeviceNet™ interface and vortex flow sensing technology. The product features, specifications,
and operating instructions described herein apply to standard WeldSaver products and may not be valid for customized
versions. For model-specific product information, please refer to the specification sheet provided with your WeldSaver
instrument or visit www.proteusind.com/wsv.

Important Safety Information

Throughout these instructions, NOTE, CAUTION and WARNING statements are used to highlight important operational
and safety information.

NOTE NOTE statements provide additional information that is important to the successful operation
of the device.

CAUTION! CAUTION statements identify conditions or practices that could result in damage to equipment
or other property.

WARNING! WARNING statements identify conditions or practices that could result in personal injury or
loss of life.

Taking proper precautions to avoid damage to your instrument’s sensors during installation helps to ensure consistent,
error-free operation, which lowers costs and assists on-time completion of your work.
The safety-related statements contained in these instructions provide an alert to installers and operators to take sensible
steps to allow the WeldSaver to operate correctly the first time and every time.

NOTE
It is recommended that the installation of this product be performed by qualified service
personnel only.

Technical Support
For technical or applications assistance, please contact: In the Detroit, MI area, local support is available from:

Proteus Industries Inc. MJM Sales, Inc.

340 Pioneer Way 45445 Mound Road, Suite 117
Mountain View, CA 94041 Shelby Township, MI 48317
TEL: (650) 964-4163 TEL: (248) 299-0525
FAX: (650) 965-0304 FAX: (248) 299-0528
E-mail: weldsaver@proteusind.com E-mail: sales@mjmsales.com

Warranty
Proteus WeldSaver products are manufactured under ISO 9001-certified processes and are warranted to be free from
defects in materials and workmanship for two (2) years from the date of shipment. The full text of this limited warranty is
available on the Proteus Industries website at www.proteusind.com/warranty.

1
2 FEATURES AND FUNCTIONS

What It Is and What It Does

The Proteus WeldSaver™ featuring DeviceNet™ is a unique coolant control unit designed to provide multiple functions to
monitor and control coolant flow.

»» It’s a Flow Meter

The large, bright digital display indicates the measured flow
rate through the system in liters per minute (LPM) or gallons
per minute (GPM), or as a value relative to a user-selected
trip-point value.

»» It’s a Flow Valve

Coolant flow to the weld cell can be turned ON and OFF using
the keypad or remotely from the weld controller.

A valve status indicator on the keypad shows whether the

solenoid valve is open or closed.

»» It’s a Flow Monitor

Coolant flow is continuously monitored and compared against
programmed trip-point values.

Flow status information is indicated using the digital display

and LED status indicators on the keypad and is communicated
to the weld controller via DeviceNet network.

»» It’s a Very Fast Leak Detector

In the event of a weld-cap loss or other break in the coolant
flow circuit, the leak is detected and coolant flow is shut off in
less than 1 second.

2
2 FEATURES AND FUNCTIONS

Flow Sensing and Measurement

The WeldSaver’s coolant supply and return channels are equipped with sensitive and rugged vortex flow sensors.
As liquid flows around a bluff body inside each flow channel, swirling vortices are formed and carried downstream at
the velocity of the flowing liquid. Alternating localized high- and low-pressure zones characteristic of a vortex stream
are detected by a piezoelectric crystal that produces a small pulse each time a vortex passes the sensor element. The
number of vortices formed is directly proportional to the linear velocity of the liquid passing through the instrument.
The frequency produced by the vortex flow sensor in the supply channel is measured by a microcomputer to calculate the
actual flow rate of the liquid.

Bluff Body Sensor Element

Vortices

Flow Channel

Flow Comparison
The WeldSaver’s microcomputer continuously compares the measured inlet flow rate with the Flow Alarm ( ) and
Flow Fault ( ) trip point values as selected by the operator.
»» When the measured flow rate is greater than the Flow Fault value, the microcomputer indicates the Flow OK
status on the keypad.
»» When the measured flow rate is less than the Flow Alarm value, but greater than the Flow Fault value, the
microcomputer indicates the Flow Alarm status ( ) on the display.
»» When the measured flow rate is less than the Flow Fault value, but greater than the Flow Alarm value, the
microcomputer indicates the Flow Fault status ( ) on the display.
»» When the measured flow rate is less than both the Flow Fault and Flow Alarm values, the trip point with the lower
programmed value determines the status that will be indicated on the display. The Flow Alarm ( ) trip point is
the lower value by default.
The weld controller makes decisions affecting weld operations based on the flow status reported by the WeldSaver.

Cap-Loss Detection
The WeldSaver’s microcomputer uses a patented algorithm to continuously monitor the output frequencies of both the
supply and return flow sensors. This algorithm is able to detect the loss of a weld cap or other catastrophic loss of flow
continuity in less than 0.3 seconds.
»» When a cap loss event is detected, the microcomputer indicates the Cap Off Fault ( ) on the display, shuts
off coolant flow, and signals the weld controller.
The weld controller makes a decision to shut down weld operations.

3
2 FEATURES AND FUNCTIONS

Functional Components

Keypad

Key Functions
KEY FUNCTION KEY FUNCTION
The RESET key clears fault conditions to restore The UP ARROW key is used in setup mode for
coolant flow and the leak detection function. moving up the parameter menu and for increasing
parameters values.

The VALVE key opens and closes the solenoid valve to The DOWN ARROW key is used in Setup Mode for
stop and restore coolant flow. It also functions as the moving down the parameter menu and for decreasing
ESCAPE key in setup mode. parameters values.

The BYPASS key turns Bypass Mode on and off to

enable or disable the leak detection function. It also
functions as the SELECT key in setup mode.

4
2 FEATURES AND FUNCTIONS

Optional Solenoid Valve

WeldSaver™ products are available with an optional electric or pneumatic solenoid valve for shutting off coolant flow.
Both versions feature a manual override function.

»» Pneumatic Solenoid Valve

Normal Operation

›› The solenoid valve is functional when the slot in the screw is in the vertical 0 position.
›› During normal operation, the valve enables the control of flow through the system, either
locally using the WeldSaver keypad or remotely from the weld controller.

Manual Override

›› The valve can be bypassed by depressing the screw and turning it 90° clockwise to the
horizontal 1 position.

›› In the manual override state, water can flow through the system to allow leak testing without
engaging 24 VDC electrical power.

Valve Configuration Normally closed (NC)

Inlet Port Connection Size G 1/8” (ISO 288)
Control Media Compressed air (filtered and lubricated)
Control Media Temperature 0–50 °C / 32–122 °F
Air Pressure Requirement 420–800 kPa / 61–116 psig

WARNING!
Do NOT exceed the pressure limit of your instrument.
Operation above the rated pressure can cause failure and create a hazard to operators and
equipment.

5
2 FEATURES AND FUNCTIONS

Optional Solenoid Valve (Continued)

»» Electric Solenoid Valve

Normal Operation
›› The solenoid valve is functional when the slot in the knob is in a horizontal position.
›› During normal operation, the valve enables the control of flow through the system, either
locally using the WeldSaver keypad or remotely from the weld controller.

Manual Override

›› The solenoid valve can be bypassed by depressing the knob and turning it 90° clockwise to a
vertical position.

›› In the manual override state, water can flow through the system to allow leak testing without
engaging 24 VDC electrical power.

NOTE
Due to pressure drop inherent in the design of the electric solenoid valve, WeldSaver products
equipped with an electric valve have a reduced upper flow limit of 30 LPM / 8 GPM.

6
3 SPECIFICATIONS AND PERFORMANCE

Performance Characteristics
Base Model Number WS2VG50 WS2VN13
Flow Range* 6.0 – 50 LPM 1.5 – 13 GPM
Connections G 3/4” (BSPP) 3/4” NPT
Coolant Supply Pressure 83 – 620 kPa / 12 – 90 psig
Coolant Return Pressure 70 – 350 kPa / 10 – 50 psig
Differential Pressure 14 – 415 kPa / 2.0 – 60 psig
Coolant Temperature 4.0 – 110 °C / 39 – 230 °F
Leak Response Time ~300 ms at most sensitive condition; ~1 sec. at sensitivity setting “FAS”
Low Flow Response < 0.2 sec.
Reset / Override Response < 1.0 sec.
Leak Detection 0.3 – 1.0 sec. depending on response time setting
Leak Sensitivity Able to detect a loss of flow continuity from 1 to 20 balanced parallel flow paths
Accuracy ± 3% of flow range
Repeatability ± 1% of flow range from 0.1 to 1.0 × flow range
Operating Environment Indoor use only
Ambient Temperature 4.0 – 50 °C / 39 – 122 °F
Max. Relative Humidity 80%
Enclosure Protection IP66 / NEMA 4X
Input Power Voltage +24 VDC ± 10%
Input Power Consumption Pneumatic solenoid valve: < 12.0 VA at normal flow; < 9.6 VA with valve closed
Electric solenoid valve: < 16.8 VA at normal flow; < 9.6 VA with valve closed
Max. Rated Input Current 0.75 A
*The stated flow ranges are valid for products equipped with a pneumatic solenoid valve and products with no solenoid valve installed. Products equipped with
an electric solenoid valve have a reduced upper flow limit of 30 LPM / 8 GPM.

CAUTION!
Do NOT exceed the maximum rated flow rate of your instrument.
Extended operation above the rated maximum flow rate of the instrument will reduce its usable
life.

WARNING!
Do NOT exceed the temperature limit of your instrument.
Operation above the rated temperature can cause failure and create a hazard to operators and
equipment.

WARNING!
Do NOT exceed the pressure limit of your instrument.
Operation above the rated pressure can cause failure and create a hazard to operators and
equipment.

7
3 SPECIFICATIONS AND PERFORMANCE

Wetted Materials
COMPONENT MATERIAL
Flow body • Fittings • Check valve (NPT models) 304 Stainless steel
Check valve (metric models) • Electric solenoid valve (optional) Brass
Pneumatic solenoid valve (optional) Nickel-plated brass
Bluff body PPA (Polyphthalamide PA6T/6I; 40% glass fiber)
Sensor element ETFE (Ethylene tetrafluoroethylene)
O-rings EPDM (Ethylene propylene diene monomer)

Dimensions
Product dimensions for standard models are provided below for reference only. (Shown with optional mounting bracket
and electric solenoid valve.) To request dimensional drawings or solid models of customized products, please contact
WeldSaver Technical Support.

BASE MODEL NUMBER D1 D2 D3

WS2VG50 345.4 mm / 13.6 in 170.2 mm / 6.7 in 99.1 mm / 3.9 in
WS2VN13 261.6 mm / 10.3 in 137.2 mm / 5.4 in 48.3 mm / 1.9 in

8
3 SPECIFICATIONS AND PERFORMANCE

Compliance and Certifications

»» DeviceNet Conformance
DeviceNet Conformance Tested™ in compliance with ODVA specifications.

»» CE Compliance
2004/108/EC Electromagnetic Compatibility Directive
2006/95/EC Low Voltage Directive

»» Environmental Compliance
Restriction of Hazardous Substances (RoHS) Directive 2011/65/EU

»» Electromagnetic Compatibility
EN 55011:2007 Industrial, Scientific and Medical (ISM) Radio-Frequency Equipment
EN 61326-1:2006 Electrical Equipment for Measurement, Control and Laboratory Use

FCC Part 15 Notice

This equipment has been tested and found to comply with the limits for a Class A digital device, pursuant to Part 15 of the
FCC rules. These limits are designed to provide reasonable protection against harmful interference when the equipment
is operated in a commercial environment. This equipment generates, uses, and can radiate radio frequency energy and,
if not installed and used in accordance with the instructions, may cause harmful interference to radio communications.
However, there is no guarantee that interference will not occur in a particular installation.

9
4 INSTALLATION AND SETUP

Tools Required
»» Adjustable wrenches »» 4 × Mounting bolts to fit #8-32 mounting holes
OR
»» Pipe wrenches
2 × M5x12 screws for models with optional mounting bracket
»» Teflon®-based pipe sealant

Pneumatic Connections

NOTE
WeldSaver products equipped with a normally closed (N.C.) pneumatic solenoid valve require
connection to a compressed air supply to enable flow through the valve.

1. Clear the air line of all contaminants.

2. Disconnect the air supply and depressurize the air line.
3. Connect the air line to the G 1/8” inlet port on the pneumatic solenoid valve. (Refer to page 5 for the inlet location.)
4. Reconnect the air supply and confirm that the pneumatic connection is secure and leak-free.

Plumbing Connections
The typical response of the WeldSaver, and thus its calibration, may be affected by the inner diameter (ID) of the incoming
pipe as well as any devices attached to the inlet connections and any nearby upstream devices.

NOTE
The inner diameter (ID) of the inlet piping or the through-hole of any connecting element must
be greater than or equal to 15.0 mm / 0.59 in.
Expanding flow profiles create flow conditions in which the accuracy and the short-term stability
of the WeldSaver may be compromised. For assistance with installations involving elbows or
other possible flow restrictions, please contact WeldSaver Technical Support.

1. Flush the cooling system.

CAUTION!
Thoroughly flush the cooling system BEFORE connecting the WeldSaver.
Failure to remove contaminants or other debris from the coolant lines and any components or
equipment installed in the cooling circuit may result in damage to the WeldSaver’s flow sensors
or the clogging of smaller orifices in the system.

2. Lubricate all pipe threads using a non-hardening pipe sealant, such as Teflon® paste, to help simplify installation and
seal plumbing connections.

CAUTION!
Do NOT allow excess pipe sealant to enter the flow sensors!
Excess material may foul the WeldSaver’s flow sensors or clog smaller orifices in the system.

10
4 INSTALLATION AND SETUP

Plumbing Connections (Continued)

3. Refer to the diagram below to identify the WeldSaver plumbing connections.

4. Make plumbing connections to the Supply, Return, To-Robot and From-Robot connection ports on the WeldSaver
using appropriate pipe fittings and sealing washers.

CAUTION!
Ensure that the correct hoses have been connected to the WeldSaver To-Robot and From-Robot
connections.
Check hose labels or trace water flow to confirm that the WeldSaver is connected to the water
circuit cooling the weld gun.
If the hose connections are not correct, the WeldSaver may NOT be able to detect the loss of a
weld cap or other loss of flow continuity.

5. Adjust pipe connections as required for proper alignment of the WeldSaver.

6. Engage the solenoid valve manual override to enable flow. (See pages 5–6 for more information.)

7. Turn water ON slowly.

WARNING!
The WeldSaver body is NOT insulated!
When using the WeldSaver with hot liquids, use personal protective equipment.

8. Check for leaks at all connections to the WeldSaver.

9. Eliminate all leaks before proceeding.
10. Disengage the solenoid valve manual override for normal operation.

11
4 INSTALLATION AND SETUP

Electrical Connections

NOTE
The WeldSaver must be connected to 24 VDC auxiliary power, DeviceNet 24 VDC power, and a
functional DeviceNet controller to perform correctly.
Proteus highly recommends connecting the WeldSaver to certified DC power supplies only.

NOTE
The wiring information below applies to standard WeldSaver products and may not be valid for
customized versions. For model-specific product information, please refer to the specification
sheet provided with your instrument or visit www.proteusind.com/wsv.

1. Refer to the wiring diagram below for the 4-pin 24 VDC power connector on the bottom of the WeldSaver body.

2. Confirm that the power cable has 24 VDC present between pins 2 and 3.

CAUTION!
Connect the power cable to the 24 VDC power source BEFORE connecting it to the WeldSaver.

3. Connect the power cable to the 4-pin connector on the bottom of the WeldSaver body.

DeviceNet Connections
1. Refer to the wiring diagram below for the 5-pin DeviceNet connector on the bottom of the WeldSaver body.

2. Confirm that the DeviceNet cable has 24 VDC present between pins 2 and 3.
3. Connect the DeviceNet cable to the bus leading to the weld controller.
4. Connect the DeviceNet cable to the 5-pin connector on the bottom of the WeldSaver body.

12
4 INSTALLATION AND SETUP

DeviceNet Operation
The WeldSaver is a general-purpose discrete I/O device that operates as a Group 2 Only Server on the DeviceNet network.
It supports Explicit messaging, Polled I/O messaging, Change-of-State (COS) messaging, and Cyclic messaging of the
predefined master/slave connection set. It does not support the Explicit Unconnected Message Manager (UCMM).

NOTE
Standard WeldSaver products are configured with a default MAC ID (node address) of 48 and a
default baud rate of 500 kBd.

Input/Output Data
The WeldSaver DeviceNet interface provides discrete 8 digital inputs and 2 analog inputs to the DeviceNet master, and
receives 4 discrete digital outputs.

DATA BYTE(S) NAME DESCRIPTION VALUE

Input 1 Input States Operational status and diagnostic information 8-bit integer (bitmap below)
2–3 Supply Flow Rate Measured supply flow rate in GPM or LPM 1/100th of flow value (analog)
4–5 Return Flow Rate Measured return flow rate in GPM or LPM 1/100th of flow value (analog)
Output 1 Output States Controls WeldSaver operating mode 8-bit integer (bitmap on page 14)

»» Input States Bitmap

BIT NAME DESCRIPTION
0 OK to Weld 0: Flow rate is below Flow Fault limit. (See page 20). Unsafe to weld.
1: Flow rate is above established limit for welding. Safe to weld.
1 Valve Closed 0: Solenoid valve is open.
1: Solenoid valve is closed.
2 Bypass Mode 0: Leak detection is enabled. (See page 20.)
1: Leak detection is disabled.
3 Flow Alarm 0: Flow rate is below Flow Alarm limit. (See page 20.)
1: Flow rate is above Flow Alarm limit.
4 Cap Loss 0: Normal operation.
1: Weld-cap loss or other break in coolant circuit has been detected. (See page 21.)
5 Valve Fault 0: Normal operation.
1: Control valve failed to respond to command to turn off coolant flow. (See page 21.)
6 Flow Sensor Fault 0: Normal operation.
1: No frequency is detected from flow sensor(s). (See page 21.)
7 Power OK 0: No auxiliary power to device.
1: Normal operation.

13
4 INSTALLATION AND SETUP

Input/Output Data (Continued)

»» Output States Bitmap
BIT NAME DESCRIPTION
0 Reset Clears fault conditions to restore coolant flow and leak detection function.
1 Water Off Closes solenoid valve to stop coolant flow.
2 Bypass Mode Turns Bypass Mode on to disable leak detection function.
3 Idle Activates solenoid valve maintenance cycling: control valve will close for one second,
once per hour.
4 Not used
5 Not used
6 Not used
7 Not used

Electronic Data Sheet (EDS)

To request the Electronic Data Sheet (EDS) file for your WeldSaver model, please contact WeldSaver Technical Support.

14
5 FUNCTIONAL TESTING

Power and DeviceNet Connectivity

1. Turn power to the The MOD status indicator will turn GREEN.
DeviceNet bus
ON.

The NET status indicator will turn GREEN and flash momentarily
until the DeviceNet Master allocation sequence has completed,
at which point it will stop flashing and remain solid GREEN.

When both the MOD and NET status indicators are solid GREEN,
the WeldSaver is ready for normal operation.

Flow Detection
1. Turn 24 VDC If the coolant flow is OFF or if the flow rate is less than the Flow
power ON. Alarm value, the digital display will indicate a FLOW ALARM
( ) condition.

The indicated flow rate will be 0.0 (if the flow is OFF) or the
actual flow rate.

2. Turn the coolant

flow ON or
increase it until
it reaches the
optimum system
flow rate.

3. Press the RESET The FLOW ALARM condition will reset and the FLOW OK status
key. indicator will turn GREEN.

The indicated flow rate will be the actual flow rate.

Valve Shut-Off
1. Press the VALVE The WeldSaver will turn the coolant flow OFF.
key.
The VALVE status indicator will turn RED.

The display will indicate a flow rate of 0.0.

15
5 FUNCTIONAL TESTING

Valve Shut-Off (Continued)

2. Press the VALVE The WeldSaver will restore the coolant flow.
key again.
The VALVE status indicator will turn OFF.

The display will indicate the actual flow rate.

Bypass Mode
1. Press the The leak detection function will turn OFF.
BYPASS key.

The BYPASS status indicator will turn AMBER.

2. Press the The leak detection function will turn ON.

BYPASS key
again.

The BYPASS status indicator will turn OFF.

Cap-Off Detection

NOTE
The DeviceNet controller (weld controller) must be operating for this test to be performed.

1. Remove a weld The WeldSaver will turn the coolant flow OFF.
cap to create
The FLOW OK status indicator will turn OFF.
a leak in the
system.
The display will indicate the CAP OFF condition ( ).

2. Reinstall the
weld cap and
confirm that it is
properly secured
to the weld gun.

16
5 FUNCTIONAL TESTING

Cap-Off Detection (Continued)

3. Press the RESET The WeldSaver will restore the coolant flow.
key.
The FLOW OK status indicator will turn GREEN.

The display will indicate the actual flow rate.

17
6 PARAMETER SETUP

WeldSaver Control Parameters

The WeldSaver features multiple control parameters that can be configured to achieve optimum performance within your
system.

»» Flow Alarm Trip Point

This is the flow rate above which the welding system should be operated. Coolant flow below this rate does not
provide sufficient cooling capacity to allow satisfactory welds to be produced.

»» Flow Fault Trip Point

This is the lowest flow rate at which the welding system should be operated. This flow rate provides sufficient
cooling capacity to allow welds to be produced at the desired rate under all ambient temperature conditions.

»» Leak Response Sensitivity

This setting determines how quickly a leak will be detected. Slowing the response reduces sensitivity to false cap-
loss events; speeding the response increases sensitivity.

»» Startup Stabilization Delay Time

This setting selects the amount of time required to purge air from the cooling system at startup that could otherwise
cause false cap-loss events.

»» Startup Leak Detection Threshold

This setting checks whether the weld cap is properly in place and is not ejected from the weld shank when water
pressure is applied. A low setting gives the most sensitive response to the loss of a weld cap at startup; a high
setting gives the least sensitive response.

»» Absolute or Relative Flow Rate Display

The liquid flow rate can be displayed as an absolute value ( ) or as a value relative to the programmed Flow
Fault ( ) or the Flow Alarm ( ) values.

»» Factory Default Value Restore

The WeldSaver parameter settings can be conveniently restored to the factory default values.

Setup Menu and Factory Default Values

»» WS2VG50 BASE MODELS
SYMBOL DESCRIPTION UNITS SELECTABLE VALUES DEFAULT
Flow Alarm Trip Point LPM 0.0 to 49.4* in increments of 0.76 7.6 LPM
Flow Fault Trip Point LPM 0.0 to 49.4* in increments of 0.76 11.4 LPM
Leak Response Sensitivity -SLO SLO nor FAS +FAS Normal
Startup Stabilization Delay Seconds 1 2 4 8 16 2 sec.
Startup Leak Threshold LPM 1.9 3.8 5.7 7.6 9.5 3.8 LPM
Flow Rate Display AbS -rEL +rEL Absolute
Parameter Restore no YES
*The upper limit of 49.4 LPM is valid for products equipped with a pneumatic solenoid valve and products with no solenoid valve installed.
Products equipped with an electric solenoid valve have a reduced upper limit of 29.6 LPM.

18
6 PARAMETER SETUP

Setup Menu and Factory Default Values (Continued)

»» WS2VN13 BASE MODELS
SYMBOL DESCRIPTION UNITS SELECTABLE VALUES DEFAULT
Flow Alarm Trip Point GPM 0.0 to 13.0* in increments of 0.2 2.0 GPM
Flow Fault Trip Point GPM 0.0 to 13.0* in increments of 0.2 3.0 GPM
Leak Response Sensitivity -SLO SLO nor FAS +FAS Normal
Startup Stabilization Delay Seconds 1 2 4 8 16 2 sec.
Startup Leak Threshold GPM 0.5 1.0 1.5 2.0 2.5 1.0 GPM
Flow Rate Display AbS -rEL +rEL Absolute
Parameter Restore no YES
*The upper limit of 13.0 GPM is valid for products equipped with a pneumatic solenoid valve and products with no solenoid valve installed.
Products equipped with an electric solenoid valve have a reduced upper limit of 8.0 GPM.

Adjusting Control Parameter Values

1. Enter setup mode by pressing either the UP ARROW or DOWN ARROW key.
»» The control parameter at the top of the parameter menu will appear on the display.

NOTE
While in setup mode, any delay of more than 30 seconds between keystrokes will cause the
WeldSaver to automatically exit setup mode without saving any changes.

2. Select the parameter that you wish to adjust by pressing the UP ARROW or DOWN ARROW keys to move up or down
the parameter stack until the symbol for the desired parameter is displayed.

3. Press the SELECT (BYPASS) key to enter edit mode for the displayed parameter.
»» The current value of the selected parameter will be displayed.
4. Press the UP ARROW or DOWN ARROW keys to increase or decrease the value of the selected parameter.
»» The allowed values for each control parameter are shown on pages 18–19 of this document.
5. Exit setup mode.
»» To save the new control parameter value and return to normal operation, press the SELECT key.
»» To return to normal operation WITHOUT saving any changes, press the ESCAPE (VALVE) key.
»» After either key is pressed, the display will momentarily display a scrolling dash and then return to the liquid flow
rate indication.

NOTE
When setup mode is exited, the WeldSaver will remember the last parameter that was accessed
or shown on the menu. If setup mode is entered again within 10 minutes, this parameter will
display at the top of the menu. After 10 minutes of inactivity has passed, the Flow Alarm Trip
Point ( ) parameter will return to the top of the menu.

If you wish to adjust the value of more than one control parameter, press the UP ARROW or DOWN ARROW key to return to
setup mode, and follow steps 1 through 5 above for each additional parameter.

19
7 STATUS CONDITIONS

STATUS CONDITION KEYPAD INDICATION

OK TO WELD
The normal operating condition in which flow conditions are within the
established limits for welding.

The display indicates the actual liquid flow rate.

The FLOW OK status indicator is GREEN.

BYPASS MODE
Leak detection is disabled. Flow monitoring is still functional.

The BYPASS status indicator is AMBER.

To exit Bypass Mode and enable leak detection, press the BYPASS key.

FLOW FAULT
The display indicates , , the actual flow rate, and a blank screen at
one-second intervals.

»» Flow has fallen below the Flow Fault flow rate

1. Stop welding until sufficient flow is reestablished.
2. Check the Flow Fault ( ) setting. Correct if necessary.
3. If the Flow Fault setting is OK, increase the flow rate if possible.
4. If the flow rate cannot be increased, reduce the Flow Fault setting.

FLOW ALARM
The display indicates , , the actual flow rate, and a blank screen at
one-second intervals.

»» Flow has fallen below the Flow Alarm flow rate

1. Check the Flow Alarm ( ) setting. Correct if necessary.
2. If the Flow Alarm setting is OK, increase the flow rate if possible.
3. If the flow rate cannot be increased, reduce the Flow Alarm setting.

20
7 STATUS CONDITIONS

STATUS CONDITION KEYPAD INDICATION

CAP OFF FAULT

The display indicates , , the actual flow rate, and a blank screen at
one-second intervals.

»» The WeldSaver has detected the loss of a weld cap and the coolant
flow has been shut off
Replace the weld cap and press the RESET key to restart the coolant flow.

»» Welding has stopped, but the weld caps are still in place (false cap-
loss event)
Reduce the Leak Sensitivity Response ( ) setting and press the RESET
key to restart the coolant flow.

FLOW SENSOR FAULT

The display indicates , , , and a blank screen at one-second
intervals.

»» There is no frequency input from the flow sensors to the WeldSaver

electronics
Replace the flow sensors.

NOTE
The indicated flow rate is always 0.05 in the event
of a flow sensor fault.

VALVE FAULT
The control valve failed to respond to a command to turn off the coolant flow.
The indicated flow rate does not decrease to 0.00.

The display indicates , , the actual flow rate, and a blank screen at
one-second intervals.

The VALVE status indicator flashes at 1-second intervals.

»» The solenoid valve manual override is engaged

Disengage manual override (see pages 5–6).

»» The solenoid valve is fouled

Clean or replace the solenoid valve.

21
8 TROUBLESHOOTING

„„ The digital display and all WeldSaver and DeviceNet status indicators are OFF
»» DeviceNet 24 VDC power is not present
1. Confirm the presence of 24 VDC at pins 2 and 3 of the 5-pin DeviceNet connector on the bottom of the
WeldSaver body.
2. If 24 VDC is present but the problem persists, replace the electronics board.

„„ The MOD status indicator is GREEN, but the digital display and all WeldSaver status indicators are OFF
»» 24 VDC power is not present
1. Confirm the presence of 24 VDC at pins 2 and 3 of the 4-pin power connector on the bottom of the
WeldSaver body.
2. If 24 VDC is present but the problem persists, replace the electronics board.

„„ The NET status indicator is OFF

»» The DeviceNet network is not powered/not online (not a WeldSaver error)
Confirm the DeviceNet network configuration settings.

„„ The NET status indicator is FLASHING GREEN continuously

»» The DeviceNet network is online, but not connected (not a WeldSaver error)
Confirm the DeviceNet network configuration settings.

„„ The NET status indicator is RED

»» The DeviceNet network has a critical link failure (not a WeldSaver error)
Confirm the DeviceNet network configuration settings.

„„ The WeldSaver does not respond when the keypad keys are pressed
»» Keypad failure
Replace the keypad assembly.

„„ The WeldSaver does not detect a cap-off condition

»» The unit is in Bypass Mode
Press the BYPASS key to exit Bypass Mode and enable leak detection.

»» The Leak Response setting is too slow

1. Enter setup mode and select the Leak Response ( ) parameter from the menu.
2. Press the UP ARROW key to select a faster response value.
3. Press the SELECT key to save the new value and return to normal operation.

22
8 TROUBLESHOOTING

„„ The WeldSaver does not detect a cap loss immediately after reset
»» The Startup Leak Detection Threshold setting is too high
1. Enter setup mode and select the Startup Leak Detection Threshold ( ) parameter from the menu.
2. Press the DOWN ARROW key to select a lower threshold value.
3. Press the SELECT key to save the new value and return to normal operation.

„„ A FLOW ALARM or CAP OFF FAULT is detected immediately after replacing a weld cap
»» The Startup Stabilization Delay setting is too short
1. Enter setup mode and select the Startup Stabilization Delay ( ) parameter from the menu.
2. Press the UP ARROW key to select a higher delay value.
3. Press the SELECT key to save the new value and return to normal operation.

„„ The WeldSaver does not shut off coolant flow

»» The solenoid valve manual override function is engaged
Disengage manual override (see pages 5–6).

»» The solenoid valve pilot flow is blocked

Clean or replace the solenoid valve.

»» The check valve is blocked or fouled

Clean or replace the check valve.

„„ The flow rate reduces over time

»» A filter in the flow circuit is clogged
Clean or replace the filter.

„„ False cap-loss events occur repeatedly at the same step in the weld cycle when rapid robot movement
occurs
»» The Leak Response setting is too fast
1. Enter setup mode and select the Leak Response ( ) parameter from the menu.
2. Press the DOWN ARROW key to select a lower response value.
3. Press the SELECT key to save the new value and return to normal operation.

„„ Coolant flow is shut off, the display indicates a flow rate of 0.00, and the VALVE status indicator is RED
»» The valve is closed
Press the VALVE key to open the valve.

Proteus Industries Inc. Information in this document was correct at the time of printing;
340 Pioneer Way, Mountain View, CA 94041 however, specifications are subject to change as Proteus Industries’
continuous improvement processes establish new capabilities.
Tel: (650) 964-4163 Fax: (650) 965-0304 © Proteus Industries Inc. All rights reserved. All other company and
www.proteusind.com sales@proteusind.com product names may be trademarks of their respective companies.
WS2VTRM Rev 001 05/2014

23