Power Wave Manager Software Manual
Contents
1. ss Tools Jolie 13 H ES Lookup Error A Profile 14 a 5 Profile A a wich a E SnapShot Profile 15 Weld elle hiite 3 Fa Ir fat TT Enable O Weldview da Profile 16 a i Profile a7 La Backup Restore Profile 17 lerne liiite 18 155 Ic 1737 Enable se Observer Profile 18 Ea ae Monitoring m Profile 19 ahane Mate 1 234 lo 244 Enable any Ins as Profile 20 i HSe _ Profile lt lt Configuration in Profile 21 Wire leed nee imite pri 396 Le 403 T Enable Training Profile 22 aD Frofile 23 do Profile 24 Profile 25 Profile 26 Profile 27 Apply Settings i IRA Language Idioma Langue Lingua Sprache Taal Jazyk Habe m i English y Connected to 10 23 8 73 EN1 To set a minimum value for WeldScore first select the appropriate weld profile and then check the enable box next to Minimum WeldScore The default as well as minimum value for this setting is 80 If a minimum WeldScore limit of less than 80 is required to keep good welds from being flagged as bad this is an indication that either the training was done incorrectly or that a variable has changed since the training was done The profile should be retrained if this is the case lowering the minimum WeldScore is not an appropriate way to compensate for training not matching the production weld To perform an action if the WeldScore falls below the minimum value set here cli2. Certain Lincoln components can be paired together ease eee _ such as certain models of wire feeders and user interfaces Current pairing configuration Available for pairing MAXsa 10 UI Module name These components are usually paired automatically and transparently to the user However if there was a problem with pairing between two or more components this section of Power Wave Manager will show a Pairing tab where components can be paired manually 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 Click on an unused slot to see which modules can be paired with it Then select the correct modules from the list on the right and drag and drop it over to the unused slot or use the arrow buttons in the middle When finished all of the required modules click the Apply Settings button Lincoln Electric O Slot 1 lt unused gt E se MAXsa 10 UI Slot 1 lt unused gt E MAXsa 19 Wire Drive 8541 MAXsa 19 Wire Drive 25506 01 25 11 14 9 Feeder Settings This section allows you to configure a multitude of parameters related to the wire feeder and user interface of the machine if available 9 1 Wire Feeder The Wire Feeder section contains settings and diagnostic information about any wire feeders that are attached to the we
3. Lincoln Electric 01 25 11 27 13 2 WeldScore WeldScore a new feature available in all third generation Power Wave models including the 1400 C300 S350 R350 and AC DC 1000 SD can be used to assist a weld quality control program It assigns a score to welds on a 0 100 scale that indicates the quality of the weld The score is based on a comparison to previously trained welds Any weld with a score of 90 or above can be considered with a reasonable amount of confidence to be a good weld This is not a guarantee of quality and is not intended to replace a quality control system WeldScore can be used independent of or together with Production Monitoring 2 1 or newer 13 2 1 How It Works Traditional weld monitoring systems measure voltage and current and must then guess what the power supply is trying to do before attempting to determine how well it is actually doing it WeldScore is built right into the power supply controller which gives it a significant advantage in that it removes the guesswork involved with how the supply should be functioning In addition to traditional voltage and current measurements WeldScore also looks at 40 50 additional variables which help to make it more reliable and accurate than any previous weld monitoring system In order to assign a score the Power Wave must first be taught what is considered to be a good weld This is done through the training section of Power Wave Manager When a s
4. gP P 505 Preference Lock N The configurable parameters will be shown in GP S06 ul Passcode o a table as shown in the illustration Each ERRE Ah gt PP 9 Group 1 Crater Delay 0 parameter can be changed by double clicking ehe E 11 After double clicking ona certain Fr 16 Push Pull Pot Option Remote Pot Enabled for all Procedures parameter Power Wave Manager will display Connected to 10 23 8 18 EN1 About What s this a window where the new value for the As Le Mn parameter can be entered There are two different types of parameters numeric where the value can be a number within a certain range and selectable where the value can be selected from one of several text descriptions When changing a certain parameter Power Wave Manager Selected user interface module PF25M User Interface y Bink status light brings up the appropriate window for changing the setting User Interface model PF25M User Interface based on its type For selectable parameters the window l j Setup Security Setti will contain a drop down box with the possible selections A yA Value p Parameter for the parameter For numeric parameters the window will een ron contain a text box where the value can be entered directly G P 2 Arc Display Mode Amps oP 3 Display True Energy No Sy i OP 4 Resto Dams ano bic Different models of Lincoln user interfaces may give a a E different list of configurable parameters sinc
5. i 10 5 2010 8 52 AM 11 41 1 10 5 2010 8 52 AM 0 22 2 10 5 2010 8 53 AM 14 63 3 10 5 2010 6 54 AM 15 47 13 2 5 Performing Out of Limit Actions Using WeldScore Power Wave Manager can be used to configure a desired minimum for WeldScore M and ranges for weld duration amperage voltage and wire feed speed for each weld profile It can then setup actions to be taken 1f these values are not met for a certain amount of time The Profile limits tab under Configuration in the Production Monitoring section of Power Wave Manager is used to setup profile limits as shown below Lincoln Electric 01 25 11 29 gt Power Wave Manager p E oj xj y Connection O y B System Status Weld Profile selection Out of limit actions Profile limits Wire package E mail setup Miscellaneous E Profile 1 gy Power Source Settings WA Calibration iit checking for this profile ae iD Frofile 2 ED Cable Settings and Tests Profile 3 Limits for profile 1 ar Voltage Reduction Device V a Profile 4 ee a Miscellaneous ss Profile 5 Ao dis EIERN E T Network Settings a Profile 6 1 00 0 5077 GE Ethernet E Profile 7 OE beats a IF Discard welds shorter than 1 5 sec gi ArcLink 5 Profile 9 El W Feeder Settings ele Wire Feeder tee User Interface Minimin elda core 90 4 M Enable
6. Er The Backup Restore section allows the user to save Power Wave settin gs memory confi guration lockout parameters This allows you to back up your welder s User Interface settings Ethernet settings and version information to a file and network settings to a file and then restore the saved settings at a later time to the same or to a different Power Wave bo Backup 10 4 1 Backup To create a backup of the currently connected Power Wave switch to the Backup tab then click the Backup button The program will ask for a location and name to be given to the new file Power Wave Manager initializes the file name with the serial number of the machine s control board plus the current date and time Once the file name is selected backing up will begin and will take a few moments 10 4 2 Restore Backup Restore Backup To restore a saved backup file onto the currently connected File to restore Z apps net 1638820033540018 01 54 22 06 18 2003 Items to restore machine switch to the Restore tab and click the Browse button to find the desired backup file or simply drag and drop i User Interface settings the backup file into Power Wave Manager 9 Setup Security settings Next select the various settings that should be restored from W Memories and limits the backup file These settings are User Interface Settings W Network Settings which includes Setup Se
7. what was done in the older AC DC1000 DeviceNet interface 8 2 2 5 Enable Passive Mode Operation If checked then the DeviceNet polled inputs will have no effect on the system except for the Weld Output disable bit and the Production Monitoring Fault Reset bit Enable this when the DeviceNet connection is used only to monitor system operation 8 2 2 6 Restore Settings from Memory on Reset DeviceNet will automatically restore weld schedule values on power up that are not accessible from a polled connection These include Weld Mode strike restrike and cold inch wire feed speeds and times for preflow postflow and burnback If the system contains an UI with memory a memory panel or a robot PLC that restore settings on power up do not check this box 8 2 2 7 Fault if No Polled Connection Detected Disables welding if a polled DeviceNet connection is not present Check this when a DeviceNet master controls the machine 8 2 2 8 Workpoint 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 Selecting the Engineering Units option indicates that scaled engineering values for Workpoint will be passed across the analog DeviceNet channel For example when the workpoint is in Inches per Minute and scaled engineering units are used then a value of 50 to 800 might be expected to be commanded on the DeviceNet analog input for the
8. 13 2 for more information on WeldScore This feature removes the necessity of setting up limits manually for each of the Weld Profiles allowing the operator to make several training welds in the same manner as they would be done in normal production Then based on the training welds Production Monitoring automatically generates limits for arc current voltage wire feed speed and time The operator can remove any welds made during the training that are considered bad welds Important A weld profile must be trained before a WeldScore will be given Note at this time the longest weld that can be trained for determining WeldScore data is one minute If training is being done in order to determine Voltage Current and WES limits then the maximum duration is 21 minutes 11 3 1 Selecting a Profile The first step to training a weld profile is to set how a profile will be selected See the Production Monitoring 2 1 manual section 4 2 1 Weld Profile Selection Tab for setting how profiles are selected 11 3 2 Training a Profile To begin training select the Training option under Production Monitoring in Power Wave Manager 3 la Production Monitoring mn i Install Et x Configuration This will bring up a screen that looks like the following Lincoln Electric 01 25 11 23 io Power Wave Manager o E lolx D antics Start training Stop training Apply training data W System Statu
9. Lincoln Electric Support for analysis When a problem or issue occurs it is recommended to record a SnapShot of the machine then clear the logs in the System EJ Calibration 29 Cable Settings 2 Miscellaneous Network Settings fils Ethernet EF DeviceNet ArcLink 3 Feeder Settings ojo Wire Feeder User Interface 4 Backup Restore A gp Tools P Lookup Error D YW WeldView Connected to 10 23 8 18 EN1 About What s this Status section then attempt to reproduce the issue If the issue is reproduced record another SnapShot and send both SnapShots to Lincoln Electric Support for analysis Lincoln Electric 01 25 11 18 10 3 WeldView Power Wave Manager Ra Connection System Status WeldView 1s a feature of Power Wave Manager that allows you to capture a high FR seinen speed trace of a portion of a weld performed as ce te 3 Network Settings fils Ethernet Elk DeviceNet ArcLink f Feeder Settings ojo Wire Feeder amp User Interface by your Power Wave The trace is a series of data points that the machine stores while welding Each record 3 I Backup Rest consists of several variables including me A D Amperage and Voltage at the time that the an YN Weldview record was written The weld trace can be used to troubleshoot or fine tune welding performance by examining the waveform of the weld during st
10. Stop trace when finished recording The recorded messages will be downloaded from the DeviceNet module and displayed in the list with all relevant fields decoded 8 2 5 Weld Limits This tab displays a list of all available weld procedures supported by the Power Wave and basic information for each procedure Click on a procedure to view the types of controls associated with the procedure Workpoint Trim Wave Control etc and the outer limits of each control This section can be used to verify that the correct weld mode information is being read over the DeviceNet connection Note Updating the machine s firmware may cause the limits of some procedures to become different 8 2 6 Weld Sequencer 3 Power Wave Manager ee Ra Connection System Status a coran status Configuration Monito Trace weld Limits Weld Sequencer lt ED Cable Settings Time Type MACID ArbID Data Translation p7 Miscellaneous P Network Settings fir Ethernet EF DeviceNet Arclink f Feeder Settings ojo Wire Feeder E User Interface bH Backup Restore OP Tools 2 Lookup Error 9 SnapShot YN WeldView wee ee O Start trace stop trace Continuous Stop when buffer full Record outgoing packets Record incoming packets 9 Without restrictions O Without restrictions Only if data is different from previous Only if data is different from previous Only if ID data are
11. are cleared in this manner the machine will remember the last time its logs were cleared and this data will be available the next time system status information is shown Note that this action will reset the machine so it should not be done while the machine is in use e SnapShot button Click this button to go directly to the SnapShot section 10 2 so that a snapshot of the system can be easily acquired Lincoln Electric 01 25 11 4 6 Power Source Settings The Power Source Settings section consists of various subsections that contain settings for to the power source component of the welding system 6 1 Calibration The Calibration section allows calibrating the machine by adjusting the amperage and voltage outputs so that they match a setpoint value This function can also be used to activate the machine output for other troubleshooting purposes The Turn Output On button ke A Warning Use caution when viewing or changing these settings 1 z R Power Source Settings arning Conn ing ca n ore TT DT ie 3 ames o Te enables the outp ut of the machine wm a ita ex he E aac wanker welding properly able settings an ests When output turns on the Output is _ Voltage Reduction Device A gt 7 Miscellaneous ON indicator will begin to flash red 4 77 Network Settings Feedback Amperage setpoint EN Ethernet Output amperage x and values will appear for Output E DeviceNet Sa id z Arclink Output volt
12. can be configured 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 uncheck the Automatic hardware sense lead selection checkbox and check the Enable remote voltage sense leads checkbox then click the Apply Settings button The system will reset and the arc voltage will then be detected at the electrode 67 lead and the work 21 lead If negative welding polarity 1s required then you may need to manually configure the correct voltage sense location If the system 1s already configured to sense arc voltage at the remote voltage sense leads then no changes are required Otherwise uncheck the Automatic hardware sense lead selection checkbox and check the Force negative weld polarity checkbox then click the Apply Settings button The system will reset and the arc voltage will then be detected at the electrode 67 lead and the positive stud Note If the sense lead selection is specified within the welding procedure in use it will have precedence over these settings Therefore some welding processes such as TIG Stick and SMAW will override these settings 6 2 2 Weld Cable Test The weld cable test allows you to automatically measure the resistance and the inductance of your welding circuit This can be used to determine how setup ch
13. different from previous Only if ID data are different from previous Only if ID AND 000007FF 00000000 Only if ID AND 000007FF 00000000 9 Connected to 10 23 8 61 EN1 About Whats this a D Power Wave Manager babaa Connection System Status on Settings status Configuration Monitor Trace Weld Limits weld Sequencer 29 Cable Settings Refresh 2 Miscellaneous gt st T Network Settings well mode Process name Description Process type Wire type Es Ethernet Ws TS TIG Pulse GTAW NotApplicable 2 Elk DeviceNet s Carbon Arc Gouge Gouge CarbonAre 2 ArcLink 10 cv co2 GMAW Steel f Feeder Settings 1 GMAW ojo Wire Feeder ow Pulse ArMix GMAW Steel E User Interface OB RapidArc ArMix GMAW _ fel Backup Restore 14 cv co2 GMAW Steel a ee OP CV ArMix GMAW Steel D n O 16 Pulse ArMix GMAW Steel Are 017 RapidArc ArCO2 GMAW Steel 18 RapidArc ArMix GMAW Steel gt a ha i t Control name Display name Limits Workpoint WFS 60 to 800 in min Trim Trim 0 5t0 1 5 waveControli UltimArc 10 to 10 9 Connected to 10 23 8 61 EN1 About Whats this This 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 Double click on one of the cells to modify a system variable in a certain state Thi
14. is expanded the program shows the number and description of the fault that the object is currently experiencing a IR Power Source Settings Y Canpration EN Cable Settings and Tests Rt Voltage Reduction Device Mintellanenun 4 T Network Settings OP Ethernet Er DeviceNet a Feeder Settings fe Wire Feeder he Lackun Restore y Observer Production Monitoring Install 2 Configuration amp Training El Refresh Display Detailed Status gt Y Clear Logs C SnapShot system Status Module information a MA Machine modet Power Wave 5350 a weld Sequencer ES Weld Sequencer is mol faulted O Previous state idle y Exd condition Hol mitishzed A Event log 4 Logs were previously cleared on 111 2016 12 00 AM Fatal error log Ep QIP switch bank 1 O Dir switen bank gt ooo jD Weld Controller a UY Neid Controller has 1 latened tauitis 4 Os Latched errors CI Thermovtal hipped A Latest eventis Fi Event tog a C Lthernet b P Event log 9 DeviceNet Process Munitor D Remate Controller In addition to the actual faulted condition an object may also have events recorded in its historical Event Log These events can provide additional information about the cause of any problem An event may be residual from a previous malfunction or it could be associated with the current malfunction An event does not always indicate a malfunction but can be posted as a status item Even objec
15. reported as an overall score in Production Monitoring A weld may receive a passing overall score if there is only a problem for a short portion 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 a 94 Out of limit error reporting is calculated over a user defined moving window of time This means that even a weld with a good overall score will cause an error to be reported if the WeldScore falls out of bounds for this defined amount of time 13 2 4 Viewing Using Observer Once a profile has been trained WeldScore data can be viewed in Power Wave Manager by selecting the Observer option under Tools Lincoln Electric 01 25 11 28 Ei Tools AO Lookup Error SnapShot ABS Weldview E LL Backup Restore Select the appropriate weld profile using one of the three options described previously and begin a weld A real time view of amperage voltage wire feed speed and WeldScore can be graphed under the Charts tab in the observer window The Settings tab allows selection of which items will be graphed For more information about the Observer function of Power Wave Manager see section 9 4 of this manual Example WeldScore Graph 100 ee Example of a Good weld Example of a Bad weld The overall WeldScore can be viewed under the Logged welds tab as the following example shows
16. system Lincoln Electric 01 25 11 22 11 2 Configuration The items in the Configuration section are used to set up Production Monitoring These items are discussed in detail in the Production Monitoring 2 1 User Manual and include e Weld Profile Selection Used to set up how the Production Monitoring profiles are selected Out of Limits Actions Used to set up what action the Power Wave will take when a weld exceeds the Production Monitoring limits for weld duration WeldScore arc current arc voltage or wire feed speed Profile Limits Used to select a weld profile and display the limits associated with it e Wire Package Production Monitoring allows the configuration of the wire package used for welding so that its usage can be tracked by the Power Wave and the user notified when the package begins to run low e E mail Setup The e mail screen provides access to all of the configuration options for the e mail feature of Production Monitoring This window allows the configuration of e mail recipients address book and e mail settings e Miscellaneous Used to set a Part Operator or Consumable serial number in the power source 11 3 Training Weld Profile Training is used to automatically generate limits for Time Voltage Current and WES for a profile It will also generate the necessary data in order to use WeldScore See section 13 1 for more information on Weld Profiles and section
17. write the new settings to the machine User limits 140 to 1250 zH The Enable User Limits check box in the Memory Setup section informs the machine whether or not to actually enforce the User Limits defined for certain parameters If this is not checked the User Limits will have no effect 9 2 3 Multiple User Interfaces If the machine is connected to more than one user interface the User Interface section will provide a drop down selection at the top of the screen to select which User Interface is to be configured To identify which of the multiple modules is currently selected click the Blink status light button This will cause the status light of the selected module to start blinking rapidly so that it could be visually identified Lincoln Electric 01 25 11 17 10 Tools 10 1 Lookup Error The Lookup Error section allows you to obtain information about any error code given by a Lincoln Electric machine or error codes given by a FANUC robot controller regarding a Lincoln power source When a welder is in a faulted condition it will flash out an error code on it s Status LEDs see the welders operator manual for how to interpret the Status LED To look up a certain error code select what type of error it is by clicking one of the two checkboxes then type in the error number in the text box and click the Lookup button A description of the error will be shown as well as a possible solution or possible c
18. 400 NA EN Machine is ready to weld E Cable Settings and Tests son Voltage Reduction Device dt 2 Miscellaneous di i y Network Settinaxz If there are no problems in the machine the program will show a green check mark and display a Machine is ready to weld message as shown in the illustration At the top of this section is a drop down box that provides the selections Diagnostics and Detailed Status The default selection is Diagnostics 5 1 Diagnostics If the program detects a malfunction in the system 1t will attempt to determine which hardware module caused the malfunction System Status Module Information E Machine name K2344 1 PW AC DC 1000 88 Weld Controller has 1 latched fault s Latched errors Thermostat tripped A Latest event s 06 22 2009 8 39 AM 36 System detected a temperature level beyond the normal sy E Y Wire Drive has 1 latched fault s Note To retrieve more information about a certain error code refer to the Lookup Error section discussed in section 10 1 You may also double click on the error to automatically go to the Lookup Error section Lincoln Electric 01 25 11 3 5 2 Detailed Status The Detailed Status selection shows the status of each logical object in the machine In the illustration on the right all objects are functioning normally except one the Weld Controller When the faulted object
19. A 24 Observer Pr i This field indicates the current 18 Production Monitoring ren ke y s gt a Instal d a A OE Unscaled values Engineering units configuration of the Power Wave s 3 Configuration a g r Training Trimj Wave Control input DeviceNet MAC ID For the PW455 az fo C C Unscaled values Engineering units an3 lo 2 Iv Analog Output PW455M ACDC1000 and PW655 and b 3 I et ae welders that use the K2436 1 Ethernet DeviceNet Communication iapply Settings Interface this value will only change if the DIP switches on the Power Wave s DeviceNet interface boards are configured to allow retrieval of the MAC ID from EEPROM memory For other welders this setting will set the Mac ID of the DeviceNet interface If this value is altered the Power Wave must be reset cycle power in order for the change to become effective Language Idioma f Langue Lingua Sprache Taal Jazyk AspK f OO OO italiano y Connected to 10 23 8 70 EN1 8 2 2 2 Baud Rate This field indicates the current configuration of the Power Wave s DeviceNet Baud Rate For the PW455 PW455M ACDC1000 and PW655 and welders that use the K2436 1 Ethernet DeviceNet Communication Interface this value will only change if the DIP switches on the Power Wave s DeviceNet interface boards are configured to allow retrieval of the Baud Rate from EEPROM memory For other welders this setting will set the Baud Rate of the Devic
20. Amperage adjustment only Short the output studs with a cable at least 10ft long in place of a Grid Load Turn output ON 3 Use adjustments to trim the feedback values to match actual measured values Ne Lincoln Electric 01 25 11 5 6 2 Cable Settings These settings allow you to configure and test your welding cables and sense a Power Source Settings Er I m Sense lead settings Weld cable test Sense lead diagnostics 53 Calibration leads ED Cable Settings and Tests Automatic selection 5 ER BEN Automatic hardware sense lead selection 2 T Network Settings V Enable remote voltage sense leads Work amp Electrode i gt SA _ Force negative weld polarity 6 2 1 Sense Lead Settings MO aie ojo Wire Feeder ee User Interface 4 Tools Note These settings will only be shown E ia SnapShot for machines that do not have DIP pa switches for modifying the sense lead Po na location They will also be hidden for i n Training machines that do not support changing the sense lead selection Use these settings to enable or disable automatic hardware sense lead selection and to modify its behavior For most CTS Language Idioma Langue Lingua Sprache Taal Jazyk Asb r applications the Automatic hardware Ch nT sense lead selection is the best method to use it reduces the chance of fairing and losing tips due to sense lead lose The system
21. LINCOLN EF SjnuextweLo ELECTRIC a THE WELDING EXPERTS Power Wave Manager User Manual Y 50050 02 Table of Contents 1 DN A O 2 2 System REGUITFCINENIIS osses aea eee eaaa OEE SEa AES 2 3 Compatible Eguipmenta u a 2 4 Establ sh ns 3 Connection 3 S System AU on 3 5 1 NE dukes sguetvaseaucavesseveunessestocsestecensseetearesssetuess 3 5 2 Detaled Status 2 2 nennen 4 5 3 Module Informatio Meesi EOAR TERASS 4 5 4 Additonal OOD CONS sera suaseececeesterseceseccoseuswessecasys 4 6 AA 5 6 1 eos A a a 5 6 2 A ERHEBEN Nana 6 6 3 Mi A 7 7 NEIWOrk Senos CORRA OE NOU nn 8 71 Ethernet url 8 AAA EEE EROE AAEE aA 8 8 2 Dere NOE anal 10 8 3 ATCEMK E E E EE E E E E E E E A 14 Y Feeder SEINES ii ii a 15 9 1 Wire Feeder A E A OS 15 9 2 User Interface usa ea covsccdanessecsucosecacaeusseaescovsctcanmesteass 16 10 TOONS se R a a a ee a ee 18 1041 Eookup Error ans Re ae 18 10 2 APA N e q E E EaR 18 10 35 Weld NIE Wii 19 LOA AO TO 20 10 3 0 1 ad IA oO E a aaa 21 11 Production Monitoring tE AR eo esartieiews 22 11 1 taera T E 22 11 2 Configuration neun 23 11 3 O eavecaueseseeeesactecese 23 12 Language Selection sus ana 26 13 Additional Informan oM ii Eee 27 13 1 Weld o Blcisventstetesesiceaeeateciecsdelede vives tecesestceaeustecceceeeiecevevizecdent 27 132 WELDS CORE M asircrerni sraa EENEN EEEE AE S 28 Lincoln Electric 01 25 11 1 1 Description Power Wave Manager gt is an application t
22. Score data is going to be cleared but does not send the command to the Power Wave to erase it To do that the profile must be saved by checking the box next to the profile and clicking on the E gt Apply training data button If training data is not applied WeldScore data will not be cleared and the Y icon will reappear next time the profile screen is loaded in Power Wave Manager 12 Language Selection Power Wave Manager has built in support for multiple languages in its user interface The following languages are presently supported Chinese Simplified Czech e tina Dutch Nederlands English French Francais German Deutsch Italian Italiano Japanese A 47 Polish Polski Portuguese Portugu s Lincoln Electric 01 25 11 CRD AA AA Power Wave Manager DAT AAR BRO am EE E FOME Tilos E DeviceNet Ss fl SEBO paja Tf WBE LINCOLN ELECTRIC Flesh HEAL BhemettiB_Lc a COSTE 10 23 8 61 COED 26 e Russian Pycckuh e Spanish Espa ol Other languages may be included in future releases By default the program automatically detects the language used by the operating system and switches the language of its user interface accordingly For example on a Japanese installation of Windows Power Wave Manager will automatically switch to using Japanese text and messages If you would like to change the language used by Power Wave Manager select the app
23. age Amperage Output Voltage anf reste eae Cap Avotage 313 Capacitor Voltages and Voltage Irina Cap Bvoltage 311 Sense Location While output is on nos I N A Be gt o make the necessary adjustments by pa Us gt Qrumoupwore J i ait server oltage mperage se clicking the up down buttons that ns aut o act gt Instal _ appear on the bottom left of the x Configuration FT en Training window The amperage setpoint can be changed by clicking the up down arrows next to the text box or by entering the desired amperage directly into the text box Language Idioma Langue Lingua Sprache Taal Jazyk fae 35 A English Note When adjusting Amperage from Power Wave Manager any external ammeter will adjust to the set amperage value When adjusting Voltage the displayed diagnostic voltage will adjust to the external voltmeter which would be holding steady Do not calibrate voltage at voltages greater than 50V When finished making adjustments click the Turn Output Off button to disable the machine s output Output will be disabled automatically if you leave the Calibration section or if you exit the application entirely 6 1 1 Recommended Procedure pd Attach machine output cables to a 300A 30V resistive grid load Turn output ON 3 Use adjustments to trim the feedback values to match actual measured values 5 6 1 2 Quick Procedure
24. anges affect the welding circuit In order to run this test the contact tip must be shorted to the work piece Click the Perform Test button to begin the inductance and resistance test Note that when this test is preformed the machine s output will be turned on for a very short time 100 milliseconds Once the test is complete it will display the resistance and inductance values that were calculated based on the downloaded weld trace The resistance value is displayed in the upper text box measured in milliohms and the inductance value is displayed in the lower text box measured in microhenries Note It is good practice to record the results of these tests when the welding system is operating well so that they can be compared 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 Lincoln Electric 01 25 11 6 6 2 3 Sense Lead Diagnostics Use these settings to troubleshoot welding issues or verify setup by manually changing the location of the sense lead Any changes made in this tab are temporary and will be reset when the machine s power is turned off Arc voltage sense leads can become detached over time due to constant movement of equipment such as robot motion The settings on this tab allow you to test and verify the connectivity and reliability of the current voltage sense selection This is done by a process of t
25. arting and ending A weld trace may also be requested by Lincoln Electric Service personnel to aid in resolving welding issues The trace can be saved to a file and sent to Lincoln Support for evaluation Y Connected to 10 6 8 14 EN1 lx a gt ka Time ms F 60ms 70ms 80ms 0 4 Oms 10ms 20ms 30ms 40ms 50ms 60ms 70ms 80ms About what s this The WeldView section can be accessed without connecting to a Power Wave so that previously saved weld traces can be reviewed at any time 10 3 1 WeldView Wizard To capture a weld trace click the WeldView Wizard button at the top left of the section The WeldView wizard allows you to fully configure the trace before starting it including the frequency triggers or extra channels to record with the trace Follow the on screen instructions in the Wizard to proceed The last step of the Wizard will wait until a weld is completed with the Power Wave This will be the weld that is recorded in the trace When the weld is completed WeldView will download the trace data from the machine and display it in the table and charts Lincoln Electric 01 25 11 WeldView Wizard Select weld trace settings Recording mode First few seconds of welding stop when buffer full Last few seconds of welding wrap around buffer Extra data channel Wire Feed Speed v Trace frequency 120000 Hz 19 10 4 Backup Restore
26. being trained Then right click on the desired weld to delete Now a popup menu will appear containing the following option Ya Delete this weld Click on this choice and the weld will be deleted from training 11 3 6 Saving Training Data When all of the training welds have been completed click on the Stop training button The status will now change to Status Not training Check the boxes next to each of the profiles to be saved Not all the profiles that had training welds taken need to be checked After the appropriate boxes are checked click on the gt Apply training data button Lincoln Electric 01 25 11 25 For example the below section shows that welds were trained for profiles 7 11 and 12 as indicated by the i icon But since only profiles 11 and 12 are checked these are the only profiles settings that will be saved Profle 0 000 08 Profile 000 Profile GOOG 1 Profes GOOO 0 Profiles 80000 Profiles 0 000 OEF Profile 0 0000 A O Profiles p 000 H mE Profile 11 GOOG Ese a be A Oh DA C 0 Profile 13 A Profile 14 c Profile 15 a OS Profile 16 Kha 1 Profile 17 11 3 7 Clearing WeldScore Training Data To clear WeldScore training data for a profile select the profile and click on the Clear WeldScore data button The Y icon next to the profile number will disappear gt Clear WeldScore data Clicking this button tells Power Wave Manager that Weld
27. ck on the Out of limit actions tab and a screen will appear that looks like the following Lincoln Electric 01 25 11 30 Out of limit Actions Configuration o i Power Wave Manager jaj x 2 Connection Ts B System Status Weld Profile selection Uut oPlimit actions Profile limits Wire package E mail setup Miscellaneous ee Power Source Settings Calibration re LA Out af limit actions 0 Cable Settings and Tests A oe eae a H Voltage Reduction Device Y Action on Duration Limit No Action tolerance sec E Bu i Miscellaneous TT Network Settings Action on weldScore Limit FaukSystem rl 0 8 EIER Ethernet a a ER DeviceNet Action on Amperage Limit No Action 0 1 a e ArcLink Action on Voltage Limit No Action 0 1 a 0 Feeder Settings elo Wire Feeder Actionman Wire Feed Speed Limit No Action a a User Interface Tools A Setting any of the above e D Lookup Error actions to Fault System or te SnapShot Alarm Latch may cause te dede welding to stop unexpectedly ABS Weldview b Backup Restore Be ae Observer 5 Production Monitoring ey Install zu a Configuration a e Training gt Apply Settings a Language Idioma Langue Lingua Sprache Taal Jazyk Asp DD Engin ml Connected to 10 23 8 73 EN1 The possible actions are e No Action The Power Wave will take no action and will n
28. core is assigned to a future weld it is done by comparing it to the taught weld Therefore it is necessary to teach the Power Wave every weld that a WeldScore is desired for Some examples of when new training is required include changes in wire feed speed voltage joint type travel speed or position WeldScore is able to accommodate both welds with very tight tolerances and welds that have some acceptable process variation If the welds taught to the Power Wave 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 ex Changes in electrical stickout or work angle and the acceptable variations are used in the teaching process then WeldScore will assign passing scores to welds that fall within those variations 13 2 2 Where to Use lt WeldScore like any statistical analysis requires a controlled 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 13 2 3 What the Score Means An instantaneous WeldScore value is calculated every 0 25 seconds The average of these scores over the entire weld is
29. curity Settings and Memory and Limit F TCPAP configuration settings and Network Settings which includes TCP IP Configuration and Security Settings If a certain set of settings should not be restored to the current machine leave the Pre corresponding check box unchecked ee 4 Security settings View file contents Note Use caution when restoring TCP IP configuration Since only one machine can have a specific IP address on the network restoring an IP address to more than one machine can cause problems on the 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 The Backup Restore section can be accessed without connecting to a Power Wave so that the contents of a backup file can be viewed at any time 10 4 3 Viewing File Contents The contents of a backup file can be viewed without restoring it to the machine After a backup file is opened or dragged onto Power Wave Manager click the View File Contents button This will display a window where the backed up information can be browsed The browsing is nearly identical to working in Power Wave Manager online with the machine except that no parameters can be modified Lincoln Electric 01 25 11 20 10 5 Observer While WeldView gives a detailed view of a portion of a weld with a short duration Obse
30. der module the different modules will show up as a pull down list at the top of the Wire Feeder section Switch between the pull down selections to configure settings for each module To identify which of the multiple modules is currently selected click the Blink status light button This will cause the status light of the selected module to start blinking rapidly so that it could be visually identified 9 2 User Interface This section contains settings that pertain to Connection gt System Status the User Interface of the welding system if poner Source Sting FETTE Calibrati es i r one 1S present aD Cables aa 2 PF1OM Wire Drive User Interface ST cl Setup Security Settings Memory Settings et Parameter Value s ip Device z Ardink g P 1 WES Units English 9 2 1 Setup Security Settings ote FPP 2 Arc Display Mode ned ojo Wire Feeder GP 4 Memory Set By Trigger No rss gP P 5 Procedure Change Method External Procedure Switch a lH Backup Restore A Pull Pot Value 0 The Setup Security section allows the user to BT a QA ni 42 Lo r F 12Tra rav wis modify several User Interface parameters and DD snapshot GP 12 Travel End Option Travel ends w stop button l if a 3 JA Weldview Ot Encoder Lockout Right Encoder Locked securi se or P 502 Memory Save Lockout No y 8 P 503 Memory Button Disable All Memories Enabled oP 504 Mode Select Panel Lock All MSP Options Unlocked
31. e different Pre P 4 Recall Memory with Trigger SPP 9 Feedh models may support varying sets of features Prrd Ass circa al y P 20 Trim and releasing the gun trigger To recall a memory quickly oP P 22 Arc i To obtain help with a particular setup parameter click the A hn ne pias correspond to the memory number For example to recall What s this button at the bottom right corner of the Pp soma Memory 3 quickly pull and release the trigger 3 times To window then click on the parameter for which you would rg Fecal memory L quickly pull anit retenes Me trigaer Tie i G P 505Preq number of user memories plus 1 Memories cannot be like more information A small window will pop up that e s06 utd recalled while the system is welding A memory panel must G P 509 UI be installed in order to use this feature contains a detailed description of the specified parameter Lincoln Electric 01 25 11 16 9 2 2 Memory Settings TB Power Wave Manager fa The Memory Settings section allows the lt a a a configuration of any parameter stored within any of Powe Source Stine m A pl Calibration ire Drive ce the memory slots accessible by memory buttons ED Cable Settings ARAS Miscellaneous Memory Set irias of the User Interface 3 7 Network Settings GS Ethernet ojo Feed head 2 4 aie Memory Memory name lay memory Cad Enable user limits If the User Int
32. eNet interface If this value is altered the Power Wave must be reset cycle power in order for the change to become effective Lincoln Electric 01 25 11 10 8 2 2 3 Analog Input Channels Hysteresis These values indicate the magnitude of change that must occur on the first three polled I O analog DeviceNet channels before the Power Wave will respond to the change In the case of a command value that is sourced from an A D whose output may dither slightly this configuration prevents unintended parameter changes This attribute is not useful for command values whose source is completely digital and should be set to 0 One exception is when the Power Wave 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 Power Wave will assign default values to the associated parameters 8 2 2 4 Interface Support This item will only appear for ACDC1000SD machines This item sets how the DeviceNet interface behaves The two available options are Standard and Legacy AC DC 1000 Using the Standard option will have the DeviceNet interface operate like a standard Mig interface does and the DeviceNet master must initialize all Sequencer state items Using the Legacy AC DC 1000 option will have the DeviceNet interface operate like an AC DC1000 DeviceNet interface where certain Sequencer state items are fanned out to other states duplicating
33. erface 1s a dual feed head system EP rel Memory 1 eas er Zunge 7 AU AE memory 2 select the feed head to configure by clicking on the oir memory 3 es g estore Memory 4 cForce Tools Qwcz 0 25 to 25 appropriate Feed Head button on top E tenor gt RA UD SnapShot Start Amps 0A N A EN WeldView Weld Amps DA 0 to 1200 Select which memory to configure by clicking the appropriate memory item Memory 1 Memory 2 etc The list of parameters corresponds to the currently selected memory item To change the name of the current memory click the button next to the name box and enter the Connected to 10 23 8 18 EN About whatsthis new name for the memory This will be the name that is displayed on the Mode Select Panel of the User Interface when this memory is selected To change any of the parameters in the list double click on the desired ERRET parameter This will bring up a window where the new value for the gt parameter can be entered Certain parameters also have configurable user Q A lachine limits 123 limits These limits can also be configured from this window The e ID EEG Machine Limits displayed below the parameter value represent the absolute limits of this parameter The User Limits as well as the Value must be within this range When finished modifying the parameter click OK to accept the changes and
34. ers that support these options The Workpoint in Amps item is used to set the output level based on Amps instead of WFS The Trim in Volts item is used to set the output level based on voltage instead of an unitless control Lincoln Electric 01 25 11 7 7 Network Settings This section consists of three subsections all of which configure the various ways that a Power Wave can be networked with other equipment 7 1 Ethernet This section provides options for all Sete Soar tea Coonen O configuring the Power Wave s network sopresa acc ec settings for use on an Ethernet network He dere ts Subnet Mask 255 255 192 0 Deren green 7 1 1 Configuration Section ent setunos a At the top of the section Power Wave e Tot a ANALES Manager displays the machine s current snapshot ms TS network settings including IP Address del astvodiccore Subnet Mask 255 255 192 0 Subnet Mask and Default Gateway a pri ee s Install 3 Configuration Training e IP Address This is the address at which the Power Wave is located on the network Any network device attempting to communicate Language Idioma Langue Lingua Sprache Taal Jazyk As 35 B English y with the Power Wave must use ER A hh Ss this address ee e Subnet Mask This number assigned by the network administrator e Default Gateway This is the IP Address of a router or other device that allows communication with add
35. esting voltage sense starting at the studs then incrementally moving to the remote voltage sense locations Note that this test can not be done with Servo Torch Automatic Test The Test sense lead selection button can additionally help troubleshoot sense lead issues by attempting to detect the sense lead location by turning on the machine s output in an OCV open circuit voltage mode and automatically reading back voltage while stepping through the various manual sense lead locations determining which location is most likely the one being used Make sure your welding circuit is open before performing this test Manual Test To start testing the voltage sense leads click on the Select sense lead location manually selection This will force the machine to sense voltage from the selected location Click the Apply button when changing the sensing selection The first location to test is Output Studs This configuration utilizes arc voltage sensing from inside the machine and does not require polarity to be configured Once the output studs arc voltage sensing location has been verified you may select the next sensing location such as 67 Positive or 67 Negative depending on the welding polarity in which the system is configured to operate Once the 67 sensing location has been verified you may select to sense at 67 and 21 if you are utilizing both remote voltage sense leads When the testing is complete re
36. ettings Link speed 10BaseT SHE Duplex mode Full Er DeviceNet 2 ArcLink LED2 function Speed f Feeder Settings ojo Wire Feeder ee User Interface UDP Connections Tools JD Lookup Error 10 23 10 35 74177 ES tied SnapShot ES weldview iba Backup Restore 2 Observer Production Monitoring Install a Configuration Training Tx stats PKTs 0 Drppd 0 Rx stats PKTs 550124 BL 0 C5 0 UC 0 ER 7 BC 4635 UDP stats In 526598 Out 452982 No Port O Errs 4642 Misc stats EDs 20 MBDs 2 Language Idioma t Langue f Lingua Sprache f Taal Jazyk Aspe OO OO Engish Connected to 10 23 8 69 EN1 Lincoln Electric 01 25 11 9 8 2 DeviceNet The DeviceNet section allows the setup and gt Power Wave Manager Fr verification of a DeviceNet interface to the p Ses Power Wave tap tes eer oc Status Configuration Monitor Trace Weld Limits Weld Sequencer DeviceNet Product Code 2 This section consists of several tabs that are FT Network Settings DeviceNet Vendor Revision 1 012 discussed below vicenet Connection State AL Arclink I O Scans per second 0 Explicit Connection State NonExistent Feeder Settings oJo Wire Feeder Polled I O EPR 0 Polled I O Connection State NonExistent iff User Interface FH Backup Restore 8 2 1 Status 54 Tec cerrara non 2 Lookup Error 108 SnapShot N WeldView This tab contains basic status informati
37. hat allows you to configure and manage a multitude of settings and configuration options within the full range of Lincoln Electric s Power Wave line of welding machines It also provides in depth diagnostics of the machine s hardware and firmware to help identify and eliminate any issues with welding or configuration 2 System Requirements Minimum hardware requirements 256MB system RAM 1 0GHz processor speed 1024x768 display resolution 50 MB free disk space Connection to a Lincoln Electric Power Wave or compatible machine through an Ethernet network or serial RS 232 cable Power Wave Manager runs under the Microsoft NET Framework Therefore it may be run within any of the following versions of Microsoft Windows Windows 7 Windows Vista Windows XP Service Pack 2 Windows 2000 Service Pack 4 Windows 98 Second Edition Must be logged on as an Administrator to the PC 3 Compatible Equipment Power Wave Manager may be used with any welding machine in Lincoln Electric s Power 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 Power Wave AC DC 1000 AC DC 1000 SD Power Wave 1400 Power Wave C300 Power Wave S350 The program may also be used to diagnose and modify settings in the following machines outside the Power Wave family that also use the digita
38. igh and low limits If the above conditions are meet then checking this box will have the absolute high and low limit always be returned unchecking the box will have the returned limits be based on the workpoint As the workpoint changes the acceptable range that the trim and waves can be in will change as well unchecking this box will have the limits report back what this range is Normally this item is checked 8 2 2 11 TAST Update Frequency This parameter is used for Through the Arc Seam Tracking The lower the number the more often the feedback is updated but higher the system load on the boards If Through the Arc Seam tracking is being used then this is usually set to a value of 10 to 20 otherwise a value of 100 is usually acceptable This value is only relevant for the PW455 455M 655 355 and ACDC1000 8 2 2 12 Meter Time Constant This parameter sets the filtering of the feedback data The default value of 400 is usually used unless Through the Arc Seam Tracking is being done then this item is usually set to a value of around 75 This value is only relevant for the PW455 455M 655 355 and ACDC1000 8 2 2 13 Analog Scans between Updates This determines how often the analog input channels workpoint trim and wave control update the system in terms of Polled I O scans For example a value of 50 means that every 50th I O scan will be accepted The setting of this item depends on how often the Power Wave is scanned For systems
39. ire feed speed These limits can be manually set and do not necessarily mean the profile has been trained for WeldScore The checkmark icon indicates the profile contains WeldScore data which cannot be manually set showing the profile has been trained In the above example profiles 1 and 2 have been trained and contain WeldScore data To begin training verify the weld profile selection has been properly configured and click on the Start taining item located at the top of the window This will bring up the following message Power Wave Manager xj This will pue the machine in Training Mode While in this mode the machine Will mot record new weld history records and its current unsaved history will be cleared Do you want ko continue a mo Clicking on yes will cause the Power Wave to enter training mode and will cause any weld history to be cleared and will prevent any more history collection until the training has completed as the above message indicates Various profiles can be trained while in this mode The selected profile can be changed as needed without leaving training mode Lincoln Electric 01 25 11 24 11 3 3 Profile Training Operation Before a weld starts the status on the top of the screen will read Status Waiting for next weld to start While welding it will say Status Waiting for weld to complete and then after a weld is finished it will once again read Status Waiting for next weld to s
40. l common controls platform e Invertec V350 V450 e Power MIG 300 e Power MIG 350 The program is not compatible with legacy Power Wave models such as the Power Wave 450 Lincoln Electric 01 25 11 2 4 Establishing a Connection When Power Wave Manager is started it displays Wn a list of categorized configuration sections on the S22 POWER WAVE a Power Emmie Rettig z left ER reece eee Conadi PE the seul pa Bl scenes Canea acu era These sections are Connection System Status Veen 9 Linaw the adaress of the weisen Power Source Settings Network Settings Feeder f eam teken KEN Settings and Tools By default Power Wave Nr Kr Manager starts up in the Connection section since PES a connection is required for accessing most of the Bm other sections except Lookup Error and nung k Install WeldView a Configuration Teainirug For assistance with connecting to your welding machine please refer to the Help Me Connect Guide included with the Power Wave Utilities installation The guide is also downloadable from http powerwavesoftware com EPT 5 System Status When the program first establishes a connection to the machine it switches to the System Status section In this tab the program displays any problems that might be present in the machine no matter how benign the issue might be Bo Connection B System Status 4 Lal Power Source Settings a BY Machine model
41. lding system Under the Settings tab you can change the feeder and gear type selection as well as stall factor and gun offset for push pull operation The feeder and gear selection appears only for feeders that support custom selections Clicking on the Change selection button will bring up a window like below Select Feeder and Gear l x Please select from the Following choices of Feeder and Gear settings Feeder selection Kern CE FH y Gear selection std Spd y OK Cancel Power Wave Manager i Ra Connection System Status E Power Source Settings E Calibration Cable Settings 2 Miscellaneous Ef Network Settings ER Ethernet Er DeviceNet Arclink Feeder Settings iff User Interface LA Backup Restore E P Tools 19 Lookup Error 18 SnapShot WN WeldView Loa setos Diagnose Push pull options Stall factor 75 Gun offset 0 Feeder gear selection Feeder MAXsa 22 29 Gear 142 1 Change selection 3 Connected to 10 23 8 36 EN1 About Whats this Select the Feeder and Gear from the listed items and then click on the OK button to change the setting Note The feeder gear selection settings will not be shown if your feeder requires its selection to be set up using DIP switches The Diagnostics tab can be used to troubleshoot and verify the operational state of your feeder The tab is separated in
42. le clicking the button in order for it to turn the machine on or off Use caution when controlling the output from Power Wave Manager 11 Production Monitoring Production Monitoring is a technology available in some Lincoln Electric Power Wave power sources This is a collection of features that allow the collecting of welding logs and gathering of statistics saving of weld profiles sending emails and tracking consumable usage and providing low Connection E e Power Source Settings Y voltage Reduction Device VF _ Miscellaneous I Feeder Settings ojo Wire Feeder ee User Interface Visible charts MV Amperage IV voltage Wire Feed speed J WeldScore I Global scale Factor GSF I Show Output ON OFF button 8 System Status Installation internet connection Diagnostics Parameter state Fanout O ide O setup O Preflow Strike Start Upslope Weldi Weld2 Downslope Crater Burnback O Postflow Restrike O Faulted i Power Wave Manager a WA Calibration Please click the button below to save a Production Monitoring Install Key for this machine After the key is saved 25 Cable Settings and Tests you may use it to add this machine to your Production Monitoring asset tree Network Settings EF Ethernet a gt A E DeviceNet Save Production Monitoring Install Key ArcLimk p a cka g e warnin gs S E or more El a Sac How would you like to use Production M
43. machine s output turns off after the weld is completed To save the log to a tab delimited text file click the Save weld log button in the toolbar the top of the screen To clear the log click the Clear weld log button l Save chart data Clear charts Save weld log Clear weld log Charts Logged welds settings This is a list of welds that have been performed by this machine during this Observer session Dt Duration 5 wel mode jor 0 EEE A A 1 co O O 403 22 AC 20 63 AE Ji 10 28 2010 9 21 AM 2 56 0 100 0 363 36 18 25 2 10 28 2010 9 21 AM 2 55 0 100 0 390 52 20 43 Lincoln Electric 01 25 11 21 10 5 3 Settings The Settings tab allows you to change which signals are visible in the graphs whether an output on off button is displayed and the parameter state fanout i e which weld sequencer states are modified when you change a welding setting such as workpoint or trim To choose which charts are visible select the desired charts using the checkboxes in the Visible charts box Note that if you add a new chart after welds have been logged the data displayed in the new chart for the old welds may not be valid If you want to control the machine s output from within Power Wave Manager check the Show Output ON OFF button option A button will appear in the toolbar allowing the machine output to be turned on or off For safety you must press and hold the Control key on the keyboard whi
44. on about the Power Wave s DeviceNet interface as well as any errors currently present on the interface DeviceNet gt gt Connected to 10 23 8 61 EN1 About Whats this 8 2 2 Configuration This tab contains detailed configuration 15 xi Connection options for the DeviceNet interface For system status general information on setting up the E m Power Source Settings i Calibration Status Configuration Monitor Trace Weld Limits Weld Sequencer L a Cable Settings and Tests m System Control DeviceNet interface refer to the SE vota Radiah NED OF maco jez OT Enable passive mode operation DeviceNet Interface S pecific ation E T Network Settings Baud Rate 125kB y O T Restore settings from memory on reset pitt Event Logging Fault if no polled connection detected document Y5003 included with the x rg F Connection timeouts M Report Trim Wave Outer Process Limits eq E Feeder Setti F Deallocation events Power Wave Utilities installation ete Sane Baan foo TAST update requency ee User Interface 1 Schedule switch errors 400 Meter time constant Tools J Lookup Error I Initialization errors so Analog scans between updates 8 2 2 1 M ID ERNS Interface support EA ee Cal 120 Cold inch wire feed speed n a u Gu ac tal Backup Restore
45. onitoring A ie SnapShot Production Monitoring service over the Web information refer to the Production mn m Backup Restore O Local Installation of Production Monitoring Monitoring 2 1 User Manual available 24 Observer E B Production Monitoring i Install 5 Configuration from Lincoln Electric Training Power Wave Manager is used to assist in installing Production Monitoring setting up weld profiles and limits training for WeldScore and backing m ___ Droplysettings up and restoring information Connected to 10 23 8 69 EN1 io x Language Idioma Langue Lingua Sprache Taal Jazyk Asek OO OO English P 11 1 Install This section is used to create an install key that is used to install a welder into Production Monitoring 2 1 Before this step is done make sure the welder has the correct IP If the welder is connected to the network through a robot Ethernet connection connect to the robot IP Do the follow steps to create an install key e Connect to the machine you wish to install using Power Wave Manager e Under Production Monitoring select Install e Click the Save Production Monitoring Install Key button A standard Windows Save file window will open Save the file in the desired location The file which has a tok extension can now be imported into the Admin section of Production Monitoring to add the welder to the
46. ot mark the weld as out of limits e Log Event The Power Wave will mark the weld as out of limits e Fault System The Power Wave will stop welding when an out of limit condition is detected e Alarm Latch The Power Wave will enter into a faulted state when the weld ends and remain faulted until the fault is reset by the operator a so called latched fault A latched fault can be reset either through a UI such as a PF10M through a DeviceNet polled IO connection or through an ArcLink compatible controller that supports this feature Note resetting or cycling the power to the Power Wave will also reset a latched fault The field labeled Out of limit tolerance sets how long the WeldScore can fall below the minimum limit specified under the profile limits tab before the action set here takes place This time represents the total amount of time the item can be out of limit for the duration of the whole weld This value is represented in seconds and has a 250 millisecond resolution Lincoln Electric 01 25 11 31
47. ourse of action to resolve the error X Ya Connection Enter the error code below to obtain detailed information about the error System Status Power Source Settings A E Calibration Dr Lincoln event or fatal error 36 OP A FANUC LECO event Event 36 System detected a temperature level beyond the normal system operating fimit EF DeviceNet ArcLink 3 I Feeder Settings ajo Wire Feeder E User Interface ld Backup Restore EP Tools Lookup Error 408 SnapShot YN WeldView Possible solution The machine has shutdown because it has overheated _ This will normally occur because the output duty cycle has been exceeded but it could be caused by insufficient air flow through the machine a faulty fan or a faulty thermostat 3 Connected to 10 23 8 18 EN1 About What s this This section can be accessed without connecting to a Power Wave so that error information can be acquired at any time 10 2 SnapShot A SnapShot is a small file that contains very detailed configuration and debugging information collected from each module in the Power Wave This file can be sent to Lincoln Electric Support to troubleshoot any possible issues that cannot be easily resolved by the user To obtain a SnapShot of the Power Wave click the Get SnapShot button and select a location on your computer where the file will be saved When the file is saved it can be e mailed to
48. resses that are outside the local area network 8 TCP IP Setup In the TCP IP setup tab click the Obtain an IP address automatically check box to allow the machine to automatically obtain network settings or click the Use the following IP address check box to manually enter network settings Caution Assigning an incorrect IP address to the Power Wave may cause it to become unreachable on the network If you are unsure about what IP address to assign to the machine consult your IT department or network administrator Once all network settings have been configured click the Apply Settings button to confirm the settings and reset the machine this is necessary for the new settings to take effect If you have modified the machine s IP address and would like to modify more settings you will need to connect to the machine using the new address Note If the machine will be used for ArcLink XT e g for use with a robotic controller you must select Obtain an IP address automatically 8 1 1 1 Network Security The Network Security tab allows the configuration of a range of IP addresses that are allowed to connect to the machine as well as another range of addresses that are allowed to modify parameters on the machine the latter range is a subset of the first Who may connect to the Power Wave over the network Lincoln Electric IP address 0 0 0 0 to 255 255 255 255 Who may control the Power Wave over the netwo
49. rk IP address 0 0 0 0 to 255 255 255 255 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 For example if the custom range is from 192 168 1 0 to 192 168 1 255 then 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 8 1 1 2 Multiple Ethernet Modules If the system to which Power Wave Manager is connected contains more than one Ethernet module e g a Power Wave AC DC 1000 connected to a System Interface module the different modules will show up as a pull down list at the top of the Ethernet section Switch between the pull down selections to configure settings for each module To identify which of the multiple modules is currently selected click the Blink status light button This will cause the status light of the selected module to start blinking rapidly so that it can be visually identified 8 1 2 Diagnostics Section The diagnostic tab under the Ethernet Network Setting item shows how the Ethernet communications are configured in the machine and gives some basic diagnostic information see below Power Wave Manager e 10 x y Connection W System Status El m Power Source Settings DA Calibration gO Cable Settings and Tests 9 Miscellaneous Configuration Diagnostics Physical link J CPU load E T Network S
50. ropriate language from the box in the lower right hand corner of the screen Language Idioma Langue Lingua Sprache Taal f Jazyk Asp Italiano You will be prompted to confirm your choice before continuing Power Wave Manager E xj 7 The program will now restart in the new language you chose Do you want to continue 2 Il programma verr riavviato la nuova lingua Yudi continuare 13 Additional Information 13 1 Weld Profiles One of the features of Power Wave Manager is the ability to see and set limit data for voltage current wire feed speed duration and WeldScore These parameters can vary widely from weld to weld The concept of weld profiles allows the Power Wave to store this data for up to 32 different welds The Power Wave can then compare the limits stored in a weld profile to the real time data values while performing a weld and take various actions if these limits are exceeded As an example consider a part that requires 10 different welds for proper assembly The user will begin by configuring 10 of the 32 programmable Weld Profiles with proper limit settings for each of the different welds The user can then begin welding the part selecting the proper profile for each of the 10 welds When the Power Wave is trained to use WeldScore the taught welds are stored in a weld profile The same profile must be selected when teaching a weld as when performing a weld to receive the proper WeldScore
51. rver graphs welding feedback at a slower rate over the course of several entire welds It also allows changing of basic welding parameters including the weld mode workpoint and wave control values 10 5 1 Charts The plots are produced by periodically reading EE oe fel Seer chart daa Sy E ELA Fern Hahn Da feedback values from the machine while it is Women recen welding as shown in the figure on the right ec The data 1s updated whenever the machine Direi output is on Itis possible to view amperage Fender setts voltage wire feed speed WeldScore if 5 rt available and global scale factor To save the wi data in the charts to a tab delimited text file chanel click the Save chart data button in the toolbar at the top of the screen The charts can be cleared by clicking the Clear charts button To change one of the welding values listed in the Setting box double click the value and enter the desired value in the resulting dialog The sidebar on the right side of the screen ee shows the status of various system components If there is a fault the respective gray dot will become red 10 5 2 Logged Welds The Logged Welds screen displays a list of the welds that have been made during the Observer session For each weld the date time of the weld weld duration weld mode workpoint WeldScore and average amperes and volts are listed A new weld appears in the list when the
52. s r Eff Power Source Settings Status Not training A Calibration MD Cable Settings and Tests Oe 00000 j Trained limits for Profile 1 2 Voltage Reduction Device Y i O Profile 0p amm o Miscellaneous fi os Profila 3 T A i Network Settings 00 Arale E fe Ethemet O y Profile 5 5 El DeviceNet gu Profile 6 cin J8 Profile 7 E W Feeder Settings o gt Profile amp E Ea ojo Wire Feeder O y Profile 9 ee User Interface pS Profile 10 on B Profile 11 i Tools e D Lookup Error EL Prarie gt 8 SnapShot O0 Profile 13 a ES Weldview o E Profile 14 Backup Restore 9 Profile 15 Lagi Observer Profile 16 gt E Production Monitoring el Rigt 17 a Ba E Install O E Profile 18 E Configuration EL iio F 8 Training 9 Profile 20 Profile 21 Profile 22 1 Profile 23 9 Profile 24 Alo 1 Duration high limit O Profile 25 EER Duration low lirit 9 Profile 26 E Start delay 8 Profile 27 Els End delay el B Profile 26 173 7 Amperage high limit D Profile 29 L 2 aor x il Profile 30 gt F z zn makin si A lear WeldScore data tal aa Fo pies AS Language Idioma Langue Lingua Sprache Taal Jazyk Hable DM English y Connected to 10 23 8 73 EM1 The green icons next to each profile name indicate which parameters have non zero limits where is time is amperage is voltage and W is w
53. s section can be used to verify that writes over DeviceNet are going to the correct locations Lincoln Electric 01 25 11 13 8 3 ArcLink E System Status Mapping status This section shows an overview of the iS Refresh E 29 b ES Cable Settings Er Automap successful logical layout or mapping of the welding ocre s so system s ArcLink network which is the Network Settings PowerSource Controller Serial number 1638820033540018 d o EEp Ethernet gt PF10M Wire Drive User Interface Serial number 1638820023050099 internal protocol used by the individual El DeviceNet BR EErEE COMETE SES eat PEREA modules in the system E _ _ _ D Power Wave Manager i Ra Connection A Arclirik iy Feeder Settings ojo Wire Feeder E User Interface A bd Backup Restore Some systems can be configured to map ang Tools a LP Lookup Error automatically or manually The display D snapshot shows the current mapping of the system and whether it is mapped automatically or manually YN WeldView Connected to 10 23 8 18 EN1 Sr Ef Group 2 ta PowerSource Controller Serial number 1638820033540018 ON PF 10M Boom Wire Drive Serial number 1638820030760003 Ela Ethernet Gateway Controller Serial number 1638820013030000 Property Details ALA 7 ArcLink About What s this 8 3 1 Pairing Setup oes
54. set the power to the machine to clear any changes made to the voltage sense location 6 3 Miscellaneous cones Wore oor W Connection The Machine time section displays the current I syam suan ower Source Settings Machine time t me on the machine s internal clock This t me E o tien and Tests Cusrent time on the welders clock 7 28 2010 10 55 48 AM Syrehronize is used when recording internal events errors pr A gt p p b 7 Network Sett otal Arc Time for this welder and Production Monitoring information The Be Ethernet N 7 A P DeviceNet 161 54 00 HH MM SS Production Monitoring application 1f present l eee Show day periodically sets the machine s clock to match ae Ureta Controter prisat 1 i i 1 Toots Vorkpoint in Amps the time of the Production Monitoring server taste tits ae SnapShot tim in Yon Y ou can also manually sync the clock by nor ax a Ae sn clicking the Synchronize button I nissan AN x psu a training The Arc time section also displays the total arc time of the Power Wave total amount of time that the machine has generated an arc The time will be shown in HH MM SS format hours minutes and seconds If the number of hours is greater than 23 click the Show days a de eye Eh IS check box to convert the hours into days and g display the result The Weld Controller options section can be used to set various control options for weld
55. tart When a profile has unsaved weld data the icon next to the profile number will change to a EX icon In the following example profile 7 has new weld data but the individual welds are hidden Clicking on will show the welds Profile 11 also has new weld data and the individual welds are showing Clicking on will hide the welds 00 Fries GOOD Profiles ODO DJ Profiles 00000 H O Profle 0 O 00 1 Profiles p 000 C Profiles 90000 DJ Profile 10 BODA 2 00 Ee 0 Po weld 1 None of the other visible profiles have new weld data as signified by the Y icon 11 3 4 What Welds to Train WeldScore works by comparing production welds to welds that have been trained In order for an accurate score to be assigned it is recommended to train at least 5 welds at each allowable production extreme For example if the electrical stickout is allowed to vary from to 34 then train 5 welds at each of these stickouts Only train the allowable extremes if the stickout may be able to increase to 1 0 but this causes a bad quality weld do not include this in training The purpose of training is to show the Power Wave the types of welds considered acceptable 11 3 5 Deleting a Weld from Training If there was a problem with a weld during training it can be deleted from the profile before training data is saved To delete a weld expand the profile by clicking on the icon next to the profile
56. to the following items e WES feedback Used to verify wire feed settings e Power feedback Used to verify feed ability of system e Cold inch wire Used for testing feeding of wire without welding e Miscellaneous Used to verify gas purge or flux fill for submerged arc systems and voltage polarity settings e Status Displays any faults in the currently selected feeder Lincoln Electric 5 9 Power Wave Manager Ra Connection System Status Power Source Settings E Calibration Cable Settings 2 Miscellaneous T Network Settings ED Ethernet El DeviceNet ArcLink Feeder Settings ojo Wire Feeder User Interface lH Backup Restore le pP Tools P Lookup Error OD SnapShot N WeldView 3 Connected to 10 23 8 36 EN1 01 25 11 loja Ea agar iria WFS feedback Cold inch wire 10 Set WFS Indhi ojo Inch forward 9 0 Actual WFS 1 0 status 200 Maximum WFS noi O Inch reverse a FI 10 Minimum WFS I O status 200 gt Cold inch speed ipm Power feedback 39 5 Input line voltage Miscellaneous 0 Motor amperage 0 Motor voltage VE fill Solenoid Pe Sense lead polarity Positive Water fault Shutdown 1 input Motor over current Motor over load Motor over voltage About Whats this 15 9 1 1 Multiple Wire Feeders If the system to which Power Wave Manager is connected contains more than one wire fee
57. ts that are ready to weld might still have events recorded in their log Each event has a time stamp and a textual description of the event For modules that have a real time clock such as a Robot or Ethernet object the time stamp will indicate the time of the event Otherwise the time stamp indicates the amount of time elapsed since the machine was powered up Connected to 10 23861 ENI It is generally recommended to periodically clear the event logs of any object that might have events so that it will be certain that any logged events will be recent and will apply to the most recent problem If the machine experiences an error severe enough that the machine is forced to reset the error is recorded in a Fatal Error Log entry as shown above 5 3 Module Information The Module Information tab displays information about each hardware module inside the Power Wave 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 Switch between different tabs at the top to view information about the corresponding hardware module 5 4 Additional Options e Refresh button Click this button to re scan the machine for problems and refresh the results in the status window e Clear Logs button Click this button to clear the logs in all modules in the system This includes Event Logs and Fatal Error Logs After the logs
58. with a scan rate of 200 or more then the default of 50 is usually acceptable For systems with very low scan rates such as 10 Hz a setting as low as 2 might be needed Once a DeviceNet connection has been established see IO Scans Sec item in the DeviceNet monitor screen in Observer for the current scan rate Note that this setting does not affect the digital I O bits updating rate 8 2 2 14 Cold Inch Wire Feed Speed 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 IPM 8 2 3 Monitor This tab contains detailed information about the polled I O data coming to and from the Power Wave s DeviceNet interface This is a troubleshooting tool for those customers implementing a DeviceNet connection to the Power Wave Refer to the DeviceNet Interface Specification for further information Lincoln Electric 01 25 11 12 8 2 4 Trace This tab allows you to record a trace of DeviceNet network traffic coming to and from the Power Wave s DeviceNet interface You may select from several configuration options including whether to run the trace continuously or stop when the internal buffer is full and whether to filter incoming or outgoing packets based on data contents or arbitration ID Click the Start trace button to inform the interface to begin capturing DeviceNet messages Click
59. workpoint This would represent a value of 50 to 800 inches per minute When the Unscaled Values option is selected the commands for Workpoint range from 0 to 32767 corresponding to the minimum and maximum workpoint of the selected weld mode For most applications Engineering Units is normally selected 8 2 2 9 Trim Wave Control Input 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 Selecting the Engineering Units option indicates that scaled engineering value for Trim or Wave Control 1 will be passed across the analog DeviceNet channels For example when the Trim is in volts and scaled engineering units are used then a value of 75 to 520 might be expected to be commanded on the DeviceNet analog input for the trim This would represent a value of Lincoln Electric 01 25 11 11 7 5 to 52 0 volts When the Unscaled Values option is selected the commands range for Trim and Wave Control 1 2 3 4 range from 32768 to 32767 with O representing a nominal value A great majority of applications will require Trim and Wave Control command values to be set near the nominal value 8 2 2 10 Report Trim Wave Outer Process Limits When the Trim and Wave are being reported in Engineering Units and these inputs are depended on the workpoint then this item is used to determine how to report back the trim and wave h
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