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Power Wave Manager Software Manual

1. oats 9 1 Snapshot E n gd 9 2 1 E R P 9 3 Creating a Weld Trace VA H a a Hb HHHHHH H HHHH 9 4 TOC 2 Power Wave Manager User Manual IM8002 Table of Contents Weld Data 9 5 Chare TaD Z77 cc nx n x xx 22x2 pprrrp prrnr g 9 5 Back p 7 RESTOL scettr acie tenere eoru saec ES DON NOU 9 6 Backing Up a PoWet SOUFCG Ae EE 9 6 Restoring a Backup iere re robe RU eene trs pers 9 7 eel A E 9 9 SEM M 9 9 Logged AINE HERES 9 10 9 11 Production Monitoring Register ERE Ce ee vn n dee 10 2 Saving an Installation Key Fil 10 2 CHECKPOINT Setup be RI 10 2 T T 10 3 CONF 9 10 3 20220 10 3 Weld Profile Selection Irene ate nk 10 4 Outsof Limit Actions Taberas trente ea aa ek etre gea a exa d n ka b ka aka Sl Ere ae a a Raa k zik R
2. 2 Power Wave Manager ej e Ea Connection 8 Refresh Display Detailed status Clear logs mal SnapShot System status gt 2 e Power source settings System status Module information 5 Calibration 4 Machine model 1400 NA ED Cable settings and tests 4 Weld Sequencer Ez seeBane n Weld Sequencer is not faulted 4 7 Network settings Previous state Idle amp Communication Status Exit condition Not initialized ArcLink Logs were previo ared DeviceNet 2 Fatal error log Ethernet 4 I Latest fatal error 4 y Wire feeder j 6 27 2013 12 30 57 PM Error 0x9511 Ethernet TCP IP stack reported a problem ole Feeder settings gt 2 All fatal errors ee User interface DIP switch hank 1 4 2 Tools Lookup error 4 Weld Controller Bnet E Weld Controller has 3 latched fault s WeldView Event log fij Backup Restore m EE DeviceNet 4 ig Production Monitoring D Process Monitor dl Register i Dor 26 Configuration Training 4 1 Event log 16 27 2013 12 31 22 PM 213 Control board is offline possibly in boot mode 16 26 2013 5 12 14 PM 213 Control board is offline possibly in boot mode e Logs were previously cleared on 6 20 2013 10 13 AM Sense Lead Spool Gun About Preferences EDITED EG GT PALU EH English United States
3. 4 5 Language Isis M a d lek 4 5 System Status Wetm 5 1 EIC NETTE 5 2 Diagnostic A E 5 2 Detailed Status Display N d k Saw ee ORAK KU SUNA Sy dG 5 3 Module Information Tab t tee ease 5 4 IM8002 Power Wave Manager User Manual TOC 1 Table of Contents Power Source Settings a j sj 0 j mer ae dee a din M 6 1 Cable Settings and Tests t ie ie P IR en ede ete eae ON 6 3 Sense Lead Settings Fas oie rere terree Ra n ere we s kan ran sek nu WAN 6 3 Weld Cable Test Tal s siy n 6 4 Sense bead Diagnostics Tab iiie certe tete n er eH a dey TERR 6 5 Miscellari amp OUs oe ere aids need Io SEES ANY ERA AERE GA e THUS EET om 6 7 Time Settings on the Power Source KK kK KEKE KAKA KAK assassins essen nnns 6 8 Total TPDInralsidui tM 6 8 Weld Controller DD m 6 8 Network Settings leo cie 7 1 Dude EM 7 2 Mapping Status Ia g 4 Em 7 2 ie c is 7 3 DeviGe NOE EEUU 7 4 M
4. Figure 4 1 Available Connection Methods 8002 Power Wave Manager User Manual 4 1 Chapter 4 Overview of Power Wave Manager Connecting to the Welding Power Source Ethernet Connection The preferred method of connecting your computer to the Welding Power Source is through an Ethernet connection even if you do not know the specific IP address of the power source Power Wave Manager can help you find it The steps below walk you through connecting to the power source r Calibration gx Miscellaneous 4 T Network settings Cable settings and tests Communication Status Power Wave Manager o Jem iss i Wa Connection LINCOLN 5 j P System status POWER WAVE 4 m Power source settings Connect Connect through the serial port Connect through Ethernet Iknow the IP address of the welder n Connect ArcLink i DeviceNet 10 23 10 90 POE Ethernet I do not know the IP address of the welder 4 wire feeder i elo Feeder settings IP Address Model Name Machine Name E 4 Tank I 10 23 10 90 Power Wave S350 Power Wave 5350 PU 2 Lookup error 10 23 10 91 K2803 1 PW AC DC 2803 1 PW AC DC je SnapShot 10235105 Power Wave C300 Power Wave C300 i I 10 23 3 104 K2803 1 PW AC DC WDSD_ARCI Backup Restore 810235105 K2803 1 PW AC DC WDSD ARC2 6 Observer I 10235106 K2803 1 PW AC DC ACDCLab 4 B Production Monitoring
5. 4 Wire feeder Figure 7 10 Weld Sequencer Tab 7 12 Power Wave Manager User Manual 8002 Ethernet Chapter 7 Network Settings Ethernet This section provides options for configuring the network settings for the modules connected to the Welding Power Source through an Ethernet connection Multiple Ethernet Modules If the system to which a Welding Power Source is connected contains more than one Ethernet module e g a Power Wave AC DC 1000 connected to a System Interface module you can select the module you want to review from the drop down list This allows you to configure settings for each module connected to the power source r Power Wave Manager Va Connection Bi system status 4 Power source settings Configuration zi Calibration Cable settings and tests Current settings Miscellaneous IP Address 10 23 10 91 4 T Network settings Subnet mask 255 255 192 0 Communication Status Default gateway 10 0 0 24 x MAC address 00 04 EE 00 66 BD DeviceNet amp Ethernet setup Network security Communication Setup 4 y Wire feeder mm m Figure 7 11 Multiple Ethernet Module Drop down If you re not sure the selection in the drop down refers to the actual Ethernet module you want to review click the Blink status light button This causes the status light of the selected module to start blinking rapidly so you can visually id
6. Trace Tab This tab allows you to record the DeviceNet network traffic coming to and from the Welding Power Source s DeviceNet interface and create a file you can send to Lincoln Electric support or keep for reference in the future This is extremely useful for troubleshooting communication issues Power Wave Manager Va Connection system status t Power Source Controller 4 Power source settings Status Configuration Monitor Trace Weld limits Weld sequencer 197 Calibration ED Cable settings and tests Time Type MACID 1 Data Translation 1 Miscellaneous 794 1 62 3FE 01 00 00 00 07 0000 Slave s Poll Response Chanc 4 T Network settings 7999 62 5F5 00 08 00 00 00 00 00 00 Master s I O Poll Command Char LL i 4 Communication Status 1118139 1 62 FF 01 07 Slave ll Re i snapsro gzrr 0 62 54 65 01 UD Masters Explicit Request WeldView 9271 1 62 5F3 40 8E 01 00 Slave s Exolicit Unconnected Re Backup Restore 4 u 245 Observer Trace type 4 a Production Monitoring 2 _ e Stop trace 5 Register Continuous Stop when buffer full 22 Configuration Monitor entire DeviceNet bus 3 Read trace Save trace Training Record outgoing packets Without restrictions Only if data is different from previous Only if ID data are different from previous Record incoming packets Without restrictions Only if data is differen
7. a blinking green status light the intended Welding Power Source 3 Click the Configure button The Change Settings window opens 82 Change Settings 5 Please specify new settings for 10 23 10 90 Address Security Obtain an IP address automatically Use the following IP address address 10 23 10 92 Subnet mask 255 255 192 0 Default gateway 10 23 11 cancer 4 Make your changes If your computer is directly connected to the Welding Power Source using an Ethernet cable you may click the Suggest Settings button This will automatically generate the proper network settings for the Welding Power Source that would make it ready to communicate with your computer 5 Click OK The Welding Power Source then resets and accepts its new network settings 4 4 Power Wave Manager User Manual 8002 Navigating Power Wave Manager Chapter 4 Overview of Power Wave Manager Serial Connection Once you have the computer and power source physically connected through a serial cable setup simply choose the Connect through the serial port option on the Connect tab of Power Wave Manager Figure 4 1 on page 4 1 Follow the onscreen instructions to establish a connection to the power source Navigating Power Wave Manager When you launch Power Wave Manager the navigation tree down the left side allows you to access configuration options for the power source to which you have connected Click the menu
8. Power Source Controller Configuration Current settings IP Address 10 23 10 90 Subnet mask 255 255 192 0 Default gateway 10 23 1 1 MAC address 00 04 00 36 49 TCPAP setup Network security Communication Setup Speed and Duplex 100 BaseT Full Duplex Figure 7 15 Communication Setup Tab You have the following options if you ever need to make adjustments 100 BaseT Full Duplex default 10 BaseT Full Duplex 100 BaseT Half Duplex 10 BaseT Half Duplex STOP Assigning an incorrect network speed and duplex on the Welding Power Source may cause it to become unreachable on the network If you are unsure about what values to assign to the Welding Power Source consult your network administrator 7 16 Power Wave Manager User Manual IM8002 LINCOLN ELECTRIC THE WELDING EXPERTS a pte r 8 Wire Feeder The Wire Feeder section contains settings and diagnostic information for any wire feeders and user interfaces attached to the Welding Power Source to which you are currently connected with Power Wave Manager Feeder Settings In the Feeder Settings section you can fine tune the behavior of the wire feeders connected to this Welding Power Source Multiple Wire Feeders If the system to which you have connected using Power Wave Manager contains more than one wire feeder module Power Wave Manager displays the different modules in the Select Wire Feeder module drop dow
9. next to the Weld Profile in the To view the limits calculated for the Weld Profile simply click the Weld Profile number to select it Power Wave Manager displays the limits under the graphs Figure 11 2 If you would like to see the limits recorded for each trained weld for that profile simply click the weld to select it Power Wave Manager also displays these limits under the graphs 8002 Power Wave Manager User Manual 11 7 Chapter 11 Training Deleting a Trained Weld from a Weld Profile Deleting a Trained Weld from a Weld Profile When you perform welds to create training models you may accidentally create a weld that is not an acceptable example You may also have an existing trained weld in a Weld Profile that throws off the limits for that profile Power Wave Manager allows you to remove individual training files from the Weld Profile STOP Youcannot undo this action Once you select Delete training weld data file from the pop up menu the file is deleted from the Weld Profile 1 Right click the Weld Profile 2 Select Delete training weld data file from the pop up menu 3 Click OK when prompted to delete the file 4 Click the Apply settings button Power Wave Manager saves the changes to the Welding Power Source Clearing Training Data There may be times when you need to start over with a Weld Profile or you just need to remove all of the training data for the profile You can clear th
10. 2 advanced com Sender e mail address PWS350 1 amp advanced com Language Idioma Jazyk Sprache Langue Lingua E mail address click to ec E mail triggers for jsmith advanced com jsmith advanced con Z System event 5 btaylor advanced co amorris amp advanced co W Service event 5 maintenance advanc V weld Profile limit exceeded lt empty gt I Q empty v Wire package warning Q lt empty gt lt empty gt Power on lt empty gt i lt empty gt Send test e mail lt empty gt L mild Apply settings 2 English United States Figure 10 8 E mail Setup Tab 10 12 Power Wave Manager User Manual 8002 Configuration Chapter 10 Production Monitoring Mail Server Configuration The following options allow you to configure the Welding Power Source to send e mail notifications to the addresses in the Address Book page 10 13 Table 10 5 explains these options in more detail Table 10 5 Configuration Options on the E mail Setup Tab Field Description Enable e mail Place a check mark in the Enable e mail notifications checkbox to turn on the notifications e mail functions of this power source Outgoing mail server Enter the IP address of the e mail server on your network Mail server port Enter the port number that the SMTP service
11. The file extension for a backup file is WMB Figure 9 7 The system loads the file and displays the settings you can restore STOP Usecaution when restoring the TCP IP configuration option Only one machine can have a specific IP address on the network Restoring the same IP address to more than one machine can cause problems on your network It is recommended to restore TCP IP configuration only to the machine from which it was originally backed up After an IP address is restored the machine must be reset in order for the setting to take effect Be sure the machine is not welding when you reset Power Wave Manager overwrites the selected settings on the connected power source with the new settings STOP Depending on the categories and settings you choose to restore the Welding Power Source may reset and interrupt welding Be sure the power source is not currently welding 9 8 Power Wave Manager User Manual IM8002 Observer Chapter 9 Tools Observer While WeldView gives a detailed view of a portion of a weld with a short duration the Observer tool graphs welding feedback at a slower rate over the course of several entire welds When you begin a weld Power Wave Manager displays a real time view of the weld The Observer tool also allows you to change some basic welding parameters including the Group Schedule Weld Mode Workpoint Trim and other values Charts Tab Power Wave Manager produces the plo
12. 30 LOG ENER KG LEN RGY RGY GY e 1504 000 Co NONO CO CN 21504 000 Power Wave Manager User Manual 8002 LINCOLN ELECTRIC THE WELDING EXPERTS Glossary ArcLink This is a communications protocol developed by Lincoln Electric for use in a welding system This protocol takes into account specific needs of a welding system and the interaction of the multiple components that make up the network Asset An asset is entry in the Asset Tree on the left side of the Production Monitoring or CheckPoint screen An asset can be either a single Welding Power Source or a Group of power sources In a manufacturing facility the asset in Production Monitoring or CheckPoint could represent a single power source station or line within the plant Bandwidth The amount of information that wires and cables can handle just like a pipe full of water and materials The pipe can only hold so much before the flow slows down and eventually clogs Board Serial Number Each component in an ArcLink system has a unique number that allows it to be identified from the other components In Lincoln Electric systems this is used to verify what component is being referenced in software Criteria user supplied piece of information used to sort or filter the data in a report DeviceNet A standard industrial networking protoco
13. NOTE If you have modified the Welding Power Source s IP address and would like to modify more settings you will need to connect to the Welding Power Source using the new address See page 4 1 for connecting to a power source Ifyou cannot connect to the Welding Power Source refer to Appendix A for troubleshooting options Network Security Sub Tab The Network Security tab allows the configuration of a range of IP addresses that are allowed to connect to the Welding Power Source as well as another range of addresses that are allowed to modify parameters on the Welding Power Source the latter range is a subset of the first This provides some control over the components and modules e g controllers wire feeders user interfaces that can connect to this Welding Power Source Power Wave Manager e JL t JL Vo Connection Power Source Controller Bi System status 4 Power Source settings Configuration 19 Calibration D Cable settings and tests Cent cet Miscellaneous IP Address 10 23 10 90 4 T Network settings Subnet mask 255 255 192 0 e Communication Status Default gateway 10 23 11 Arcink MAC address 00 04 00 36 49 DeviceNet Ethernet TCPAP setup Network security Communication Setup 4 y Wire feeder o o Feeder settings Who may connect to the power source over the network 2 User interface IPAddress 0 0 0 1 to 255 255 255 254 4 77 Tools 4 4
14. is not a guarantee of quality and is not intended to replace a quality control system How WeldScore Works Traditional weld monitoring systems measure current and voltage and must then guess what the Welding Power Source is trying to do before attempting to determine how well it is actually doing it WeldScore is built right into the Welding Power Source control system which gives the control system a significant advantage by removing the guesswork involved with how the power source should be functioning In IM8002 Power Wave Manager User Manual 11 1 Chapter 11 Training WeldScore addition to traditional current and voltage measurements WeldScore also looks at 30 to 40 additional variables that help to make it more reliable and accurate than traditional weld monitoring systems Consistency and repeatability are the keys to make your use of WeldScore effective In order to assign score the Welding Power Source must first be taught what is considered to be an acceptable weld This is done through the training section of Power Wave Manager When a score is assigned to a future weld it is done by comparing it to the taught weld Therefore it is necessary to teach the Welding Power Source every weld for which a WeldScore is desired Some examples of when new training is required include changes in wire feed speed voltage joint type or position WeldScore is able to accommodate both welds with very tight to
15. Teach the two CALL instructions as shown above To teach the TorchMate Adjust instruction 1 Press F1 INST 2 Cursor to line Macro and press Enter 3 Atnew submenu cursor to line TorchMate Adjust and press Enter FANUC Program References Prior to v7 70P 21 The following sections are simply a list of the code and programs related to Production Monitoring CheckPoint on the FANUC robot For more in depth information about the FANUC robots please refer to the FANUC operator manuals as appropriate Programs Installed to Operate Production Monitoring CheckPoint WR AL AT computer RD AL AT computer PM SEL VER PM OFF IM8002 Power Wave Manager User Manual B 5 Appendix B FANUC Robots FANUC Robot Application Prior to v7 70P 21 PM ON ALERT 1 ALERT 2 ALERT 3 ALERT 4 ALERT 5 ALERT 10 Listing of Program PM SEL 13 R 1 AR 1 2 IF R 1 0 OR R 1 gt 31 CALL ALERT 10 3 LBL 1 4 set profile selection 5 CALL WR_AL AT 1 17 1008 R 1 3 4 6 verify that the write was ok 1 IF R 3 lt gt 0 JMP LBL 1 8 IF R 4 lt gt 0 JMP LBL 1 9 read limit counts 10 R 1 R 1 25 11 R
16. IF SARCLINK 55 05 lt gt 0 JMP LBL 3 9 IF R 5 lt gt SARCLINK ATR SINT VALUE CALL ALERT 1 10 R 1 R 1 1 11 Get Time Limit counts 12 LBL 4 13 CALL RD AL AT 1 17 R 1 14 IF SARCLINK ATR SSTATUS lt gt 0 JMP LBL 4 15 IF R 6 lt gt SARCLINK ATR SINT VALUE CALL ALERT 2 16 RII REL 4 1 17 Get I Limit counts 18 LBL 5 19 CALL RD AL AT 1 17 R 1 20 IF SARCLINK ATR SSTATUS lt gt 0 JMP LBL 5 21 IF R 7 SARCLINK ATR SINT VALUE CALL ALERT 3 22 R 1 R 1 1 23 Get V Limit counts 24 LBL 6 25 CALL RD AL AT 1 17 R 1 26 IF SARCLINK ATR SSTATUS lt gt 0 JMP LBL 6 27 IF R 8 lt gt SARCLINK ATR SINT VALUE CALL ALERT 4 28 R 1 R 1 1 29 Get WFS limit counts 30 LBL 7 31 CALL RD AL AT 1 17 R 1 32 IF SARCLINK ATR SSTATUS lt gt 0 JMP LBL 7 333 IF R 8 SARCLINK ATR SINT_ VALUE CALL ALERT 5 END Listing of Program PM OFF 1 CALL WR AL AT 1 1 END Listing of Program PM ON 1 CALL WR AL AT 1 1 END 7 999 0 O 7 999 1 0 0 IM8002 Power Wave Manager User Manual B 7 Appendix B FANUC Robots FANUC Robot Application v7 70P 21 or Later FANUC Robot Application v7 70P 21 or Later This section reviews FANUC support for Production Monitoring CheckPoint starting with the ArcTool v7 70P 21 release or later See page B 1 for information on supporting Production Mo
17. If the last digit of welding set point is zero 0 the Power Wave will use Weld Profile 10 With this method the user can access only 10 of the available Weld Profiles in Power Wave Manager constricting procedure adjustments Despite these limitations this method is simple and effective and may be the preferred choice for many applications Allow an external controller to When you choose this option for selecting the Weld Profile you tell select the Weld Profile the Welding Power Source to provide an external controller e g DeviceNet controller such a PLC or an ArcLink controller FANUC RJ3iB v6 4 with direct access to all Weld Profile numbers on the power source The controller must be one that communicates to the power source over a DeviceNet or ArcLink network Select Weld Profile based on When you choose this option you have configured the Welding Power User Interface memory Source to use the memory buttons on the connected User Interface to selection select the Weld Profile This method offers ease of use and straightforwardness in selecting the Weld Profile but the number of Weld Profiles that can be selected are limited by the number of physical buttons on the User Interface For example if there are only six memory buttons on the User Interface the Weld Operator can only choose from six Weld Profiles With this configuration chosen if the Weld Operator does not choose a memory button before performing the weld
18. It is also available at various electronics retailers and online stores by searching for the keywords DB9 to DB25 modem cable If your computer does not have a serial port you will need to purchase a USB to Serial adapter that converts one of your computer s USB ports to a serial port If you are using a USB to Serial adapter make sure the drivers for the adapter are properly installed 2 2 Power Wave Manager User Manual 8002 LINCOLN ELECTRIC THE WELDING EXPERTS a pte r 3 Installing Power Wave Manager Once you have physically connected the Welding Power Source and your computer you must perform two main steps to install Power Wave Manager Update the firmware on each power source you connect to Install the Power Wave Manager software on the computer s you want to use to connect to the power source Update Welding Power Source Firmware Firmware is the memory and programming code within the Welding Power Source that is the control program for the machine Making sure you have the latest firmware ensures that you have the latest features available for the power source including the most recent version of the Production Monitoring and CheckPoint software To install the latest firmware Procedure Details 1 Login to the computer as a user with Contact your IT department if you do not have administrative privileges administrator privileges 2 Open your browser and go to The Login pag
19. 10 23 8 107 K2344 2 PW 1 L3 Register amp 10 23 8 108 K2344 2 PW AC DC ColumnBoomArc2 E 1 96 Configuration 10 23 3 120 PM350 PM350 x 9 Training C3 10 23 8 126 Optimarc CV CC 500 Optimarc 10 23 8 147 Arc Tracker Arc Tracker My welder is not in the list 5 Configure 4 Check for Updates English United States v Refresh List Language Idioma Jazyk Sprache Langue Lingua Sz Taal Jezyk Not connected Figure 4 2 Connecting Using an Ethernet Connection To connect the Power Wave Manager application to the power source through an Ethernet connection 1 Open Power Wave Manager Generally you can select Start All Programs Lincoln Electric Power Wave Manager from the computer s main menu When Power Wave Manager opens it automatically displays the Connect tab for you Figure 4 2 2 Choose the Connect through Ethernet option 4 2 Power Wave Manager User Manual 8002 Connecting to the Welding Power Source Chapter 4 Overview of Power Wave Manager 3 Choose know the IP address of the welder if An IP address is a numeric identifier for a device you know the network address and type the network similar to a phone number and is IP address in the text field composed of four numbers each ranging from 0 OR to 255 All devices that participate on the network must each have a uniqu
20. 14 03 P em ig 2013 24 031414 mi d ran Profile 5 Q Profile 6 Profile 7 103 Weldview 2 Backup Restore amp Ob Profile 9 24 Observer 2 E nt Profile 10 Profile 11 gt Profile 12 26 Configuration e Raa i p ini Value Prope 2 Training Profile 14 peur Q Profile 15 amp 6 57 Duration high limit E Profile 16 la 5 38 Duration low limit Profile 17 Start delay Profile 18 a o End delay Profile 19 la 371 a1 Amperage high limit 1 Apply settings Preferences T TT LL WEE PALU English United States Connected to 10 23 10 90 Figure 11 1 Weld Training Window For any Weld Profiles in the list with existing limits green icons appear that represent each limit recorded for that profile WeldScore Time 9 Amperage Voltage 9 and Wire Feed Speed If the Weld Profile contains an active limit i e a check mark in the Enabled checkbox with values greater than zero 0 the green icon appears next to that Weld Profile number Ifthe WeldScore limit is not enabled and there is a value entered in the field the icon appears but is gray limit is not enabled or the value for the limit is zero 0 the icon does not appear Generally when you create a training model for a Weld Profile only the WeldScore Time and Wire Feed Speed
21. 4 B Power source settings Settings Diagnostics 15 Calibration WD Cable settings and tests Miscellaneous Stallfactor 75 2 427 Network settings Communication Status Gun offset 90 z ArcLink DeviceNet Feeder selection Ethernet Feeder PF25M Feedhead 4 Wire feeder ojo Feeder settings Gear Normal Spd 35T ee User interface a Tools g Change selection P lookup error ww ri ge Figure 8 2 Wire Feeder Settings Tab Table 8 1 Fields on the Settings Tab rea Stall factor The Stall factor controls the stall torque of the push motor when using a push pull gun The wire feeder is factory set to not stall unless there is a large resistance to feeding wire The stall factor can be reduced to stall more easily and possibly prevent the feeder wire from bird nesting Increasing the stall factor raises the motor torque and decreasing the stall factor lowers the motor torque Do not increase the stall factor more than necessary A high stall factor may increase the occurrence of bird nesting and a low stall factor may cause the wire to burn back to the tip NOTE If youare experiencing bird nests check for other feeding problems before adjusting the stall factor Gun offset The push pull Gun offset option adjusts the wire feed speed calibration of the pull motor The procedure should only be performed when other possible corrections do not solve the push pull feeding prob
22. 9 3 displays a line graph for each aspect of the weld you traced including raw voltage raw current and more You can scroll through the charts to review the information If you want to review the charts in more detail click the zoom icons The Zoom in icon amp displays the IM8002 Power Wave Manager User Manual 9 5 Chapter 9 Tools Backup Restore data in smaller segments of time The Zoom out icon condenses data and displays the time segments in larger segments For example if your chart currently displays one second of data segmented every millisecond and you click the Zoom in icon the chart begins to expand that one second into parts of a second When you click the Zoom out icon the display condenses again to show you the data segmented every millisecond Displays vary depending on the weld data You can also click the Max Zoom icon 3 to quickly display the most time segments or click the Min Zoom icon to view the fewest time segments Backup Restore The Backup Restore section of Power Wave Manager allows you to save Welding Power Source settings e g memory configuration lockout parameters and network settings to a backup file You can use this file to restore the saved settings at a later time to the same Welding Power Source or to a different power source e g if you want to configure each power source the same way Backing Up a Power Source The Backup tab Figure 9 6 provides you with th
23. Crater wetaview WI Burnback Postflow V Restrike Show Output ON OFF button Figure 9 10 Settings Tab If you want to control the machine s output from within Power Wave Manager place a check mark next to the Show Output ON OFF button option This displays a button in the toolbar allowing you to turn the output of the Welding Power Source on or off For safety you must press and hold the Ctrl key on the keyboard while clicking the button in order for it to turn the power source on or off STOP Use extreme caution when controlling the output from Power Wave Manager The output does not automatically shut off if you change screens or exit Power Wave Manager 8002 Power Wave Manager User Manual 9 11 Chapter 9 Tools Observer THIS PAGE INTENTIONALLY LEFT BLANK 9 12 Power Wave Manager User Manual IM8002 LINCOLN ELECTRIC THE WELDING EXPERTS 1 0 Production Monitoring You use the Production Monitoring section of Power Wave Manager to help you configure the Production Monitoring or CheckPoint software on this Welding Power Source whichever is applicable You also use this section to configure Weld Profiles and create training models for the Welding Power Source Power Wave Manager Le Te yrs W Connection istration Diagnostics TO Registration Diagnostics system status 4 m Power source settings Please click the button
24. DC 1000 Choose the Standard option to make the DeviceNet interface operate like a standard MIG interface The DeviceNet master must initialize all sequencer state items Choose the Legacy AC DC 1000 option to make the DeviceNet interface operate like an AC DC1000 DeviceNet interface where certain sequencer state items are fanned out to other states duplicating what was done in the older AC DC1000 DeviceNet interface 7 8 Power Wave Manager User Manual IM8002 DeviceNet Chapter 7 Network Settings Monitor Tab The Monitor tab contains detailed information about the polled input output data coming to and from the Welding Power Source s DeviceNet interface This is a troubleshooting tool for those customers implementing a DeviceNet connection to the Welding Power Source For detailed information about the data on this tab refer to the DeviceNet Interface Specification Document Y50031 included with the Power Wave Manager installation You can find the document under the Start menu of the computer 93 Power Wave Manager es Connection Select DeviceNet module PowerSource Controller v Blink status light ol System status Status Configuration Monitor Trace weld limits Weld sequencer 4 Power source settings Do Calibration N Cable settings and tests a 3 Miscellaneous Byte 0 Byte 1 Byte 0 Byte1
25. Select sense lead location manually Backup Restore Output studs Observer 4 Production Monitoring 67 Positive 1 Register Configuration 67 and 21 Training 67 Negative Preferences 28 Taal Jezyk English United States v Connected to 10 23 10 91 Figure 6 4 Sense Lead Diagnostics NOTE You cannot perform this test with ServoTorch Automatic Test Power Wave Manager can also help you troubleshoot sense lead issues The software automatically attempts to detect the sense lead location by turning on the Welding Power Source s output in an open circuit voltage OCV mode and reading back voltage The system does this while stepping through the various manual sense lead locations determining which location is most likely the one being used STOP Make sure your welding circuit is open before performing this test To perform the automatic test choose the Detect sense lead location automatically option in Power Wave Manager and click the Test sense lead selection button 6 6 Power Wave Manager User Manual IM8002 Miscellaneous Chapter 6 Power Source Settings Manual Test If you know want to step through each sense lead manually you can use Power Wave Manager to test them individually and force the Welding Power Source to sense voltage from the location you choose To perform the test choose the Select sense lead
26. Wire Drive Motor Current Mainly for diagnostics this output sends the current driving the motor If the current deviates from the current expected this could indicate a problem such as the wire being stuck or that the machine just isn t running efficiently Basically non AC DC machines use either the Actual WFS option or the Wire Drive Motor Current option AC DC machines use either the Actual WFS option or the Commanded WFS option The appropriate options are visible for that machine Analog Input Channels Analog input channels Interface Support Interface support These values indicate the magnitude of change that must occur on the first three polled 1 0 analog DeviceNet channels before the Welding Power Source will respond to the change In the case of a command value that is sourced from an A D whose output may differ slightly this configuration prevents unintended parameter changes The attribute is not useful for command values whose source is completely digital and should be set to 0 One exception is when the Welding Power Source has an Analog Interface module In this case set these values to a 30 Input channels will be ignored if their Active boxes are unchecked in which case the Welding Power Source will assign default values to the associated parameters This field only appears for AC DC 1000 SD machines It sets how the DeviceNet interface behaves for the machine The two available options are Standard and Legacy AC
27. a check mark in the checkbox next to the appropriate options Table 10 6 explains each one in a little more detail Table 10 6 E mail Triggers Z System event When a System Event occurs within the Welding Power Source e g a thermostat fault when it is reprogrammed with new software or when one of its hardware components is replaced removed or added the power source sends an e mail if there is a check mark next to this option Service event To trigger an e mail to this e mail address when a service event occurs place a check mark next to this option The power source uses these events for specific troubleshooting and reports them during general operation Weld Profile limit When a completed weld has exceeded one or more of the limits defined in a exceeded given Weld Profile the power source sends an e mail message Wire package When the consumable package reaches the limit set in the Warning weight warning field page 10 11 the power source sends an e mail to this address when there is a check mark next to this option Power on Choosing this trigger causes the power source to send out an e mail when the power source is turned on or reset Sending an E mail Test Once you have established your e mail settings and entered the person s address into Power Wave Manager you can test the e mail address to make sure the recipient receives e mail notifications properly To test the e mail settings simply click the addres
28. alter any warranty with respect to the sale of our products Lincoln Electric is a responsive manufacturer but the selection and use of specific products sold by Lincoln Electric is solely within the control of and remains the sole responsibility of the customer Many variables beyond the control of Lincoln Electric affect the results obtained in applying these types of fabrication methods and service requirements Subject to Change This information is accurate to the best of our knowledge at the time of printing Please refer to www lincolnelectric com for any updated information 900 THE LINCOLN ELECTRIC COMPANY 22801 St Clair Avenue Cleveland OH 44117 1199 U S A Phone 1 216 481 8100 www lincolnelectric com
29. below to save Production Monitoring Installation Key forthis power source After the key is saved you may use it to add this power source to Production Monitoring zs Calibration Cable settings and tests Power Source name 250_200profiles Miscellaneous 4 Network settings Communication Status i Save Production Monitoring Installation 94 ArcLink amp 29 E DeviceNet E Ethernet j Wire feeder CheckPoint Setup Feeder settings w i 2 User Enable CheckPoint over the Internet 4 22 Tools CHECKPOINT i O Lookup error SnapShot j Weldview DNS server 10 4 2 178 Backup Restore Enable Proxy Server CheckPoint Test 24 Observer d 4 B Production Monitoring L Proxy Server Send Test Message 05 Register Proxy Server IP Status 26 Configuration Training m Preferences J RT A Idioma Jazyk Sprache Langue Lingua United States Connected to 10 23 10 90 EN1 Figure 10 1 Installation Section NOTE If you do not see the Production Monitoring section the navigation tree you probably have an older version of Power Wave Manager See page 3 4 for information on installing the latest version IM8002 Power Wave Manager User Manual 10 1 Chapter 10 Production Monitoring Register Register The Register section in Power Wave Manager allows you to p
30. cable test tab Figure 6 3 allows you to measure the resistance and the inductance of your welding circuit This can be used to determine how setup changes affect the welding circuit In order to run this test the contact tip must be shorted to the work piece STOP Donottrigger the power source during this test The power source will be triggered for a short time Please verify output is turned off and PA short contact tip to work before proceeding Click the Perform test button to begin the inductance and resistance test STOP When you perform this test the Welding Power Source s output will be turned on for a very short time 100 milliseconds Once the test is complete Power Wave Manager displays the values that were calculated based on the downloaded weld trace The resistance value appears in the Resistance field measured in milliohms and the inductance value appears in the nductance field measured in microhenries Figure 6 3 6 4 Power Wave Manager User Manual IM8002 Cable Settings and Tests Chapter 6 Power Source Settings T Power Wave Manager va Connection status Power source settings Sense lead settings Weld cable test Sense lead diagnostics Conte Caabration UD Cable sett nd bests Do not trigger the power source during this test The power source will be triggered VEO HOS GAS automatically for a short time Please verify output is tur
31. case the macro instruction to set the Production Monitoring Weld Profile number is SET PM PROF profile number where profile number is an integer in the range of 1 to the maximum number of profiles available This macro is selected in the TP program editor by selecting MACRO from the instruction list and then choosing the macro name from the list that follows If your system includes multiple weld equipment there is a specific macro for each equipment and will display as SET PM PROF E1 SET PM PROF E2 etc After selecting the SET PM PROF macro add the Weld Profile number by pressing F4 CHOICE selecting Constant and entering the desired profile number Part Serial Number Selection The Lincoln Production Monitoring feature includes support for a serial number that is associated with each weld You can set the serial number from a Teach Pendant program by using the SET PM PART macro and passing the serial number as an argument The serial number can be directly entered or can be indirectly referenced by a register string register or group input The instruction format appears as follows 1 J P 1 100 FINE 2 PM PART ABC1234567 IM8002 Power Wave Manager User Manual B 9 Appendix B FANUC Robots Procedure Enabling Arc Production Monitor 3 SET PM PROF 1 4 J P 2 20 FINE Weld Start 1 1 5 L P 3 WELD SPEED CNT 100 etc Alternate serial numbe
32. click Configure 11 Editthe Ethernet settings to those provided See page 4 3 for more details on the settings by your IT department available 12 Click OK The Welding Power Source resets and accepts its new network settings 13 Unplug the Ethernet cable from the Welding Power Source 14 Reconnect the Welding Power Source to the new settings should take effect plant network again Ethernet Settings Seem Valid but Still Cannot Connect If you have checked the Ethernet settings and they are valid use the following information to verify communications and physical connections Check the physical network connections to the computer and the power source Check for a solid green or yellow light near each Ethernet jack If you see a light the physical connections are probably not the issue Cycle the power to the Welding Power Source off then back on The power source could still have a residual network connection in its memory under some circumstances If you continue to have trouble connecting verify the following Do you have multiple Ethernet adapters enabled This could cause issues Verify that the Ethernet communications are going through a single adapter To do this temporarily disable any additional adapters If you are using an Ethernet cable connection try to temporarily disable any wireless communication on the computer This could help the computer to directly connect to the Welding Power Source through
33. icons appear and sometimes only the WeldScore icon depending on how you have chosen to use the Weld Profile 11 4 Power Wave Manager User Manual IM8002 Training Profiles Chapter 11 Training When a Weld Profile has one or more training files associated with it the gray icon 9 next to the Weld Profile number appears as a star icon amp Click the plus icon to expand the Weld Profile and view the training files created The training files use the date and time naming convention and are stored in the folder selected under the Preferences button page 4 1 See page 11 7 for details on viewing the limits calculated for the Weld Profile and for the individual training files To train a Weld Profile Procedure 1 Click Production Monitoring gt Training The Training section opens Figure 11 1 in the navigation tree of Power Wave Manager 2 Click the Start training button at the top of The system goes into Training Mode and does not the window record new weld history This helps maintain production data integrity for the Production Monitoring and CheckPoint software applications NOTE Thesystem clears any unsaved weld history data from the Production Monitoring server computer or the CheckPoint data center 3 Click Yes to send the power source into The top of the window now displays the text Training Mode Waiting for next weld to start 4 Select the Weld Profile you want to train by See
34. in memory field as well as a way to reset the machine if there is an Alarm Latch detected from an out of limits condition click the Reset fault button At the top of the tab Power Wave Manager displays the current status of the monitoring software on the power source i Power Wave Manager tg 22 V Connection Registration Diagnostics system status Baz 4 Power source settings Production Monitoring is currently ready no faults 9 Calibration Reset fault 80 Cable settings and tests 00 Miscellaneous Welding history 4 T Network settings Read weld history Number of welds in memory 5 amp Communication Status 1 A Arclink Date time Duration s Profile WeldScore Amperage Volta 5 0 4 24 2013 3 27 49 23 1 3716 871 2 224 Ethernet 1 4 24 2013 3 28 28 PM 31 1 371 6 3713 22 4 4 y Wire feeder m 2 4 24 2013 3 29 57 26 1 3714 371 3 224 o o Feeder settings gira p 3 4 24 2013 3 32 34 PM 14 1 3714 G711 22 4 User interface 4 22 Tool 4 4 24 2013 3 35 04 PM 2 1 1 371 4 3711 223 M ENERO pe Figure 10 3 Diagnostics Tab You can view the list of welds in a few different formats depending on your Welding Power Source From the Read weld history drop down menu simply select the highest number format that works with your Welding Power Source Format 1 displays basic information about each weld Format 2 includes more detailed inform
35. issue you need to connect directly to the Welding Power Source through a temporary connection and change the permanent Ethernet settings See Chapter 2 for more details on cables and connecting to the Welding Power Source You can also use a serial connection as an alternative Procedure Details 1 Contact your local IT department for the correct Ethernet settings for the Welding Power Source 2 Temporarily disconnect the Welding Power Source from the network 3 Plug an Ethernet cable into the computer TIP You may need to use a cross over cable with running Power Wave Manager some older computers in order to make the connection 4 Plug the other end of the Ethernet cable into Microsoft Windows assigns a temporary IP the Welding Power Source address to the computer and the Welding Power Source so they can communicate 5 Launch Power Wave Manager IM8002 Power Wave Manager User Manual A 1 Appendix A Troubleshooting Cannot Connect to a Power Source 6 On the Connect tab choose do not know the IP address of the welder 7 Click the Refresh List button Only one IP address should appear 8 Select the welder and click Connect TIP When you select the power source the green status light on the machine should begin to blink The system automatically takes you to the System status section in Power Wave Manager 9 Click Connection in the navigation tree 10 Select the welder and
36. item in the navigation tree to display the available options on the right side of the window By default Power Wave Manager starts up in the Connection section and allows you to connect to a power source In order to access the other menu items of Power Wave Manager with the exception of Lookup Error and WeldView you must connect to a power source x Power Wave Manager e Je 152 V Connection LINCOLN li System status ELECTRIC POWER WAVE 4 ffi Power source settings Calibration Cable settings and tests Connect through the serial port E _ Connect Miscellaneous Connect through Ethernet lt 4 1 Network settings Communication Status Iknow the IP address of the welder ArcLink EF DeviceNet 10 23 10 91 Ey Ethernet Ido not know the IP address of the welder 4 y Wire feeder o o Feeder settings ee User interface 4 22 Tools Lookup error Gm SnapShot WeldView Backup Restore 24 Observer Figure 4 3 Power Wave Manager Language Selection Power Wave Manager has built in support for multiple languages By default the program automatically detects the language used by your operating system and switches the language of the interface accordingly For example on a Japanese installation of Windows Power Wave Manager automatically switches to using Japanese text and messages If yo
37. location manually option and choose one of the following options Click the Apply settings button to confirm your choice and click the Test sense lead selection button to perform the test Repeat for each option you want to test Output studs This configuration utilizes arc voltage sensing from inside the Welding Power Source and does not require polarity to be configured 67 Positive or 67 Negative Choose the option depending on the welding polarity in which your system is configured to operate 67and 21 Use this option to test both remote voltage sense leads STOP When you have completed testing cycle the power to the Welding Power Source off then back on to clear any changes made to the voltage sense location Be careful that no welding is currently in progress Miscellaneous In the Miscellaneous section under Power source settings you can synchronize the date and time on the power source You can also see the lifetime arc time for the power source You can also set a couple of options for the selected weld controller NOTE Anytime you make changes to the options in this section be sure you click the Apply settings button to commit your changes Power Wave Manager Va Connection B System status Power source settings E5 Calibration Cable settings and tests 21 Miscellaneous 4 T Network settings Communication Status ArcLink EF DeviceNet EF Ethernet Wire feeder ojo Feeder sett
38. or the Arc Production Monitor Package R788 option The controller is powered on and running at Cold Start normal operating condition Procedure 1 Gotothe System Variables menu by pressing MENU gt 0 Next gt 6 System gt F1 Type gt Variables 2 Move the cursor to SAWELEPM and If you have more than one weld equipment in your press ENTER system there will be an index for each equipment so the first equipment will appear as SAWELEPM 1 B 8 Power Wave Manager User Manual IM8002 Procedure Enabling Arc Production Monitor Appendix B FANUC Robots 3 Press Enter again to display the variables in this structure 4 Change the state of SPM ENABLE from FALSE to TRUE Weld Profile Selection The Arc Production Monitor option allows you to specify the Weld Profile for each weld in the TP program by calling a macro and passing the profile number as an argument The macro call is placed ahead of the Arc StartorWeld Start instruction in the TP program For example a TP program may appear as follows 1 J P 1 100 FINE 2 SET PM PROF 1 ce J P 2 20 FINE Arc Start 1 4 L P 3 WELD SPEED CNT 100 etc If you are using the Weld Procedures method for programming welding the TP program will appear as follows 1 J P 1 100 FINE 2 PM PROF 1 3s J P 2 20 FINE Weld Start 1 1 4 L P 3 WELD SPEED CNT 100 etc In either
39. page 10 4 for details on the Weld Profile using the method chosen for this Welding selection tab Power Source on the Weld Profile selection tab under Production Monitoring gt Configuration 5 Physically make all the welds necessary to If you have short welds to train you can train them set the accepted values for this Weld Profile succession with a short pause in between If typically between three to five welds however you have long welds to train train them one at a time and verify the data has transferred before beginning the next training weld NOTE After you complete a training weld the computer must read the data from the Welding Power Source If you start a new weld before Power Wave Manager reads this data the new weld may not be recorded In general it takes about one second to read data from every 63 seconds of welding This means a very long training weld lasting 21 minutes could take up to 20 seconds to be transfer to the computer IM8002 Power Wave Manager User Manual 11 5 Chapter 11 Training Training Profiles 6 Repeat steps 4 and 5 for each Weld Profile you want to train during this session 7 Once you have finished training the Weld 8 9 Profile s click the Stop training button at the top of the window Click OK when prompted to take the power Source out of training mode Verify there is a check mark next to each Weld Profile you want to save to the Welding Power Sou
40. that were trained r Power Wave Manager Va Connection System status 4 m Power source settings z Calibration Cable settings and tests 3 Miscellaneous 4 T Network settings 8 Communication Status A Arclink EF DeviceNet EF Ethernet Wire feeder lo Feeder settings ee User interface 22 Tools Jo Lookup error Gm SnapShot WeldView Backup Restore 24 Observer 4 ig Production Monitoring l Register Configuration Training 9 Connected to 10 23 10 90 EN1 Start training _ Stop training ov WeldScore Voltage Amperage Wire Feed Speed y Weld Duration Status Not training d Profile 1 H Profile 2 2 Profile 3 E Profile4 2U13Apr24 03 1342 2013Apr24 03 13 52 2013Apr24 03 14 03 2013Apr24 03 14 14 Profile 5 Q Profile 6 Q Profile 7 Q Profile 8 Profile 9 Profile 10 Profile 11 Profile 12 118 Profile 13 Profile 14 Profile 15 Profile 16 Profile 17 Profile 18 Profile 19 S gt Apply settings Preferences Language Idioma Jazyk Sprache Langue Lingua m Trained limits for Profile 4 Value Property a 6 57 Duration high limit a 5 38 Duration low limit Start delay alo End delay a 371 81 Amperage high limit 0 English United States Figure 11 2 Welds Trained for Weld Profile
41. the cable without interference If the computer is running some type of security software or firewall this may block the IP address of the Welding Power Source Check with your local IT department A 2 Power Wave Manager User Manual IM8002 LINCOLN ELECTRIC THE WELDING EXPERTS Appendix B FANUC Robots FANUC Systems and IP Addresses When connecting to Welding Power Sources that provide welding power for FANUC robot controllers it is important to understand the connection path between the computer running Power Wave Manager and the Power Wave power source The FANUC robot controller acts as a proxy server for messages between Power Wave Manager and the connected Power Wave Welding Power Source FANUC R 30iA and R 30iB robot controllers include two Ethernet ports Port 1 is normally connected to a building network Port 2 is connected to the local Power Wave Welding Power Source When you connect Power Wave Manager to the Power Wave power source the most convenient way to do this is to connect the computer running Power Wave Manager to the same network as Port 1 of the robot controller When you start Power Wave Manager choose the know the address of the welder option on the Connection tab and enter the IP address assigned to Port 1 of the robot controller The proxy server will pass messages to the Power Wave Welding Power Source For more detailed information please refer to the ArcTool Setup and Ope
42. the menu enter the following Host Name local ws 1incolncheckpoint com Inte rnet Address 216 26 175 3 NOTE The Host Name and IP address of the cloud server may be different than the values shown above Please consult Lincoln Electric for details about this data Upon completion of these entries cycle power on the robot controller and Power Wave Reference Here follows th AWELEPM System Variable e listing of the SAWELEPM system variable structure SAWELEPM 1 1 30 SPM ENABLE RUI Ez RUE 5 EXISTS SWP NUM WP NUM NEHA I A p H SPAI SOPER 123456789012345678 SCONS 123456789012345678 SPART CFG SOP VELDSCORE 95 VELDSCORE 0 RT 123456789 gt ER 1 CONS CFG C O15 WN EF SDE BUG IM8002 Power Wave Manager User Manual B 15 Appendix B FANUC Robots Procedure Enabling Arc Production Monitor p pop ep pa o 20 21 22 SWP NUM MAX SALARM SLATCH AL SFAULT SALARM PT SALARM PN SFAULT PT SFAULT PN STRUE ENE 2 3 24 WIR LO P ARM YP UM XP UM RGY TYP SWIR LO PNUM 25 SWIRE LOW 26 27 28 SWIRE_IN SPART_MAX SPREV_ENE 29 SWELD ENE
43. uses to connect to the e mail server The standard port number for SMTP servers is 25 Only change this number if recommended by your local IT department DNS server Enter the IP address of your network s DNS server This is only required if you specified a host name for your mail server rather than an IP address If you are unaware of this information contact your local IT department Power Source name The power source combines these two fields into an e mail address for the and Company name power source and uses this address for e mail alerts it generates Enter the company s domain name in the Company name field There is generally no need to change the Power Source name field as it defaults to the current power source s name from the Registration tab automatically helping you maintain a consistent naming convention and ensuring all files using this name can be easily found and loaded Sender E mail Address Power Wave Manager combines the Power Source name and Company name fields to produce an e mail address for the power source When the Welding Power Source sends an e mail alert to addresses in the address book this e mail address appears as the sender of the e mail Address Book The Welding Power Source contains an internal address book capable of storing up to 12 different e mail addresses 62 characters in length or less You can configure each address to receive an e mail notification when one or more events occur
44. wa WAN e a E waye Y FUERO VE ey Ec 2 Revision History Introduction System Requirements sire R eda dad ene ud sce 1 1 Compatible Equipment ius oie pete etre dak kak aka eee ha w n a ka n ka cu Wa Ya ae tutae de dala kk d ses aa e Fa en Ea d 1 1 Connecting the Power Source 55 5 2 1 Ethernet COHDOCHOTI n 2 1 Serial Cable n k E E U evv n k ku uv ak da v k d v R 2 2 Installing Power Wave Manager Update Welding Power Source nnne nennen nennen nennen KAK KA KRA KA 3 1 Installing Power Wave 3 4 Overview of Power Wave Manager Setting a Preferences 4 1 Connecting to the Welding Power 5 Eek kerk kek kek kk enne KAK KAK KAK KAK KAK A KA KAK KRA 4 1 Ethernet Connection rose dre Na 4 2 Finding the IP Address of a 4 3 Modifying the Ethernet Settings of a Power 5 enne 4 3 Serial Connection KA Ka ba 4 5 Navigating Power Wave Manager A kek keke kk ek kek KAKA AKA KAKA KAKA KA KAKA KAKA
45. weld trace Read trace from power source te ace setting 4 Power source settings L OPEN kud Save Search Raw Voltage gt 4 x Ej Weld data Charts ED Cable settings and tests i Miscellaneous 4 T Network settings Communication Statws s Antink gt Devicetict Ub ttnemet Wite teeder Feeder settings 853 User interface Took Lookup error Ks Snapshot Weldview k Backu vRest re 4 Observer 4 Production Monitoring Regnter d Configuration Training Idioma Jazyk Sprache Langue Ungua Tant oe BR CETUS utes Connected to 10 238 168 Figure 93 WeldView IM8002 Power Wave Manager User Manual 9 3 Chapter 9 Tools WeldView Creating a Weld Trace The WeldView Wizard allows you to fully configure the trace before starting it including the trace frequency the event that begins the trace i e the trigger event and if you want to record an extra channel with the trace Power Wave Manager revers system cut 4 Power source settings Ba open Seach jil 2 P Cantration Weld data 1 ess WB Cable settings Miscellaneous 4 T Network settings Melek trace settling Communication E i Devicehet d V Ethernet 4 9 Recording mode Feeder settings 9 First 4 17 sec
46. your skin and that of your helpers from the arc rays Protect other nearby personnel with suitable non flammable screening and or warn them not to watch the arc nor expose themselves to the arc rays or to hot spatter or metal A 5 a Welding may produce fumes and gases 5 b 5 0 5 d 5 e FUMES AND GASES CAN BE DANGEROUS 23 X 0 hazardous to health Avoid breathing these fumes and gases When welding keep your head out of the fume Use enough ventilation and or exhaust at the arc to keep fumes and gases away from the breathing zone When welding with electrodes which require special ventilation such as stainless or hard facing see instructions on container or MSDS or on lead or cadmium plated steel and other metals or coatings which produce highly toxic fumes keep exposure as low as possible and within applicable OSHA PEL and ACGIH limits using local exhaust or mechanical ventilation In confined spaces or in some circumstances outdoors a respirator may be required Additional precautions are also required when welding on galvanized steel The operation of welding fume control equipment is affected by various factors including proper use and positioning of the equipment maintenance of the equipment and the specific welding procedure and application involved Worker exposure level should be checked upon installation and periodically thereafter to be certain it is within applicable OSHA PEL an
47. 03 23 1 15 922 191 6 e Communication Status 71 4 24 2013 2 36 35 31 1 15 967 118 98 A Arctink 32 4 24 2013 2 40 43 26 1 15 97 9 260 76 DeviceNet Ethernet 4 y Wire feeder o o Feeder settings TIP Figure 9 9 Logged Welds Tab To save the log to a tab delimited text file click the Save weld log button on the top toolbar To clear the log click the Clear weld log button Table 9 1 Columns on the Logged Welds Tab Field Description Date time This column represents the date and time that the weld began Duration s This column represents the length of time in seconds from the time listed in the Date time column to the time the Welding Power Source stopped welding Weld mode This column displays the number of the Weld Mode used for this weld Workpoint This column displays the value of the workpoint variable for this weld WeldScore The application displays the WeldScore for this weld A value appears here only if you used a Weld Profile for this weld and there was a training model created for that Weld Profile 9 10 Power Wave Manager User Manual IM8002 Observer Chapter 9 Tools Field Description Average amps Hundreds of times per second the Welding Power Source takes a measurement of the arc current being used while the welder is active for this weld When the weld is complete the power source averages those measurements together The Average amps column displays that averag
48. 1 R 1 2013 12 Get runt counts 13 LBL 3 14 CALL RD AL AT 1 17 R 1 15 SARCLINK 55 05 lt gt 0 JMP LBL 3 16 R 5 ARCLINK ATR INT VALUE 17 R 1 R 1 1 18 Get Time Limit counts 19 LBL 4 20 CALL RD AL AT 1 17 R 1 21 IF SARCLINK ATR SSTATUS lt gt 0 JMP LBL 4 22 R 6 SARCLINK ATR SINT VALUE 23 R 1 R 1 1 24 Get I Limit counts 25 LBL 5 26 CALL RD AL AT 1 17 R 1 27 IF SARCLINK ATR SSTATUS lt gt 0 JMP LBL 5 28 R 7 SARCLINK ATR SINT VALUE 29 R 1 R 1 1 30 Get V Limit counts 31 LBL 6 32 CALL RD AL AT 1 17 R 1 33 IF SARCLINK ATR SSTATUS lt gt 0 JMP LBL 6 34 R 8 ARCLINK ATR SINT VALUE 35 R 1 R 1 1 35 Get WFS limit counts 37 LBL 7 38 CALL RD AL AT 1 17 R 1 39 IF SARCLINK ATR SSTATUS lt gt 0 JMP LBL 7 40 R 9 ARCLINK ATR INT VALUE END B 6 Power Wave Manager User Manual 8002 FANUC Robot Application Prior to v7 70P 21 Appendix B FANUC Robots Listing of Program PM VER 1 R 1 AR 1 1 2 IF R 1 O OR R 1 gt 31 CALL 10 3 R 1 RI 25 4 R 1 R 1 2013 5 Get runt counts 6 LBL 3 7 CALL RD AL AT 1 17 R 1 8
49. 11 Chapter 7 Network Settings DeviceNet m Power Wave Manager 5 amp J 2 lt d Vo Connection Select DeviceNet module Power Source Controller v Blink status light I System status 4 Power source settings status Configuration Monitor Trace Weld limits weld sequencer Calibration D Cable settings and tests Refresh 1 Miscellaneous um a Weld mode Process name Description Process type Wire type Wire size Network settings p typ typ i Communication Status 1 Soft 7018 SMAW Stick N A iA Ardink G2 Crisp 6010 SMAW Stick N A Ji 18 DeviceNet Touch Start TIG GTAW NotApplica N A Ethernet 994 SMAW Stick N A 4 W Wire feeder G 5 STD CV GMAW GasShield None Feeder settings G 6 FCAW S SSFCAW SelfShield None 56 User interface 097 FCAW G SSFCAW GasShield None 4 2 Tools 008 TS TIG Pulse GTAW NotApplica N A i i 2 Lookup error ang Arc Gouge Gouge CarbonArc N A FE SnapShot 10 Cv co2 GMAW Steel 035 in ri WeldView 1 CV ArMix GMAW Steel 035 in j 12 Pulse ArMix GMAW Steel 035 in 2 13 RapidArc ArMix GMAW Steel 035 in 4 B Production Monitoring i2 DanidAre Arkiv CAAMA Steal NAG in m 0 Register fj m m m J r Configuration Training Control name Display name Limits workpoint Amps 15to350A e WaveControll Arc Force 10 to 10 e WaveControl2 Hot Start 0 to 10 About
50. 4 T Network settings yt yt yt yt 408 Communication Status Trigger Sched Select 0 Arc Detect Proc Select Ack i d A Arctink Disable Output Proc Select Rdy Touch Sensed Limit Error Cold Inch Fwd Attr Request Gas Fault Weld Complete DeviceNet Touch Sense PM Alarm Reset Wire Fault PM Alarm Fault Elk Ethernet Cold Inch Rev Water Fault Gas Purge On 4 y Wire feeder Gas Purge Inverter Fault Feed Head 1 iojo Feeder settings Fault Reset Wire Stick Toggle Bit E 22 User interface DeviceNet Fault Attr Response 4 2 Tools Analog reference 1 2 3 Analog feedback 1 2 3 Lookup error Workpoint WFS 0 Volts 0 8 SnapShot Trim Volts 0 Amps 0 163 WeldView Arc Control 0 WES 0 lt Backup Restore 24 Observer Raw Polled I O data In 00 00 00 00 00 00 00 00 Out 00 08 00 00 00 00 00 00 Production Monitoring i E Register Analog Input 1 fan out Strike Weld Burnback Restrike 36 Configuration 9 Training Analog Input 2 fan out Strike Weld Burnback Restrike Analog Input 3 fan out Strike Weld Burnback Restrike State Enable 1 Idle Setup Strike Weld Restrike Faulted State Enable 2 Idle Setup Strike Start Upslope Weld Restrike Faulted Language Idioma Jazyk Sprache Langue Lingua Lr Connected to 10 23 10 90 English United States 2 Figure 7 7 Monitor Tab IM8002 Power Wave Manager User Manual 7 9 Chapter 7 Network Settings DeviceNet
51. AN 2 0 v Unscaled values 9 Engineering units AN3 0 I y Analog output Actual WFS O Commanded WFS E gt Apply settings age Idioma Sprache Langue 33 Taal Jezyk 27778 English United States a Connected to 10 23 10 91 Figure 7 6 Configuration Tab Table 7 1 Fields on the Configuration Tab Field Description System Control MAC ID This field displays the current media access control MAC ID of the DeviceNet interface installed on this Welding Power Source For the following power sources the MAC ID is usually set by a DIP switch located on the gateway board but you can also set the MAC ID from Power Wave Manager PW455 PW455M ACDC1000 PW655 and Welding Power Sources that use the K2436 1 Ethernet DeviceNet Communication Interface For other Welding Power Sources that do not have a DIP Switch you must use IM8002 Power Wave Manager User Manual 7 5 Chapter 7 Network Settings DeviceNet ME HK Baud Rate Event Logging Enable passive mode operation Restore settings from memory on reset Fault if no polled connection detected Report Trim Wave Outer Process Limits Power Wave Manager to set the MAC ID of the DeviceNet interface STOP If you change the MAC ID you must cycle the power to the Welding Power Source off then back on in order for the change to take effect Be careful not to cycle the power while the power source is c
52. Also see item 1 c Read and follow NFPA 51B Standard for Fire Prevention During Welding Cutting and Other Hot Work available from NFPA 1 Batterymarch Park PO box 9101 Quincy Ma 022690 9101 Do not use a welding power source for pipe thawing A 7 8 7 b 7 d TA 7 9 A SAFETY CYLINDER MAY EXPLODE IF DAMAGED Use only compressed gas cylinders containing the correct shielding gas for the process used and properly operating regulators designed for the gas and pressure used All hoses fittings etc should be suitable for the application and maintained in good condition Always keep cylinders in an upright position securely chained to an undercarriage or fixed support Cylinders should be located Away from areas where they may be struck or subjected to physical damage A safe distance from arc welding or cutting operations and any other source of heat sparks or flame Never allow the electrode electrode holder or any other electrically hot parts to touch a cylinder Keep your head and face away from the cylinder valve outlet when opening the cylinder valve Valve protection caps should always be in place and hand tight except when the cylinder is in use or connected for use Read and follow the instructions on compressed gas cylinders associated equipment and CGA publication P I Precautions for Safe Handling of Compressed Gases in Cylinde
53. Connected to 10 23 10 90 EN1 Figure 5 3 Detailed Status There are two types of error logs a Fatal Error Log and an Event Log These are historical histories for the component and could include log entries from a previous issue When you expand the component displaying the Error icon amp Power Wave Manager displays the number and description of the error or event Figure 5 3 These log entries can provide additional information to help you find the cause of any problems NOTE An event does not always indicate a malfunction An event can be posted as an informational entry Even components that are ready to weld may have events recorded in their log IM8002 Power Wave Manager User Manual 5 3 Chapter 5 System Status Module Information Tab Module Information Tab The Module information tab displays information about each hardware module attached to the Welding Power Source This information includes versions of the hardware and firmware of each module serial numbers Weld Set name and miscellaneous information such as firmware revision numbers and checksums You can switch between different sub tabs to view information about the corresponding hardware module TIP TheSoftware Version is important to know when updating the firmware on the Welding Power Source See step 7 on page 3 3 Power Wave Manager 2 lt V Connection 3 Refr
54. FANUC Robots Procedure Enabling Arc Production Monitor At the top of the Wire menu the Current weight of the wire supply is displayed Each of the settings for this menu can be changed by moving the cursor to the respective line and entering the desired value The Wire Material entry on line 5 allows you to select from the F4 CHOICE key as shown in Figure 11 4 WP TEST Cl LINE 0 T2 ABORTED 5 6 rent weight 14 9 1b ning weight 14 9 1b itial weight 15 0 1b 1 User Defined 3 Stainless 4 Alum 4043 5 Alum 5356 ning signal 33 U OFF e diameter 0 045 in e material Steel 6 Wire density 0 283 lb in3 TYPE CHOICE Figure 11 4 Changing a Setting The wire density is automatically entered for the listed materials and you can specify a different value by choosing the User Defined material choice When the Warning weight is reached the Digital Output specified on the Warning signal line will turn on It can be reset by changing the Warning weight or by pressing F2 RESET to restore the initial weight value WeldScore Display WeldScore can be displayed on the robot Teach Pendant when the Arc Analog Meter option 1599 is installed on the robot controller You can also create your own teach pendant menu that includes the display of WeldScore by pointing the display control to the system variable SAWELEPM equip num SI WELDSCORE Refer to the FAN
55. Lookup error Who may control the power source over the network SnapShot 13 weldview IP Address 0 0 0 2 to 255 255 255 253 Backup Restore Figure 7 14 Network Security Tab For each of the two ranges the user can select either all addresses addresses only within the machine s subnet or a custom range of addresses IM8002 Power Wave Manager User Manual 7 15 Chapter 7 Network Settings Ethernet For example if the custom range is from 192 168 1 0 to 192 168 1 255 a computer whose IP address is 192 168 1 10 will be able to access this machine but a computer whose IP address is 192 168 2 1 will not Communications Setup Tab Network speed how fast your network can transmit data and the duplex setting the two way communication allowed on that network dictate how effective the communication is between your Welding Power Source and the network The speed and duplex of the Welding Power Source should match the speed and duplex of your network Welding Power sources are shipped with default settings that operate properly with most networks You typically do not need modify this setting r Power Wave Manager Connection Bi system status 4 Power source settings gf Calibration Cable settings and tests 2 Miscellaneous 4 T Network settings W Communication Status ArcLink DeviceNet Ethernet a y Wire feeder o o Feeder settings ee User interface 4 22 Tools
56. M8002 Power Wave Manager User Manual 5 1 Chapter 5 System Status System Status Tab System Status Tab The System status tab displays any problems that may be present in any of the components of the Welding Power Source including hardware firmware and software e g DeviceNet module wire drives or user interfaces r Power Wave Manager V Connection Refresh Display Y gt Clear logs SnapShot Bi system status 4 Power source settings System status Module information E5 Calibration 4 fli Machine model Power Wave 5350 Cable settings and tests Weld Controller is not ready Miscellaneous 4 Wire Drive is not ready 4 T Network settings 4 Latest event s Communication Status 00 00 13 87 Wire Drive failed to find another object Obj class 14 Arclink 00 00 13 87 Wire Drive failed to find another object Obj class 14 DeviceNet 00 00 13 87 Wire Drive failed to find another object Obj class 14 Ethernet SS Figure 5 2 System Status Tab Diagnostic Display Power Wave Manager automatically runs a diagnostic on the Welding Power Source when you connect to a power source and displays the System status section for you when the connection is successful If there are no problems with the Welding Power Source the Ready icon displays and indicates that the machine is ready to weld Figure 5 1 on page 5 1 If the program d
57. Operator s Manual LINCOLN ELECTRIC POWER WAVE MANAGER EZ T TT Register your machine www lincolnelectric com register LINCOLN sale PARTS Authorized Service and Distributor Locator www lincolnelectric com locator Save for future reference Need Help Call 1 888 935 3877 to talk to a Service Representative Hours of Operation 8 00 AM to 6 00 PM ET Mon thru Fri After hours Use Ask the Experts at lincolnelectric com Date Purchased A Lincoln Service Representative will contact you no later than the following business day For Service outside the USA Code ex 10859 Email globalservice lincolnelectric com Serial ex U1060512345 IM8002 issue Date Jul 13 Lincoln Global Inc All Rights Reserved THE LINCOLN ELECTRIC COMPANY 22801 St Clair Avenue e Cleveland OH 44117 1199 U S A Phone 1 216 481 8100 www lincolnelectric com THANK YOU FOR SELECTING A QUALITY PRODUCT BY LINCOLN ELECTRIC PLEASE EXAMINE CARTON AND EQUIPMENT FOR DAMAGE IMMEDIATELY When this equipment is shipped title passes to the purchaser upon receipt by the carrier Consequently Claims for material damaged in shipment must be made by the purchaser against the transportation company at the time the shipment is received SAFETY DEPENDS ON YOU Lincoln arc welding and cutting equipment is designed and built with safety in mind However your overall safety ca
58. P The default path is the directory set under the Preferences button page 4 1 The system begins generating the file Depending on the amount of data this process could take several minutes Once complete Power Wave Manager displays a confirmation that the file was created successfully 4 Click OK Once you save the file you can e mail it to Lincoln Electric Support for analysis to the e mail address they provide to you 9 2 Power Wave Manager User Manual IM8002 WeldView Chapter 9 Tools WeldView WeldView is a feature of Power Wave Manager that allows you to capture a high speed trace of a weld performed by your Welding Power Source The trace is a series of data points that the machine stores while welding Each record consists of several variables including amperage and voltage at the time that the record was written You can use the weld trace to troubleshoot or fine tune welding performance by examining the waveform of the weld during starting and ending NOTE Lincoln Electric service personnel may request a weld trace to aid in resolving welding issues Click the Save button to save a trace file that you can send to Lincoln Electric Support for evaluation TIP If the Acquire new weld trace and Read trace from power source buttons are disabled the feature may not be supported by the connected Welding Power Source 21 Power Were Manager V Connection B System nns WP Acquire mew
59. Power Wave Manager Setup Security Settings Tab The Setup Security Settings tab allows the user to modify several User Interface parameters and security settings The parameters and settings available on this tab vary depending on the User Interface connected Please refer to the appropriate Operator Manual for more detailed information on these parameters r Power Wave Manager Va Connection System status 4 Power source settings Calibration Cable settings and tests 2 Miscellaneous Network settings 8 Communication Status Arclink DeviceNet Ethernet j Wire feeder Feeder settings ee User interface 4 22 Tools 2 Lookup error SnapShot WeldView Backup Restore 24 Observer ig Production Monitoring E Register Configuration 15 Training 9 Connected to 10 23 10 90 EN1 Setup Security Settings Memory Settings PF25M User Interface User Interface model PF25M User Interface Parameter P 1 Wire Feed Speed Units P 2 Arc Display Mode P 3 Display Options P P 4 Restore Memory By Trigger 5 Procedure Change Method dP P8 TIG Gas Control P P 9 Feedhead 1 Crater Delay P9 Feedhead 2 Crater Delay PA6 Push Pull Pot Option P 17 Remote Control Type 20 Trim Displayed as Volts dP P 22 Arc Start Loss Error Time P 24 Push Pull Type P 25 Joystick Configuration P 27 UI Langu
60. Preferences Language Idioma Jazyk Sprache Langue Lingua S Taal Jezyk English United States Connected to 10 23 10 90 Figure 7 9 Weld Limits Tab NOTE Updating the firmware on the Welding Power Source may cause the limits of some procedures to change Weld Sequencer Tab The Weld sequencer tab contains advanced configuration settings for the Weld Sequencer component of the system It presents an array of sequencer controlled system attributes grouped by welding state This useful diagnostic tool can help you verify that the settings are correct If you need to modify a system variable double click the appropriate cell Refer to the DeviceNet documentation provided by Lincoln Electric for more information n 93 Power Wave Manager amp V Connection Select DeviceNet module Power Source Controller Blink status light Bl System status 4 Power source settings Status Configuration Monitor Trace Weld limits Weld sequencer EF Calibration Cable settings and tests SchedulelA 02 Miscellaneous 4 T Network settings Attribute Idle Setup Preflow Strike Start Upslope 40 Communication Status State Timer Enable False True False True False False i ArcLink State Enable True True False True True False EF DeviceNet State Timer Preset 0 20 0 1500 0 0 ER Ethernet State Counter 0 0 0 0 0 0
61. Source a x six d k nina a c lk koda 11 l k RE e nennen aha ina A 1 IP Address or Other Ethernet Settings on the Welding Power Source Are Invalid A 1 Ethernet Settings Seem Valid but Still Cannot Connect 2 keke A 2 IM8002 Power Wave Manager User Manual TOC 3 Table of Contents FANUC Robots FANUC Systems and IP Addresses ie n ene ert e eei ee ee e UR B 1 FANUC Robot Application Prior to v7 70P 21 sssesesseeeeeeeeenenn nennen nennen nennen B 1 B 2 Setting LiMitS B 3 Adding Production Monitoring CheckPoint to Welding B 3 tiet a FER EE P abe E ek bereka D n B 4 Erroneous Low Time Limit Alarms kek ke nena B 5 FANUC Program References Prior to 7 70 21 B 5 FANUC Robot Application v7 70P 21 or Later M nnne een B 8 Procedure Enabling Arc Production MOn tOrF i kk kk B 8 COQ O yaxa Wak A b Hak B 8 RHET TEES DL IDOL enka Ra ak naa hd AN Sada B 8 Weld Profile Sele c
62. Source to which you have connected has a user interface module attached the User interface section of Power Wave Manager provides you the ability to configure that module including integration of specific welding process configurations i e sequences schedules procedures profiles and modes Multiple User Interfaces If there are more than one User Interface connected to this Welding Power Source the User Interface section provides a drop down at the top of the window so you can select which User Interface to configure 8 4 Power Wave Manager User Manual IM8002 User Interface Chapter 8 Wire Feeder F Power Wave Manager Va Connection Ii System status 4 m Power source settings 19 Calibration Cable settings and tests i 33 Miscellaneous 4 Network settings 8 Communication Status LLL iow Selected user interface module PF25M User Interface a User Interface model PF25M User Interface Setup Security Settings Memory Settings Parameter PA Wire Feed Speed Units P 2 Arc Display Mode Value English Amps Figure 8 4 Multiple User Interface Drop down If you re not sure the selection in the drop down refers to the actual user interface you want to review click the Blink status light button This causes the green status light on the User Interface to start blinking rapidly and you can verify you have the correct device selected in
63. UC iPendant Controls reference manual for details about creating your own menus on the teach pendant The Arc Analog Meter option allows you to display the weld current voltage and wire feed speed as graphical representations of an analog meter The Arc Analog Meter display is selected by pressing the STATUS key followed by the F1 TYPE key and selecting the Anlg Meter option from the list Select either F2 METER1 or F4 METER2 to display a pop up menu to choose WeldScore as a displayed variable B 12 Power Wave Manager User Manual IM8002 Procedure Enabling Arc Production Monitor Appendix B FANUC Robots Dist Spd 123 2mm Average 0 A 0 0 V Arc Welding irc On Time0 0 18 2 23 40 Arc Detect TYPE METER1 SCRN METER2 Figure 11 5 Arc Analog Meter While welding these meters display the actual values of the selected parameters Atthe end of the weld the WeldScore meter displays the average value for the previous weld Proxy Server Function for CheckPoint Cloud Server Data Storage When the robot controller Ethernet Port 1 is connected to a network that allows access to the Internet messages from the Lincoln Power Wave Welding Power Source can be forwarded to a user specified Proxy Server which forwards these messages to the CheckPoint cloud server that acts as the repository for welding data The Proxy Server option appears in the collection
64. UNG ATENCAO Chinese Korean LEIA E COMPREENDA AS INSTRU ES DO FABRICANTE PARA ESTE EQUIPAMENTO E AS PARTES DE USO E SIGA AS PRATICAS DE SEGURAN A DO EMPREGADOR fhWBCEHO h oimR ETtEISOBe ETRRML TPS ELT RHORSRE E oT TEU AR PERI NE TRAE ERPS RAN RRR EAN PRR TRA TUR ED BERR SEL 1 xime mu SHS FA BAPE Brea BEHE a Lal al allg saql geil api anu in CUSTOMER ASSISTANCE POLICY The business of The Lincoln Electric Company is manufacturing and selling high quality welding equipment consumables and cutting equipment Our challenge is to meet the needs of our customers and to exceed their expectations On occasion purchasers may ask Lincoln Electric for advice or information about their use of our products We respond to our customers based on the best information in our possession at that time Lincoln Electric is not in a position to warrant or guarantee such advice and assumes no liability with respect to such information or advice We expressly disclaim any warranty of any kind including any warranty of fitness for any customer s particular purpose with respect to such information or advice As a matter of practical consideration we also cannot assume any responsibility for updating or correcting any such information or advice once it has been given nor does the provision of information or advice create expand or
65. User Manual IM8002 Backup Restore Chapter 9 Tools To create a backup of the Welding Power Source to which you are currently connected 1 Click the Backup Restore menu item 2 On the Backup tab click the Backup button The program prompts you for a location where you would like to save the file The default location is the path you established under the Preferences button page 4 1 The file name defaults to the serial number of the control board in the Welding Power Source plus the current date and time 3 Click OK The system creates the backup file The backup could take a few moments Restoring a Backup You can use a backup file to restore the same power source to a previous state or you can use a backup file to quickly configure another power source as you set up your production line When you use a backup file you choose the settings you want to restore and the process overwrites the existing settings on the connected power source Power Wave Manager fe js ey Connection t System status Backup Restore 4 Power source settings POE F Calibration File to restore G Users UserTest Desktop Kari WDS50002_1638820111740022_2013Mar27_11 27 41 wmb ED Cable settings and tests i mA a Items to restore 11 Miscellaneous lt T Network settings Ethernet User Interface cable Settings Miscellaneous DeviceNet Production Monitor wire Feed W
66. Welding Power Source s output 6 2 Power Wave Manager User Manual IM8002 Cable Settings and Tests Chapter 6 Power Source Settings Cable Settings and Tests The Cable settings and tests section allows you to configure and test your welding cables and sense leads for the Welding Power Source to which you are connected Sense Lead Settings Tab Use these settings to enable or disable automatic hardware sense lead selection or to modify the behavior through manual settings For most applications the Automatic hardware sense lead selection is the best method to use This method reduces the chance of fairing and losing tips due to sense lead losses NOTE The Sense lead settings tab is only available for those Welding Power Sources that do not have DIP switches for modifying the sense lead location The settings are also not available for Welding Power Sources that do not support changing the sense lead selection n Power Wave Manager Ry Connection 4 m Power source settings Calibration WD Cable settings and tests d 33 Miscellaneous Network settings ka EF DeviceNet Weld Controller Sense lead settings Weld cable test Sense lead diagnostics Automatic selection Automatic hardware sense lead selection Enable remote voltage sense leads Work Electrode a Figure 6 2 Sense Lead Settings Tab Enabling
67. Welding Power Source must use the power source s address to make the connection Subnet mask This number is assigned by your local IT department A subnet is a section of a computer network Subnets are used to divide up large networks into small sections for ease of management increased performance and increased security Default gateway This is the IP address of a router or other device that allows communication with addresses that are outside your local area network MAC address This field displays the current media access control MAC ID of the module selected in the drop down at the top of the window TCP IP Setup Sub Tab On the TCP IP setup tab you can configure the IP address of the power source changing from the current address to a new IP Generally you may need to use Dynamic Host Configuration Protocol DHCP to find an open IP address for initial configuration for use prior to system integration or for mobile or remote welding equipment Generally though you need to use a static IPs subnets and gateway addresses assigned by your IT department for most fixed production equipment A static IP is required for Production Monitoring and CheckPoint STOP Assigning an incorrect IP address to the Welding Power Source may cause it to be unreachable on the network F Power Wave Manager E X Connection Select Ethernet du B System status 4 m Power source settings Configuration Calibration Power Source Controlle
68. Work Sense Lead You can configure the system to force sense arc voltage from the work sense lead 21 lead instead of the negative output stud This requires connecting to the voltage sense connector and attaching the work lead to the work To enable the work sense lead 1 Remove the check mark from the Automatic hardware sense lead selection checkbox 2 Place a check mark in the Enable remote voltage sense leads checkbox 3 Click the Apply settings button IM8002 Power Wave Manager User Manual 6 3 Chapter 6 Power Source Settings Cable Settings and Tests Enable Negative Welding Polarity If negative welding polarity is required for the Welding Power Source such as in some Innershield applications you may need to configure the correct voltage sense location manually NOTE Ifthe system is already configured to sense arc voltage at the remote voltage sense leads no changes are required To enable negative welding polarity 1 Remove the check mark from the Automatic hardware sense lead selection checkbox 2 Place a check mark in the Force negative weld polarity checkbox 3 Click the Apply settings button NOTE Ifthe sense lead selection is specified for a welding procedure that selection will have precedence over the settings you set here Therefore some welding processes such as TIG GTAW stick MMAW and SMAW will override the Power Wave Manager settings Weld Cable Test Tab The Weld
69. a more reliable protocol than UDP since it controls the delivery of data and verifies the order in which the data is sent UDP User Datagram Protocol used in the transmission of data between two or more devices It is a faster protocol than TCP but it does not guarantee data delivery or the order in which the data is sent Weld History Data on welds that the Welding Power Source has made This statistical data includes information on current voltage wire feed speed duration and weld status Weld Mode particular process that is selected in the Welding Power Source The Welding Power Source has a weld table that contains a large variety of processes that the system can use to define welding procedures Each process is listed as a Weld Mode Weld Profile configurable set of limit settings that Welding Power Source compares to welding data it collects as it welds Weld Totals A cumulative count of welds performed in each Weld Profile Each total count includes the number of welds and a count of each variable that was out of limits per Weld Profile Welding Set Point A value that the Welding Power Source utilizes to regulate its output levels GLS 2 Power Wave Manager User Manual IM8002 NOTES LINCOLN Spanish AVISO DE PRECAUCION French ATTENTION German WARNUNG ATENCAO E IR Chinese x H E 9 Do nottouch electrically live parts or electrode wi
70. a description of the error as well as possible solutions or a possible course of action to resolve the error IM8002 Power Wave Manager User Manual 9 1 Chapter 9 Tools SnapShot SnapShot A SnapShot is a small file that contains very detailed configuration and troubleshooting information collected from each module in the Welding Power Source including the User Interface memories This can help Lincoln Electric Support to troubleshoot any possible issues that cannot be easily resolved When a problem or issue occurs with the Welding Power Source record a SnapShot of the Welding Power Source clear the logs in the System status section page 5 1 and attempt to reproduce the issue If you can reproduce the issue record another SnapShot and send both files to Lincoln Electric Support for analysis r Power Wave Manager 14 Va Connection System status 4 Power source settings E5 Calibration 80 Cable settings and tests 2 Miscellaneous Network settings 1 Communication Status ie Save SnapShot Arclink DeviceNet Ethernet 4 0 Wire feeder lo Feeder settings ee User interface 4 PF Tools Figure 9 2 Saving a Troubleshooting File To save a SnapShot of the Welding Power Source 1 Click the SnapShot menu option under the Tools menu 2 Click the Save SnapShot button The Save SnapShot dialog opens 3 Leave the default path and click Save TI
71. ack NOTE Ifthe system contains a user interface with a memory panel or a robot PLC that restores settings on power up do not check this box This option disables welding if a polled DeviceNet connection is not present Place a check mark in this checkbox when a DeviceNet master controls the machine When you choose to report the Trim Wave Control input in Engineering units and these inputs are dependent on the Workpoint place a check mark in this checkbox to report back the high and low limits of the Trim and Wave Control parameters Typically this item is checked If there is no check mark in this checkbox the returned limits will be based on the Workpoint As the Workpoint changes the acceptable range for the Trim and Wave Control change as well removing the check mark from this box also reports back that acceptable range 7 6 Power Wave Manager User Manual IM8002 DeviceNet Chapter 7 Network Settings LEE eserin TAST update frequency Meter time constant Analog scans between updates Cold inch wire feed speed This parameter is used for Through the Arc Seam Tracking TAST The lower the number the more often the feedback is updated but higher the system load on the boards In general if TAST is being used this frequency is set to a value between 10 and 20 Otherwise a value of 100 is usually acceptable This value is only relevant for the PW455 455M 655 355 and ACDC1000 This parameter sets
72. age P 29 Feedback Persist dP P 501 Encoder Lockout P P 502 Memory Save Lockout dj P 503 Memory Button Disable P 504 Mode Select Panel Lock PA P 505 Preference Lock dP P 28 WorkPoint Displayed as Am P 81 Negative Electrode Polarity Value English Amps Standard Display No External Procedure Valve manual 0 0 P 8 TIG Gas Control o Please select a new value for this item Remote Pot Enable Joystick MIG Gun Valve manual No 0 OK Cancel Default WFS Trim English Yes No No Both Encoders Unlocked No All Memories Enabled All MSP Options Unlocked No Language Idioma Jazyk Sprache Langue Lingua 228 Taal Jezyk a English United States U Figure 8 5 Setup Security Settings Tab To change a parameter double click the parameter to open the edit window Figure 8 5 Simply make your change and click OK 8002 Power Wave Manager User Manual 8 5 Chapter 8 Wire Feeder User Interface Memory Settings Tab The Memory Settings section allows you to configure any of the memory buttons that exist on the User Interface module s attached to your welding system Memory buttons allow you to preset weld settings for those welds commonly performed using this power source NOTE Ifthe User Interface is a dual feed head system click the appropriat
73. age 7 Voltage V Wire feed speed IPC MIT EIUS T REPETI Mi tnoisn Unted Connected 10100 30 CANI Figure 9 8 Observer Tool IM8002 Power Wave Manager User Manual 9 9 Chapter 9 Tools Observer TIP TIP Logged Welds Tab To save the data in the charts to a tab delimited text file click the Save chart data button on the top toolbar Click the Clear charts button to clear the data from the screen and start fresh Click the plus icon at each corner of the chart to collapse the panel next to it if available The Logged Welds tab displays a list of the welds that were made during the Observer session The Observer session begins when you click into the Observer section of Power Wave Manager The session ends when you close Power Wave Manager or disconnect the power source Each weld that you create during this time appears on the Logged welds tab when the Welding Power Source s output turns off after you complete the weld Power Wave Manager b Connection System status s Save chart data Y Clear charts 5 Save weld log gt Clear weld log 4 fil Power source settings Charts Logged welds Settings E5 Calibration 80 Cable settings and tests This is a list of welds that have been performed by this machine during this Observer session 2 Miscellaneous Date time Duration Weld mode Workpoint WeldScore Average Network settings 3o 4 24 2013 2 35
74. ail notifications are disabled when CheckPoint is CHIVA NT 2 Lookup error enabled Alerts will be generated from the cloud SnapShot fh Save Production Monitoring Installation Key Figure 10 2 Save an Installation Key File On the Registration tab of Power Wave Manager Figure 10 2 simply click the Save Production Monitoring Installation Key button and save the file on your computer or network Close Power Wave Manager when finished STOP Itis recommended that you do not change the text in the Power Source name field especially after creating files from the power source e g training files or backups Power Wave Manager uses the Power Source name to organize and name weld training backups SnapShot files weld logs calibration logs and more If you change a name you will have to find and load files manually CheckPoint Setup The options in the CheckPoint Setup section of this tab allow you to enable CheckPoint for the Welding Power Source to which you are currently connected and to verify that connection For more in depth details on setting up CheckPoint please refer to the CheckPoint User Manual 10 2 Power Wave Manager User Manual IM8002 Configuration Chapter 10 Production Monitoring Diagnostics Tab The Diagnostics tab provides you with a way to view a list of welds that the power source currently has in its memory since the last time it powered on the Number of welds
75. ain a specified level of quality The Weld Profile is selected through a system controller user interface or other device prior to initiating each weld as required by the production sequence As an example consider a part that requires 10 different welds for proper assembly The Weld Engineer begins by configuring 10 of the available Weld Profiles with proper limit settings for each of the different welds The Weld Operator can then begin welding the part selecting the proper Weld Profile for each of the 10 welds There are several ways of selecting the Weld Profile page 10 4 Based on welding set point Through DeviceNet using a PLC Through an ArcLink compatible controller Through memory buttons on the power source s User Interface The Welding Power Source can compare the limits stored in a Weld Profile to the real time data values collected while performing a weld and take various actions if the weld exceeds these limits page 10 5 Power Wave Manager provides up to 32 Weld Profiles on supported second generation Welding Power Sources and up to 200 Weld Profiles on some supported third generation power sources In order to make use of the 200 Weld Profiles on third generation Welding Power Sources be sure you have the latest version of the Welding Power Source firmware page 3 1 and the latest version of the Power Wave Manager software page 3 4 Weld Profile Selection Tab The Weld Profile selection tab allows you to c
76. ant to copy 2 Select Copy training weld data file from the The system prompts you for the profile to which pop up menu you would like to save the copy 3 Select the appropriate Weld Profile and click OK 4 Click Apply settings Power Wave Manager saves the changes to the Welding Power Source 8002 Power Wave Manager User Manual 11 9 Chapter 11 Training Copying a Weld File THIS PAGE INTENTIONALLY LEFT BLANK 11 10 Power Wave Manager User Manual IM8002 LINCOLN ELECTRIC THE WELDING EXPERTS A ppen dix A Troubleshooting Inevitably there will be an issue when working with a software program or installing software that you need a little extra information to help troubleshoot and solve the problem There are some common minor issues you might be able to fix without a call to support NOTE If you continue to have trouble please contact your local IT department or Lincoln Electric Production Monitoring support For support in the USA or Canada dial 1 800 691 5797 The direct dial number is 1 727 786 0121 You can also e mail support at support lincolnelectricproductionmonitoring com Cannot Connect to a Power Source There are multiple reasons you may not be able to connect to the IP address of a power source or why the IP address may not show up in the list of addresses Here are some possibilities IP Address or Other Ethernet Settings on the Welding Power Source Are Invalid To correct this
77. ara a vista ouvido e corpo BL SRE WE TH H B 29 CEC EES y A a ee cil ali n a DTI READ AND UNDERSTAND THE MANUFACTURER S INSTRUCTION FOR THIS EQUIPMENT AND THE CON SUMABLES TO BE USED AND FOLLOW YOUR EMPLOYER S SAFETY PRACTICES SE RECOMIENDA LEER Y ENTENDER LAS INSTRUCCIONES DEL FABRICANTE PARA EL USO DE ESTE EQUIPO Y LOS CONSUMIBLES QUE VA A UTILIZAR SIGA LAS MEDIDAS DE SEGURIDAD DE SU SUPER VISOR LISEZ ET COMPRENEZ LES INSTRUCTIONS DU FABRICANT EN CE QUI REGARDE CET EQUIPMENT ET LES PRODUITS A ETRE EMPLOYES ET SUIVEZ LES PROCEDURES DE SECURITE DE VOTRE EMPLOYEUR LESEN SIE UND BEFOLGEN SIE DIE BETRIEBSANLEITUNG DER ANLAGE UND DEN ELEKTRODENEIN SATZ DES HERSTELLERS DIE UNFALLVERHUTUNGSVORSCHRIFTEN DES ARBEITGEBERS SIND EBEN FALLS ZU BEACHTEN Keep your head out of fumes Use ventilation or exhaust to remove fumes from breathing zone Los humos fuera de la zona de res piraci n Mantenga la cabeza fuera de los humos Utilice ventilaci n o aspiraci n para gases Gardez la t te l cart des fum es Utilisez un ventilateur ou un aspira teur pour ter les fum es des zones de travail Vermeiden Sie das Einatmen von Schweibrauch Sorgen Sie f r gute Be und Entl ftung des Arbeitsplatzes e Mantenha seu rosto da fuma a Use ventila o exhaustao para remover fumo da zona respira
78. are often different than the rest of the weld e g if the power source is in a burn back state The End delay must be within the range of 0 1 seconds to 10 0 seconds Place a check mark next to this option to tell Production Monitoring or CheckPoint that it should not record welds where the duration of the weld is shorter than the combined Start delay and End delay times If this option is unchecked welds that are greater than 0 4 seconds but less than the Start plus End delay time will be recorded but will be marked as a Short Weld Every quarter of a second the Welding Power Source compares the performance of the current weld against the trained weld for the selected Weld Profile When the weld is complete the power source averages those measurements together for an overall WeldScore The Minimum WeldScore field allows you to enable the action you selected for WeldScore on the Out of limit actions tab page 10 5 If the overall WeldScore for the weld falls below the value you enter here the system performs the action you selected in the Action on WeldScore limit drop down on the Out of limit actions tab Even if you do not have the alerts enabled the power source still calculates WeldScore on machines that support this value if a training model exists 8002 Power Wave Manager User Manual 10 9 Chapter 10 Production Monitoring Configuration Field Description for that Weld Profile and displays t
79. art Control Panel from the main computer menu e g Select Tools Options from the menu Dialog Box Application Window Titles and Field Names The titles of dialog boxes and application windows are shown in italics Field names and selections made from drop down menus etc are also shown in italics e g The Print Preview window opens e g Select All Shifts from the drop down list IM8002 Power Wave Manager User Manual 1 Preface Notes Warnings and Tips Notes Warnings and Tips Notes stops and tips appear throughout the manual They provide additional information that is important for you to know about the topic NOTE note is important piece of information STOP You should definitely read the information in a stop table It could help you prevent a situation from which you cannot recover TIP Atiptable helps you with some interesting or useful information about using the program 2 Power Wave Manager User Manual IM8002 BIEN ELECTRIC THE WELDING EXPERTS Revision History Change Description July 2013 Initial Release as IM8002 8002 Power Wave Manager User Manual REV 1 Revision History REV 2 Power Wave Manager User Manual IM8002 LINCOLN ELECTRIC THE WELDING EXPERTS a pte r 1 Introduction Power Wave Manager is an application that allows you to configure and manage a multitude of settings and configuration options wit
80. ated near the indicator light Then Digital Output 1 turns off turning off the indicator light B 4 Power Wave Manager User Manual IM8002 FANUC Robot Application Prior to v7 70P 21 Appendix B FANUC Robots Erroneous Low Time Limit Alarms A low time limit can occur if the duration of the weld is less than the sum of the Start and End delays as set by someone like a Weld Engineer during the setup of Weld Profiles page X When the TorchMate and Touch Sensing options are used the momentary touch the wire makes at the part or at the TorchMate block is enough to cause a low time limit to be generated If these become a nuisance it is possible to turn off Production Monitoring CheckPoint prior to running a Touch Sensing routine or running TorchMate Adjust and then turn it back on again prior to making a weld Two programs are installed the robot to turn Production Monitoring CheckPoint on or off PM OFF and PM ON These are entered as a CALL instruction To avoid tampering with the original TorchMate Adjust program it may be desirable to create a new program titled TorchMate for example that begins with a line to turn off Production Monitoring CheckPoint followed by the TorchMate Adjust instruction and finishing with a line that turns Production Monitoring CheckPoint on again ready for the next weld Here is a sample program TORCHMATE 1 CALL PM OFF 2 Torchmate Adjust 3 CALL PM ON END
81. ation about each weld Format 3 includes the most information about each weld including WeldScore and part serial numbers Configuration The Configuration section allows you to set up the Weld Profiles needed on this Welding Power Source set up e mail notifications from the power source manage the consumables used by the power source and more NOTE When you finish changing configuration options on one or more tabs be sure to click the Apply settings button to commit your changes Otherwise you will lose your new settings Weld Profiles One of the principal goals of Production Monitoring or CheckPoint is to report on welds that are outside of user defined limits with respect to WeldScore current voltage wire feed speed and duration This goal would be simple to implement if the Welding Power Source were to perform only one type of weld over and over However in practical applications this is not the case The assembly of many different industrial components requires welds of varying type and length IM8002 Power Wave Manager User Manual 10 3 Chapter 10 Production Monitoring Configuration Weld Profiles allows the Welding Power Source to apply different limit settings for each weld that is performed on a certain part A Weld Engineer creates a Weld Profile for each weld needed to make a part The Weld Profile configures the power source to complete a certain type of weld within certain limits needed to obt
82. ble into the power source You use the Wire package tab in Power Wave Manager to do this Simply enter the details of the consumable and click the Apply settings button Table 10 4 explains the fields in more detail r Power Wave Manager 8 9 9 Pe JL Jes 4 ag Weld Profile selection Out of limit actions Profile limits Wire package E mail setup Miscellaneous fi System status 5 small setup j Power source settings z Calibration Initial weight Ib 500 Cable settings and tests Miscellaneous Current weight Ib 351 Replenish 42 Network settings Communication Status Warning weight Ib 15 2 ini 3 et Wire diameter 0 035 2805 Ethernet Metal density Ib in User Defined Density 0 283 4 y Wire feeder ojo Feeder settings ee User interface f AZ vok 2 1 Figure 10 7 Wire Package Tab Once you restock the power source after it runs out click the Replenish button to reset the Current weight field to the same value as the nitial weight field provided the new wire is the same Remember to click the Apply settings button to commit the change to the power source Table 10 4 Fields on the Wire Package Tab LEM ER Initial Weight Enter the original weight of the wire package as indicated on the container Current weight If the package is partially used you can enter the cu
83. cation to a Welding Power Source to do any configuration you physically connect your computer to the power source using one of three methods A direct connection between your computer and the Welding Power Source using an Ethernet cable from your computer to the port on the power source Anexisting company network connection A serial connection IP Addresses An IP Internet Protocol address is the location of the Welding Power Source on the network e g 10 23 10 91 Any device on the network that wants to communicate with the Welding Power Source must use the IP address to make the connection IP addresses can be set up as dynamic where the computer network automatically assigns an IP address to the machine or as a static IP address where an IT department assigns a specific address to each device on the network Power Wave Manager can handle either scenario page 4 3 however it is best to check with your local IT department for the policies used on your network Ethernet Connection The Ethernet connection is the recommended method of connecting your computer to your power source The Ethernet port on your computer and on the Welding Power Source is an RJ 45 jack which resembles a wider telephone jack For an Ethernet connection your computer can be physically connected to the Welding Power Source over the network in one of the following ways Direct connection between the computer and the Welding Power Source
84. ce or ground use the following equipment Semiautomatic DC Constant Voltage Wire Welder DC Manual Stick Welder AC Welder with Reduced Voltage Control In semiautomatic or automatic wire welding the electrode electrode reel welding head nozzle or semiautomatic welding gun are also electrically hot Always be sure the work cable makes a good electrical connection with the metal being welded The connection should be as close as possible to the area being welded Ground the work or metal to be welded to a good electrical earth ground Maintain the electrode holder work clamp welding cable and welding machine in good safe operating condition Replace damaged insulation Never dip the electrode in water for cooling Never simultaneously touch electrically hot parts of electrode holders connected to two welders because voltage between the two can be the total of the open circuit voltage of both welders When working above floor level use a safety belt to protect yourself from a fall should you get a shock Also see Items 6 c and 8 4 a 4 b 4c SAFETY Le ARCRAYS CAN BURN _ 24 Use a shield with the proper filter and cover plates protect your eyes from sparks and the rays of the arc when welding or observing open arc welding Headshield and filter lens should conform to ANSI Z87 standards Use suitable clothing made from durable flame resistant material to protect
85. d ACGIH TLV limits Do not weld in locations near chlorinated hydrocarbon vapors coming from degreasing cleaning or spraying operations The heat and rays of the arc can react with solvent vapors to form phosgene a highly toxic gas and other irritating products Shielding gases used for arc welding can displace air and cause injury or death Always use enough ventilation especially in confined areas to insure breathing air is safe Read and understand the manufacturer s instructions for this equipment and the consumables to be used including the material safety data sheet MSDS and follow your employer s safety practices MSDS forms are available from your welding distributor or from the manufacturer Also see item 1 b A 6 a Remove fire hazards from the welding area If 6 b 6 c 6 d 6 e 6 f 6 9 6 h 6 1 6 j WELDING AND CUTTING SPARKS CAN CAUSE FIRE OR EXPLOSION e nin N Ne this is not possible cover them to prevent the welding sparks from starting a fire Remember that welding sparks and hot materials from welding can easily go through small cracks and openings to adjacent areas Avoid welding near hydraulic lines Have a fire extinguisher readily available Where compressed gases are to be used at the job site special precautions should be used to prevent hazardous situations Refer to Safety in Welding and Cutting ANSI Standard 249 1 and the operating informatio
86. d d 10 5 Profile Limits TERT LS DE 10 7 Wire Package lab ire OE ERE 10 11 E mail 10 12 Miscellaneous zx gt gt o ee pppp bkk b_w_rorrmr_m_rmeeboougDzgmm 10 15 Training Before You Begin Training a Ve H na d ewe iaa 11 1 nun ene cn desde Kin aa ees O 11 1 How WeldScore Works iiid ev Tr VERA KEK WENE M A HA Ke WA E EWARA n 11 1 Where to Use WeldScore da kal d u e aw K Rd da 11 2 Meaning of the WeldScore ValUe nni KA KAKA 11 2 Weld Profile Training MEM 11 3 Weel dS tO Trail quee EY x EO Rae eso oe E SN ria Les Gee WR PRAE WR GeV 11 3 P 11 4 Viewing the Calculated Limits for a 2222 kk k k kk ke k y kk kek KA KAK KARA 11 7 Deleting a Trained Weld from a Weld keke nnne 11 8 Clearing Training Data t sik w n K DA 11 8 Loading a W ld ke na 11 9 Copying a Weld File ec ave SAN 11 9 Troubleshooting Cannot Connect to a Power
87. de the limits set by the Weld Profile causes the power source to enter into a faulted state when the weld ends also known as a latched fault In order for the power source to continue welding the Weld Operator must clear the fault You can reset an Alarm Latch fault on the Diagnostic tab under Production Monitoring Register page 10 3 or by cycling the power to the Welding Power Source off then back on Profile Limits Tab The Profile limits tab is where you set limits or adjust trained limits for every Weld Profile available to the Welding Power Source Each power source stores all Weld Profiles that are available but it can only access the profiles based on the choice you make on the Weld Profile selection tab page 10 4 You can set the profile limits manually on the Profile limits tab or you can teach the power source what you consider to be a weld within limits STOP Be sure you plan your Weld Profiles before you begin See page 11 1 for more details STOP Forinformation on training a weld for a Weld Profile please refer to Chapter 11 8002 Power Wave Manager User Manual 10 7 Chapter 10 Production Monitoring Configuration r 19 Power Wave Manager Connection Weld Profile selection Out of limit actions Protwe limits Wire package E mail setup Miscellaneous System status 4 ff Power source settings for profile 14 E 2 Ca
88. ds M bA p a b u k n k AA B 9 Part Serial Number Selection nennen nnne Kek kek KAK KAK KA A KA KAK KK A KA B 9 Production Monitoring Error Handlinmg B 10 Wire Monitor Set p M ehl cx B 11 WeldScore Display Um B 12 Proxy Server Function for CheckPoint Cloud Server Data Storage B 13 Reference SAWELEPM System Variable ccccccccccesscccsseccssecesseccssecessesessecsseeecseecesueeceeeses B 15 Glossary TOC 4 Power Wave Manager User Manual IM8002 LINCOLN ELECTRIC THE WELDING EXPERTS Preface Typographical Conventions Used Before using this guide it is important to understand the typographical conventions used to identify and describe information Cross References Cross references to chapters sections page numbers headings etc are shown in an italic typeface e g Refer to Text You Type Using the Keyboard on page 1 Text You Type Using the Keyboard Text that you type using the keyboard is shown ina Courier typeface e g Type John Smith the Name field Keys You Press and Buttons You Click Keys that you press on the keyboard and buttons icons that you click with the mouse are shown in a bold sans serif typeface e g Press Enter e g Click OK to continue Menus You Select Menus and the selections you make from the menus are shown in a bold sans serif typeface e g Select St
89. e When you choose the Unscaled values option the commands for Workpoint range from 0 to 32767 corresponding to the minimum and maximum Workpoint of the selected Weld Mode This indicates whether the values passed to the system through the analog DeviceNet channels for the Trim and Wave Control parameters are raw values or scaled engineering values For example when the Trim is in volts and you choose Engineering units a value between 75 and 520 might be expected to be commanded on the DeviceNet analog input for the Trim This would represent a value of 7 5 to 52 0 volts When you choose the Unscaled values option the commands for Trim and Wave Control range from 32768 to 32767 with 0 representing a nominal value A great majority of applications will require Trim and Wave Control command values to be set near the nominal value 8002 Power Wave Manager User Manual 7 7 Chapter 7 Network Settings DeviceNet LEM OON Analog output This setting controls the value that is reported by the power source s third analog feedback The options that appear vary depending on the machine A great majority of applications will use the default Actual WFS option Actual WFS This option reports the actual wire feed speed of the feeder through the third analog feedback Commanded WFS Typically used for non Lincoln Electric wire feeders this option sends the recommended wire feed speed through the third analog feedback
90. e IP address Choose don t know the IP address of the welder if you need to scan the network to find the welder s address See page 4 3 for NOTE If there is IP address already more information on finding the IP address displayed in the text field it is the IP address of the last Welding Power Source that was connected Be sure you enter the correct address for the current Welding Power Source you want to update For example 10 23 10 90 is a valid IP address 4 Click the Connect button The system attempts to connect to the Welding Power Source If the connection is established successfully the software automatically displays the System status section for you Chapter 5 If Power Wave Manager could not connect to the Welding Power Source there may be a couple of solutions you can try Please refer to Appendix A for more information Finding the IP Address of a Welder If you don t know the IP address of a Welding Power Source or if you are having trouble connecting when you enter a specific IP address you can have Power Wave Manager scan your network for welders When you choose the do not know the IP address of the welder option on the Connect tab the system automatically begins scanning your network for power sources Once it completes the scan Power Wave Manager displays the results in the list along with the model name and machine name Simply click on each Welding Power Source in the list until you see the green
91. e been eliminated y 1 d A Electric current flowing through any conductor 2 C SAFETY Keep all equipment safety guards covers and devices in position and in good repair Keep hands hair clothing and tools away from V belts gears fans and all other moving parts when starting operating or repairing equipment In some cases it may be necessary to remove safety guards to perform required maintenance Remove guards only when necessary and replace them when the maintenance requiring their removal is complete Always use the greatest care when working near moving parts Do not put your hands near the engine fan Do not attempt to override the governor or idler by pushing on the throttle control rods while the engine is running To prevent accidentally starting gasoline engines while turning the engine or welding generator during maintenance work disconnect the spark plug wires distributor cap or magneto wire as appropriate To avoid scalding do not remove the radiator pressure cap when the engine is hot ELECTRIC AND MAGNETIC FIELDS MAY BE DANGEROUS _9 ES N causes localized Electric and Magnetic Fields EMF Welding current creates EMF fields around welding cables and welding machines EMF fields may interfere with some pacemakers and welders having a pacemaker should consult their physician before welding Exposure to EMF fields in welding may have other health effects w
92. e displays WWW powerwavesoftwa re com 3 Enter your username and password in the Email If you re creating a new account follow the and Password fields and click Sign In onscreen instructions and return to this step OR when finished Once you log in the system displays the Power Wave Resource Center LINCOLN ELECTRIC THE WELDING EXPERTS Click the Register Today link to create an account Power Wave Software POWER WAVE RESOURCE CENTER EM IM8002 Power Wave Manager User Manual 3 1 Chapter 3 Installing Power Wave Manager Update Welding Power Source Firmware Procedure 4 Inthe Quick Links section click the Power Wave Power Feed MAXsa Software link 5 Click the Download Power Wave Bundle FREE button to run the update The system displays a page containing the Download Power Wave Bundle FREE button Download Power Wave Bundle FREE File Size 11 1 MB ast Updated 08 20 12 NOTE Depending on your Windows version you may have to click Run or Allow to permit your system to launch the file The system opens the Lincoln Electric System Update Utility window where you tell the utility how to find the Welding Power Source you want to update f B Lincoln Electric System Update Utility m 10 23 8 147 6 Choose the Connect through Ethernet option and enter the IP address of the Welding Power Source you want to update C Connect thro
93. e feed head button at the top of the list to access the memory buttons specific to that feed head F Power Wave Manager 5 Va Connection system status 4 Power source settings User Interface model PF25M User Interface 87 Calibration Cable settings and tests PF25M User Interface Setup Security Settings Memory Settings 2 Miscellaneous ole Feed head 1 4 77 Network setti r T W EM Status Memory Ardink E Memory 1 stept O V Enable user limits DeviceNet Memory 2 Ethernet W Memory 3 Parameter Value User Limits 4 P Wire feeder Memory 4 weld Mode 22 N A ole Feeder settings I Memory 5 uttimarc 0 2 10 to 10 4 User interface US Memory 6 Preflow Time 0 s Off N A ni dle BS Memory 7 Run in wes 32 in min N A 4 ld Memory 8 Start Time 0 s Off N A start Amps 0A N A Backup Restore start Trim 1 N A A Observer weld Amps 0A 0 to 32767 4 ig Production Monitoring weld Trim 0 5 to 1 5 L3 Register crater Time 0 s Off N A Configuration Crater Trim 1 N A v Training Burnback Time 0 s Off N A Posttlow Time 0 s Off N A Spot Timer 0 s Off N A About Preferences K English United States gt Connected to 10 23 10 90 EN1 Figure 8 6 Memory Settings Tab Memory Buttons The number of memory slots that appear on the Memory Settings tab depe
94. e list of information in various categories that you will save when you click the Backup button Click through the sub tabs to see what the backup file could contain The backup file will include the information if that information exists on the Welding Power Source r Power Wave Manager Je es V Connection Backup Restore Bi system status Power source settings EF Calibration Cable settings and tests Items to backup 3 Miscellaneous 4 77 Network settings User Interface Cable Settings Miscellaneous DeviceNet Production Monitor Wire Feed W gt Communication Status Production Monitoring configuration Arclink Weld Profile Selection Method EF DeviceNet Spei eid Ethernet Out of Limit Action Settings 4 Wire feeder Weld Profile Settings ojo Feeder settings Wire Package Settings a ee User interface Email Settings 44 Tous Machine Name JY Lookup error SnapShot WeldView Backup Restore 24 Observer ig Production Monitoring Register Configuration Training This allows you to create a backup file that contains your Production Monitoring configuration WeldScore parameters User Interface settings Ethernet settings and other configuration information About Preferences Ex English United States gt Connected to 10 23 10 90 EN1 Figure 9 6 Backup Tab 9 6 Power Wave Manager
95. e training data as well as any limits you entered manually on the Profile limits tab under Production Monitoring gt Configuration To clear data for a Weld Profile Procedure Deta 1 Right click the Weld Profile 2 Select Remove all welds and clear the training model from the pop up menu 3 Click OK to confirm you want to clear Power Wave Manager clears data on the Welding the data Power Source and resets the machine NOTE This process could take some time Power Wave Manager disables certain functions until the process is complete 4 Click OK when prompted that the machine has been reset 11 8 Power Wave Manager User Manual IM8002 Loading a Weld File Chapter 11 Training Loading a Weld File If you need to load an existing weld training file from the Preferences folder page 4 1 you can easily do so with Power Wave Manager 1 Right click the Weld Profile to which you want to load the file 2 Select Load training weld data file from the pop up menu 3 Navigate to the weld data file you want to load 4 Select the file and click Load The system adds the training file to the profile 5 Click Apply settings Power Wave Manager saves the changes to the Welding Power Source Copying a Weld File If you need to copy a weld training file from one Weld Profile to another Weld Profile on the Welding Power Source Power Wave Manager allows you to do this 1 Right click the Weld Profile you w
96. e value for this weld Hundreds of times per second the Welding Power Source takes a measurement of the arc voltage being used while the welder is active for this weld When the weld is complete the power source averages those measurements together The Average volts column displays that average arc voltage value for this weld Average volts Settings Tab The Settings tab allows you to identify which weld sequencer states are modified when you change a welding setting on the Charts tab such as Workpoint or Trim Place a check mark next to the appropriate states NOTE In order to see a parameter in the charts for the weld you must choose the signal before you begin welding Adding the signal after completing the weld does not create any data to display Power Wave Manager Va Connection B system status 4 Power source settings reme e Save chart data Clear charts Save weld log Clear weld log Turn output OFF Charts Logged welds Settings IQ pn Me 18 E5 Calibration 80 Cable settings and tests Miscellaneous Network settings d Communication Status ArcLink DeviceNet Backup Restore 24 Observer Parameter state fanout State Idle Setup Preflow Ethernet Strike 4 wire feeder v Start ojo Feeder settings Upslope ee User interface v Weld1 4 2 Tools V Weld2 JO Lookup error Downslope i SnapShot V
97. eckPoint data center Total Welding Lifetime The Arc time section displays the total amount of time that the Welding Power Source has generated an arc over its lifetime The time appears in 55 format hours minutes and seconds If the number of hours is greater than 23 place a check mark in the Show days checkbox to convert the hours into days and display the result Weld Controller If the Welding Power Source supports the following features you can use the Weld Controller section to set a couple of control options Workpoint in Amps Use this option to base the output level on Amps instead of wire feed speed Trim in Volts You can use this to set the output level based on voltage instead of a unitless control STOP If you make changes to the Weld Controller and click Apply settings button the Welding Power Source automatically resets Be careful that no welding is currently in progress 6 8 Power Wave Manager User Manual IM8002 THE WELDING EXPERTS a pte r ri Network Settings The Network settings section provides you with the flexibility to configure the connection of the Welding Power Source to other equipment You can connect various components through the use of ArcLink technology DeviceNet communications and or Ethernet connections The Network settings section allows you to review and monitor these settings Communication Status Under Communication status Power Wave Manager disp
98. ecutively E mail Triggers In the E mail triggers section you can select which event s in the Welding Power Source generate an e mail notification to the address selected on the left Each time the event occurs that e mail address will receive an e mail 2 User inlerface 4 4 voos E mail address dick to ec E mail triggers for ssman acvanced com 2 Lookup error snapshot jsmith advanced com J 7 System event Weld blaylor advarced cor WeldView E J Service event be Sackup Restore amortis advar ced co HE Observer masntenance a vanc F Weld Profile limit exceeded 4 gg Production Monitoring Q empti Register empty e Wwe package warning 3 Configuration empty Training empty e m empty empty gt Send test e mai d a 3 Figure 10 10 E mail Triggers For example if you have a check mark next to the Weld Profile limit exceeded option Figure 10 10 and a Weld Operator completes a weld whose WeldScore is below the minimum score allowed the 10 14 Power Wave Manager User Manual IM8002 Configuration Chapter 10 Production Monitoring power source will generate an e mail If the Weld Operator completes the next weld and the WeldScore is again below the minimum the power source generates another e mail To assign an e mail trigger to an e mail address simply make sure you have the e mail address selected and place
99. eds the wire into the weld Maximum WES This field displays the uppermost limit to the wire feeder s speed capability This is the highest speed at which the wire feeder can make a successful weld Minimum WES This field displays the lowest limit to the wire feeder s speed capability This is the slowest speed at which the wire feeder can make a successful weld Status These indicators display the current status of the wire feeder to which you are connected Cold inch Wire In the Cold inch Wire section you can use the Inch forward and Inch reverse buttons to feed the wire through the feeder without welding The nching and O status indicator lights let you know that the machine is in use and the input output communication status The Cold inch speed ipm field allows you to set the speed at which the machine feeds when you click the inching buttons This defaults from the current speed on the wire feeder Power feedback The fields in the Power feedback section provide you with the power details for the wire feeder so you can keep your eyes on the power as you diagnose Miscellaneous In the Miscellaneous section the Gas purge or Flux fill button depending on your system allows you to prepare the wire feeder The Solenoid indicator lets you know when the feeder is active when using the button The Sense lead polarity field displays the polarity for the machine to which you are connected User Interface If the Welding Power
100. eldSci 0089 Communication Status V Production Monitoring configuration i Arclink 5 DeviceNet V Weld Profile Selection Method 5 Ethernet 4 y Wire feeder Feeder settings Out of Limit Action Settings V Weld Profile Settings 1 042 User interface 4 Tools F 2 Lookup error i SnapShot Machine Name WeldView 5 Backup Restore o Observer ig Production Monitoring LJ Register Wire Package Settings V Email Settings 96 Configuration i Training E Restore Figure 9 7 Restoring to a Backup File IM8002 Power Wave Manager User Manual 9 7 Chapter 9 Tools Backup Restore To load a settings file and overwrite the existing settings on this Welding Power Source 1 2 8 Click the Backup Restore menu item Click the Restore tab Click the Browse icon next to the File to restore field Navigate to and select the backup file you want to load into this power source Click Open Click the tab for the category of settings you want to restore Place a check mark next to each setting you want to upload to the connected power source Repeat steps 7 and 6 for each category containing settings you want to restore 9 Click the Restore button The system displays the categories of settings you can restore The Open file dialog appears
101. entify the module Configuration The top portion of the Configuration section displays the Welding Power Source s current network settings including IP address subnet mask and default gateway Table 7 3 explains the data under Current settings in more detail The sub tabs in this section allow you to make modifications to these connection settings as well as configure the address of the machines you want to allow access to the Welding Power Source and adjust the communication speed of the power source over the network n Power Wave Manager Connection Ii System status 4 Power source settings Configuration z Calibration 0 Cable settings and tests Power Source Controller Current settings 53 Miscellaneous Address 10 23 10 90 T Network settings Subnet mask 255 255 192 0 Communication Status Default gateway 10 2311 amp Ardink MAC address 00 04 EE 00 36 49 DeviceNet Ethernet TCP IP setup Network security Communication Setup 4 y Wire feeder i ji o o Feeder settings Obtain an IP address automatically ee User interface Figure 7 12 Configuration Tab 1M8002 Power Wave Manager User Manual 7 13 Chapter 7 Network Settings Ethernet Table 7 3 Fields under Current Settings Field Description IP Address This is the location of this Welding Power Source on the computer network Any device on your network that wants to communicate with the
102. er performance Rejected Weld A weld that was either not consistent enough or long enough to apply statistical equations to generate reasonable limit information Robotic Feeder I O The PF10R feed head comes with an External I O Connector that can be reconfigured through Power Wave Manager to reroute the I O from its normal operation to be utilized as a Weld Profile selection Shift Times A Production Monitoring or CheckPoint feature used to trigger events at a specific time of day that will allow the tracking of usage and clearing out of Weld Totals and Weld History There are a total of 6 shift times that can be utilized on a daily basis Short Weld Welds with a duration that is less than the sum of the Start Delay time plus the End Delay time SMTP Simple Mail Transfer Protocol the standard protocol used for sending e mail through an e mail server Spreadsheet Application A computer tool such as Microsoft Excel that arranges values into rows and columns Subnet A section of a network Subnets are used to divide up large networks into small sections for ease of management increased performance and increased security Tab Delimited Text File Generic text file format that is used for arranging data in a spreadsheet Most spreadsheet applications can import this file format with little or no conversion by the user TCP Transmission Control Protocol used in the transmission of data between two devices It is
103. er Wave family that utilizes the digital controls platform This list includes but is not limited to Power Wave 355M Power Wave 405M Power Wave 455M 455M STT 455R and corresponding CE models Power Wave 655 IM8002 Power Wave Manager User Manual 1 1 Chapter 1 Introduction Compatible Equipment Power Wave AC DC 1000 AC DC 1000SD Power Wave i400 Power Wave C300 Power Wave S350 Power Wave S500 The program may also be used to diagnose and modify settings in the following Welding Power Sources outside the Power Wave family that also use the digital common controls platform Invertec V350 V450 Power MIG 300 Power MIG 350MP NOTE The Power Wave Manager application is not compatible with legacy Power Wave models such as the Power Wave 450 The application also does not support dual wire feeding system NOTE Notall Welding Power Source models have an Ethernet port However you can upgrade some models to utilize Ethernet by adding the Communication Interface module available from Lincoln Electric as K2207 2 or K2436 1 depending on the Power Wave model Connecting to robotic applications could vary from the information in this manual Please refer to the appropriate Operators Manuals for more information 1 2 Power Wave Manager User Manual IM8002 THE WELDING EXPERTS a pte r 2 Connecting the Power Source Any time you need to connect the Power Wave Manager appli
104. erform some of the necessary installation procedures for the Production Monitoring and CheckPoint applications as well as review the current welds in the memory of the Welding Power Source For more information on either of these applications refer to the Production Monitoring User Manual or the CheckPoint User Manual whichever is relevant for your power source model Saving an Installation Key File Each individual power source has a unique installation key file The system uses these files to register the equipment in Production Monitoring or CheckPoint The steps below walk you through how to save the installation key file for the Welding Power Source Each Welding Power Source you add to Production Monitoring or CheckPoint needs its own key file r Power Wave Manager amp 5 V Connection Registration Diagnostics system status ae 4 Power source settings Please click the button below to save a Production Monitoring Installation Key for this power source lar Calibration After the key is saved you may use it to add this power source to Production Monitoring 0 Cable settings and tests Power Source name WDC3001_1638820100280011_10 23 8 75 2 Miscellaneous Network settings 1 Communication Status AL ArcLink DeviceNet Ethernet 4 wire feeder CheckPoint Setup ojo Feeder settings 22 User interface 4V Enable CheckPoint over the Internet 4 2 Tools Em
105. esh Display Y gt Clear logs SnapShot System status Pe PP 4 Power source settings System status Module information Jf Calibration Power Source Controller USB Module PF25M Wire Drive Cable settings and tests J Miscellaneous Property Value 4 77 Network settings Basic Information 8 Communication Status Arctink Software Version 528057 15 EF DeviceNet e Hardware Version G4800 4M0 Ethernet e Serial Number 6413920120520241 4 j Wire feeder weld Set Version 2123241 05E76549 o o Feeder settings Advanced Information 22 User interface ji 4 P Tools e Main Code Version Y01020 30 D1582DF5 JD Lookup error 9 Boot Code Version 101001 09 99DC9462 SnapShot Parameter Version 528057 15 0000ADE7 WeldView FPGA Version Y01302 07 Backup Restore Version Y01204 03 Figure 5 4 Module Information Tab 5 4 Power Wave Manager User Manual IM8002 LINCOLN ELECTRIC THE WELDING EXPERTS a pte r 6 Power Source Settings The Power source settings section consists of various subsections that contain settings for the Welding Power Source component of the welding system You will access the Power Source Settings when you first set up your Welding Power Source but once you have your Welding Power Sources set up and welding you will use this section infrequently You may need to recalibrate the machine over time or as processes change Calibration The Calibration section allows you to ca
106. et interface refer to the DeviceNet Interface Specification Document Y50031 included with the Power Wave Utilities installation Power Wave Manager 2 53 X Connection Select DeviceNet module PowerSource Controller Blink status light Bi system status 4 fll Power source settings Status Configuration Monitor Trace Weld limits Weld sequencer Calibration System control D Cable settings and tests HE Miscellaneous MAC ID 62 Enable passive mode operation 4 T Network settings TT Restore settings from memory on reset Communication Status Baud rate 125 X AL ArcLink Fault if no polled connection detected Interface support DeviceNet Report Trim Wave Outer Process Limits Ethernet Event logging T E fi 4 y Wire feeder Connection timeouts TAST update frequency o o Feeder settings 15 2 i Meter time constant 22 User interface Deallocation events 4 Dis Bus errors 50 Analog scans between updates Lookup error rm SnapShot 30 A Cold inch wire feed speed WeldView Initialization errors Backup Restore iag Observer Analog input channels Polled I O connection 4 ig Production Monitoring j j Workpoint input E Register Hysteresis Active i ax Configuration ani x 7 Unscaled values Engineering units Training 2 Trim Wave Control input
107. etects an event or a malfunction in the Welding Power Source it will attempt to determine which component caused the malfunction and displays the Error icon along with any error codes or log entries to help you correct the problem To retrieve more information about a certain error code refer to the Lookup error section on page 9 1 You can also double click the icon next to the error and the system automatically takes you to the Lookup error section Each event has a time stamp and a description For modules that have a real time clock such as a robot or Ethernet module the time stamp will indicate the time of the event Otherwise the time stamp indicates the amount of time that passed since the Welding Power Source powered up before the power source experienced the error For example in Figure 5 2 the Weld Operator powered up the power source and 13 seconds later the event occurred 5 2 Power Wave Manager User Manual IM8002 System Status Tab Chapter 5 System Status Detailed Status Display If you see error icons and need to look into the problems further you can select Detailed status from the Display drop down and view additional information for each component connected to the Welding Power Source In Figure 5 3 all components are ready to weld except two the Weld Controller and the User Interface Click the arrow gt in front of each component to review the details if there are any available
108. f California to cause cancer birth defects or other reproductive harm 1 g ARC WELDING CAN BE HAZARDOUS PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY OR DEATH KEEP CHILDREN AWAY PACE 1h MAKER WEARERS SHOULD CONSULT WITH THEIR DOCTOR BEFORE OPERATING Read and understand the following safety highlights For additional safety information it is strongly recommended that you purchase a copy of Safety in Welding amp Cutting ANSI Standard 249 1 from the American Welding Society P O 351040 Miami Florida 33135 or CSA Standard W117 2 1974 A Free copy of Arc Welding Safety booklet E205 is available from the Lincoln Electric Company 22801 St Clair Avenue Cleveland Ohio 44117 1199 BE SURE THAT ALL INSTALLATION OPERATION MAINTENANCE AND REPAIR PROCEDURES ARE PERFORMED ONLY BY QUALIFIED INDIVIDUALS 2 b A FOR ENGINE POWERED EQUIPMENT 1 a Turn the engine off before troubleshooting and maintenance work unless the maintenance work requires it to be running 1 b Operate engines open well ventilated areas or vent the engine exhaust fumes outdoors 1 Do not add the fuel near an open flame welding arc or when the engine is running Stop the engine and allow it to cool before refueling to prevent spilled fuel from vaporizing on contact with hot engine parts and igniting Do not spill fuel when filling tank If fuel is spilled wipe it up and do not start engine until fumes hav
109. feeder Ft Figure 5 1 System Status Tool Bar At the top of the System status section Figure 5 1 there is an action bar that allows you to change your display clear the history and save a SnapShot of the current activity on the power source Refresh button This button allows you to rescan the Welding Power Source for problems The most recent results are displayed on the System status tab Display drop down The Display drop down allows you to switch between Diagnostics page 5 2 and Detailed Status page 5 3 Clear logs button This button deletes the Event and Fatal Event log histories in all modules of the Welding Power Source The system records the date and time the logs were cleared and displays this information under the appropriate component STOP When you click the Clear logs button the Welding Power Source resets and stops welding Be sure the power source is not currently welding When you click the Clear logs button Power Wave Manager uses the date and time of the local host computer rather than the date and time on the selected Welding Power Source SnapShot button This button allows you to save a file that contains detailed configuration and debugging information collected from each module in the Welding Power Source This can help Lincoln Electric Support to troubleshoot any possible issues that cannot be easily resolved See page 9 2 for more details I
110. figuration options within the Lincoln Electric Power Wave family of Welding Power Sources It also provides in depth diagnostics of the Welding Power Source s hardware and firmware to help identify and eliminate issues with welding or configuration Ifyou already have Power Wave Manager installed you can simply open the software Depending on your version of the software the system automatically checks for and installs any updates If it doesn t do this automatically you can click the Check for Updates button If the software updates you can skip ahead to the next section 1 Login to the computer as a user with Contact your IT department if you do not have administrative privileges administrator privileges 2 Open your browser and go to The Login page displays www powerwavesoftware com 3 Enter your username and password in the These are the same credentials you used when Email and Password fields and click Sign In updating the Welding Power Source firmware Once you log in the system displays the Power Wave Resource Center LINCOLN ELECTRIC THE WELDING EXPERTS Power Wave Software p K LINKS system sor vertet V350 PHO V450 RO end Power MOS ar n 3000509 Software zx The Operating displayed on Power Wavet Power Software Prodection Monitoring 2 2 Power Wave pe Power Wave POWER WAVE N RESOURCE CENTER m M A 4 Inthe Quick Links sec
111. he value in the system NOTE The default as well as minimum value for this setting is 80 If you need to set a minimum WeldScore limit of less than 80 to prevent your welds from triggering limit alerts either the training was performed incorrectly or a variable has changed since the original training was done The Weld Profile should be retrained instead of lowering the minimum WeldScore value NOTE Ifthe Minimum WeldScore field is grayed out either the power source does not support WeldScore or the power source has older firmware that needs to be updated See page 3 1 for details on upgrading the power source s firmware Weld duration limits s Enter the minimum and maximum amount of time in seconds that you consider acceptable for a weld made using this Weld Profile If the overall duration of the weld falls below the minimum value or above the maximum value set for the weld the system considers that out of limit When this happens the power source performs the action you selected in the Action on duration limit drop down on the Out of limit actions tab page 10 5 Amperage limits Enter the minimum and maximum amps for the arc current you consider acceptable for a weld made using this Weld Profile If the overall amperage used to make the weld falls below the minimum value or above the maximum value set for the weld the system considers that out of limit When this happens the power source performs the acti
112. hed Alarm Prevents the Welding Power Source from making another weld until the alarm has been acknowledged This setting can be utilized for verifying a welding setup before making another weld Module Number The Welding Power Source consists of modules that communicate with each other to create a welding system The module number is the name given to each one of these devices Octet A number ranging from zero to 255 used in IP addresses GLS 1 Power Wave Manager User Manual IM8002 Glossary PLC through Welding Set Point PLC Programmable Logic Controller a specialized device used in the control of industrial processes Port In a specific network such as a TCP or a UDP network a port is an endpoint to a logical connection The port number defines what type of information will be transmitted An example would be port 80 for HTML data or port 25 for e mail data Proxy Server A proxy is a server that stands between an external network such as the Internet and an organization s internal private networks It serves as a firewall and prevents external users from directly accessing the internal information resources or even knowing the location of those resources All external requests for information are intercepted by the proxy server and checked for their validity Only authorized requests are passed on to the internal server This security however comes at the cost of inconvenience to genuine users and slow
113. here is no check mark next to Enable the system automatically ignores the limit Remember to click the Apply settings button to commit your changes Table 10 3 explains each of the limits available NOTE When you enable the Minimum WeldScore option you can only set the Weld duration limit and or the Wire feed speed limit Since you must train a weld in order for WeldScore to be effective the trained weld already includes the amperage and voltage limits Next to each Weld Profile in the list are icons that represent each limit available in that Weld Profile WeldScore Time Amperage o Voltage and Wire Feed Speed f the Weld Profile contains an active limit i e a check mark in the Enabled checkbox with values greater than zero 0 the green icon appears next to that Weld Profile number If the WeldScore limit is not enabled and there is a value entered in the field the icon appears but is gray f the limit is not enabled or the value for the limit is zero 0 the icon does not appear Ifyou have made changes to a Weld Profile and have not clicked the Apply settings button the gray icon 9 at the beginning of the Weld Profile changes to a red icon 9 10 8 Power Wave Manager User Manual IM8002 Configuration Chapter 10 Production Monitoring Table 10 3 Limits Available for Each Weld Profile Start delay End delay Discard welds shorter than n seco
114. hich are now not known All welders should use the following procedures in order to minimize exposure to EMF fields from the welding circuit 2 0 1 Route the electrode and work cables together Secure them with tape when possible Never coil the electrode lead around your body Do not place your body between the electrode and work cables If the electrode cable is on your right side the work cable should also be on your right side Connect the work cable to the workpiece as close as pos sible to the area being welded not work next to welding power source 2 d 2 2 d 3 A 3 a 3 b 3 c 3 d 3 e 3 f 3 g 3 h 3 i 3 j ELECTRIC SHOCK CAN KILL The electrode and work or ground circuits are electrically hot when the welder is on Do not touch these hot parts with your bare skin or wet clothing Wear dry hole free gloves to insulate hands Insulate yourself from work and ground using dry insulation Make certain the insulation is large enough to cover your full area of physical contact with work and ground In addition to the normal safety precautions if welding must be performed under electrically hazardous conditions in damp locations or while wearing wet clothing on metal structures such as floors gratings or scaffolds when in cramped positions such as sitting kneeling or lying if there is a high risk of unavoidable or accidental contact with the workpie
115. hin the full range of the Lincoln Electric Power Wave line of Welding Power Sources It also provides in depth diagnostics of the welding power source s hardware and firmware to help identify and eliminate issues with welding or configuration Depending on how your company is organized and who is configuring your power sources you install Power Wave Manager on a computer with some kind of cable or network access to the Welding Power Sources on the floor This could be a laptop you use to walk the floor and configure the power sources Or you might choose to install the software on a central server System Requirements Minimum hardware requirements for the computer on which you install Power Wave Manager 256 MB of system RAM 1 0 GHz processor speed 1024x768 display resolution 50MB free disk space Connection to a Lincoln Electric Welding Power Source or compatible Welding Power Source through an Ethernet network or serial RS 232 cable Power Wave Manager runs under the Microsoft NET 2 0 framework Therefore it can run on the following versions of Microsoft operating systems Windows 7 Windows Vista Windows XP Service Pack 2 Windows 2000 Service Pack 4 Windows 98 Second Edition You must be logged in to the computer as a user with Administrator privileges in order to install Power Wave Manager Compatible Equipment Power Wave Manager may be used with any Welding Power Source in the Lincoln Electric Pow
116. iate safety procedures when performing actions on this tab Be careful that the Welding Power Source is not currently welding before calibrating IM8002 Power Wave Manager User Manual 6 1 Chapter 6 Power Source Settings Calibration The following is the recommended procedure for calibrating your power source 1 Attach Welding Power Source output cables to a 300A 30V resistive grid load 2 Open Power Wave Manager 3 Connect to the power source 4 Display the Calibration section 5 Click the Turn output ON button The Turn Output ON button enables the output of the Welding Power Source When you turn the output on the indicator will begin to flash red 9 and values will appear under Feedback for Output amperage Output voltage Capacitor voltages and Voltage sense location 6 Use the plus and minus icons and El to This adjusts the actual measured values on the the right of Amperage adjust Figure 6 1 to Welding Power Source to match Power Wave calibrate the Welding Power Source to the Manager value you set in Power Wave Manager 7 Use the plus and minus icons to This adjusts the feedback in Power Wave the right of Voltage adjust Figure 6 1 to Manager to match the Welding Power Source 1 e calibrate Power Wave Manager to the STOP Donot calibrate voltage at voltages Welding Power Source greater than 50V 8 Click the Turn output OFF button The Turn Output OFF button disables the
117. ings ee User interface 4 22 Tools 2 Lookup error m SnapShot 13 Weldview Weld Controller Power Source time Current time on this power source 3 13 2013 3 45 54 PM Arc time Total arc time for this power source 00 34 56 HH MM SS Show days Weld Controller options 2 Workpoint in Amps Trim in Volts Figure 6 5 Miscellaneous Section 8002 Power Wave Manager User Manual 6 7 Chapter 6 Power Source Settings Miscellaneous Time Settings on the Power Source The Power Source time section displays the current time on the Welding Power Source s internal clock The power source uses this when recording internal events errors and information that it sends to Production Monitoring and CheckPoint NOTE The Production Monitoring and CheckPoint application if present periodically sets the clock on the Welding Power Source to match the time of the Production Monitoring server or the CheckPoint data center whichever is applicable If the time shown on the Welding Power Source does not match the time on your local computer you can manually synchronize the clocks Simply click the Synchronize button and the software changes the time on the Welding Power Source to match the time on your computer NOTE The Synchronize button is not available when CheckPoint is enabled The power source updates the time automatically from the Ch
118. k V ArcLink XT V DeviceNet V Ethernet V CheckPoint Communications O Pause Language Idioma Jazyk Sprache Langue Lingua 35 Taal Jezyk ETE English United States Connected to 10 23 10 91 EN1 Figure 7 1 Connection Status IM8002 Power Wave Manager User Manual 7 1 Chapter 7 Network Settings ArcLink ArcLink The ArcLink section provides you with an overview of all the welding system components connected to this Welding Power Source using the ArcLink technology This section of Power Wave Manager also provides you with the opportunity to pair devices together if they haven t automatically paired themselves See page 7 3 for more on pairing Mapping Status Tab The Mapping status tab provides you with the logical layout or mapping of the components connected to the power source with an ArcLink connection The display shows the current mapping of the system and the serial numbers of the components If you have recently connected a new component to the power source click the Refresh button to display the most up to date ArcLink connection information r Power Wave Manager ael ml zs Va Connection Mapping status system status Power source settings fj Refresh 9 Calibration 4 Automap successful ED Cable settings and tests 4 T Group 1 82 Miscellaneous Power Source Controller Serial number 6413920120520232 In
119. l usually used by a PLC to control networked devices in a Master Slave relationship DNS Domain Name Service used for translating host names to an IP address so that networked equipment can be given an alphanumeric name instead of a number See Host Name for an example of what a DNS server does E mail Electronic Mail an electronic message that is transferred over a communications network or the Internet Ethernet A telecommunications networking protocol used to connect computers to each other Firmware The memory and programming code within the Welding Power Source that provides the control program for the Welding Power Source Front End The front end to a software program is the part of the application with which you as the user interact e g buttons you click windows that display Host Name Alphanumeric name that is used to represent networked equipment at a specific IP address An example would be www google com instead of 216 239 37 99 HTML Hyper Text Markup Language the document format used for web pages on the Internet Intranet An internal website to your company that no one on the outside can access unless given user names and passwords to do so IP Address A number that identifies a device on the network This number is a 32 bit numeric address written as four octets separated by periods also referred to as dots The numbers range from zero to 255 An example would be 192 168 1 45 Latc
120. lays an active graph and provides you with the real time communication status of the various components connected to this Welding Power Source This section is useful for identifying problems or errors in communication Use the checkboxes at the bottom of the graphs to add or remove graphs from your displays NOTE The graphs displayed for you depend on the hardware connected to and supported by the Welding Power Source TIP Tx means transmitted and Rx means received 5 Power Wave Manager 2 pa Va Connection ArcLink System status Object Count 18 i W Tx Packets Il Bus Errors 4 Po source settin aU di W Rx Packets E Errors g Calibration Cable settings and tests 2 Miscellaneous Lost Messages Network settings ee e x Packets 9 Status E Retry Count Ethernet 4 y Wire feeder lo Feeder settings ee User interface DeviceNet Link Speed 125KB Scans Second 0 4 2 Tools WB Messages Bus Errors A Lookup error W Rx Messages CAN Errors m SnapShot Lost Messages WeldView Ethernet Backup Restore Link Speed i00BaseT TCP 1 Observer E Duplex Mode Full UDP 0 4 Production Monitoring Bi Tx Packets Tx Errors E Register W Rx Packets Rx Errors 2 Configuration Unrecognized UDP Messages 9 Training CheckPoint Communications W Tx Packets Socket Errors T Message Errors Arclin
121. ldScore available on third generation machines due to the volume of data required when training for WeldScore the longest weld you can perform for training is up to 60 seconds one minute in duration for a meaningful WeldScore Otherwise the power source begins to overwrite the old data in the buffer and the WeldScore for that Weld Profile will not be accurate On second generation power sources that do not support WeldScore you can still use training models to help you set limits for current voltage wire feed speed and duration The longest weld you can train is up to 1260 seconds 21 minutes before the power source begins to overwrite the data in the buffer When you create those training files for each Weld Profile the power source calculates the limits for you automatically You can adjust those calculated limits under Production Monitoring Configuration Profile limits in Power Wave Manager page 10 7 Welds to Train You should train each Weld Profile that is being used for shorter welds where the welds are consistent and repeatable The longer the weld the less consistent and the less repeatable it becomes You must train any Weld Profile you want to use to implement WeldScore WeldScore works by comparing production welds to welds that have been trained In order for an accurate score to be assigned you should train between three to five welds at each allowable production extreme for each Weld Profile F
122. le when the Welding Power Source is directly connected to the network NOTE Ifthe robot is an E model an E Cell for example the network connection must be directly to the Welding Power Source external Ethernet module B 2 Power Wave Manager User Manual IM8002 FANUC Robot Application Prior to v7 70P 21 Appendix B FANUC Robots Production Monitoring CheckPoint Installed and or Set up For Production Monitoring the software from the Production Monitoring CD has been installed on a computer connected to the same network as the Welding Power Source or the robot If using CheckPoint be sure your company s account has been created and the robot s IP registered in the data center Please refer to the appropriate User Manual for detailed information Setting Limits Before Production Monitoring CheckPoint is enabled for the robot limits have to be established ahead of time Power Wave Manager has a built in tool to simplify this task called Weld Profile Training By running a series of test welds the Training function will collect data and automatically calculate a set of limits that can be used as a starting point and adjusted as needed See Chapter 11 for more in depth information Adding Production Monitoring CheckPoint to Welding Programs Two programs also already installed in the robot will be run at the time of the weld one to select the Weld Profile titled PM SEL and one to compare data
123. lems Refer to the Operator Manual for your wire feeder for more information Feeder and Gear t you need to change the feeder or the gear ratio click the Change selection button and make your selections from the drop downs This process could take some time and disable certain functions in Power Wave Manager until the process is complete STOP Power Wave Manager resets the Welding Power Source when you click OK to change feeder or gear ration Be sure the machine is not welding NOTE The Feeder selection options are only available for feeders that support custom selections and are not available if the wire feeder requires the use of DIP switches to make these selections 8 2 Power Wave Manager User Manual IM8002 Feeder Settings Chapter 8 Wire Feeder Diagnostics Tab You can use the Diagnostics tab to troubleshoot and verify the operational state of your wire feeder If you have multiple wire feeders connected to this welding power source you can select the wire feeder from the Select Wire Feeder module drop down at the top of the window Figure 8 1 on page 8 1 STOP Buttons on this tab control the wire feeder powered by the Welding Power Source Be sure to exercise all appropriate safety procedures when performing actions on this tab d a r Power Wave Manager Va Connection system status Power source settings Calibration 3 Miscellaneous 4 17 Network settings C
124. lerance between 0 8 seconds to 1 3 seconds or greater as appropriate STOP If you set the Out of limit tolerance field for a long time period any welds that are shorter than this tolerance will never trigger the action you select For example John at Advanced Manufacturing set the tolerance for the Action on voltage limit to 2 0 seconds where the normal range might be 0 5 to 1 5 seconds The welds made yesterday each took around one second to complete There was a problem with the welder and the arc voltage ran too low all day Since the voltage was not out of limits longer than 2 0 seconds for over the course of each weld no one knew until the end of the day and all parts had to be scrapped and redone li Power Wave Manager Va Connection system status 4 Power source settings 19 Calibration 2 Miscellaneous Network settings ArcLink DeviceNet EF Ethernet 4 y Wire feeder ojo Feeder settings ee User interface 4 22 Tools Lookup error SnapShot 13 Weldview Backup Restore 24 Observer t Register lt Configuration Training Cable settings and tests Communication Status ig Production Monitoring Language Idioma Jazyk Sprache Langue Lingua S23 Taal Jezyk eS EESECETST Weld Profile selection Out of limit actions Profile limits Wire package E mail setup Miscellaneous leid Profile selection Out of li
125. lerances and welds that have some acceptable process variation If the welds taught to the Welding Power Source all have very little variation then the only welds that will receive a passing WeldScore are ones that meet that very tight tolerance Likewise if there is room for some variation e g small changes in electrical stickout and the acceptable variations are used in the training process then WeldScore will assign passing scores to welds that fall within those variations Where to Use WeldScore WeldScore like any statistical analysis method or technique requires a controlled process WeldScore works best with a consistent and repeatable process It will produce the most accurate results with single pass welds or welds with a small number of passes because as more passes are used the process inherently becomes less repeatable If there are a large number of variables that are allowed a significant amount of variation the criteria may be too broad for the WeldScore to be a meaningful value Meaning of the WeldScore Value An instantaneous WeldScore value is calculated every 0 25 seconds The average of these scores over the entire weld is reported as an overall score displayed on the User Interface in Production Monitoring or in CheckPoint Keep in mind that this overall WeldScore is an average over the entire weld A weld could still have a high WeldScore even if there is a problem for a short po
126. librate the Welding Power Source by adjusting the amperage and voltage outputs so that they match setpoint values You can also use this function to activate the Welding Power Source output for other troubleshooting purposes To change the amperage setpoint you can click the up or down arrows next to the Amperage setpoint field or type the specific value directly in the field 2 Connection t Weld Controller Syviren status 4 Power source settings Waening Connet wekding cables to load bank before tebang Do not makr changes on this FF Caabration screen while Incorrect may prevent the power source from welding 89 Cablesetingsandtes Pe al Miscellaneous a T Metmork settings E Communication Status Arink 7 Devicefet V Ethernet 4 4 wie feeder Amperage setpoint 15 of Feeder settings EF User interface Feedbock 4 2 Toots Output amperage 174 7 DP Lookup error z nagShot Outputvetage 64 WeldView Output is ON bed S ckup Restore CapAvotage 3 2 245 Obnerve 2 lli E output or v Reguter Voltage teme location studs l Configuration Training Aqd ntmer t Voltage adjust Ampengeadus Restore factory defauits J Preterences Connected to 10 23 10 90 ENT Figure 6 1 Calibration STOP Buttons on this tab control the output of the Welding Power Source sure to exercise all appropr
127. libration rote d Sta lay 100 ED Cable settings and tests Prose eo art delay 5 ot Miscellaneous Potes OOO e End delay 010 4 Metwork settings Profle 5 e Communication Status 6 e Discard welds shorter than 1 1 sec Arclink Mi welds J DeviceNet Profle 8 n ne VET ethernet Frotie 9 90 Enable 4 wire feeder Profile 10 Feeder settings rosie 11 eo Wela duration limits 5 I Protie 12 Uterimterface un 13 6 to 167 J 4 P Tools Profile 13 P Lookup error QOO Amperage limits WB Soso5hot Peste 15 14 to 17 Enable WeldViseve Protie 16 Gackup Restore Protie 17 Voltage limits V 24 Observer Profile 18 16 5 to 168 Lnabie Production Monitoring Protie 19 Register Protie 20 Wwe feed speed limits pom d Configuration Q Profle 21 0 to J Enable Profile 22 Profle 23 O rrotie 24 Protie 25 Profile 26 27 h amp Apply settings About Preterenzes Language Idioma lary Sprache Langue Lingua 4 Taal 1 ryk Connected to 10 23 1050 Figure 10 6 Profile Limits Tab To change settings in a particular Weld Profile simply click the Weld Profile to select it and make changes to the fields on the right Place a check mark in the Enable checkbox to tell the power source to use that limit for the profile If the values are zero 0 or t
128. ly choose a folder on your computer where Power Wave Manager can store these files Your computer must have permissions to access to this folder whether specific to your user account or a user group of which your account is a member If you do not Power Wave Manager prompts you again to select a folder Check with your local IT department if you need permissions to the folder to which you want to save files Connecting to the Welding Power Source Once you have physically connected the Welding Power Source to the computer with an Ethernet cable or a serial cable setup Chapter 2 you can open Power Wave Manager and connect to the software within the power source When you first open Power Wave Manager the system displays the Connection section Figure 4 1 From here you can choose your connection method Ethernet or a serial connection Power Wave Manager GEI el Connection LINCOLN 3 s System status ELECTRIC POWER WAVE 4 ffl Power source settings Cond j 2 Calibration 80 Cable settings and tests Connect through the serial port V connect i TERSENA due Connect through Ethernet 4 Network settings 7 Communication Status know the IP address of the welder A Arclink NS E DeviceNet 10 23 10 91 5 Ethernet Ido not know the IP address of the welder 4 y Wire feeder 22 o Feeder settings 548 User interface 4 22 Tools
129. mit actions Action on duration limit Out of limit tolerance Log Event Action on WeldScore limit Log Event 0 1 2 Action on amperage limit Log Event X 0 12 Action on voltage limit Log Event X 0 5 2 Action on wire feed speed limit Log Event X 0 14 A Setting the action to Fault system may cause welding to stop unexpectedly English United States Connected to 10 23 10 90 EN1 Figure 10 5 Out of Limits Tab 10 6 Power Wave Manager User Manual IM8002 Configuration Chapter 10 Production Monitoring TIP Ifthe Action on WeldScore limit value field is grayed out either the power source does not support WeldScore or the power source has older firmware that needs to be updated See page 3 1 for details on upgrading the power source s firmware Table 10 2 Available Actions When a Weld is Out of Limits Field Description Log Event This option tells the Welding Power Source to create an event log entry to record that the weld was out of limits The power source continues welding even if the weld does not meet limits set on the Weld Profile Fault System If you select this option the power source will stop the weld currently in progress Alarm Latch when it detects the weld has gone outside the limits set by the Weld Profile The Weld Operator can make adjustments and begin welding again When you select this option a weld that goes outsi
130. n Click the drop down and select the wire feeder for which you would like to view settings mn Power Wave Manager E Connection Bl system status 4 m Power source settings Es Calibration 48D Cable settings and tests Miscellaneous Stallfactor 75 a T Network settings Communication Status Gun offset 0 Select Wire Feeder module MAXsa 19 Feedhead Controller Blink status light Settings Diagnostics Push pull options E OG ArcLink DeviceNet Feeder selection Ethernet Feeder MAXsa 22 amp 29 Wire feeder ojo Feeder settings Gear 571 ee User interface Change selection Figure8 1 Multiple Wire Feeder Module Drop down If you re not sure the selection in the drop down refers to the actual machine you want to review click the Blink status light button This causes the green status light on the wire feeder to start blinking rapidly and you can verify you have the correct device selected in Power Wave Manager IM8002 Power Wave Manager User Manual 8 1 Chapter 8 Wire Feeder Feeder Settings Settings Tab Under the Settings tab you can change the stall factor and gun offset for push pull operation as well as change the feed head and gear type Table 8 1 explains the fields in more detail r 4 Power Wave Manager Jer 8533 Vo Connection PF25M Wire Drive Bi system status
131. n be increased by proper installation and thoughtful operation on your part DO NOT INSTALL OPERATE OR REPAIR THIS EQUIPMENT WITHOUT READING THIS MANUAL AND THE SAFETY PRECAUTIONS CONTAINED THROUGHOUT And most importantly think before you act and be careful A WARNING This statement appears where the information must be followed exactly to avoid serious personal injury or loss of life CAUTION This statement appears where the information must be followed to avoid minor personal injury or damage to this equipment Li ne Y KEEP YOUR HEAD OUT OF THE FUMES DON T get too close to the arc Use corrective lenses if necessary to stay a reasonable distance away from the arc READ and obey the Material Safety Data Sheet MSDS and the warning label that appears on all containers of welding materials USE ENOUGH VENTILATION or exhaust at the arc or both to keep the fumes and gases from your breathing zone and the general area IN A LARGE ROOM OR OUTDOORS natural ventilation may be adequate if you keep your head out of the fumes See below USE NATURAL DRAFTS or fans to keep the fumes away from your face If you develop unusual symptoms see your supervisor Perhaps the welding atmosphere and ventilation system should be checked WEAR CORRECT EYE EAR amp BODY PROTECTION PROTECT your eyes and face with welding helmet properly fitted and with proper grade of filter plate See ANSI 249 1 PROTECT you
132. n for the equipment being used When not welding make certain no part of the electrode circuit is touching the work or ground Accidental contact can cause overheating and create a fire hazard Do not heat cut or weld tanks drums or containers until the proper steps have been taken to insure that such procedures will not cause flammable or toxic vapors from substances inside They can cause an explosion even though they have been cleaned For information purchase Recommended Safe Practices for the Preparation for Welding and Cutting of Containers and Piping That Have Held Hazardous Substances AWS F4 1 from the American Welding Society see address above Vent hollow castings or containers before heating cutting or welding They may explode Sparks and spatter are thrown from the welding arc Wear oil free protective garments such as leather gloves heavy shirt cuffless trousers high shoes and a cap over your hair Wear ear plugs when welding out of position or in confined places Always wear safety glasses with side shields when in a welding area Connect the work cable to the work as close to the welding area as practical Work cables connected to the building framework or other locations away from the welding area increase the possibility of the welding current passing through lifting chains crane cables or other alternate circuits This can create fire hazards or overheat lifting chains or cables until they fail
133. nds where n is the Start delay time plus the End delay time Minimum WeldScore This is the amount of delay the power source should use when applying limits at the beginning of this weld The Start delay is the amount of time in seconds that the power source should wait directly after the start of a weld before it begins to apply the limits entered for this Weld Profile This option is necessary because the start of a weld is often unpredictable and may fall out of limits easily The Start delay must be within the range of 0 1 seconds to 10 0 seconds NOTE Thecombined Start delay and End delay times must be 0 7 seconds or greater if the Production Monitoring firmware on the power source is at revision 4 If the total is less than 0 7 Power Wave Manager automatically adjusts the Start delay value so the total equals 0 7 seconds If the Production Monitoring firmware revision is 5 or greater the combined Start delay and End delay times must be 0 4 or greater If the total is less than 0 4 Power Wave Manager automatically adjusts the Start delay value accordingly This is the amount of delay the power source should use when applying limits at the end of this weld The End delay is the amount of time in seconds directly before the end of a weld that the power source should stop applying the limits entered for this Weld Profile This option is necessary because at the end of a weld the set points for the Welding Power Source
134. nds on the number of buttons on the physical User Interface To edit a memory button simply click the memory button to select it e g Memory 1 in Figure 8 6 The parameters currently set for that memory button appear on the right Each memory button has text that displays on the Mode Select Panel of the User Interface To change this text click the Edit button next to the Memory name field in Power Wave Manager Enter the new name and click OK 8 6 Power Wave Manager User Manual IM8002 User Interface Chapter 8 Wire Feeder Memory Parameters To edit a parameter double click the entry The parameter s edit window opens Figure 8 7 Simply enter a new value and click OK The Weld Modes and parameters that are available for the memory buttons vary depending on the individual User Interface Please refer to the appropriate Operator Manual for details on the memory parameters for your User Interface 8 al Preflow Time s Please select a new value for this item Machine limits 0 to 25 0 5 ok Cancet Figure 8 7 Editing Memory Parameters User Limits If you have a check mark in the Enable User Limits checkbox the User Interface enables the User limits fields for certain parameters and enforces the values defined in the those fields Figure 8 8 With this checked if you enter a value that is above the upper limit Power Wave Manager automatically changes that value to match the upper limit when yo
135. ne by a process of testing voltage sense starting at the studs then incrementally moving to the remote voltage sense locations NOTE Anychanges made in this tab are temporary and are reset when the power to the Welding Power Source is turned off IM8002 Power Wave Manager User Manual 6 5 Chapter 6 Power Source Settings Cable Settings and Tests E Power Wave Manager Le Jer Eza Vo Connection Select contro odule Weld Controller Blink stat B System status 4 pi source settings Sense lead settings Weld cable test Sense lead diagnostics A Calibration 1 Cable settings and tests Changes to sense lead location can affect welding performance The power source must be 3 Miscell turned off to reset all manual changes 21 Miscellaneous 4217 Network settings Communication Status ArcLink Arc starting problems or erratic arc behavior can be an indication of voltage sense lead DeviceNet problems The following options allow the sense lead to be temporarily routed through Ethernet other locations to assist in verifying and diagnosing the location of the voltage sense lead j Wire feeder o o Feeder settings Voltage sense location 67 and 21 updated when power source is triggered ee User interface M Tools Voltage sense lead selection 2 Lookup error Detect sense lead location automatically Q A SnapShot sense tend selection WeldView
136. ned off and short contact tip to Miscellaneous work before proceeding 4 Network Communication Status Ardink test can help evaluate your welding cables by measuring their electrical resistance and b Deviceet inductance High cable inductance can potentially decrease weiding quality Ethernet a Wire feeder le Feeder settings Test results ee Resistance moy 4 Toots gt Perfoem test Lookup erer Inductance uit d oos weldView bed 5ackup Restore 55 Obterver 4 Production Monitoring instal HK Configuration training TE English United Sates Connected to 10 238 168 ENT Figure 6 3 Weld Cable Test Tab TIP Itis good practice to record the results of these tests when the welding system is operating well You can then use those values to compare to values taken when there are welding problems on the same weld cell This may help isolate the problem when the old and new numbers are significantly different Sense Lead Diagnostics Tab The Sense lead diagnostics tab helps you troubleshoot arc starting problems or erratic arc behavior by testing and changing the location of the sense lead temporarily Over time the constant movement of equipment such as robot motion can cause arc voltage sense leads to detach The settings on this tab allow you to test and verify the connectivity and reliability of the voltage sense selection currently set This is do
137. nitoring CheckPoint in a FANUC robot prior to the v7 70P 21 release Refer to the FANUC ArcTool Setup and Operations Manual for full details about configuring the software and using this feature with the FANUC robot ArcTool v7 70P 21 and later provides enhanced support for Production Monitoring CheckPoint The new features are available when either the Lincoln America Package R787 or the Arc Production Monitor Package R788 software option is installed in the robot controller There is an additional option entitled Arc Analog Meter option J599 that provides a display of WeldScore current voltage and wire feed speed in real time on the teach pendant that may be used When the Lincoln America Package R787 is installed on the robot controller the following functions are provided through the teach pendant Weld Profile selection Part serial number setting Production Monitoring error handling Proxy server support for weld data forwarding to the CheckPoint cloud server Wire usage monitor setup If the Arc Production Monitor Package R788 is installed the full suite of Internet Connectivity and Customization R558 features and the Arc Analog Meter option J599 are installed as well Procedure Enabling Arc Production Monitor Conditions The following conditions must be met The robot controller is configured with ArcTool V7 70P 21 or later and the option list includes either the Lincoln America Package R787
138. o o Feeder settings 2 User interface 4 22 Tools LL i p Lookup error ACEI Weld Profile selection Out of limit actions Profile limits Wire package E mail setup Miscellaneous Part serial number Enter new serial number Operator ID Enter new serial number Consumable Lot number Enter new serial number Update Update Update Current value 9278567898 Current value Current value 989856789870898 Figure 10 11 Miscellaneous Tab 7 10 16 Power Wave Manager User Manual IM8002 THE WELDING EXPERTS pter 1 1 Training For third generation Welding Power Sources you need to create training models in order to use WeldScore For second generation power sources which do not support WeldScore training models simply help you set limits for current voltage and wire feed speed You use both the Profile limits tab page 10 7 and the Training section this chapter to maintain your Weld Profiles Before You Begin Training a Weld Before you begin setting up your Weld Profiles and creating training models you need to do some planning Planning the Weld Profiles helps make sure that they provide that consistent and repeatable process so important for an accurate WeldScore Be sure you have completed the following before you begin teaching welds on the Welding Power Source Read through this Training chapter in i
139. of Host Communication options available on the Teach Pendant and is selected by pressing MENU SETUP Host Comm and then selecting the item labeled Proxy Server Figure 11 6 PM TEST LINE anore SETUP Protocols 6 12 Protocol Description 1 TCP IP TCP IP Detailed Setup 2 TELNET Telnet Protocol 3 SNIFF Ethernet Sniffer 4 SM Socket Messaging Device 5 PC SHARE PC Share Setup 6 Proxy Server 7 PPP Point to Point Protocol B PING Ping Protocol 9 HTTP HTTP Authentication 10 FTP File Transfer Protocol TYPE DETAIL SHOW Figure 11 6 Proxy Server Function IM8002 Power Wave Manager User Manual B 13 Appendix B FANUC Robots Procedure Enabling Arc Production Monitor Pressing ENTER yields Figure 11 7 b TkST LINE 12 Proxy Setup 1 11 External Proxy Enable Server 172 22 194 19 Port 8080 Exceptions 1 frc com 2 3 pderob 4 1 TRUE TALSE Figure 11 7 Enable Proxy Server Enable the Proxy Server function by placing the cursor on the line labeled Enable and pressing F4 TRUE Move the cursor to the line labeled Server and enter the IP address of the Proxy Server in your local area network If you do not know the IP address of the Proxy Server consult with your IT department or the person who handles the network configuration at your site Exceptions that do not need the proxy server func
140. ommunication Status Arclink EF DeviceNet F Ethernet 4 y Wire feeder ojo Feeder settings ee User interface 4 2 Tools 2 Lookup error SnapShot WeldView fe Backup Restore 24 Observer ig Production Monitoring Ll Register Configuration Training Dou 9 Connected to 10 23 10 90 ED Cable settings and tests PF25M Wire Drive Settings Diagnostics WFS feedback 50 Set WFS 0 Actual WFS 815 Maximum WFS 30 Minimum WFS Status Water fault Shutdown 1 input Motor overcurrent Motor overload Motor overvoltage Power feedback 39 8 Input line voltage 0 Motor amperage Motor voltage Cold inch wire Inching Inch forward status Inching E Inch reverse 2 VO status 110 24 Cold inch speed ipm Miscellaneous Sense lead polarity Positive Ji ss Figure 8 3 Diagnostics Tab English United States z IM8002 Power Wave Manager User Manual 8 3 Chapter 8 Wire Feeder User Interface Table 8 2 Fields on the Diagnostics Tab WFS feedback The fields in the WFS feedback section displays the wire feed speed information coming from the wire feeder This includes Set WFS This is the wire feed speed that was set in the Weld Profile being used for the weld or that was set manually on the machine by the Weld Operator Actual WFS This field displays the actual speed at which the feeder fe
141. on includes two programs WR AL AT VR and RD AL AT VR that form the basis of Production Monitoring CheckPoint robotic interface These two program names are seen in the Select Menu program listing along with the all other programs in the robot s memory KAREL Software The KAREL software function must be enabled KAREL is a FANUC software tool that performs functions behind the scenes out of view during normal robot operations To check to see if it is enabled 1 Press the Menu key 2 Cursor to line 0 and press Enter Cursor to line System and press Enter 3 4 Press F1 Type key 5 Cursor to line Variables and press Enter 6 Cursor down to line SKAREL ENB and set the value to 1 if it isn t already and press Enter Registers Nine registers need to be set aside and dedicated for Production Monitoring CheckPoint use By default the robot has 200 registers available for use to perform math functions This can be increased to 500 if needed This manual will use registers 1 through 9 for examples Ethernet Module The Welding Power Source must have the Ethernet module installed set up and running on a network A network connection can also be established to the Welding Power Source through the robot providing it has been set up configured and is running on a network Refer to FANUC documentation for more information NOTE Production Monitoring CheckPoint e mail functionality is only availab
142. on you selected in the Action on amperage limit drop down on the Out of limit actions tab page 10 5 Voltage limits V Enter the minimum and maximum volts for the arc voltage you consider acceptable for a weld made using this Weld Profile If the overall voltage used to make the weld falls below the minimum value or above the maximum value set for the weld the system considers that out of limit When this happens the power source performs the action you selected in the Action on voltage limit drop down on the Out of limit actions tab page 10 5 Wire feed speed limits Enter the minimum and maximum speed in inches per minute for the wire ipm feeder that you consider acceptable for a weld made using this Weld Profile If the overall wire feed speed used to make the weld falls below the minimum value or above the maximum value set for the weld the system considers that out of limit When this happens the power source performs the action you selected in the Action on wire feed speed limit drop down on the Out of limit actions tab page 10 5 10 10 Power Wave Manager User Manual IM8002 Configuration Chapter 10 Production Monitoring Wire Package Tab In order for Power Wave Manager Production Monitoring or CheckPoint to notify you when the consumable on the Welding Power Source is running low or to allow the monitoring software to calculate a variety of values you need to enter the details of the consuma
143. onds of welding stop when buffer fu 88 User interface Last 4 17 seconds of welding harap around buffer 4 2 Took JP Lookup error Trace frequency 120000 Hz snapshot 4 WeldView bed Restore 2445 Observer Description File Name 4 Production Reguter Configuration Training Extra data channel Wire Feed Speed Connected to 10 23 10 90 ENT Figure 9 4 WeldView Wizard To capture a weld trace 1 Select to Tools WeldView from the navigation tree 2 Click the Acquire new weld trace button The WeldView Wizard window opens to the trace on the top toolbar settings step Figure 9 4 3 Choose your trace settings and click Next The trigger settings step displays WeldView Wizard CY mm A You configure the weld trace to begin upon a trigger comd amp tion Ure the controls below to specify if you would bke to use trigger for this trace V Use trigger Raw zj zex 9 4 Power Wave Manager User Manual IM8002 WeldView Chapter 9 Tools 4 If you want the trace to begin only when a You can skip to step 7 if you do not want to use a specific event occurs place a check mark in trigger Make sure there is no check mark in the the Use trigger checkbox Use trigger checkbox 5 Select the event from the drop down 6 Enter the specific value of the event in the text field 7 Click Next The Perform weld ste
144. onfigure how this Welding Power Source chooses the Weld Profile to use for a weld Table 10 1 explains each option in more detail Simply choose the appropriate option and click the Apply settings button r Power Wave Manager Je es V Connection Weld Profile selection Out of limit actions Profile limits Wire package E mail setup Miscellaneous system status E i 4 Power source settings Select Weld Profile automatically based on the last digit of Workpoint 19 Calibration ED Cable settings and tests Attow an external controller to select the Weld Profile Miscellaneous Network settings Communication Status Select Weld Profile based on User Interface memory selection z Arclink Ek DeviceNet Ethernet M Figure 10 4 Example Weld Profile Selection Tab TIP Ifan option does not appear on the Weld Profile selection tab the Welding Power Source to which you are connected does not support that feature 10 4 Power Wave Manager User Manual IM8002 Configuration Chapter 10 Production Monitoring Table 10 1 Options on the Weld Profile Selection Tab Description Select Weld Profile When you choose this option the last digit of the welding set point automatically based on the becomes the Weld Profile number currently in use al OP ie kik For example if the welding set point is set to 125 the Power Wave will use Weld Profile 5 for the given weld
145. or example John at Advanced Manufacturing has a weld where the electrical stickout is allowed to vary from 5 8 to 3 4 He trained five welds one at each of these stickouts Only train the allowable extremes for the weld For example if the stickout can increase to 1 but you consider this out of limits for an acceptable weld do not include this in the training The purpose of training is to demonstrate to the Welding Power Source the types of welds you consider acceptable IM8002 Power Wave Manager User Manual 11 3 Chapter 11 Training Training Profiles Training Profiles Be sure you are connected to the Welding Power Source on which you want to train the welds and that all components are working properly STOP Be sure you have read Before You Begin Training a Weld on page 11 1 before you continue Power Wave Manager e le Jp Vo Connection Start training Stop training System status 4 Power source settings WeldScore Voltage Amperage Wire Feed Speed y Weld Duration z Calibration Cable settings and tests Status Not training j Miscellaneous 4 T Network settings P edin eid 3 Profile 1 Trained limits for Profile 4 ommunication Status z Arclink Profle2 i 1 Profile 3 DeviceNet Ce e ik Ethernet n d profile 4 e 2 8 dus 2013 24 03 1342 ire ler 1 K jo Feeder settings kl 2013Apr24 03 13 52 F3 User interface 2013Apr24 03
146. p displays 8 Make the weld with the power source The status light on the Welding Power Source changes to solid green to indicate the machine is currently welding 9 Once you complete the weld click the The power source transfers the data to Power Next button Wave Manager and displays it on the Weld data and Charts tabs TIP To transfer the data from the power source manually or re read the last trace made simply click the Read trace from power source button Weld Data Tab On the Weld data tab Power Wave Manager displays the data collected from the weld trace in tabular form Scroll through the data to review the information Figure 9 5 ED Cable cettingt and teste 2 Miscellaneous Raw Voltage Raw Current Arc Status Weld Sequ Weld Mod Weld Mod Weld Mode Active Page Wee Feed p Tn 140625 44815 0 2 1 8 22 015625 078125 0 2 1 8 22 9 6 balat 03125 5048828331 0 2 1 n o Ethernet 0 0 0 2 1 22 9 4 9 Wire feeder 015625 4839081 0 2 1 22 Jo Feeder cettings 045625 9 9 2 1 s a 9 9 22 User interface 0 115625 181304 0 2 1 s 2 4 7 Toots 015625 070125 0 2 1 22 0 JO tookup eror 05125 0 0 2 1 22 0 SeapShot 045625 40488281 0 2 1 s z 9 9 Weldview 0 15625 508821 0 1 22 thu Restore lll oun 07833 G Figure 9 5 WeldView Data in Tabular Form Charts Tab The Charts tab Figure 9 3 on page
147. pairing was successful you will not see the Pairing setup tab B Power Wave Manager ec v Connection Mapping status Pawing setup E t Current Available f 4 e urrert paring configuration for 7 Calibration 4 MAX a 10 U1 Module name ED Cable settings and tests o Slot 1 unused 1 MAX 4 19 Wire Orive 8541 scere J maxa Ut E MAXsa 19 Wire Drive 25506 4 Network settings Communication Status sett lt unused gt I E theme 4 P Wite feeder sje feeder settings User intectace 4 P Tools JO Lookup emer uz SmapShot f WeldView 2 Bactup Rectore rt NO Figure 7 3 Pairing Setup Tab Each module that requires one or more other modules to be paired with it will be shown in the list on the left with slots that can be filled by modules from the list on the right To pair two modules together 1 Click an unused slot under the module you Power Wave Manager displays any other want to pair with another modules on the right side that are available for you to pair it with 2 Click the module on the right and drag it over You can also click the arrow buttons between the to the left and drop it over the unused slot two panes to move the modules back and forth 3 Click the Apply settings button IM8002 Power Wave Manager User Manual 7 3 Chapter 7 Network Settings DeviceNet DeviceNet The DeviceNet section allo
148. program is run that Weld Profile will be monitored Alarm Alert Programs Whenever a weld goes out of limits the system posts an alarm to the top of the teach pendant screen It may be desirable for additional actions to take place such as a warning light to illuminate Six additional programs are installed in the robot for ease of adding additional actions to take place These programs are titled ALERT 1 through ALERT 5 and ALERT 10 They are used as follows ALERT 1 Weld Profile Runt occurred ALERT 2 Weld Profile Time Limit occurred ALERT Weld Profile current Limit occurred ALERT 4 Weld Profile V voltage Limit occurred ALERT 5 Weld Profile WFS wire feed speed occurred u ALERT 10 Invalid Profile has been selected The program names have already been created but it is the end user s responsibility to set these programs up as needed and to install the necessary electrical and mechanical interfaces necessary to allow these programs to work Refer to the FANUC Controller Electrical Connection and Maintenance Manual for interfacing instructions Here is an example program ALERT 4 1 DO 1 ON 2 WAIT UI 6 ON DO 1 OFF END This program turns on Digital Output 1 if a Voltage Limit occurs DO 1 may be wired to an indicator light to alert the operator if a Voltage Limit has occurred The light will remain on until User Input 6 is received which may be triggered by a reset switch loc
149. r Cable settings and tests Current settings i gl Miscellaneous IP Address 10 23 10 90 42 Network settings Subnet mask 255 255 192 0 B 4 Communication Status Default gateway 10 23 11 Ardink MAC address 00 04 00 36 49 EF DeviceNet gt EF Ethernet TCP IP setup Network security Communication Setup 4 y Wire feeder ojo Feeder settings Obtain an IP address automatically 429 User interface Use the following IP address 4Z Tools Lookup error Address 10 23 10 91 SnapShot WeldView Subnet mask 255 255 192 0 L popped Default gateway 10 23 1 1 Figure 7 13 TCP IP Setup Tab 7 14 Power Wave Manager User Manual 8002 Ethernet Chapter 7 Network Settings Simply choose the Obtain an IP address automatically option if you want the Welding Power Source to assign the IP address automatically using a dynamic IP address STOP Ifyou choose this option the Welding Power Source obtains a different IP address every time it connects to a network If you want to assign a specific address to this Welding Power Source choose the Use the following IP address option and enter the appropriate information Table 7 3 on page 7 14 explains these fields in more detail Once you have configured the network settings click the Apply settings button and cycle the power to the Welding Power Source off then back on in order for the new settings to take effect
150. r body from welding spatter and arc flash with protective clothing including woolen clothing flame proof apron and gloves leather leggings and high boots PROTECT others from splatter flash and glare with protective screens or barriers IN SOME AREAS protection from noise may be amp appropriate BE SURE protective equipment is in good condition Also wear safety glasses in work area AT ALL TIMES SPECIAL SITUATIONS DO NOT WELD OR CUT containers or materials which previously had been in contact with hazardous substances unless they are properly cleaned This is extremely dangerous DO NOT WELD OR CUT painted or plated parts unless special precautions with ventilation have been taken They can release highly toxic fumes or gases Additional precautionary measures PROTECT compressed gas cylinders from excessive heat mechanical shocks and arcs fasten cylinders so they cannot fall BE SURE cylinders are never grounded or part of an electrical circuit REMOVE all potential fire hazards from welding area ALWAYS HAVE FIRE FIGHTING EQUIPMENT READY FOR IMMEDIATE USE AND KNOW HOW TO USE IT SECTION A WARNINGS CALIFORNIA PROPOSITION 65 WARNINGS Diesel Engines Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer birth defects and other reproductive harm Gasoline Engines 11 The engine exhaust from this product contains chemicals known to the State o
151. r entry formats include SET PM PART ABC1234567 SET PM PART R n SET PM PART SR n SET PM PART GI n If your robotic welding system includes the Multi Equipment feature there will be four versions of the Set PM PART macro as follows SET PM PART 1 SET PM PART E2 SET PM PART E3 SET PM PART E4 Select the appropriate macro for the weld equipment you are using to set the serial number You add the serial number to the macro call by selecting F4 CHOICE and choosing the desired entry method from the pop up list Production Monitoring Error Handling The Lincoln Production Monitoring feature allows you to specify three response actions when an out of tolerance error is encountered Table B 1 Production Monitoring Error Handling Log Event Post Warning error and turn on user defined Digital Output Alarm Latch Post Warning error turn on user defined Digital Output allow current weld to complete but prohibit starting next weld until user reset Fault System Post Pause error turn on user defined Digital Output execute Burnback Wire Stick Check and stop welding These errors are posted to the teach pendant error line as well as added to the alarm log and appear as follows for example LECO 866 PM V alarm hi 1 lo 0 wp 10 This message means there was a Production Monitoring alarm caused by the arc voltage exceeding the specified threshold in Weld Profile 10 The detail display from the alarm log menu
152. rations manual for your FANUC robot FANUC Robot Application Prior to v7 70P 21 Production Monitoring CheckPoint is a tool within the Welding Power Source that sends weld process data to a remote computer for monitoring You can also use it to alert the robot operator if a weld process has exceeded predetermined limits You can monitor the following limits WeldScore current voltage wire feed speed and time If the robot exceeds the limits set for the weld an alarm can be generated at the robot to alert the operator Production Monitoring CheckPoint uses programs already loaded into the robot to monitor and to check if the weld is within the limits set in the Weld Profile These programs will then generate an alarm or other desired action to alert the robot operator NOTE Production Monitoring CheckPoint determines if a weld is within specified limits It does not determine if the weld is good or bad Page B 8 discusses support for Production Monitoring CheckPoint in FANUC robot starting with the v7 70P 21 release IM8002 Power Wave Manager User Manual B 1 Appendix B FANUC Robots FANUC Robot Application Prior to v7 70P 21 Requirements When you want to implement Production Monitoring CheckPoint for the FANUC robot you need to make sure you have met the following requirements ArcTool Software The robot must have ArcTool software version 6 40 1M or later installed This versi
153. rce and click the Apply settings button Enable WeldScore Alerts Power Wave Manager adds a check mark next to each profile you have trained during this session and changes the gray icon to a star icon 2 Each weld training file you add appears with a red icon to indicate unsaved training data The system finishes processing all the data and displays the information under each Weld Profile Figure 11 1 on page 11 4 This process takes some time and disables certain functions in Power Wave Manager until the process is complete NOTE Power Wave Manager also resets the Welding Power Source when you save the Weld Profiles to the machine 1 Select Production Monitoring gt Configuration from the navigation tree 2 Click the Profile limits tab 3 Select the Weld Profile 4 Place a check mark in the Enable checkbox The gray WeldScore icon amp should change to a next to the Minimum WeldScore value green icon 5 Repeat steps 3 and 4 for each Weld Profile where you want to monitor WeldScore 6 Click Apply settings Power Wave Manager saves the changes to the Welding Power Source 11 6 Power Wave Manager User Manual IM8002 Viewing the Calculated Limits for a Weld Chapter 11 Training Viewing the Calculated Limits for a Weld If there are welds trained for a Weld Profile you will see an arrow icon Training section Click the icon to expand the Weld Profile This displays the welds
154. rrent weight of the package in this field However if the package is new this weight should be the same as the Initial weight field Warning weight The power source can generate notifications to replace the wire package when it gets low You can set the alert for Production Monitoring on the E mail setup tab page 10 12 and in each user s account in the main CheckPoint application Both applications rely on the value entered in the Warning weight field Wire diameter Enter the diameter of the wire loaded for the power source The power source uses the diameter of the wire when calculating several values that it sends to Production Monitoring or CheckPoint Metal density From the drop down select the density of the metal from which the wire is composed If none of the available options apply to the wire loaded into the power source select User Defined Density from the drop down and enter the density value in the text field that appears IM8002 Power Wave Manager User Manual 10 11 Chapter 10 Production Monitoring Configuration E mail Setup Tab The E mail setup tab provides you with the ability to configuration e mail alerts such as system events and wire package warnings for up to 12 e mail addresses This requires collecting a bit of information before you begin NOTE When you enable CheckPoint the options on this tab are disabled E mail notifications are processed from the data center rather than b
155. rs available from the Compressed Gas Association 1235 Jefferson Davis Highway Arlington VA 22202 FOR ELECTRICALLY e POWERED EQUIPMENT 8 a Turn off input power using the disconnect 8 b 8 c Switch at the fuse box before working on the equipment Install equipment in accordance with the U S National Electrical Code all local codes and the manufacturer s recommendations Ground the equipment in accordance with the U S National Electrical Code and the manufacturer s recommendations Refer to http www lincolnelectric com safety for additional safety information Welding Safety Interactive Web Guide for mobile devices D Get the free mobile app at http gettag mobi NOTES LINCOLN LINCOLN ELECTRIC THE WELDING EXPERTS Table of Contents Preface Typographical Conventions Used e sete tite kaza kb Vala Feo exa nk KEN Kaw n 1 Cross Refererices i d eie Mgr emat alain 1 Text You Type Using the Keyboard 2 1 kal yay kk eene nn nas 1 Keys You Press and Buttons You 1 Menus X E 1 Dialog Box Application Window Titles and Field 1 Notes Warnings and Tissus rice oret eere er Ap KAREN Sanay k ee kan
156. rtion of the weld time For example if a 50 inch weld has a score of 95 for 49 inches but a score of 45 for the last inch the overall score will be 94 However that last inch is actually problematic and not acceptable The Out of Limit features in Power Wave Manager alert you when the WeldScore goes below the minimum you set for a defined moving window of time This helps ensure the integrity of the overall WeldScore See pages 10 5 and 10 7 for more details on these features 11 2 Power Wave Manager User Manual IM8002 Weld Profile Training Chapter 11 Training Weld Profile Training You use Weld Profile Training to create training files for the welds you consider acceptable when a Weld Operator uses that specific Weld Profile Training helps you generate limits for current voltage wire feed speed and duration for a Weld Profile automatically Training a weld also generates the necessary data in order to use WeldScore You generally perform three to five training welds in the same manner as they would be made in normal production This provides you with a good average on the weld and allows a bit of flexibility when making welds in production If you make any welds during training that are outside of the acceptable limits you can simply remove those welds from the training STOP You musttrain a Weld Profile in order for the power source to provide a WeldScore If your intent is to train a weld to implement We
157. s in the E mail address list and click the Send test e mail button The Welding Power Source attempts to send out an e mail as soon as you click the test button but the amount of time it takes for the recipient to receive the e mail depends on the e mail server in your company If the recipient hasn t received the e mail within about half an hour verify the address and try again or contact your IT administrator for assistance Miscellaneous Tab The Miscellaneous tab displays the part serial number operator ID and consumable lot number currently being used by the Welding Power Source for the welds that it makes These numbers can come automatically from a robotic system an external controller or the mobile app but you can update the numbers manually in Power Wave Manager if necessary IM8002 Power Wave Manager User Manual 10 15 Chapter 10 Production Monitoring Configuration Click inside the appropriate field and type the serial number Click the Update button to commit your changes Once you update with the new number Power Wave Manager displays it in the Current value field You can also click Apply settings to commit changes made to all serial numbers E Power Wave Manager Va Connection Bi system status 4 fil Power source settings z Calibration Cable settings and tests 3 Miscellaneous 4217 Network settings 1 Communication Status z ArcLink DeviceNet Ethernet a Wire feeder
158. shows additional information as follows ARC 097 25 50V 162 1A Pos 71 2mm WARN 19 Sept 11 12 51 The detail reports the current voltage and weld distance from the arc start position when the error was posted B 10 Power Wave Manager User Manual IM8002 Procedure Enabling Arc Production Monitor Appendix B FANUC Robots You identify the Digital Output port number for an alarm log event and alarm latch by setting the system variable SAWELEPM equip ALARM PNUM The Digital Output port number for a fault level alarm is set in SAWELEPM equip S FAULT PNUM Wire Monitor Setup Menu Another feature of Lincoln Production Monitoring allows you to monitor the filler wire used and post an alarm when the wire supply is below a user specified threshold The Arc Production Monitor option includes a Wire Status menu for setting the warning threshold value and for resetting the wire supply The Wire Status menu can be found by pressing the STATUS pendant key then selecting F1 TYPE and choosing Wire The menu appears as shown in Figure 11 3 WP TEST Gl LINE 0 T2 ABORTED 5 6 Current weight 14 9 1b 1 Warning weight 14 9 1b 2 Initial weight 15 0 1b 3 Warning signal DO 33 U OFF 4 Wire diameter 0 045 in 5 Wire material Steel 6 Wire density 0 283 1b in3 TYPE RESET kg lb CHOICE HELP Figure 11 3 Wire Monitor Setup IM8002 Power Wave Manager User Manual B 11 Appendix B
159. stance 0 427 Network settings 22 PF25M User Interface Serial number 100002012296021 Instance 0 Communication Status Q PF25M Wire Drive Serial number 100002012312005 Instance 0 z ArcLink EF DeviceNet EF Ethernet 4 y Wire feeder ojo Feeder settings ee User interface 4 2 Tools Jo Lookup error M SnapShot WeldView fe Backup Restore 24 Observer ka 4 ig Production Monitoring Value 1 Register 26 Configuration cru toad Training Number of times powered up 128 Number of times reset 482 ArcLink events lost 0 CAN messages lost 0 ArcLink Preferences EDITT TAG ISTE REI ESSET TRAE GAST RANGE REESE RATES EI English United States Connected to 10 23 10 90 Figure 7 2 Mapping Status If you click on a component the system displays the available history for that specific component at the bottom of the window You can see how many times the unit has powered up how many times it was reset and several other pieces of information 7 2 Power Wave Manager User Manual 8002 ArcLink Chapter 7 Network Settings Pairing Setup Certain Lincoln Electric components can be paired together such as dual head wire feeders and user interfaces The system usually pairs these automatically for you However if there was a problem with pairing between two or more components Power Wave Manager displays the Pairing setup tab Figure 7 3 NOTE If automatic
160. status light on the Welding Power Source you want start to blink rapidly Click Connect See Appendix A for common reasons you may experience problems connecting to the power source NOTE The Welding Power Source must be on the same subnet as the Power Wave Manager application in order to retrieve the IP address when using this option Modifying the Ethernet Settings of a Power Source In some circumstances it is necessary to change the Ethernet settings of the Welding Power Source For example you may be moving the Welding Power Source from one location to another on a network or a Welding Power Source fails to connect even though it appears in the list IM8002 Power Wave Manager User Manual 4 3 Chapter 4 Overview of Power Wave Manager Connecting to the Welding Power Source STOP When you click the OK button the Welding Power Source resets and stops welding Be sure to only click this button if the power source is not currently welding STOP Ifthe Welding Power Source is currently part of a network contact your network administrator to verify you can make changes to the Ethernet settings of the power source To change the network settings including the IP address on a power source 1 Onthe Connect tab of Power Wave Manager choose do not know the IP address of the welder and select the power source from the list 2 Verify the selected Welding Power Sourcehas This helps you ensure you change the settings on
161. stop automatically when the buffer on the power source is full of data The options in these sections allow you fine tune the amount of data being buffered Data buffers can only hold so much data If you carefully choose the type of messages you want to trace you can fit more messages into the trace Without restrictions Choose this option to run the trace wide open and including all data This option fills the buffer very quickly with fewer messages Only if data is different from previous Choose this option to include only those DeviceNet messages whose ID is different from the previous message Only if ID data are different from previous Choose this option to include only those DeviceNet messages where both the ID and the data are different from the previous message Only if ID AND Choose this option to include only specific messages in the trace The Weld limits tab displays a list of all available Weld Modes supported by the Welding Power Source to which you are currently connected as well as basic information for each mode When you click on a Weld Mode Power Wave Manager displays the types of controls associated with it e g Workpoint Trim and Wave Control and the outer limits of each control These appear below the list of Weld Modes Figure 7 9 You can use this section to verify that the correct Weld Mode information is being read over the DeviceNet connection 8002 Power Wave Manager User Manual 7
162. t ria ka J ai BIB FeLi RRR RRL TP L et 1 STF ERR ENTRAR SLE Beale n am yr p AI a gu lali Du hekan Yam gi lk dum Ae aes Turn power off before servicing Desconectar el cable de alimentaci n de poder de la m quina antes de ini ciar cualquier servicio D branchez le courant avant l entre tien Strom vor Wartungsarbeiten abschal ten Netzstrom v llig ffnen Maschine anhalten Nao opere com as tampas removidas Desligue a corrente antes de fazer servico toque as partes el tricas nuas b CT Ce I t E RIBS ETEA yE EFST Feu a HATENA TIRE JEHIR ALE dlya dl dei 2 gl Do not operate with panel open or guards off No operar con panel abierto o guardas quitadas N op rez pas avec les panneaux ouverts ou avec les dispositifs de protection enlev s Anlage nie ohne Schutzgehdause oder Innenschutzverkleidung in Betrieb setzen Mantenha se afastado das partes moventes opere com os paineis abertos ou guardas removidas dox BYR LEE THREE Liki TF Eh n TEK EST E ae ia M echec uir Eel J Alae LE 1 E A Rm Nd AE Du Ku lal Spanish AVISO DE PRECAUCION French ATTENTION German WARN
163. t from previous Only if ID data are different from previous Onlyif ID AND 000007FF 00000000 OnlyifID AND 000007FF 00000000 English United States gt Connected to 10 23 10 90 EN1 Figure 7 8 Trace Tab Simply set your options and click the Start trace button when you re ready to capture DeviceNet messages Click the Stop trace button when you have the information you need Power Wave Manager downloads the recorded messages from the DeviceNet module and displays them in the list with all relevant fields decoded Table 7 2 explains your options in more detail NOTE The Read trace button allows you to transfer the buffered data from the Welding Power Source into Power Wave Manager manually if needed TIP Clickthe Save trace button to export the data to a file that you can send to Lincoln Electric Support for troubleshooting or keep for your own reference in the future 7 10 Power Wave Manager User Manual 8002 DeviceNet Chapter 7 Network Settings Table 7 2 Options on the Trace Tab Trace type Record outgoing packets and Record incoming packets Weld Limits Tab This option helps you control how much data you collect with the trace Continuous Choose this option if you want the trace to keep recording data until you click the Stop trace button regardless how long the trace is Stop when buffer full Choose this option if you want the trace to
164. tain information about any error code given by a Welding Power Source Figure 9 1 When a Welding Power Source is in a faulted condition it flashes an error code using the Status light and blinking in red and green Please refer to the Operator Manual for the Welding Power Source for more detailed information on interpreting the error code on the specific power source TIP The Lookup error section is available even if you are not connected to a Welding Power Source r Power Wave Manager Jer Ma Connection fl System status 4 Power source settings o gf Calibration H 80 Cable settings and tests 5 Miscellaneous 4217 Network settings 0 Communication Status i 5 2 Arclink E DeviceNet BER Ethernet 4 y Wire feeder o 00 Feeder settings o User interface 4 Tools o J Lookup error 26 Enter the error code below to obtain detailed information about the error Event Lincoln event or fatal error FANUC LECO event Event 26 The paired mapping of one or more modules in the system has failed Module pairing may not be configured properly Description Posible Solution 1 Update the system with the latest firmware Figure 9 1 Lookup Error Tool To look up a certain error code choose the type of error from the Event options type in the error code number in the text field and click the Lookup button The system displays
165. th skin or wet clothing Insulate yourself from work and ground No toque las partes o los electrodos bajo carga con la piel o ropa mojada Aislese del trabajo y de la tierra Ne laissez ni la peau ni des v tements mouill s entrer en contact avec des pi ces sous tension Isolez vous du travail et de la terre Ber hren Sie keine stromf hrenden Teile oder Elektroden mit Ihrem K rper oder feuchter Kleidung Isolieren Sie sich von den Elektroden und dem Erdboden Nao toque partes el tricas e electro dos com a pele ou roupa molhada 1501 da pe a e terra wl HB Ji OR A HM EGE n f n b d L j 4 eR lLArr A76 SRR E T Tu a A Ak Ek z Ae TI e UR Hirt n J k MR HB REWS UR B om nig ecu yE EE ERA EL FEM UE ULSI nr Keep flammable materials away Mantenga el material combustible fuera del rea de trabajo Gardez l cart de tout mat riel inflammable Entfernen Sie brennbarres Material e Mantenha inflam veis bem guarda dos LOOT Ko HE E ati Ties Ris p H HUETSLTALUTAS sum sm Wear eye ear and body protection Prot jase los ojos los o dos y el cuerpo Prot gez vos yeux vos oreilles et votre corps Tragen Sie Augen Ohren und K r perschutz Use prote o p
166. the filtering of the feedback data The default value of 400 is usually used unless TAST is being done With TAST this field is usually set to a value around 75 This value is only relevant for the PW455 455M 655 355 and ACDC1000 This determines how often the analog input channels i e workpoint trim and wave control update the system in terms of polled I O scans For example if you enter 50 every 50th I O scan will be accepted The setting of this item depends on how often the Welding Power Source is scanned For systems with a scan rate of 200 or more the default is generally 50 For systems with very low scan rates such as 10 Hz a setting as low as 2 might be needed This parameter sets the feed speed of the wire while cold inching or jogging the wire This value is used for either cold inching forward Jog or cold inching reverse Jog This value is in units of inches per minute IPM Polled I O Connection Workpoint input Trim Wave Control input This indicates whether the values passed to the system through the analog DeviceNet channels for the Workpoint parameter are raw values or scaled engineering values For most applications choose Engineering units For example when the Workpoint is in inches per minute and you choose Engineering units a value between 50 and 800 might be expected to be commanded on the DeviceNet analog input for the Workpoint This would represent a value of 50 to 800 inches per minut
167. the power source uses the last Weld Profile by default On second generation Welding Power Sources and third generation power sources that have not upgraded this means Profile 32 On third generation Welding Power Sources that support this feature this means Profile 200 See page 10 3 for more details on Weld Profiles Select Weld Profile based on When you select this option the I O from the analog interface is Analog Interface I O configured to choose the Weld Profile Out of Limit Actions Tab On the Out of limit actions tab you tell this Welding Power Source what action to take when a weld exceeds limits established on the Profile limits tab page 10 7 You can also provide the Welding Power Source with a short amount of tolerance time before it takes that action The Out of limits tolerance fields represent the total accumulative amount of time the weld can be outside the limit before the selected action occurs IM8002 Power Wave Manager User Manual 10 5 Chapter 10 Production Monitoring Configuration When setting the Out of limit tolerance for WeldScore remember that the sample rate is 0 25 seconds You should choose a tolerance value according to the fewest number of samples you want to include For example a value of 0 3 seconds in the Out of limit tolerance field only ensures one sample A value of 0 6 seconds ensures two samples And so on We recommend no less than three to five samples which means setting your to
168. ties Setup Wizard Power Wave Utilities Setup This wizard w l you through the installation of Power Wave t s recommended thet you dose al other appbcaeone before startng Setup wil make it possible to relevant system fles without having to reboot your computer Check Next to continue Cancel The system extracts files and installs the Power Wave Utilities on your computer Once it is complete the final page of the Setup Wizard opens IM8002 Power Wave Manager User Manual 3 5 Chapter 3 Installing Power Wave Manager Installing Power Wave Manager Procedure Details 10 Click the Finish button to exit the installer Congratulations You have installed Power Wave Manager and can now configure your Welding Power Source 3 6 Power Wave Manager User Manual IM8002 LINCOLN ELECTRIC THE WELDING EXPERTS pte r 4 Overview of Power Wave Manager Power Wave Manager is a software application that allows you to configure and manage the Power Wave family of Welding Power Sources Once you connect to a Welding Power Source you have a multitude of tools at your disposal Setting a Preferences Folder When you first open Power Wave Manager the system may prompt you to set a Preferences folder This folder houses weld training files and is the backup location used for storing weld logs backups SnapShots and other files Simp
169. tion click the Power The system displays a page containing the Wave Utilities link Download Power Wave Utilities FREE button 3 4 Power Wave Manager User Manual IM8002 Installing Power Wave Manager Chapter 3 Installing Power Wave Manager Procedure Details Download Power Wave Utilities FREE 5 Click the Download Power Wave Utilities FREE button to run the update 6 Select your language from the drop down and click OK 7 Click Next on the Welcome screen to move to the License Agreement and continue the installation 8 You must accept the License Agreement and click Next to continue 9 Leave the default value in the Destination Folder field and click Install File Size 13 2 MB Last Updated 01 31 12 NOTE Depending on your Windows version you may have to click Run or Allow to permit your system to launch the file TIP If you haven t logged in as a user with administrative privileges you may have to download the file open the location where you downloaded it right click the file and select Run as administrator The system displays the nstaller Language dialog If you are running an older version of Power Wave Manager the system prompts you to remove the old version Click OK to allow the installer to remove the old version If this is a new installation or once the old version is removed the system displays the installation welcome window Welcome to the Power Wave Utili
170. tion can be entered in the Exceptions list It is also necessary to add the Host Name and Address of the Lincoln CheckPoint server in the TCP IP menu After configuring the Proxy Server menu press the PREVIOUS key to return to the main Host Comm menu Figure 11 8 5_TEST LINE MEN AsonTED 1 12 Protocol Description 1 Hez TCP IP Detailed Setup 2 TELNET Telnet Protocol 3 SNIFF Ethernet Sniffer 4 PC SHARE PC Share Setup 5 RIPE ROS Ethernet Packets 6 PROXY Proxy Server 7 PPP Point to Point Protocol B PING Ping Protocol 9 HTTP HTTP Authentication 10 FTP File Transfer Protocol 1 DETAIL smov Figure 11 8 TCP IP Menu B 14 Power Wave Manager User Manual 8002 Procedure Enabling Arc Production Monitor Appendix B FANUC Robots Move the cursor to the TCP IP item and press F3 DETAIL or Enter to display the detail menu Figure 11 9 19_TT37 LINE WIR avoereo EE SETUP Host Comm TCP IP 5 40 Robot name ARCROBO1 Port 2 IP addr 192 168 2 151 Subnet Mask 255 255 255 0 Board address 00 0 4 0 72 40 Router IP addr 172 22 64 1 Host Name LOCAL Internet Address 1 216 26 175 3 2 nWw uR wuRnw odo d d e d e d 224254 3 x k amp x XXX E Wr m kr 24 4 amp kk amp kk amp kk gt us lincolncheckpoint com Figure 11 9 Enter Host Name and IP Address In the Host Name table in the lower section of
171. titled PM VER They will be listed in the Select key program listing along with all other programs Through the use of a CALL instruction PM SEL will be selected and run just before the ARC START point is recorded After the ARC END point instruction PM VER will be selected and run When these two instructions are entered a Weld Profile number 1 through 32 will be identified as part of the instruction Here is a sample weld program 1 J P 1 100 CNT100 2 J P 2 100 CNT100 3 CALL PM SEL 1 4 J P 3 100 FINE ARC START 1 5 L P 4 40 in min FINE ARC END 1 6 CALL PM VER 1 7 J P 5 100 CNT100 8 J P 1 100 CNT100 END To teach the Production Monitoring CheckPoint instructions 1 Press F1 INST 2 Cursor to the line CALL and press Enter 3 Atnew submenu cursor to line Call Program list of programs appears and press Enter IM8002 Power Wave Manager User Manual B 3 Appendix B FANUC Robots FANUC Robot Application Prior to v7 70P 21 4 Cursorto PM SEL or PM VER and press Enter 5 With the cursor now just past the SEL or VER press F4 Choice 6 Cursor to Constant and press Enter The word Constant now appears on the line 7 Select the Weld Profile number you want to Instruction is now complete and should appear assign and press Enter similar to the example program above Now whenever this
172. ts entirety Be sure you fully understand the nature of WeldScore and how to create a training model Determine how many Weld Profiles you need Decide which Weld Profile numbers you want to use on this Welding Power Source Decide how many example welds you want to train for each Weld Profile you want to use If you train a small number of consistent and repeatable welds you create a low tolerance for variability in production A larger number of training welds allows a bit of flexibility when making welds in production Plan the attributes of each example weld in terms of parameter settings and physical changes Remember You want to create an acceptable average for the training model using these individual training welds Page 11 3 explains the welds to train in more detail WeldScore WeldScore a new feature available in all third generation Welding Power Source models including the Power Wave i400 C300 S350 S500 and AC DC 1000 SD can be used to support a weld quality control program It assigns a score to welds on a 0 to 100 scale that indicates the acceptability of the weld The score is based on a comparison to previously trained welding conditions A weld with a score of 85 to 90 or above can be considered with a reasonable amount of confidence to be an acceptable weld WeldScore can be used independently on the power source or together with Production Monitoring or CheckPoint NOTE WeldScore
173. ts on the Charts tab by periodically reading feedback values from the Welding Power Source as it welds Figure 9 8 The data updates whenever the Welding Power Source output is on The graphs display Amperage Voltage Wire Feed Speed WeldScore if available and Global Scale Factor TIP Thecheckboxes at the bottom control which graphs you can see on the Charts tab Remove the check mark to hide the graph Replace the check mark to display it again The Information section of the tab displays the status of various system components connected to this Welding Power Source if supported When the indicator is green this means the status is good If there is a fault the respective gray indicator changes to red The Arc detect indicator changes to green when it detects an arc and yellow if the output is on but the system cannot detect any arc e g when there is not enough voltage to create an arc Power Wave Manager Wg Connection zd Save chart data charts Save weld fog s Clear weld log g System ion 4 RB Power source settings Charts Legged Settings ahibiation WD Cable settings ond testi Mucellaneous Network settings Conmunxaton Status Feeder settings 4 ld 8 ste Observer 4 qn Production Monitoring insesi gt Configuration haning perty value dole MhedulelA Weld mode i Wort port janpi 15 woe Y uc 0 7 amper
174. u click OK The same is true if you enter a value that is below the lower limit The system automatically changes that value to match the lower limit For example if the upper User limit is 410 and you enter a value of 654 Power Wave Manager automatically changes the value to 410 If the lower User limit is 60 and you enter a value of 50 Power Wave Manager automatically changes the value to 60 If this is not checked the values in the User limits fields have no effect u Weld WFS in min se Please select a new value for this item Machine limits 80 to 815 User limits 60 to 410 654 ok Cancet Figure 8 8 Entering a Limit Higher than the User Specified Limit The Machine limits displayed represent the absolute limits of this parameter The User limits as well as the entered value must be within this range When finished modifying the parameter click OK to write the new settings to the machine IM8002 Power Wave Manager User Manual 8 7 Chapter 8 Wire Feeder User Interface THIS PAGE INTENTIONALLY LEFT BLANK 8 8 Power Wave Manager User Manual IM8002 LINCOLN ELECTRIC THE WELDING EXPERTS Chapter 9 Tools The Tools section of Power Wave Manager provides you with the ability look up an error codes you receive from a Welding Power Source create backup and troubleshooting files and view the weld as it is being made Lookup Error The Lookup error section allows you to ob
175. u would like to change the language used by Power Wave Manager select the appropriate language from the Language drop down Figure 4 4 Check for Updates About Preferences Language Idioma Jazyk Sprache Langue Lingua 22 Taal Jezyk English United States zi 9 Connected to 10 23 10 91 EN1 Figure 4 4 Changing the Language of Power Wave Manager IM8002 Power Wave Manager User Manual 4 5 Chapter 4 Overview of Power Wave Manager Language Selection THIS PAGE INTENTIONALLY LEFT BLANK 4 6 Power Wave Manager User Manual IM8002 LINCOLN ELECTRIC THE WELDING EXPERTS a pte r 5 System Status When Power Wave Manager first establishes a connection to the Welding Power Source it switches to the System status section and provides you with in depth information about the Welding Power Source With the System status section you can review each component of the Welding Power Source review a module if there is a problem and create a SnapShot file for troubleshooting r Power Wave Manager b Connection 4 isplay Bl system status 4 Power source settings System status Module information o fit Calibration 4B Machine model K2803 1 PW AC DC 1000 SD 7780 Cable settings and tests Machine is ready to weld o R Miscellaneous 427 Network settings 88 Communication Status 1 gf Arclink EJ DeviceNet 1 BER Ethernet 0 Wire
176. ugh the Serial Port Connect through Ethernet I know the IP address of the welder C I do not know the IP address of the welder go v What is an IP address TIP If there is an IP address already displayed it is the IP address of the last Welding Power Source that was connected Be sure you enter the correct address for the current Welding Power Source you want to update You can enter the IP address for the Welding Power Source in one of two ways Type the specific IP address into the know the IP address of the welder field Choosing the do not know the IP address of the welder option The update utility scans your network and displays a list of Welding Power Source IP addresses on the same subnet NOTE If this Welding Power Source has older firmware the IP address will not show up using this method TIP If you run into a problem please refer to 3 2 Power Wave Manager User Manual 8002 Update Welding Power Source Firmware Chapter 3 Installing Power Wave Manager 7 Click the Connect button once you have entered the IP address for the power source you are updating Lincoln Electric System Update Utility LINCOLN the Troubleshooting section Appendix A The software scans the Welding Power Source to verify if the firmware currently on the machine is up to date TIP You can also see this information under System Status Module Information Soft
177. ultiple DeviceNet 7 4 Status TID ka Lawaz 7 4 Contig rablon eren ERE URET EAR NUR Bm _a 7 5 varsa 7 9 rJ emmo 7 10 Weld Limits TaD ETE 7 11 5 kixs M M 7 12 T JE OREL ARAN k w w n LOS LI LUDERE 7 13 Multiple Ethernet kk kk kk k k nnn nnns nnns nsn KAHR 7 13 Cornifigul atiOrno eie YE YE EBED Re te ees iade DD a 7 13 Wire Feeder Feeder Settlligs inre sap ea Cr E W ee e KN Ka er ew KA SE RE AN ea WE HELAT 8 1 Multiple Wire Feeders i Maku a x aiei 8 1 Settings s ea eee ya I EUR ECL E NIY 8 2 Diagnostics TaD 5 4 y dett G H KRA T sk 8 3 al zu vv denned 8 4 Multiple User Interfaces ec seke h En ba n NT Eun n n k 8 4 Setup Security Settings Tab enne nennen k kek kK ke k k entree trn seen nnne 8 5 Memory Settings Tabac t e EE Co ee wa eges cbe ed e Ye EE ERE Cae musa ds 8 6 Tools 2
178. urrently welding This field displays the current baud rate configured in the DeviceNet interface installed on this Welding Power Source For the following power sources the Baud Rate is usually set by a DIP switch located on the gateway board but you can also set the baud rate from Power Wave Manager PW455 PW455M ACDC1000 PW655 and Welding Power Sources that use the K2436 1 Ethernet DeviceNet Communication Interface For other Welding Power Sources that do not have a DIP Switch you must use Power Wave Manager to set the Baud Rate of the DeviceNet interface STOP If you change the Baud Rate you must cycle the power to the Welding Power Source off then back on in order for the change to take effect Be careful not to cycle the power while the power source is currently welding The Event Logging checkboxes allow you to control the types of issues that create a log entry when they occur on this DeviceNet module Place a check mark in this checkbox when you need to use the DeviceNet connection only to monitor system operation When you enable passive mode the polled inputs from DeviceNet have no effect on the system except for the Weld Output disable bit and the Production Monitoring Fault Reset bit DeviceNet will automatically restore weld schedule values on power up that are not accessible from a polled connection These include weld mode strike restrike cold inch wire feed speeds and times for preflow postflow and burnb
179. ware Version in Power Wave Manager See Figure 5 4 on page 5 4 n Update Status amp Details Description ELECTRIC 3 Power Wave S500 Power Source 3 amp PF10M PF10M Wire Drive User Int 525629 22 3 5500 PFC Controller 5500 PFC Co Firmware 528804 04 Update NOT REQUIRED NOT REQUIRED 528805 3 REQUIRED Update not required Machine firmware is newer or equal to updates included in this package Click Continue to generate a report listing current Firmware 7 Release Notes Config file pwave lego 8 If the firmware is not up to date you must click Continue to update the Welding Power Source 9 Exitthe program once the firmware has finished updating 10 23 8 147 The system proceeds with the update If the firmware is already up to date you will receive the message Update not required and you can click Exit to close the window 10 Repeat steps 4 through 9 for each power source you need to update 1M8002 Power Wave Manager User Manual 3 3 Chapter 3 Installing Power Wave Manager Installing Power Wave Manager Installing Power Wave Manager Once you update the Welding Power Source s you need to upgrade to the latest version of Power Wave Manager If installing Power Wave Manager for the first time these instructions are also for you Power Wave Manager is a software application that allows you to manage a multitude of settings and con
180. which may require crossover cable on older computers power sources Plug one end of the Ethernet cable to the port on your computer and the other end into the Ethernet port of the Welding Power Source This is the preferred method Computer and Welding Power Source connected to the same network switch Computer and Welding Power Source on the same corporate network may include switches and routers NOTE Notall Welding Power Source models have an Ethernet port However you can upgrade some models to utilize Ethernet by adding the Communication Interface module available from Lincoln Electric as K2207 2 or K2436 1 depending on the Power Wave model Connecting to robotic applications could vary from the information in this manual Please refer to the appropriate Operators Manuals for more information IM8002 Power Wave Manager User Manual 2 1 Chapter 2 Connecting the Power Source Serial Cable Connection Serial Cable Connection If the Welding Power Source you are trying to connect to has a serial port and your computer also has a serial port that is a DE 9 male connector a nine pin connector also referred to as a DB9 you can connect to the Welding Power Source with a nine to 25 pin serial cable The serial port on the Welding Power Source is a DB 25 female connector 25 pins Figure 2 1 Serial Cable Connection This cable is available at Lincoln Electric automation division as part number AD1207 2
181. within the Welding Power Source E mail Triggers on page 10 14 IM8002 Power Wave Manager User Manual 10 13 Chapter 10 Production Monitoring Configuration TT T ole Feeder settings PWS350_1 advencedcom TT ee User interface 4 2 2 E mail address click to ec E mail triggers for 4 2 Lookup error e SnapShot Q empty System event WeldView Q empty F semi i 5 Backup Restore empty oe 44 Observer lt empty gt 4 7 Weld Profile limit exceeded 44 Production Monitoring Q empty 5 i Register Q empty 2 _ Wire package warning Configuration Q empty 9 Training Q empty J Power on Q empty Q empty Q empty qe Figure 10 9 Address Book To add a user to the address book click empty slot in the address list to activate a text field Type the address and press Enter on the keyboard To edit an address simply click on the address and begin typing Press Enter on the keyboard to commit your changes To delete an address click on the address and press the Delete key on your keyboard TIP E mail addresses can contain uppercase and lower case letters the digits 0 through 9 the characters The address can contain the period character provided that it is not the first or last character in the local part of the address It also cannot appear two or more times cons
182. ws the setup and verification of the DeviceNet connections of various modules to the Welding Power Source NOTE Modifying DeviceNet settings is highly technical If you are uncomfortable with making changes contact your local IT support for assistance You should also consult the appropriate Lincoln Electric Operator Manual for the module you have installed Multiple DeviceNet Modules If the system to which a Welding Power Source is connected contains more than one DeviceNet module e g a Power Wave connected to a robot teach pendant you can select the module you want to review from the drop down list This allows you to configure settings for each module r Power Wave Manager Wo Connection Select DeviceNet module PowerSource Controller Blink status light B system status 4 e Power source settings la Calibration Cable settings and tests DeviceNet product code 3 2 Miscellaneous Network settings 8 Communication Status Arclink DeviceNet scans second 0 Ethernet Configuration Monitor Trace Weld limits Weld sequencer DeviceNet vendor revision 1 011 Connection state a Figure 7 4 Multiple DeviceNet Module Drop down If you re not sure the selection in the drop down refers to the actual DeviceNet module you want to review click the Blink status light button This causes the green light on the selected machine to start blinking rapidl
183. y so you can visually identify the module Status Tab The Status tab displays basic information about the DeviceNet interface on the Welding Power Source as well as any errors currently present on the interface Remember You can select each module connected using DeviceNet from the Select DeviceNet module drop down at the top of the window to see information about that specific module Power Wave Manager Connection Power Source Controller System status CL E Ez 4 Power source settings Status Configuration Monitor 1 1 Weld limits Weld sequencer z Calibration WD Cable settings and tests DeviceNet product code 2 21 Miscellaneous 4 77 Network settings 4 Communication Status DeviceNet vendor revision 1 012 Connection state Arclink DeviceNet scans per second 0 Ethernet wire feeder Polled VO EPR 0 Figure 7 5 Status Tab 7 4 Power Wave Manager User Manual IM8002 DeviceNet Chapter 7 Network Settings Configuration Tab Use the Configuration tab to review and or edit options for the DeviceNet interface connected to this Welding Power Source Power Wave Manager reads these options from the connected Welding Power Source and displays them here The available fields depend on the DeviceNet module Table 7 1 explains each of the fields in more detail NOTE For more information on setting up the DeviceN
184. y the power source Please refer to the CheckPoint User Manual for more information Before setting up the Welding Power Source to send e mails collect the following information List of e mail addresses that will receive e mail alerts IP address or host name of the SMTP e mail server IP address or host name of the DNS server the power source should use for e mail Port number on which the e mail server receives e mail TIP Contact your local IT department for assistance on obtaining the information about the e mail server or the DNS server Power Wave Manager Va Connection Bi system status 4 ffi Power source settings E5 Calibration Cable settings and tests 3 Miscellaneous Network settings 1 Communication Status ArcLink DeviceNet Ethernet Wire feeder o o Feeder settings ee User interface 4 22 Tools 2 Lookup error SnapShot WeldView fe Backup Restore 24 Observer Production Monitoring EJ Register 3 Configuration Training mm Kan Connected to 10 23 10 90 EN1 JL er Iss Weld Profile selection Out of limit actions Profile limits Wire package Miscellaneous E mail setup Mail server configuration Outgoing mail server 10 4 2 239 Mail server port o DNS server 10 4 2 178 Enable e mail notifications Power Source name 1

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