Home

Dr. Livingstone, I Presume 2400 Welding System User Manual

1. TRIGGER LED WON T STOP BLINKING Weld monitor is triggering due to external noise A D Threshold may be set to low Check setting Adjust as necessary READY LED IS RED Monitor fault Call Livingston Service 8701 QOr SNI SSPO PROBLEM POSSIBLE CAUSE OR POSSIBLE FIX SYMPTOM THE A D READING ON Weld monitor failure Shutdown and restart the weld monitor If the any or all A D THE INPUT MONITOR channels are pegged saturated there is a problem with the REMAINS AT weld monitor Call Livingston Service MAXIMUM VALUE Both the sensor in question and the sensor cable have been examined repaired and or replaced but the A D reading for the FORCE CURRENT or VOLTAGE channel remains at 32767 THE A D READING ON THE INPUT MONITOR IS FROZEN Both the sensor in question and the sensor cable have been examined repaired and or replaced but the A D reading for the FORCE CURRENT or VOLTAGE channel is frozen static Weld monitor failure Shutdown and restart the weld monitor If any or all A D channels remain frozen there is a problem with the weld monitor software Call Livingston Service ASNOOr SNI SSPO 6 01 PROBLEM THE DISPLACEMENT WINDOW CANNOT BE FOUND The displacement sensor has been mechanically disconnected and extended retracted but the readings on the Input Monitor do not make sense POSSIBLE CAUSE OR SYMPTOM Sensor failure
2. E Yes I m sure Tolerance Defaults Graph Setup Pods Server Toroid Settings Calibrate Voltage Calibrate Force Calibrate Displacement Zero Displacement f Shutdown Windows too Quit All Livingston programs but don t shutdown Windows Close this User Interface Window but don t quit Weld Monitor Change MAC ID amp Copy setup Chang MAC ID Change Baud Download Firmware PodServer Settings PodServer MAC ID PodServer Baud Rate Driver Scan Range Min Scan Range Max 0436 INS 763 Rev D Recommended Database Management This section discusses recommendations for maintaining WeldWise 2400 databases to get the best system performance calculate database size and backup the WeldWise 2400 configuration to prepare for a quick and easy recovery if the configuration needs to be restored Database file overview The WeldWise 2400 uses two database files when the system is online and collecting data Livco mdb contains the entire configuration Welddata mdb contains all of the stored weld data Understanding what and how information is stored in these database files should make it easier to determine the best database management for a particular system
3. Sensor cable failure Inspect sensor cable for physical damage A cable that is deformed severed partially severed shredded abraded and or has bare wires showing may be suspect Disconnect sensor cable from the weld monitor and replace Try to reposition cable new to avoid recurring damage Spiral wrap or guards will also help to protect cable Refer to Section 6 Possible Sensor Cable Failure Inspect electrical connections for damage poor connections and or corrosion Replace connectors and or cable 8 01 AA QOr SNI SSPO PROBLEM POSSIBLE CAUSE OR SYMPTOM POSSIBLE FIX EVERY WELD IS REJECTED The Weld Summary screen indicates that any or all Displacement parameters Initial Thickness Final Thickness Setdown Expansion are out of tolerance CONT D Sensor cable CONT D Use the Input Monitor to observe the displacement channel readings Mechanically disconnect one end of the sensor and extend retract until you are reading within the window of the displacement channel Try flexing different areas of the sensor cable looking for any area that causes the readings on the Input Monitor to jump Replace the cable if flexing any part of it causes intermittent readings Using the cable pinout documentation for your system check the continuity of all connections relating to this sensor Repair or replace cable as necessary EVERY WELD IS REJECTED The Weld Summary screen
4. The Zero Displacement feature is used to center the displacement readings within the 9 window Typically displacement is zeroed using a zeroing gauge block to represent the initial part stack up projection welds or zeroed with electrodes closed spot welding Refer to the Input Monitor screen in chapter 6 WMS Reference Guide to use the Zero Displacement feature Refer to Chapter 9 Frequently Asked Questions and Chapter 8 Calibrating the Sensors for how to calibrate the displacement sensor Example A linear potentiometer with a 4 stroke will have a usable displacement window of 0 360 9 of 4 If the potentiometer is extended to a stroke of 1 and the displacement is zeroed at this point then the 9 window would be 4 5 0 180 of the stroke relative to 1 In other words the weld monitor would measure usable readings when the actual stroke is between 0 820 and 1 180 The calibrated readings reported by the monitor within this window would be 0 180 to 0 180 In the example the maximum allowed displacement change is 0 180 during the weld Note If in the example the part stack up physically changed by greater than 0 180 then the reading reported by the monitor would be in error since the displacement was saturated at some point during the weld The solution would be to use a longer stroke sensor or mechanically change the ratio of electrode movement to sensor stroke to enlarge t
5. Low High Cursor Unit 35 682 Update SEGMEHT TOLERAHCES Segment 1 22 WHC 32 Segment Summary Segment Tolerance High Limit RELATIVE Segment Tolerance Low Limit RELATIVE Figure 6 46 Segment Tolerancing 0433 INS 400 Rev E 6 29 Setup Menu Setup Menu General Setup e General Setup This option displays the General Setup Setup Utilities screen which controls setup parameters for a POD ID Tolerance Defaults e Setup Utilities Graph Setup This option displays the Utilities Menu which provides diagnostic and calibration utilities Pads Server e Tolerance Defaults Figure 6 49 Setup Menu This option displays the Tolerance Defaults screen which controls the halfcycle and segment default tolerances used when a master is created e Graph Setup This option displays the Graph Setup screen which controls the graph display units for data parameters e Pods Server Pod Server only This option displays the Pod Pod Server Setup screen which provides the status of any all PODs on the network MAC IDs baud rates and POD Server settings can be changed in this screen New firmware can also be downloaded to a Pod 6 30 0433 INS 400 Rev E General Setup The General Setup is used to change the general configuration of WeldWise 2400 The Value Current ID at the bottom of the screen is the ID Mode Internal to which the configuration settings apply
6. Click once on pod to highlight it in the Column to filter window It will appear above the Only include rows where windows If you are using a 2400 use the first pull down list to select equals In the second window type 60 If you are using a POD Server with a number of PODs type the POD ID number whose data you wish to look at into the second window Query Wizard Filter Data i2 x Filter the data to specify which rows to include in your query If you don t want to filter the data click Next Column to filter Only include rows where pod equals B binselect C And Or recordtype weld z El segment And C Gr halfeycle cyclelenath cycleon cyclemid sz or fel Seen 0454 APP 121 Rev A 12 14 16 Go back to the Column to filter window and click once recordtype to highlight it Once you have clicked another field the pod field will appear in bold It will appear in the first of the Only include rows where windows Use the first pull down list to select equals In the second window type 2 Note Recordtype 2 is weld summary 0 is a Halfcycle summary 1 is a Segment summary See Chapter 6 in the User s Manual for further information 17 Go back to the Column to filter window and click once on weld to highlight it It will appear under the Only include rows where windows Use the first pull down list to select is
7. KT Bebe pickbox Right y axis parameter pickbox 1500 4 Table Graph button t wai number select display Figure 6 8 Halfcycle Summary graph Weld Halfcycle Count The Halfcycle Summary graph can display two parameters at a time as shown in figures 6 8 and 6 9 Halfcycle data points are shown with the points connected to form a trace The summary graph displays data traces for any two parameters The halfcycle count of the weld including the pre weld and post weld segments is shown on the Figure 6 9 Halfcycle Summary x axis horizontal graph e Left Right axis Parameter Select Master 3 13 01 3 50 40 PM M01 The left parameter select box corresponds to the left y axis vertical and the brighter trace on the touch screen The right parameter select box corresponds to the y axis on the right and the dimmer trace on the touch screen Beginning Segment Y Zoom only UMEN Weld Halfcycle Count E Zoom only Total Segments Graph description The parameter pick box on the right can also be set to Hcycle Limits figure 6 10 or Segment limits If a master has qualified the weld Hcycle Limits or Segment Limits will show the upper and lower tolerance limits on each halfcycle for the parameter in the left pickbox Figure 6 10 Current Rms shown with Halfcycle tolerances 6 6 0433 INS 400 Rev E e Zoom Button Expands the graph in the horizontal direction Wh
8. POSSIBLE FIX Try re zeroing the displacement sensor See the appropriate sensor troubleshooting section Repair or replace sensor Call Livingston Service if the problem persists 10 30 WMS Road Main Screen Main Menu LI Trend Graph I Halfcycle Summary Mastering P3 Pod or 2400 Zoom Full Graph Table Weld Summary System Log Delete System Log Entries Database Management H Import Utilities New Select master Tolerancing l P3 Pod or 2400 Edit Master Select Master Copy Replace Master Import All Import Masters Import Masters From Floppy Import Setup Import Setup From Floppy II Export Utilities H Export All Export Masters Export Masters From Floppy Export Setup Export Setup From Floppy Compact Database Update Master Delete Master Repair Database Delete All Welds Scope Data 2400 only ITI Zoom Full Update Master E etup General Setup Menu Setup Utilities H Input Monitor Shutdown No didn t really mean to come here please take me back
9. Force option Point 1 th 2 Depending on the type of welder you will need to either a Set the squeeze force with just enough pressure to hold the part in place Using an external force meter to read the force enter Sallarete BOCE Ente Point 1 from the value displayed This value is listed as optional but is highly recommended to reduce error Press ENTER to input the value Or Figure 8 7 Calibrate Force screen b With the electrodes unclamped enter 0 for Point 1 This value is listed as optional but is highly recommended to reduce error Press ENTER to input the value 3 Clamp the electrodes and apply full weld force Record the Point 2 value as shown on the external force meter Press ENTER to input the value 4 Use the ESCAPE button to exit the screen then go to the Input Monitor display to check the values Note If an external hand held force gauge is not available relative force measurement input values may be calculated as follows Air Oil Cylinder Multiply the ratio of the cylinder by the airline pressure psig Input this number as the Point 2 value For example a 22 1 cylinder with an 80 psi line pressure 22 80 1760 165 force at the tips Enter 1760 in the Point 2 value field 8 6 0435 INS 400 Rev D Air Cylinder Multiply the surface area of the bore of the cylinder by the airline pressure Input this number as the Point 2 value For example an 8 b
10. LED Indicators There are two active LED indicators on the front panel that illuminate in response to weld monitoring e Upper Trigger LED Yellow Indicates the monitor is busy or thinking Red Indicates the last weld did not match the master Reject Green Indicates the last weld matched the master Accept e Lower Ready LED Green Indicates that the monitor is ready to record welds Off Indicates that the monitor is not ready to record welds 11 20 0439 INS 400 Rev C Common Uses of RWMA Material Electrode Material Properties Material To Be Welded Electrodes for welding aluminum alloys Class 1 i Z High current and heat magnesium alloys coated materials brass and High Conductivity f h d Soft conduction bronzes Can be used for both spot and seam welding They are used for the spot and seam welding of Class 2 and pond cold and hot rolled steel stainless steel and low 2 conductivity brass and bronze They are also used Medium Conductivity electrical and thermal 1 for th Medium Hard properties as flash welding dies and as electrodes for the welding of galvanized steel and other coated materials Electrodes for the spot and seam welding of high resistance materials such as stainless steel Class 3 Fish oressure nichrome and monel metal As a casting they are Low Conductivity taice used for flash butt and projection welding Very Ha
11. 5 12 WMS Reference Guide This chapter reviews every screen in the WMS program There is an organizational chart WMS Road Map for the all screens in Chapter 11 Appendices Main Program Screen The main program screen of the WeldWise 2400 is shown in figure 6 1 below It displays information from the most recently recorded weld Weld Master ID gt GE GE Weld Number Display Parameter Display 1 gt 4 Weld Status High Limit indicator weld Status Low Limit indicator Parameter Display 2 gt Voltage Rms 0 000 5 000 60 POD ID select Parameter Display 3 gt 0 000 1 500 Job Status High Limit indicator 4 Job Status Low Limit indicator Parameter Display 4 gt gt 100 Clear Job Status button Figure 6 1 Main program screen e Pod ID Select This field displays selects the ID that is currently in use Weld data on the main screen corresponds to the displayed ID Unless noted otherwise when navigating to other screens all data settings commands and updates are specific to this Pod ID e Weld Master ID If the Pod ID has been set up to compare welds to a master contains master tolerance limits the Master ID is displayed If masters are not enabled or there is no master for this weld the display will read No Master If the weld data for this weld was used to generate a master then the display will read Master Weld In the figure above
12. A measure in degrees of how long the weld timer SCR s were turned on allowing current flow during a halfcycle The average conduction angle for a segment or weld Resistance dynamic The calculated dynamic resistance of the workpiece during the halfcycle equal to Voltage RMS divided by Current RMS The average resistance for a segment or weld 0433 INS 400 Rev E 6 9 Energy The calculated energy during the halfcycle equal to Current RMS multiplied by Voltage RMS The average energy for a segment or weld Power Factor Power Factor is not yet implemented and will display zero Cyc Len Cyc Len shows the number of samples per halfcycle in the A D conversion For Rtype 0 this number is typically between 102 and 107 half cycle 60Hz sampled at 12 5kHz This field is used by Livingston technicians as a diagnostic tool and should generally be ignored Date Time The date and time when the halfcycle segment or weld data was recorded MasterID Name of the master used to qualify the weld Bin Select Binary Master Select For each POD ID there are up to 15 masters which are selected using the binary select inputs The Bin Select reported in the weld data indicates the binary select setting or master number used for this weld Example A Bin Select of 3 indicates that master associated with binary select 3 was used Typically the binary select number corresponds with the weld schedule number or the sequential order of welds
13. Accept Stat CurrentFims 0 006786633 1 If the SELECT button is pressed while an individual data record is highlighted the pop up window will display the Halfcycle and Segment High and Low Tolerance limits for that parameter as shown in figure 6 14 If a master was NOT used to qualify this weld then no limits will be displayed The tolerance limits displayed are taking from the master In figure 6 14 the Master weld ki z data for this halfcycle for CurrentRms is DOC and the ue are set to 10 Graph relative tolerancing in the master The high Figure 6 14 Pop up window displaying tolerance tolerance limit is 0 006786 10 10 006786 limits for selected parameter The Low tolerance limit 15 0 006786 10 9 993214 E III Use ESCAPE or Arrow Keys to close the pop up window Refer to the topic Identifying and Interpreting Accept Status Codes Chapter 11 in the Appendices of this manual for more information about the Accept Status codes CurrentRms The RMS Root Mean Square current in a halfcycle or average RMS current for a segment or weld CurrentPeak The peak positive or negative current in a halfcycle or the peak current in a segment or weld 0433 INS 400 Rev E VoltageRms The RMS voltage in a halfcycle or average RMS voltage for a segment or weld VoltagePeak The peak positive or negative voltage in a halfcycle or the peak voltage in a segment or weld Force The av
14. Masters are not enabled Go to the General Setup menu and set Masters Enabled to Yes Weld schedule has changed Change weld schedule back to what it was when the Master was created create a new Master or adjust Master Tolerance Limits for the new schedule Tolerances are set improperly Adjust the tolerances Calibration has been changed Check calibration and recalibrate sensor if necessary Refer to Chapter 8 Calibrating the Sensors Note If an Export Setup was performed the last time this sensor was properly calibrated an Import Setup may be performed to reload the saved calibration settings Refer to Chapter 6 WMS Reference Guide Incorrect Bin Select Depending on system configuration the Bin Select may be Internally or Externally selected Refer to Trouble With Bin Select or Accept Reject Section 7 of this Chapter No welds are being detected Refer to Trouble With Weld Count Sensor failure Inspect sensor for physical damage Inspect electrical connections for poor connections or corrosion Replace sensor if any damage is found Replace the sensor and Re calibrate Refer to Chapter 8 Calibrating the Sensors for more information about this screen 9 01 AA 0077 SNE S STO PROBLEM POSSIBLE CAUSE OR POSSIBLE FIX SYMPTOM EVERY WELD IS Sensor cable failure Inspect sensor cable for physical damage A cable that is REJECTED The weld summary scr
15. No The weld monitor calculates average values for the Segment and Weld Summaries using data only from halfcycles in which there was measurable current within the weld segment Yes The weld monitor calculates average values using data from all of the halfcycles in the weld segment including null cycles Note The Avg Null Cycles setting only affects values calculated from Current and Voltage Force and Displacement related calculations are not affected by this setting Weld Type Default Setting AC This parameter should be set to the type of weld being monitored AC The weld monitor is set to monitor single phase AC welds All other settings are for use with a POD weld monitor and should not by used for WeldWise 2400 monitor operation Weld History Depth Default Setting 100 The Weld History Depth determines the number of welds displayed in the Weld Summary screen NOTE Depending on the WeldWise 2400 software revision other General Setup parameters my appear on the screen For ease of use and familiarity the user interface portion of the software and the databases used by the software are shared between some Livingston products For this reason parameters used with other products may appear but will not be functional Please contact Livingston Customer Service or visit the website www livco com to see if a more current manual is available 0433 INS 400 Rev E 6 37 Setup Utilities Input Monitor e Input Mo
16. For specifics on using each database operation refer to Database Management in Chapter 6 WMS Reference Guide The following diagram is intended to provide a basic understanding of what information is within each database file and what information is exchanged during the different database operations masters mdb contains a backup of masters with tolerance limits Located on the WeldWise 2400 hard drive setup mdb contains a backup of general setup sensor calibration graph setup and tolerance defaults Located on WeldWise 2400 hard drive EXPORT MASTERS EXPORT SETUP IMPORT SETUP IMPORT MASTERS livco mdb file in use by the weld fmasters cmp is EXPORT MASTERS monitor contains configurations EXPORT SETUP TO fsetup cmp is a compressed TO FLOPPY including masters with tolerance FLOPPY compressed version of limits sensor calibration last weld version of masters mdb IMPORT MASTERS information system log general 4_ IMPORT SETUP setup mdb Located on floppy FROM FLOPPY setup tolerance defaults and FROM FLOPPY Located on floppy disk Drive A graph limits Located on WeldWise disk Drive A 2400 hard drive P IMPORT ALL EXPORT ALL weldcopy mdb is a backup copy of welddata mdb Located on WedlWise 2400 hard drive livcopy mdb is a backup copy of livco mdb Located on WeldWise 2400 hard drive IMP
17. Inspect electrical connections for damage poor connections and or corrosion Replace connectors and or cable Use the Input Monitor screen to observe the force channel readings Try flexing different areas of the sensor cable looking for any area that causes the readings on the Input Monitor to jump Replace the cable if flexing any part of it causes intermittent readings Disconnect the sensor cable from the weld monitor amp sensor and then using Livingston sensor cable documentation check continuity of all connections within the cable Repair or replace cable as necessary EVERY WELD IS REJECTED The Weld Summary screen indicates that Current Voltage Energy Resistance or Conduction Angle Parameters are out of tolerance Calibration has changed Inspect and re enter toroid calibration factor if necessary Refer to Chapter 8 Calibrating the Sensors Tolerances are set improperly Adjust the tolerances Voltage lead failure or poor connections Inspect the voltage leads for severed or abraded wires or poor connections and repair as necessary Weld process has changed due to shunt tooling change or tooling failure Check welded parts for missing parts nuts etc Check nut feeder Inspect the shunts and tooling 01 01 QOr SNI SSPO PROBLEM POSSIBLE CAUSE OR POSSIBLE FIX SYMPTOM EVERY WELD IS Sensor cable failure Inspect sensor cable for physical dama
18. The most recent weld summary data for the selected parameter is displayed The units displayed may be changed in the Tolerance Defaults screen In figure 6 3 the weld summary data for Current Rms is displayed in KA e Graph Low High Limit Each parameter has its own graph limit settings These can be specified in the Graph Setup option of the Setup Menu In figure 6 3 the Graph Low limit is 2 and the Graph High limit is 12 e Parameter High Low Limit Indicators These are displayed if the current weld s parameters are not within the master tolerance limits The top arrow will flash if a value exceeded its high limit the bottom arrow will flash if a value is below its low limit If the value for that parameter is within tolerances no indicator is displayed Note If a parameter was out of tolerance but is not shown in one of the parameter displays the Weld Status high low indicators will flash In this situation you can scroll through the parameters or use the Weld Summary to determine why a weld has failed e Bar Graph and Trend Graph Display button This field shows the parameter value as a bar graph between the high and low graph limits Note If the data value falls outside the graph limits the bar will not be visible Graph limits may be changed using the Graph Setup option of the Setup menu The bar graph also serves as a button to display a trend graph for the selected parameter Touch on 4 055 IN touch screen or navigate to
19. e Pressure Sensors These sensors are typically small transducers that connect to the supply line of a hydraulic or pneumatic cylinder They work by sensing the pressure driving the piston attached to the rod that applies force to the work piece Typically these sensors show less detail and are less sensitive than a mechanically connected load cell but still provide valuable data about the consistency of weld force Hydraulic Excellent results can be achieved by installing a hydraulic sensor into the hydraulic cavity of an air over oil type cylinder not into the intensifier line The intensification of a small amount of oil gives a very high resolution that can show minute changes in force This arrangement provides force measurement nearly as good as a load cell however it is susceptible to problems caused by leaky seals cylinders or air in the hydraulics Pneumatic Typically installed in the airline feeding an air cylinder the problem with this type of sensor is that it measures line pressure rather than tip force The type of sensor that is best depends entirely on the application The best performing solution is a pancake load cell built into the weld tooling while the next best solution a hydraulic pressure sensor requires having an air over oil cylinder A pneumatic sensor can be used with an air cylinder but the force reading will be less accurate due to the compressibility of air Ultimately any of these sensors will work we
20. welds that are always made within the specified weld lobe will consistently be of high quality The question is how can you determine if welds are being made consistently within the lobe If a weld control is programmed to deliver a certain amount of current at a certain amount of force how can you ensure that the right amount of current and force was delivered at the tips The amount of current coming out of the transformer may be correct but is the current density at the workpiece where it should be How do you know if the weld is good The most common method of answering these questions is through destructive testing It s hard to dispute the quality of a weld after it has been pulled apart and inspected However destructive testing produces a lot of scrap metal and while it will reveal whether the weld is good or bad it cannot explain the specific details of why or how a weld turned out the way it did Resistance weld monitoring provides a way to see what is happening while each weld is being made Critical parameters such as resistance and current density can be observed and measured at the workpiece during the weld process The next chapter will discuss how this process works The following is an abbreviated guide of commonly encountered welding problems and their possible causes adapted from documents published by the Resistance Welder Manufacturers Association and reprinted with permission 1 8 0428 INS 400 Rev E X
21. 0 Monitor Version doit exe 8 008 8 8 0 0 Revision C 001 Notable changes to the Pod User s Manual starting with the following software versions User Interface livcoset exe 8 011 8 11 0 0 Monitor Version doit exe 8 008 8 8 0 0 Warranty amp Repair Policy Added Contact Information Updated all address phone information to reflect Livingston s new Vermont location 0446 INS 400 Rev C 001 14 1
22. A cable that is deformed severed partially severed shredded abraded and or has bare wires showing may be suspect Disconnect sensor cable from the weld monitor and replace with a spare sensor cable Try to reposition the new cable to avoid recurring damage Spiral wrap or guards will also help to protect cable Refer to Section 6 Possible Sensor Cable Failure 81 01 ASNOOP SNI SSVO PROBLEM POSSIBLE CAUSE OR POSSIBLE FIX SYMPTOM CALIBRATED Sensor Cable or weld monitor failure Inspect electrical connections for damage poor connections DISPLACEMENT CONT D and or corrosion Replace connectors and or cable SIGNAL IS INDICATING A FROZEN static Use the Input Monitor screen to observe the displacement READING channel readings Mechanically disconnect one end of the CONT D sensor and slowly extend retract until you are reading within the window of the displacement channel Refer to Chapter 9 FAQ for additional information about the displacement window Try flexing different areas of the sensor cable looking for any area that causes the readings on the Input Monitor to jump Replace the cable if flexing any part of it causes intermittent readings If the displacement window cannot be found then the sensor OR the sensor cable may be failing To check the sensor cable refer to Section 6 Possible Sensor Cable Failure or refer to Trouble With Hardware If the cable and weld monitor appear to be OK
23. Current values are not displayed The values in this screen change as the 3 Displacement monitor continuously updates each channel Voltage Force If the sensor has not been properly calibrated the usi aoe incoming calibrated readings shown in the Value Current Maste column will not be correct T Figure 6 52 Input Monitor Use the Input Monitor after calibrating a sensor to check the validity of your calibration adjustment A D values of 32767 and 32768 indicate saturation or overflow on that channel If all of the A D values appear frozen you may have a problem with your monitor Refer to Chapter 10 Troubleshooting Guide for more information e External Master Select This value indicates the binary select Master Select number that the weld monitor is receiving from the External inputs at the rear of the monitor e Current Master Select This value indicates the master that is in use whether from an external or internal selection If the Binary Select Master select value does not correspond to an existing master then the Current Master Select will be 0 No Master e Zero Displacement This button is used to re establish the range in which the displacement readings are being taken Refer to Chapter 11 Displacement Channel Overview for additional information 0433 INS 400 Rev E 6 39 Toroid Settings Utility The screen is used to calibrate the current reported by the weld monitor This calibra
24. Displacement sensor Figure 7 2 Attaching the Monitor Sensor cable to a 2400 0434 INS 400 Rev C 7 1 Types of Sensors Current A Livingston supplied toroid must be used with a Livingston weld monitor No substitutions can be made Voltage Livingston uses voltage leads to read incoming voltage signals and to calibrate the weld monitor These leads are typically included with the Livingston shipment Force A variety of force sensors is available for use with Livingston weld monitors e Load Cells Possibly the best for measuring small changes in force a load cell measures directly from the electrode tooling and is therefore not susceptible to changes in force readings related to seal leakage sticky cylinders or valves etc Load cells are generally designed into the tooling of the weld head by the machine manufacturer Due to the time and cost of tooling modification this type of sensor may be less desirable when installing in a retrofit application Weld Thru Load Cell This sensor works very similar to the above load cell but installs directly into the weld loop so that weld current can flow right through the sensor This particular load cell comes with a male and female RWMA taper and is perhaps the easiest to retrofit although there are a few issues to consider Approximately 1 75 of adjustment at the electrodes is required for sufficient clearance of the sensor body and cable to incorporate it into the weld loop
25. EAO z 0 0 0 8 imit 0 0 0 9 B 0 873 Figure 5 9 Pop up window of failed parameters in the Figure 5 10 Tolerance Limits are displayed by using Halfcycle Summary the SELECT key on a parameter value once a master has been made and toleranced ESCAPE to the Data Menu and then select Weld Summary 0432 INS 400 Rev E 5 5 5 6 The screen will look similar to figure 5 11 below Unlike the Halfcycle Summary screen the Weld Summary screen displays recorded weld summary information for each weld made The most recent weld recorded will always be at the top of the list you can scroll down to see information for each weld Definitions of additional parameter headings in this screen can be found in Chapter 6 WMS Reference Guide For the Weld Summary screen use the SELECT key the same way as in the Halfcycle Summary screen to get a breakdown of failed parameters Status B E 65941 0 41 41 41 41 41 15941 41 Figure 5 11 Weld Summary 0432 INS 400 Rev E Creating a Master Now that you have observed recorded weld data we will make a master which will provide known good values to compare subsequent welds against Note An appropriate weld schedule should be established before creating a master General Setup Parameters and tolerance defaults should be set appropriately before creating a new master To start data capture for a new master 1 Use ESCAPE to exit the Weld Summary screen the
26. FAQ for further information about tolerancing CEA Figure 6 43 New tolerance limits were assigned to the segment that was added and the master was updated 0433 INS 400 Rev E 6 27 Delete Segment Line Move the cursor to a segment line other than the first segment line and use the Up Arrow button to delete the line Once the segment has been deleted the tolerance limits will be those to the left of the cursor Use the Update button to record any segment line or tolerancing changes 6 28 3 13 01 3 50 40 PM M01 Select Master Update Tolerancing Master Current Rms Low High 5 5 HALFCYCLE TOLERANCES Segment 1 Hcycle 10 WHC 20 a M Figure 6 44 The segment line has been removed and the Update button has not been pressed The different tolerance limits for the removed segment are still shown Limits REL Cursor Unit 9 03 KA 3 13 01 3 50 40 PM M01 Limits REL Select Master Cursor Unit Update 9 03 Tolerancing Master Current Rms Low High 5 5 HALFCYCLE TOLERAHCES Segment 1 Hcycle 10 WHC 20 Figure 6 45 The master has been updated The tolerance limits return to those of the segment to the left of the cursor 0433 INS 400 Rev E Segment Tolerancing allows each segment summary the average of all halfcycles in a segment to be toleranced as shown in figure 6 46 Tolerancing Master 3 28 01 2 28 48 PM M01 Current Rms Limits REL Select Master
27. For all its reliability however destructive testing doesn t tell the whole story While it can easily be determined whether a weld is good or bad uncovering the precise factors that made it that way is not as straightforward Was there an excess or deficiency of one or many factors during the weld At what point or points in the welding process did the excess or deficiency occur Resistance weld monitoring can provide immediate answers to these questions With the advent of advanced computer technology today s methods of observing and testing individual weld integrity have advanced significantly keeping in step with ever evolving safety and quality standards By monitoring the welding process compliance with international quality standards such as ISO and or QS 9000 or MVSS is simplified Weld quality can be instantly verified with electronic documentation of individual weld characteristics hard copy of weld data can even be printed for comprehensive record keeping or for inspection It s hard to dispute the integrity of a product when the most critical stages in the manufacturing process have been systematically observed recorded and analyzed It s important to realize that weld monitoring is not a substitute for destructive testing Rather monitoring and destructive testing go hand in hand While destructive testing can unconditionally guarantee whether an individual weld is good or bad monitoring can show why that particular weld was go
28. Microsoft Excel should be selected Click Finish Query Wizard Finish What would you like to do next Save Query View data or edit query in Microsoft Query le lt Back Cancel 12 16 0454 APP 121 Rev 22 The Returning Data To Microsoft Excel window will appear asking where you want to put the data Click OK Note This will paste the data into the uppermost left hand corner of the spreadsheet Returning External Data to Microsoft Excel 21x Where do you want to put the data Lok Existing worksheet Cancel T T Lema C New worksheet Properties PivotTable Report Parameters 23 You should now have a spreadsheet containing weld data for the 2400 or whichever POD ID you selected of recordtype 2 sorted by ID You should save this file with a name in case you want to return to it at a later date Use Save As to store this file wherever you want Save this workbook on your computer X Microsoft Excel Eile Edit view Insert FArmat Tools Data Window Help Ose SRK BBS MOB a 0 U GF we t 2 AL w y G Autoshapes NX IC arial 0 BZUESZSSEs GR EE 7 K20 gu Sii Book2 IA IE ER mi pn masterid pod binseleci recordtypt weld segmen halfcycle cyclelength cycleon cyclemid date act 2 5002 No Master 60 0 2 207 3 18 43 5 0 05
29. Procedure The WMS program uses databases to keep track of configuration settings and weld data Properly shutting down or exiting the software is important since improper shutdown may result in a corrupt database Many times a corrupt database can be repaired but other times data may not be recovered Proper Manual Monitor Shutdown Procedure shutdown 1 Use either the ESCAPE key or MENU key to Are you sure you want to shut me down return to the Main Menu 2 Select Shutdown 3 You will be taken to a shutdown menu with four Yes l m sure Shutdown Windows different options too 4 Select option 2 Yes Im sure Shutdown Quit all Livingston programs but Windows too Once this option is selected the don t shutdown Windows program will initiate its shutdown cycle Close this User Interface Window but don t quit Weld Monitor Figure 4 4 Shutdown screen A message box will appear with the header Shutdown in Progress It is crucial to let the monitor finish this cycle uninterrupted When it has finished another message box will appear saying It is now safe to turn off your computer When this message appears and only when this message appears the Livingston monitor can be turned off using the power switch on the back panel of the unit Uninterruptible Power Supply UPS Many manufacturing facilities have frequent power problems For permanent installations the installation of a UPS uninterruptible powe
30. Query X Microsoft Excel Booki Eg A FAM 4 eR EB Get External Data al Create New Query 3 The Choose Data Source window will appear Under the Databases tab New Data Source will be highlighted Click OK Choose Data Source lt New Data Source gt 1 123 12 10 0454 APP 121 Rev A 4 New Data Source window will appear The first item will ask for a name Type in whatever name you wish to call your query Create New Data Source JEJEDUA QEIEMIL Table GT VOUT date source optionally Save My User rara lit tie Gate source QENMUGT 1 5 second item will ask for a driver Select Microsoft Access Driver mdb from the pull down list Create New Data Source 21x first query mdb SEEGUE GESU LED ETOTVOUNQELE source a n SEVETMUSETIU Password Inte date Source QENMIHOM le Cancel 6 Click Connect 0454 APP 121 Rev A 12 11 7 The ODBC Microsoft Access Setup window will appear Under Database click Select ODBC Microsoft Access 97 Setup Ea OK l Cancel Help Create Repair Compact Advanced System Database None Database Options gt gt 8 The Select Database window will appear On the bottom right is a windo
31. Setup monitor 5 4 0432 INS 400 Rev E At the bottom of the Halfcycle Summary screen are two buttons Zoom and Table In between them is a box labeled Weld that is followed by the number of the weld being displayed Selecting the Table button will display a table of the collected weld data for the weld pemr EY us Cur m by the halfcycle as shown in figure 5 8 D 0 01 Definitions of these parameters be 0 0 1 0 0058763 found in Chapter 6 WMS Reference Guide 5 AE ee The information shown in this table is for 5 one weld the weld number displayed on the 0 0 bottom of the screen To see data for past D 0 welds select the Weld number by touching it on the screen and using the arrow keys to scroll through or enter the desired weld Em number Weld 10 Graph Figure 5 8 Halfcycle Summary table To return to graph format select Graph Highlight any cell in the Accept Status column and press the SELECT key A window will appear giving a summary of failed parameters as shown in figure 5 9 By highlighting a specific parameter value and pressing the SELECT key a window will display the high and low tolerance limits for that parameter based on the master tolerances Refer to Chapter 6 WMS Reference Guide for addi Master No Master Master 3 20 01 11 35 05 AM MO1 Segment Hey YC Segment cr itional details 0 setdown Under limit 0 0 0 7
32. To change the graph scale for these screens use the radio buttons to select Hcycle for halfcycle tolerancing or Segment for segment tolerancing in the Graph Setup screen Master ID S LUN Parameter Pickbox gt Current Rms Limits REL Select Master Low High Cursor Unit Low High Limit Boxes 5 5 9 03 HALFCYCLE TOLERANCES ST ee 1 Cursor Halfcycle Position Tolerance Limit Mode Select Master Button 4 Update Master Button Cursor Halfcycle Value Cursor Tolerance High N Segment Line Segment Line Tolerance Low Limit Figure 6 41 Tolerancing Master halfcycles Note You will not be able to use tolerancing until a master has been created and selected Once master tolerances have been edited the Update button must be used in order for the weld monitor to begin using these new tolerances 0433 INS 400 Rev E 6 25 e Master ID When a master is selected the Master ID is displayed at the top of the screen The tolerancing screen adjusts the limits for this master e Select Master Button This option displays a list of stored masters and allows one to be picked for tolerance editing e Parameter Pickbox Each parameter can be selected for tolerancing The values for the selected parameter are shown on the y axis vertical The graph scale for each parameter can be adjusted via the Graph Setup option of the Setup menu e Cursor Cursor Halfcycle Pos
33. WMS Reference Guide Tolerances are set improperly Adjust the tolerances OOP SNI S S70 1701 PROBLEM POSSIBLE CAUSE OR POSSIBLE FIX SYMPTOM EVERY WELD IS Sensor is reading outside of usable range Zero the displacement Refer to Chapter 8 Calibrating the REJECTED The Weld Summary screen indicates that any or all Displacement parameters Initial Thickness Final Thickness Setdown Expansion are out of tolerance CONT D window Sensors or Supplementary Procedure if applicable If monitoring more than specific weld with the weld monitor e g weld gun shuttles or moves to multiple locations when welding verify that the initial and final stack ups are within the displacement window for each weld being made Refer to the FAQ for more information about the displacement window Mechanical problems loose displacement brackets or loose tooling Check the tooling and brackets for looseness or mechanical slop Check for loose electrodes Repair as necessary Welds are being made with missing parts Check welded parts for missing parts nuts etc Check nut feeder Mechanical binding Check for mechanical binding Process timing has changed Weld head is extending too late or retracting too soon Check for mechanical binding Check for PLC program changes Sensor failure Refer to Section 3 Trouble With Displacement Sensor Readings or Channel
34. Weld current Squeeze time Weld time Hold time Electrode force Design of the electrode Workpiece material The Weld Cycle Material variables include Coating thickness and type Part fit up Surface condition amp cleanliness of materials A typical resistance weld is broken down into several distinct periods as shown in figure 1 1 below Electrode Force Welding Cycle Welding Current l Figure 1 1 A typical weld cycle The Squeeze Time is when the weld heads electrodes come together and build up to a specified amount of force before the current is fired The Weld Time is when the current is actually passing through the workpieces This is when the metals are being heated enough to melt and fuse together to form what is called a weld nugget 0428 INS 400 Rev E During the Hold Time electrode force is still applied even after the weld current has ceased During this period the weld nugget cools and the metals are forged under the force of the electrodes The continuing electrode force helps keep the weld intact until it solidifies cools and the weld nugget reaches its maximum strength Critical Factors in Welding Understanding the resistance weld process requires an understanding of the main factors involved and how they work together This section will review current voltage resistance and power as well as the various functions of the electrodes and how they affect su
35. a variable position The potentiometer is used as a voltage divider to indicate position of the electrodes For proper installation please refer to Chapter 7 Installing the Sensors The weld monitor provides a 10 volt excitation voltage for the sensor The signal returned from the potentiometer is 0 to 10 volts depending on the position of the potentiometer shaft For example a 4 stroke linear potentiometer will return 0 volts when the shaft is fully extended 10 volts when fully retracted and 5 volts at a position of 2 mid stroke Depending on wiring and sensor mounting opening and closing the electrodes may cause a positive or a negative voltage change The weld monitor will accommodate either polarity by setting the Displacement Polarity accordingly in the General Setup Refer to WMS Reference Guide in Chapter 6 In order to get an accurate high resolution measurement over a relatively small window of travel of the sensor the displacement channel is designed to read an input voltage of 0 45 volts which corresponds to 9 4 5 of the sensor s full stroke When viewed using the Input Monitor screen see chapter 6 WMS Reference Guide the A D reading will saturate at 32767 0 45 volts and 32768 0 45 volts Since the displacement sensor returns a signal from 0 to 10 volts the displacement channel will be saturated over all but 9 of the stroke Note This saturation is normal and will not damage the displacement channel
36. deal of information about working with Charts END 12 20 0454 APP 121 Rev A Document 0454 299 Author E Barbiero LIVINGST Date 11 27 01 amp COMPANY INC Revision B Location Livco livco Doc App Notes APPLICATION NOTE Category 2400 Pod Server Ethernet Applies to 2400 Pod Server Subject Ethernet Networking requirements 2400 Pod Server with default factory settings PC WELD MONITOR NETWORKING REQUIREMENTS AND RECOMMENDATIONS Objective The following are a list of requirements and recommendations when establishing a network connection between a PC and a 2400 or Pod Server Please note that setup configurations will vary from system to system it is strongly recommended that your Systems Administrator or IT person be involved in this process Requirements e You will need a laptop or desktop computer running Windows 95 98 NT 4 0 or 2000 e The computer must be have MS Office 97 or newer with MS Excel e The computer must have a 10 or a 10 100Mbit Ethernet card e You will need a crossover Ethernet cable to connect the monitor directly to your computer or you can connect the monitor to your existing network using a straight Ethernet cable e Livingston monitors currently run Windows NT 4 0 The default network protocols are TCP IP and NetBEUI Your computer will need to run both of these protocols or your system administrator can install different protocols on the 2400 Pod Server Ple
37. expulsion While BA monitoring provides an account of the beginning and end of the weld process the key middle portion of the process is unwisely overlooked Mass Monitoring Mass monitoring provides a more in depth examination of the weld process but does it by averaging all the measured parameters during the course of the weld Using the weld nut from the displacement example in the previous section we ll examine force during the weld process The nut and workpiece are clamped together under pressure between the electrodes and the weld current is fired generating heat and creating a weld A Mass monitor will measure parameters during the weld process and will provide an average for each after the weld is made In this particular example the monitor might indicate that the average force during the weld was 800 165 Suppose however that subsequent destructive testing of the part showed that the weld was bad Why would this be the case if the monitor indicated that the average force was appropriate The trouble with this type of monitoring system lies in the averaging of the parameters before a result is presented Recall that a typical weld cycle can be broken up into three separate sections the pre weld weld and post weld segments If the force during each of these sections was 1700 300 and 400 lbs respectively the average would be 800 Ibs The end result appears acceptable but the averaging only serves to disguise substantial irregula
38. fm Calculator im Calculator Es Edi View Help 260 C f Dec C Oct C Bin Degrees Radians Grads p Backspace c ES sel cf wef shell e pum IEEE el PoP Pa aa m E Figure 11 3 Edit View Help 100000100 C Hex Dec C Oct Bin Dword Word Byte aE eee Er Es 8 Ha LE n I T p Eus t es Figure 11 4 0459 INS 400 Rev D Table 11 5 Accept Status Code Values Fo 1 00000000 00000000 00000000 00000001 CURRENTRMS Hi 3 8 00000000 00000000 00000000 00001000 CURRENTPEAK LOW 6 64 00000000 00000000 00000000 01000000 VOLTAGEPEAK HI 8 256 00000000 00000000 00000001 00000000 FORCE HI 9 512 00000000 00000000 00000010 00000000 FORCE LOW 0459 INS 400 Rev D 11 13 Attaching Peripherals The WeldWise 2400 includes ports on the back panel for connecting an external keyboard video monitor and mouse There is also a port for connecting a UPS All peripherals should be connected to your Livingston monitor before the monitor is powered on You may connect a video monitor at any time while monitoring however a keyboard and mouse require connection prior to powering on The following is a description of how to attach these peripherals to your Livingston monitor
39. for all of the different record types When calculating the number of records recorded per weld do not forget to include the number of halfcycles in all of the segments including the PRE and POST Example A WeldWise 2400 monitors 2 welds during one process cycle Both welds have a PRE and POST of 10 and welds of length 16 halfcycles and 20 halfcycles respectively There are 5000 process cycles per day Assume 3 segments PRE WELD POST collecting all of the halfcycle segment and weld summary data Records per weld 1 36 halfcycles total from all segments 3 segments 1 weld summary 40 Records per weld 2 40 halfcycles 3 segments 1 weld summary 44 Database size per process 84 records X 280bytes 23520 bytes Total database size per day 23520 bytes X 5000 process cycles per day 117 600 000 bytes 117 600 000 bytes gt 117 6 Mbytes Note When only weld summary data records are collected this calculation gives 2 8 Mbytes per day This is a more typical value for a data collection in a production environment 0614 INS 400 Rev D 11 5 Backup of WeldWise 2400 Settings One feature with a WeldWise 2400 is that the entire configuration can be quickly restored provided the proper steps have been taken ahead of time The export database utilities provide a great way to back up all of the settings Refer to the diagram at the beginning of this document or to the Database Management section in Chapter 6 WMS Re
40. for the segment 2 Weld Summary average for the weld e Hcycle Halfcycle In a halfcycle data record Rtype 0 this field contains the halfcycle number of the data record In a segment record Rtype 1 this field contains the number of halfcycles in the segment In a weld record Rtype 2 this field contains the number of halfcycles in the weld Note Many weld timers control the length of a weld on a cycle basis If this is the case the number of halfcycles of weld current should be twice the cycle count of the weld timer 0433 INS 400 Rev E 6 7 6 8 Accept Status The Accept Status field will be zero if the weld was within all specified tolerances in the master If the Accept Status field is not zero alg ept Status then at least one parameter of the weld was outside of the master tolerance limits Use the arrow keys to scroll through the rows data records and columns data parameters To determine the parameters that were out of tolerance in a given row data record highlight the Accept Status and press the SELECT button A pop up window will display the failed parameters as shown in figure 6 13 Refer to the topic Identifying and Interpreting Accept Status Codes Chapter 11 in the Appendices of this manual for more information about the Accept Status codes Figure 6 13 Pop up window displaying all parameters that were out of tolerance Master 3 15 01 11 39 26 AMMO1 4
41. for use Masters are not enabled The Binary Select Value will default to 0 Go to the General Setup menu and set Masters Enabled to Yes External Binary Select is not working Go to the General Setup menu and set Binary Select Mode to External Refer to the General Setup Section Binary Select Mode in Chapter 6 WMS Quick Start Guide for information on External select modes Weld Monitor Malfunction Shutdown and restart the weld monitor If the problem persists contact Livingston Service THE BIN SELECT IS INCORRECT AND IS NOT 0 The weld summary screen indicates that weld data is being recorded with the wrong Binary Select Internal Binary Select is not set correctly Go to the General Setup menu and set Binary Select Mode to Internal Set Internal Binary Select to the desired value External Binary Select is not working Go to the General Setup menu and set Binary Select Mode to External Refer to the General Setup Section Binary Select Mode in Chapter 6 WMS Quick Start Guide for information on External select modes Note A binary select of 16 indicates that a Master was created when the external input were selecting a binary select of 0 Weld Monitor Malfunction Shutdown and restart the weld monitor If the problem persists contact Livingston Service 9701 QOr SNI SSPO PROBLEM THE EXTERNAL BIN SELECT IS NOT WORKING CORRECTLY T
42. go a long way in troubleshooting a Livingston system Check for obvious problems first such as loose sensors or cables and or physically damaged components Pay attention to the system settings especially calibrations and zeroing A sensor that is not properly calibrated can cause all kinds of problems including inaccurate master data and tolerances Examining weld data can also provide a good indication of something not functioning properly For example a Setdown of 0 000 for a projection nut weld does not make much sense However if the displacement sensor was not properly zeroed and the data being measured is outside of the displacement window the Setdown parameter will be zero The following chart is not intended to be a comprehensive problem solver for every possible situation rather it is designed to provide the user with a starting point from which to diagnose possible causes of system problems If you are unsure about or are having serious problems with a Livingston system contact Livingston Service for assistance Notes e It is OK ifa force sensor does not read zero when the electrodes are open The tooling itself has weight and the amount supported by cabling shunts etc is not repeatable e When troubleshooting displacement be sure to check the rigidity of the displacement bracket While observing the displacement channel on the Input Monitor with the gun closed force attempt to move one end of the displacement sensor If
43. greater than or equal to In the second window type 0 Note DO NOT use the pull down list in the second window The reason for this is that you will have to wait for the entire database to be searched For example if you have 8000 welds you will have to wait for the system to find all 8000 weld records and display them in the pull down box It is much faster and easier to simply type in a number in this window for this particular field Don t press this pull down arrow when filtering the weld field Type in a number instead Query Wizard Filter Data Filter the data to specify which rows to include in your query If you don t want to filter the data click Next Column to filter Only include rows where weld fis greater than or equal td ja C And Or C od or C And Gr pe 0454 APP 121 Rev A 12 15 18 Click Next gt 19 The Query Wizard Sort Order window will appear This allows you to sort the returned information by whichever parameter you want We ll use ID as an example Select ID from the pull down list and Descending most recent welds will appear first Query Wizard Sort Order 21x Specify how you want your data sorted If you don t want to sort the data click Next Sort by E ID C Ascending Then by z tJ lt Back Cancel 20 Click Next gt 2 The Query Wizard Finish window will appear The button next to Return Data to
44. indicates that Force Parameters are out of tolerance Calibration has changed Check calibration and recalibrate sensor if necessary Refer to Chapter 8 Calibrating the Sensors Note If an Export Setup was performed the last time this sensor was properly calibrated an Import Setup may be performed to reload the saved calibration settings Refer to Chapter 6 WMS Reference Guide Tolerances are set improperly Adjust the tolerances Welds are being made with missing parts and the weld gun is not closing completely Check welded parts for missing parts nuts etc Check nut feeder Weld gun or solenoid valve failure Check the force at the electrodes Verify that solenoid valves or servo is working correctly Force sensor failure Refer to Section 2 Trouble With Force Sensor Readings or Channel ASNOOr SNI SSPO 6 01 PROBLEM POSSIBLE CAUSE OR POSSIBLE FIX SYMPTOM EVERY WELD IS Sensor cable failure Inspect sensor cable for physical damage A cable that is REJECTED The Weld Summary screen indicates that Force Parameters are out of tolerance CONT D deformed severed partially severed shredded abraded and or has bare wires showing may be suspect Disconnect sensor cable from the weld monitor and replace Try to reposition new cable to avoid recurring damage Spiral wrap or guards will also help to protect cable Refer to Section 6 Possible Sensor Cable Failure
45. located on a cylindrical housing on the cable This value is entered directly into the monitoring program The toroid does not need to be re calibrated When a toroid is installed or replaced a new calibration factor must be entered in the Toroid Settings screen To enter the toroid calibration factor Toroid Calibration T L i IM ali pum 1 From the Utilities Menu select Toroid Settings 2 Enter the number shown on the calibration factor sticker located on the cylindrical housing on the cable Be sure to input the value as whole number without a decimal For example a calibration value of 0 319 would be input as 319 Hit Enter to confirm Percent 100 00 3 Click the Update Cal Factor to put new l 2 air Figure 8 2 Screen with Default Cal Factor calibration factor into the monitor s memory 4 Use ESCAPE to end the toroid calibration Return to screen note the change in last weld s current RMS reading in Figure 8 3 after Cal Factor update Toroid Calibration 100 00 Figure 8 3 New Toroid Cal Entered and Updated 0435 INS 400 Rev D 8 3 Percentage Adjustment The current reading from a Livingston toroid may not match the local factory weld current standard There are three reasons for this 1 The way a toroid is mounted on the welding bus can affect the accuracy of the reading 2 There is no recognized standard for high current calibration so calibrations tend to vary among manufa
46. pad and touch screen of a Livingston weld monitor without requiring an external keyboard video monitor or mouse The touch pad refers to the cluster of arrow and control keys on the right hand front panel These keys allow the user to scroll through menus screens and fields in the program making selections and performing tasks The touch screen refers to the touch sensitive display The touch screen itself is interactive by pressing an item on the display the user can select or move it and navigate through menus Depending on the equipment setup and available space it may be convenient to use a keyboard video monitor and or mouse Although there are several different methods for performing each command and executing various tasks in the WMS program there are certain functions such as renaming masters which are only possible using a keyboard However these functions are optional and have no effect on the quality of weld monitoring Use of a video monitor and mouse is optional A floppy disk drive is located on the front of a 2400 This drive is used to copy certain settings onto a floppy disk for later use or to install software upgrades 0431 INS 400 Rev D 4 1 WMS Navigation and Editing There are two modes in the WMS program navigating mode and editing mode Navigating mode simply refers to moving from one portion of the screen to another or from screen to screen Editing mode refers to selecting an item for change and or actually cha
47. parameters can be measured in different units i e inches or millimeters Change the value in the Unit field to select the measurement display units for a data parameter NOTE Units should be chosen prior to setting up a system Units can be changed after a system has been calibrated and the reported data will be recalculated to match the new unit However Masters will retain the unit of measure that was set when the master was created Once the units have been changed all masters should be deleted and new masters created e Low Set the default Low Limit value for each data parameter e High Set the default High Limit value for each data parameter 6 44 0433 INS 400 Rev E Graph Setup This option allows you to customize the graph scale settings for each parameter These settings affect the high and low display limits for the Main Screen bar graphs Trend Graph display and the graphs in the Summary and Tolerancing screens Radio buttons also allow separate settings for Halfcycle Segment and Weld displays Note These graph settings are global and used for all IDs 0433 INS 400 Rev E Graph Setup Q Hcycle Segment Figure 6 60 Graph Setup Weld 6 45 Shutdown Menu The Shutdown Menu gives you 4 different exit Are you sure you want to shut me down options Figure 6 64 shows the typical options e No I didn t really mean to come here please take me back Yes l m sure Shutdown Windows too Us
48. procedure is basically the same as the procedure for the voltage and force channels A piece of metal with known thickness less than 0 100 or less than 4 5 of the displacement sensor stroke will be required as a reference For more information on the Displacement Input Channel refer to Chapter 11 Displacement Channel Overview Figure 6 58 Displacement calibration fields 0433 INS 400 Rev E 6 43 Tolerance Defaults Setup Tolerance Defaults Hcycle Segment Weld Parameter Measure Unit Low These tolerance defaults settings are global and used for all IDs Cond4ngle ak REL When a master is first created the default REL measurement mode units and High Low limits for RAES REL both Halfcycle and Segment displays are specified by REL A REL this table These settings have no impact on any TE EL master that has already been made Use the radio jw REL buttons at the top of the screen to select the display to EET NE be toleranced owerF ac REL REL Note The input monitor screen units for Sui REL displacement are taken from the Initial Thickness units setting in the Tolerance Defaults table Figure 6 59 Tolerance Defaults Screen e Measure Tolerancing Mode This field can be set to REL or ABS measure for each parameter REL Relative Limits All tolerance limits are relative to the master ABS Absolute Limits The master values are ignored and all limits are absolute e Unit Some
49. procedure specific to your application l 2 3 4 Select Master Edit Master Copy Replace Update Delete Master Figure 6 35 Mastering screen Press the New button Using the same weld schedule and bin select make several of the same type of weld marking the weld number on each workpiece Press the Done button Destructively test all of the welds made during mastering Using the Edit Master option delete any welds from the master that failed destructive testing Update the master New welds will now be compared to the known good welds in the master Note Using different bin selects multiple masters can be made at the same time For more information about refer to Chapter 9 FAQ The Mastering options are described below Some option buttons will be disabled text shown fuzzy during the mastering process or if no masters exist for the selected POD ID e New Done This option button starts and ends the mastering process Once the New button is pressed the screen reads Initializing master memory The button text then changes to Done and the screen reads Creating new master Ready to accept welds Once you have finished adding welds to the master use the Done button to end the mastering process When the Done button is pressed the software calculates a master from the average of the welds that were included in the master The Master ID name defaults to be the current date and time When the mas
50. psi pounds Ibs or kilograms kg indicates the amount of pressure being applied to the electrodes before during and after the weld process Electrode force is typically provided by air hydraulic or spring pressure Changes in force can result in a significant increase or decrease in resistance as the weld is taking place This is particularly true of welders using 2 4 0429 INS 400 Rev C air over oil cylinders If the electrode force drops too low resistance can increase between the electrodes and the workpiece resulting in expulsion If the electrode force becomes too great the resistance is lowered resulting in poorly formed nuggets or even brittle welds particularly with coated metals Excessive force also reduces electrode life causing tips to mushroom more quickly Electrode displacement measured in inches or millimeters indicates the relative movement of the electrodes during the welding process The displacement measurement corresponds with the nugget formation at the weld site as the materials being welded become molten the metal expands pushing up against the electrodes Force is maintained as the electrodes push back applying pressure to the weld Follow up force is critical in containing nugget expansion and in eliminating weld expulsion How Monitors Work Typically a weld monitor receives input from the welder through a variety of sensors that can be configured for specific applications These sensors measure the c
51. reading of 32767 indicates that the input channel is saturated and reading its maximum value It is possible that the voltage leads were connected too close to the transformer Typical readings are between 10V to 15V at the transformer and depending on the size of the secondary loop will be approximately 3 to 0 5 volts out at the electrodes This variation is due to the voltage drop along the secondary loop If it is not possible to connect any closer to the electrodes inline resistors can be used to attenuate the incoming voltage If the A D reading remains at maximum value when not welding zero volts on the secondary refer to Section 8 Trouble With Hardware FROZEN A D READING ALL The Input Monitor indicates a constant static A D reading for voltage This value never changes the other sensor channels do not change or update either Weld monitor problem If other channel readings are not changing the data may not be updating Shutdown and restart the weld monitor If problem persists contact Livingston Service WELDS ARE RECORDED WHEN THE WELDER IS NOT WELDING The transformer secondary is not properly grounded Check the transformer for grounding issues The transformer secondary should be grounded either directly or through a grounding inductor A ImegaOhm resistor in parallel with a 0ImicroFarad 600V capacitor may also be used 0 QOr SNI SSPO 6 POSSIBLE SE
52. segment summary data records will be recorded and stored in the database If a segment summary is stored in the database then the associated weld record must be stored also If Segment Data Mode is set to All then Weld Data Mode is also automatically set to All Failed Ifa weld is rejected segment summary data is recorded only for those segments that contained failed halfcycles If Segment Data Mode is set to Failed Weld Data Mode cannot be set to None None No segment summary data records will be recorded Weld Data Mode Default Setting weld summary data records will be recorded and stored in the database Failed Weld summary data is recorded for failed welds only None No weld summary data records will be recorded but Accept Reject signals are still asserted Scope Enable Default Setting 0 Scope Mode allows raw weld data to be captured at a high sample rate and stored in the Waveform table of the Livco mdb database The Waveform data is overwritten each time weld data is captured in Scope Mode The Scope Enable should be set to 0 for production applications 0 Scope Mode is disabled 1 Scope Mode is enabled This function is for diagnostic purposes and should only be used under the direction of a Livingston representative Due to the significant amount of data processed in Scope Mode the 2400 may be busy for a considerably long period of time after a weld has been completed Increasing the Trigger Pre a
53. that should be clarified Ohm s Law states that V Voltage I Current x R Resistance What does this mean in real world terms Returning to the pipe example the more water pressure there is in a pipe more voltage the more water can flow through that pipe more current If the size of the pipe decreases more resistance then the water flow will decrease less current but the pressure drop along the pipe will increase more voltage Joule s Law states that H Heat I Current x V Voltage x T Time the current is allowed to flow Or written differently H Heat 1 Current squared x R Resistance x T Time the current is allowed to flow Note V Voltage I Current x Resistance so the two equations are the same just stated differently The second version of this law is probably more common in the field Joule s Law is an equation that gives the amount of heat energy delivered to something It would seem sensible to assume that it s the amount of heat delivered to the weld However it is important to consider all the factors in the equation Current Voltage and Time Joule s Law assumes that each of these factors remains constant in the secondary of the welding transformer A weld controller or weld timer may indeed provide a constant amount of current at the electrodes but recall Ohm s Law Voltage equals Current times Resistance or written differently Current equals Voltage divided by Resistance Factors
54. the Master ID is 3 13 01 3 50 40 PM MOI where 3 13 01 3 50 40 PM is the data time when the master was created followed by M01 which indicates which Binary Select is associated with the master Binary Select 01 for this master There are a total of 15 binary selects available for use with a WeldWise 2400 e Weld Number Display This field displays the weld number corresponding to the weld data on the Main Screen This is the number of monitored welds since the weld data was last deleted from the database 0433 INS 400 Rev E 6 1 Weld Status High Low Limit Indicators One or both of the indicators will be displayed if the most recent weld was rejected The top arrow will flash if a parameter exceeded high limits the bottom arrow will flash if a parameter exceeded low limits Both indicators will flash when both high and low limits were exceeded Both indicators will also flash if there is no master made or if masters are not enabled in the General Setup Job Status High Low Limit Indicators One or both of the indicators will be displayed if for any of the welds were rejected since the Job Status was last cleared Both indicators will also flash if no master has been created and updated or if masters are not enabled in the General Setup Menu Weld Job Status Good Indicator If all of the weld parameters are within the master tolerance limits a Check Mark is displayed in place of the high low limit indicators Clear Job S
55. the bar graph and use 2 000 12 00 SELECT A trend graph of the last 30 welds is Figure 6 4 Touch touch screen on the displayed The weld number is displayed on the X parameter bar graph to display a Trend Graph axis horizontal and the data parameter value is that parameter displayed on the y axis vertical To return to the Main Screen use the ESCAPE button Trend Graph for Current Rms Last 30 welds through Weld 56 Figure 6 5 Example of a Trend Graph for Current Rms 0433 INS 400 Rev E 6 3 Main Menu Options Main Menu Selecting the MENU button on the touch pad displays the Main Menu as shown in figure 6 6 You can return to the Main Menu from sub menus by using the MENU or ESCAPE buttons Mastering Tolerancing Note If you are using an external keyboard you may quickly access menu options by holding Setup down the ALT key and pressing the underlined letter For example to go to the Data Menu from the Main Menu hold down ALT and press D e Data Figure 6 6 Main Menu This option displays the Data Menu which allows you to review weld data access the system log and perform database backup restore options e Mastering This option displays the Mastering screen which allows you to create and edit weld masters e Tolerancing This option displays the Tolerancing Master screen which allows you to adjust the high and low tolerance limits of each parameter in a selected master e S
56. there were in the waveform The current sampling rate used by Livingston monitors in Scope Mode is about 104 samples per halfcycle When the screen is zoomed as shown in figure 6 34 the graph heading will read 500 Samples at Sample x where x is the first sample number of a 500 sample series The graph can be scrolled across in increments of 100 samples using the Left Right Arrows Note The integration algorithm for the current waveform is not the same as the algorithm used to calculate current for the main program screen For this reason baseline drift may be observed in DC waveforms 6 20 Current Toroid gM aveform for Weld 22 1144 Samples Refresh Zoom Figure 6 33 Scope Enable with waveform displayed Current Toroid Waveform for Weld 22 1144 Samples 500 samples Sample 0 7500 0 7500 Ful Figure 6 34 Scope Enable in zoom view 0433 INS 400 Rev E Mastering Screen In order to be sure that production welds are good it must be verified that the parameters of each weld match the parameters of a known good weld A master is made from a weld or welds which are proven to be good through destructive testing The master is the average of all parameters for these welds The general procedure for creating a master is as follows Note Individual applications may have different procedures for creating masters If this is the case you should create masters according to the
57. thing As a rule calibration is done only once while zeroing is done during periodic maintenance whenever tooling tips or shunts are changed and whenever work piece material thickness changes e g a new lot or batch of parts Frequency of Calibration Each set of sensors connected to the WeldWise 2400 inputs needs to be calibrated just once A re calibration is necessary only if new sensor is substituted for an existing sensor existing sensor is removed and remounted You doing a re calibration periodically every 6 months largely done for force transducers You are re calibrating to troubleshoot a sensor or sensor cable problem 0435 INS 400 Rev D 8 1 The Input Monitor Sensor calibration is managed through the Utilities Menu under the Setup Utilities option of the Setup Menu The Input Monitor display shows the real time readings on all sensor input channels Use this display after calibrating a sensor to check the validity of the calibration adjustment To view the Input Monitor 1 Select Setup from the Main Menu Ch A D Values Input 2 Choose Setup Utilities 3 Select Input Monitor For each input channel 0 3 raw incoming A D values are displayed as well as incoming calibrated values and unit measurements see note If the sensor has not been properly calibrated the incoming calibrated readings shown in the Value column will not be correct Force Displacement External M
58. to update settings to the weld monitor 5 ESCAPE to the main program screen 0432 INS 400 Rev E 5 1 Gathering Data 1 Make one weld and then look at the main screen of the monitor It should appear similar to the figure below Please refer to Main Program Screen in Section 6 WMS Reference Guide for main screen specifics Weld Master ID 3 Weld Number Weld Status last weld recorded 4 Weld Status Indicators Parameter Display 42 gt CERUL 0 000 5 000 60 4 ID Select Parameter Display 43 83102 0 000 1 500 4 Job Status Indicators Parameter Display 4 u Mel MU 100 4 Clear Indicators Button Figure 5 2 Main screen Weld Master ID Indicates which master the displayed weld data was compared to If masters are not enabled or if there aren t any updated masters it will say No Master If there is an active master the name of the master will be displayed Weld Number The weld number indicates which weld corresponds to the displayed data In figure 5 2 the weld number is 3 This means that for Weld 3 the Current Rms was 8 494 KA the Voltage Rms was 0 886 Volts the Force was 664 Ibs and the Hcycle On Cnt was 20 Halfcycles Each time a weld is recorded by the monitor the weld count will increase Parameter Displays Four parameters may be viewed on the main screen at one time In this example Current RMS Voltage RMS Force
59. tolerance limits gt Use either the Import or the Import Masters utility to recover the known good masters OR gt Ifa floppy was created with the Export Masters from Floppy then insert the floppy and use the Import Masters from Floppy option What if at some point a sudden lost of power to the WeldWise 2400 causes a hard shutdown of the unit resulting in corrupt databases gt Use the Import All option for a full recovery and consider installing a UPS What if something happened that physically damaged the WeldWise 2400 to the point that it needed to be replaced 1 Find your spare WeldWise 2400 2 Find your backup copy of livco mdb and welddata mdb that you luckily stored on another computer 3 Copy the backup files livco mdb and welddata mdb into the livcosetup folder located on the spare WeldWise 2400 4 Install the spare WeldWise 2400 and attach the sensor cable 5 Resume production 0614 INS 400 Rev D 11 7 Importing Exporting Tables This procedure describes how to import and or export default calibration tables to a floppy disk It is recommended that you make copy of the default calibration settings in your Livingston monitor before performing sensor calibration It is also recommended that you make a copy of the calibration settings after you have calibrated the sensors in use on the welder you will be monitoring You will need two blank formatted floppy dis
60. utilities For example if the livcopy mdb and setup mdb files are in synch then using the Import or the Import Masters will provide the same master related results System Performance As the livco mdb and welddata mdb databases get larger it takes longer for the weld monitor to sort through all of the data records to find the data it s looking for and in some cases it takes longer to add new data records Example when creating masters The most noticeable effect is that the weld monitor will be slower when displaying weld data in the halfcycle and weld summary data screens This change in performance is unperceivable if database maintenance is performed regularly Note Once the welddata mdb database reaches capacity just under 1 gigabyte the weld monitor will no longer be able to collect data The main screen will still display incoming welds however the halfcycle and weld summary screen data will no longer be up to date All accept and reject signals will still function normally 0614 INS 400 Rev D 11 3 Recommended maintenance Refer to Database Management section in Chapter 6 the WMS reference Guide for more information about the database operations referenced in this document It is likely that a weld monitor recording welds made by a transfer line robot will gather significantly more weld data than a system recording welds from a manually fed pedestal welder For a typical system performing database maintena
61. what the resulting halfcycle data looks like We ll use an increased halfcycle count as an example 1 2 ESCAPE to the main program screen Voltage Rms 0 000 5 000 Increase the weld cycle count by 2 on your weld controller 0 000 Make a weld using the new weld schedule and observe the monitor screen You should seea SENE Me Rej blinking arrow in the Weld Status box as shown in figure 5 16 If one of your displayed Figure 5 16 Main program screen showing parameters is Hcycle On Cnt you ll also see REJECTED weld small blinking arrow next to the bar graph Go to the Halfcycle Summary screen It should look something like figure 5 17 Notice that although the line representing Master 3 13 01 3 50 40 PM M01 Current Rms has remained within the tolerance ar boundaries it has extended past the Weld segment boundary Because of the 4 added halfcycles in the weld schedule this weld did not match the master the master was made without the extra 2 cycles and as a result was not passed REJECTED Remove the two additional cycles from your weld schedule before proceeding Figure 5 17 Halfcycle Summary of REJECTED weld 0432 INS 400 Rev E 5 9 Tolerancing In the WMS program welds are accepted or rejected based on specific tolerances assigned for individual parameters within an active master Tolerances can be defined as relative or absolute values Refer to the Tolerancing in section 6 WMS Reference Guide fo
62. 15 Waterman Road South Royalton VT 05068 The Customer must return the damaged product to the Company within 10 business days from the date of the RMA Non verified problems or defects may be subject to an 80 00 evaluation charge The Company will contact the Customer within 2 business days of receipt of the damaged product with a time estimate for repair All warranty repairs are performed at the Company s manufacturing facility This warranty does not apply to on site service or repair 0079 PRD ADM Rev D 11 23 OBTAINING NON WARRANTY SERVICE Advance authorization is required prior to all returns to the Company Before returning any product the Customer must first contact the Customer Service Department at 802 763 2934 A Company technician will ask for a description of the problem and try to solve it over the phone if possible If this is not possible the technician will require the following information for the defective product 1 part number 2 serial number 3 ship to and bill to addresses The technician will then issue a return material authorization RMA number The damaged product must be packaged in its original shipping carton or equivalent to ensure adequate protection Damage sustained in transit is not covered under warranty and is the responsibility of the Customer It is recommended that the Customer obtain insurance to cover damage that might occur during shipping Shipment to the Company shall be at the Cust
63. 30 99 8 57 3 4980 No Master 60 0 2 206 3 18 43 5 0 06 30 99 8 56 4 4958 No Master 60 0 2 205 3 18 43 5 0 06 30 99 8 56 5 4936 NoMaster 60 0 2 204 3 18 43 5 0 06 30 99 8 53 4914 No Master 60 0 2 203 3 18 43 5 0 06 30 99 8 53 4892 No Master 60 0 2 202 3 14 56 1 0 05 30 99 8 52 m Ao d bin 20D 9 4 lt gt M Nsheeti 0454 121 12 17 24 25 To keep the headers on top click once on the 2 at the beginning of row two to highlight the entire row On the top toolbar under Window select Freeze Panes You will now be able to scroll down through the weld data while preserving the top headers X Microsoft Excel File Edit View Insert Format Tools Data Window Help DSM SAY Xm c fex Oz OB om le MGSO Pm ac eee MR IA TAT gei 002 Sii Book2 EE mestorid pod binselectrecordtyp MEN 1 Book2 No Master 60 1 06 7 4980 No 06 30 99 8 56 45 E 0 2 206 3 5 0 4958 No Master 0 2 205 9 5 0 06 30 99 8 56 4936 Mo Master 60 0 2 204 3 18 43 5 0 06 30 99 8 53 89478 4914 Mo Master 60 0 2 203 3 18 43 5 0 06 30 99 8 53 89478 4892 Mo Master 60 0 2 202 3 14 56 1 0 06 30 99 8 52 89478 hin n ac e c4 ona47o i 4 M Nsheetl Sheet Z Shesk4 Sheet 4 Let s say for example that you wanted to look at Current Rms plotted ag
64. 400 Rev D Determining the file size of the stored weld data The following can be used as an aide to determine how quickly the welddata mdb database will fill up with weld data This database can hold up to gigabyte minus some overhead of weld data Each weld data record is approximately 280 bytes in size This means that 125 000 weld records would be approximately 35Mbytes in size For a review of the different data modes please refer to the General Setup section of Chapter 6 WMS Reference Guide Depending on the weld data mode settings it is possible to collect data for each half cycle segment or weld It is even possible to shut off data collection altogether The number of records collected for a single weld is dependent on the data modes The most data is collected when all three modes are set to ALL Typically only weld summary data is collected unless there is a special need to record the more detailed halfcycle data Example when trouble shooting a weld process Records per weld 1 binary select halfcycles segments weld summary for 1 weld Records per process cycle Records per weld weld 1 Records per weld weld 2 etc Database size per process cycle bytes Records per process cycle X 280 bytes each Total Database size per day Database size per process cycle X process cycles per day The following example calculates the size based on the worst case setting only to demonstrate how to account
65. 5 for Troubleshooting Sensors If the A D reading remains at maximum value the sensor may be OK Disconnect the sensor cable from the weld monitor If the A D reading changes to a value of less than 100 the sensor cable should be repaired or replaced If the AD reading remains at maximum value then refer to Section 8 Trouble With Hardware Intermittent Rejected welds due to one of the sensor channels Use the Input Monitor to observe the channel readings Exercise the sensor in question Try flexing different areas of the sensor cable looking for any area that causes the readings on the Input Monitor to jump Replace the cable if flexing any part of it causes intermittent readings ANOOr SNI SSPO Sc Ol 7 TROUBLE WITH BIN SELECTS OR ACCEPT REJECT PROBLEM POSSIBLE CAUSE OR POSSIBLE FIX SYMPTOM THE BIN SELECT IS No Master has been created for the If a Master does not already exist for this Bin Select create a ALWAYS 0 The weld summary screen indicates that weld data is being recorded with the Binary Select of 0 Main screen indicates that the weld was recorded with No Master requested Binary Select The value will default to 0 new Master for this Binary Select value Refer to Chapter 5 WMS Quick Start Guide or Supplementary Procedure if applicable No master has been updated to the weld monitor In the Mastering screen select the Master and click Update to load the master
66. 8 53 KA the high tolerance limit for hcycle 10 will be 14 03 KA and for hcycle 11 it will be 13 53 K A If a weld is made using that master and the Current Rms for hcycle 10 in Segment 1 is 10 KA the weld will be rejected and the parameter Current Rms will be flagged as out of tolerance ABS Absolute Limits The master data values are ignored and tolerances are absolute Only the master segment structure is used For example for a given master the high tolerance limit for Current Rms is set to 5 If the cursor halfcycle value for hcycle 10 is 9 03 KA and the cursor halfcycle value for hcycle 11 is 8 53 KA the high tolerance limit for both halfcycles will be 5 KA 6 26 0433 INS 400 Rev E Segment Line When a master is originally created a weld is divided into three segments More segments can be added if desired in the Tolerancing Master screen Segment lines are placed at the beginning of each segment with the exception of segment 0 The initial size of these segments can be set in the General Setup screen Segment 0 Pre weld The pre weld is the segment before current flows through the part Current and Voltage data are zero but tolerances can be placed on force and thickness before current flow begins Segment 1 Weld segment Tolerances are placed on all parameters during weld current flow The first segment line marks the beginning of current flow and cannot be deleted or moved Segment 2 Post weld The post weld is
67. 8485 38 252224 1 05336797 1 57008195 0 T Picture gt 18 2 99 8 53 89478485 38 252224 1 05336797 1 57008195 0 18 2 99 8 53 89478485 38 252224 1 05336797 1 57008195 0 T Map 14 2799 8 52 89478485 33 2679024 0 6659013 1 01 673448 l Object d MOD 2047241 4d 27 7070070 n ecccenna47 1 Co Hyperlink 27 The Chart Wizard Step 1 of 4 Chart Type window will appear Under the Standard Types tab click once on XY Scatter in the Chart tvpe window Under Chart sub type leave the default selection highlighted it should be the top most selection Click Finish Chart Wizard Step 1 of 4 Chart Type 24x Standard Types Custom Types Chart type Chart sub type Bubble lil Stock catter Compares pairs of values Press and hold to view sample 0454 APP 121 Rev A 12 19 28 You will now have a chart that appears over the spreadsheet For easier viewing right click on the white border of the chart and select Cut Go to Sheet2 of the workbook and paste the chart anywhere in the sheet 29 You can now format the chart as you like The x axis represents Current Rms in KA while the y axis represents Force in lbs To change the title of the chart double click on the title box and type in the desired title To format the legend double click on it and modify it as desired The axes can also be modified by double clicking on them The Microsoft Help feature also contains a great
68. BLE CAUSE OR SYMPTOM POSSIBLE FIX WELDS THAT SHOULD BE REJECTED ARE NOT BEING REJECTED The weld summary screen indicates that welds have an ACCEPT status of 0 for parts that should be REJECTED Tolerances are improperly adjusted Analyze the weld data and process to determine which parameters need tighter tolerances to REJECT defective welds Displacement sensor was not zeroed before a new Master was created Displacement readings are inaccurate or static Check the zero reference of displacement sensor and zero if necessary Create a new Master or set of Master Tolerance Limits and examine the weld data for inconsistencies A sensor was not calibrated correctly before a new Master was created or was recalibrated after the master was created Using the Input Monitor check the calibration of the sensors and recalibrate if necessary Create a new Master or set of Master tolerance limits and examine the weld data for inconsistencies A sensor is malfunctioning and a new Master was created Sensor readings are inaccurate or static Using the Input Monitor check the calibration of the sensors and recalibrate 1f necessary Create a new Master or set of Master tolerance limits and examine the weld data for inconsistencies AA QOr SNI SSPO l 01 PROBLEM WELD COUNT DOES NOT INCREASE POSSIBLE CAUSE OR SYMPTOM Sensor cable disconnected POSSIBLE FIX Check to se
69. BLEM POSSIBLE CAUSE OR POSSIBLE FIX SYMPTOM INACCURATE A D Sensor failure reading of 32767 indicates that the input channel is READINGS The Input Monitor indicates the displacement sensor A D readings are changing but the readings may not be correct saturated and reading its maximum value There may be a problem with the sensor sensor cable or weld monitor Disconnect the sensor from the sensor cable If the A D reading changes to a value of less than 100 the sensor may be malfunctioning Repair or replace the sensor If the A D reading remains at maximum value then the sensor may be OK and the sensor cable or weld monitor may be malfunctioning Refer to Section 6 Possible Sensor Cable Failure Sensor cable failure Disconnect the sensor from the cable if reading remains the same Disconnect cable from the weld monitor If the A D reading changes to a value within 100 from 0 the sensor cable should be repaired or replaced If the A D reading remains at maximum value refer to Section 8 Trouble With Hardware Weld monitor failure Try using a spare weld monitor Use the Input Monitor screen to observe the displacement channel readings Mechanically disconnect one end of the sensor and slowly extend retract until are reading within the window of the displacement channel See Displacement Sensor Overview See if the A D input readings compare to what the sensor readings should be If the values are sti
70. E to exit the window Return to the Input Monitor screen and check the readings both with and without the second gauge block in place The values displayed should correspond to those that were entered when calibrating the displacement sensor Note If it is not possible to position two known thicknesses calibration may be done with the tips together Zero with the electrodes closed together then use a shim or washer of a known thickness placed between the electrodes for calibration Once you have verified the values with the Input Monitor re zero with the full part stack up clamped up Zeroing the Displacement The Zero Displacement button on the Input Monitor screen centers the range of the displacement readings so that incoming values will be within the appropriate measurement range The monitoring program compensates for the incoming voltage readings to establish a mid range setting at the appropriate sensitivity Refer to Chapter 6 WMS Reference Guide for more details 0435 INS 400 Rev D 8 5 Calibrating Force An external handheld force gauge is required to determine the exact amount of force that is being applied during this calibration If an external force gauge is not available refer to the note below Should you have any problems with your force calibration due to an unusual force sensor and or equipment setup please contact Livingston technical support To calibrate the force 1 From the Utilities Menu choose the Calibrate
71. EFORE amp AFTER MONITORING MASS MONITORING DYNAMIC MONITORING EFFECTS OF DIFFERENT FACTORS HOW MONITORS WORK MORE BENEFITS TOLERANCING AND MONITORING INTRODUCTION LIVINGSTON WELDWISE MONITOR SIGNATURES amp MASTERS TOLERANCES MEASURED PARAMETERS SEGMENTS DATA COLLECTION 0427 INS 400 Rev D 1 1 1 2 1 2 1 3 1 3 1 3 1 4 1 4 1 4 1 6 1 6 1 7 1 8 1 9 1 10 iii GETTING FAMILIAR WITH THE WELDWISE 2400 THE FRONT PANEL WMS NAVIGATION AND EDITING NAVIGATION EDITING OTHER BUTTONS THE BACK PANEL PROPER SHUTDOWN PROCEDURE WMS QUICK START GUIDE GENERAL SETUP GATHERING DATA CREATING A MASTER ACCEPTING REJECTING WELDS TOLERANCING SUMMARY WMS REFERENCE GUIDE MAIN PROGRAM SCREEN MAIN MENU OPTIONS DATA MENU OPTIONS HALFCYCLE SUMMARY SCREEN WELD SUMMARY SCREEN SYSTEM LOG SCREEN DATABASE MANAGEMENT DATABASE IMPORT SCREEN DATABASE EXPORT SCREEN SCOPE DATA SCREEN MASTERING SCREEN EDIT MASTER SCREEN TOLERANCING SCREEN SETUP MENU GENERAL SETUP SETUP UTILITIES INPUT MONITOR TOROID SETTINGS UTILITY VOLTAGE CALIBRATION UTILITY FORCE CALIBRATION UTILITY DISPLACEMENT CALIBRATION UTILITY TOLERANCE DEFAULTS SETUP iv 4 1 4 2 4 2 4 2 4 3 4 4 4 5 5 1 5 2 5 7 5 8 5 10 5 11 6 6 1 6 4 6 5 6 6 6 11 6 12 6 13 6 16 6 18 6 20 6 21 6 24 6 25 6 30 6 31 6 38 6 39 6 40 6 41 6 42 6 43 6 44 0427 INS 400 Rev D SHUTDOWN MENU INSTALLING T
72. FTER THE ONSET OF WELD CURRENT NOTE ACCEPT REJECT TIMING IS INDEPENDENT OF K WELD CURRENT ACCEPT REJECT MODE gt 200ms gt 200ms WELD TIMER HOLD AND WELD COMPLETE SIGNALS ACCEPT REJECT TIMING IS DEPENDENT ON THE WELD MONITOR POST SETTING TYPICALLY THE POST IS SHORTER THAN THE WELD TIMER HOLD THE ACCEPT REJECT RELAY STATE CHANGE MAY OCCUR DURING OR AFTER THE WELD TIMER HOLD OR WELD COMPLETE SIGNAL BUSY STAT MODE POINT OF REJECT DRAWN EJB DATE 04 03 03 LI 1 CHKD DATE 04 03 03 COMPANY INC REV DESCRIPTION BY DATE TITLE SIZE DWG NO REV BINARY SELECT amp ACC REJ TIMING A 0308 DWG 400 D SHEET 1 1 11 19 0308 DWG 400 Rev D WeldWise 2400 Specifications External Controls and Connectors The WeldWise 2400 features Video connector VIDEO VGA for connecting an external monitor Parallel port connector PRINTER to support an external printer or other parallel port device 2 serial ports COMI for an external mouse and COM2 for a UPS Built in Ethernet port ETHERNET for network connectivity Connector for an external keyboard AT KEYBOARD Sensor input connector SENSOR CABLE for acquiring current voltage force and displacement data A 9 pin Interlock connector INTERLOCK for Accept Reject signaling and PLC interfacing
73. GE ict 1 Separate configuration settings for each ID are 10 maintained in the database After the settings in this menu are adjusted for a particular weld process application they should be archived using an Export Setup command For more information refer to Database Export options in Chapter 6 NOTE Pod Servers and the WeldWise 2400 use the same User Interface software and by default contain the same General Setup parameters in the livco mdb database Not all of these parameters are used by BOTH the Pod Server and 2400 systems Please refer to General Setup Parameter descriptions below in order to determine which parameters apply to your system e Current ID This refers to the ID whose general configuration settings are shown and edited in this menu Current ID is typically set to 60 e Update Configuration button This button is used to Update the settings to the weld monitor The settings will not take effect until updated Figure 6 50 General Setup Menu 0433 INS 400 Rev E 6 31 GENERAL SETUP Parameter Descriptions e Binary Select Mode Default Setting Internal Binary Select inputs are to select different masters for a single weld head For each ID there are up to 15 masters which can be on line and immediately available for use This is useful when a single weld head has several weld schedules Typically the binary select number corresponds with the weld schedule number or the sequential order of weld
74. HAN NORMAL CALIBRATED DISPLACEMENT SIGNAL IS INDICATING A FROZEN STATIC READING A D READING IS FROZEN ALL CHANNELS A D READING IS PEGGED 32767 FROZEN A D READING DISPLACEMENT ONLY INACCURATE READINGS 32767 4 TROUBLE WITH TOROID 10 21 INTERMITTENT LOW HALFCYCLE COUNT HALFCYCLES ON WELDS ARE RECORDED WHEN THE WELDER IS NOT WELDING WELDS ARE RECORDED BUT THE CURRENT IS NOT READING CORRECTLY 0455 INS 400 Rev C 10 1 5 TROUBLE WITH VOLTAGE LEADS READINGS OR CHANNEL 10 22 CALIBRATED VOLTAGE SIGNAL IS READING HIGHER OR LOWER THAN NORMAL CALIBRATED VOLTAGE SIGNAL IS INDICATING A FROZEN STATIC READING A D READING IS PEGGED 32767 A D READING IS FROZEN INACCURATE READINGS 32767 WELDS ARE RECORDED WHEN THE WELDER IS NOT WELDING 6 POSSIBLE SENSOR CABLE FAILURE 10 24 7 TROUBLE WITH BIN SELECT OR ACCEPT REJECT 10 25 THE BIN SELECT IS ALWAYS ZERO THE BIN SELECT IS INCORRECT AND IS NOT ZERO THE EXTERNAL BIN SELECT IS NOT WORKING CORRECTLY ACCEPT REJECT SIGNALS NOT WORKING PROPERLY 8 TROUBLE WITH HARDWARE 10 27 THE TRIGGER LED IS YELLOW THE READY LED IS OFF THE TRIGGER LED WON T STOP BLINKING THE READY LED IS RED THE A D READING ON THE MONITOR REMAINS AT THE MAXIMUM VALUE THE A D READING ON THE INPUT MONITOR IS FROZEN THE DISPLACEMENT WINDOW CANNOT BE FOUND 10 2 0455 INS 400 Rev C Troubleshooting Guide Before You Begin A little common sense will
75. HE SENSORS TYPES OF SENSORS CURRENT VOLTAGE FORCE DISPLACEMENT INSTALLING THE CURRENT TOROID INSTALLING THE VOLTAGE LEADS INSTALLING THE FORCE SENSOR INSTALLING THE DISPLACEMENT SENSOR TESTING SENSOR INSTALLATION CALIBRATING THE SENSORS IMPORTANT NOTES FREQUENCY OF CALIBRATION THE INPUT MONITOR INSTALLING SWAPPING TOROIDS PERCENTAGE ADJUSTMENT CALIBRATING DISPLACEMENT ZEROING THE DISPLACEMENT CALIBRATING FORCE CALIBRATING VOLTAGE FREQUENTLY ASKED QUESTIONS TROUBLESHOOTING GUIDE APPENDICES WMS ROAD MAP RECOMMENDED DATABASE MANAGEMENT IMPORTING EXPORTING TABLES DISPLACEMENT CHANNEL OVERVIEW SENSOR CALIBRATION UTILITIES OVERVIEW IDENTIFYING AND INTERPRETING STATUS CODES ATTACHING PERIPHERALS INTERLOCK INTERFACE BINARY SELECT amp ACCEPT REJECT TIMING WELDWISE 2400 SPECIFICATIONS 0427 INS 400 Rev D 6 45 6 46 7 7 8 1 8 1 8 2 8 3 8 4 8 5 8 6 8 8 10 11 11 1 11 2 11 8 11 10 11 11 11 12 11 14 11 18 11 19 11 20 COMMON USES OF RWMA MATERIAL WARRANTY amp REPAIR POLICY APPLICATION NOTES APP NOTE 118 Changing WeldWise 2400 Identification and IP address APP NOTE 121 Copy weld data and use it to create an MS Excel chart APP NOTE 307 Replacing a Pod CONTACT INFORMATION vi 11 21 11 23 12 12 1 12 7 12 21 13 0427 INS 400 Rev D Overview of Resistance Welding Introduction In simplest terms welding is a process by which two or more pieces of meta
76. IEU OF ANY AND ALL OTHER WARRANTIES EXPRESS OR IMPLIED INCLUDING ANY IMPLIED WARRANTY OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE ANY UNAUTHORIZED DISASSEMBLY OR ATTEMPT TO REPAIR VOIDS ANY WARRANTY OBTAINING SERVICE UNDER WARRANTY Advance authorization is required prior to all returns to the Company Before returning any product the Customer must first contact the Customer Service Department at 802 763 2934 A Company technician will ask for a description of the problem and try to solve it over the phone if possible If this is not possible the technician will require the following information for the defective product 1 part number 2 serial number 3 ship to and bill to addresses The technician will then issue a return material authorization RMA number The damaged product must be packaged in its original shipping carton or equivalent to ensure adequate protection Damage sustained in transit is not covered under warranty and is the responsibility of the Customer It is recommended that the Customer obtain insurance to cover damage that might occur during shipping Shipment to the Company shall be at the Customer s expense Repaired or Replacement products shipped ground to the Customer shall be at the Company s expense Expedited shipment of Repaired or Replacement products at the Customer s request shall be at the Customer s expense Products should be shipped to the Customer Service Department c o the Company 4
77. KVA going out As the math illustrates the results are the same The initial and final amperage and voltage may be different but because the ratio is the same the total amount of power is also the same Resistance As mentioned earlier resistance is defined as the opposition that a substance offers to the flow of electric current Resistance is calculated by dividing the Voltage by the Current and is measured in Ohms When written Ohms are represented by the Greek letter Omega Q Since resistance to the current is what generates the heat in the workpiece it is critically important that the area with the greatest resistance be at the interface between the two parts being joined This interface is also known as the faying surfaces Remember that the heat is where the resistance is and the resistance is where the heat will be If the area with the most resistance is for example where the lower bus bar connects to the transformer of the welder and not at the faying surfaces of the workpieces then that s where the heat will go Likewise if the greatest resistance is at the contact area between the electrode tip and the workpiece the heat generated there will cause the tip to weld directly to the workpiece Electrodes Typically made of copper alloys electrodes actually have three separate functions to conduct current to the workpieces being welded to transmit the proper pressure or force to those workpieces to produce and forge a good wel
78. LIVINGSTON THE WELD MONITORING SPECIALISTS WeldWise 2400 Lal User s Manual Disclaimer Livingston amp Company makes no warranty of any kind with regard to this material including but not limited to implied warranties of merchantability and fitness for a particular purpose Livingston amp Company shall not be liable for errors contained herein or for incidental consequential damages in connection with the furnishing performance or use of this material Copyright This document contains proprietary information that is protected by copyright All rights are reserved No part of this document may be photocopied reproduced or translated to another language without the prior written consent of Livingston amp Company The information contained in this document is subject to change without notice 2007 Livingston amp Company All rights reserved 0453 INS 400 Rev F Product Road The Livingston User s Manual includes the following sections e Overview of Resistance Welding Explains the fundamentals of resistance welding and factors that affect the quality of resistance welds e Introduction to Resistance Weld Monitoring Explains the fundamentals of resistance weld monitoring and reasons for weld monitoring Tolerancing amp Monitoring Describes Livingston s concept of resistance weld monitoring and terminology used regarding Livingston equipment e Getting Familiar With the WeldWise 2400 A brie
79. NSOR CABLE FAILURE PROBLEM POSSIBLE CAUSE OR SYMPTOM POSSIBLE FIX POSSIBLE SENSOR CABLE FAILURE Unknown everything else replaced Inspect sensor cable for physical damage A cable that is deformed severed partially severed shredded abraded and or has bare wires showing may be suspect Disconnect sensor cable from the weld monitor and replace Try to reposition new cable to avoid recurring damage Spiral wrap or guards will also help to protect cable Inspect electrical connections for damage poor connections and or corrosion Replace connectors and or cable Using the cable pinout documentation for your system check the continuity of all connections relating to the sensors Repair or replace cable as necessary The Input Monitor indicates 32767 A D reading for one of the sensor readings FORCE CURRENT VOLTAGE The input channel is saturated and reading its maximum value One of the sensors FORCE CURRENT VOLTAGE seems to give usual readings and the calibration hasn t been changed Constant failure on the DISPLACEMENT channel Use the Input Monitor to observe the incoming sensor readings If the A D readings for the FORCE CURRENT or VOLTAGE channels are 32767 there may be problem with the sensor sensor cable or weld monitor hardware Disconnect the sensor from the channel in question If the A D reading changes the sensor may be malfunctioning refer to Sections 2 3 4
80. ORT ALL EXPORT ALL welddata mdb file in use by the weld monitor contains the weld data collected for all Pods Located on WeldWise 2400 hard drive 11 2 0614 INS 400 Rev D Probably the most difficult concept for users to understand is that each Import Export operation imports exports data to from a different file or files For example the Export writes to livcopy mdb and welddata mdb but does NOT write any information to masters mdb or setup mdb The Export Masters only writes information to the masters mdb but does NOT write any master related information to livcopy mdb The Export Setup only writes information into the setup mdb file and so on Similarly for the Import utilities the Import and Import Masters both import master related information Import All also imports additional information but since the information is imported from different files it is possible that the master related information is different Note In order to keep all of the various database files in synch all Export operations should be performed any time it is necessary to perform any one of the Export operations This will ensure that that master related information is the same in both livcopy mdb and masters mdb It will also ensure that the calibration and setup information is the same in both livcopy mdb and setup mdb Keeping the files in synch will also avoid confusion when using the import
81. Once this setting has been toggled the change does not take effect until the next weld has been processed e Relay Out 1 Default Setting N O N O The unenergized state of the Relay 1 contacts is normally open N C The unenergized state of the Relay 1 contacts is normally closed Note Once this setting has been toggled the change does not take effect until the next weld has been processed 6 36 0433 INS 400 Rev E Displacement Polarity Default Setting Positive Positive Displacement data is recorded and displayed indicating positive displacement changes for positive voltage changes at the displacement sensor Negative Displacement data is recorded and displayed indicating negative displacement changes for positive voltage changes at the displacement sensor Setting the Displacement Polarity to Negative will invert the halfcycle graph displayed in the halfcycle summary screen Displacement polarity should be set so that opening the electrodes will cause an increase in displacement when viewed using the Input Monitor screen see Chapter 6 and closing the electrodes will cause a decrease in displacement This will ensure that Expansion and Set Down are calculated properly Avg Null Cycles Default Setting No The weld monitor calculates average values for parameters within the weld segment Within a given segment there may be halfcycles in which there was no measured current referred to as null cycles
82. Otherwise a new master should be created 6 22 0433 INS 400 Rev E e Update When a master is created edited or selected it must be updated in order for the weld monitor to begin qualifying welds with the new edited master A master must also be updated before using the replace function e Delete Master This button deletes the selected master e Pod ID The current Pod ID is selected displayed You can select create edit and update masters that are associated with the displayed Pod ID 0433 INS 400 Rev E 6 23 Edit Master Screen The Edit Master screen is shown below in figure 6 39 The graph line represents the data for the displayed parameter and weld number The shaded area represents the average of all the welds included in the master set If there was more than one weld used to create the master the screen will display the first weld in the set Master ID LT Parameter pickbox gt Current Rms Edit Pod ID Edit Bin Sel Edit Pod ID Edit Bin Sel buttons Mastering weld 1 of 6 Weld number AIt R select display gt Current Weld 60 Delete Add Delete button Figure 6 39 Edit Master e Parameter Pickbox The parameter select box corresponds to the y axis vertical This allows you to view data for any of the parameters while editing a master e Weld Number Select Display The weld number select allows you to select any of the welds tha
83. RANG 4 YELLOW Livco Interlock Cable 5 GREEN 610 INTERLOCK BLUE 6 7 VIOLET 8 WHITE 9 BLACK RELAY OUTPUT MODES MODE RELAY 1 RELAY 0 BUSY STAT BUSY STATUS ACC REJ ACCEPT REJECT OUTPUTS CONNECTOR FRONT VIEW NOTE 5 Relay outputs nominal 24 volts AC or DC Range 0 to 50 volts max current 1 amp NOTE 6 Outputs are optically isolated DRAWN EJB JDATE 01 11 06 LI 1 CHKD MPS DATE 01 11 06 amp COMPANY INC REV DESCRIPTION BY DATE TITLE ISIZEJDWG REV 2400 INTERLOCK INTERFACE A 0340 DWG 400 C SHEET 1 F 1 0340 DWG 400 Rev C 11 18 WELD CURRENT WELD INITIATE WELD COMPLETE WELD SCHEDULE LINES TO 2400 BIN SELECT LINES WELD MONITOR INTERNAL TIMING ACCEPT RELAY 1 REJECT RELAY 0 STATUS ACCEPT RELAY 0 STATUS REJECT RELAY 0 WELDWISE 2400 BIN SELECT amp ACCEPT REJECT TIMING SQUEEZE WELD HOLD K WELD CURRENT 80ms 80ms PRE WELD POST BIN SELECT SIGNAL BIN SELECT SIGNAL BIN SELECT SIGNAL BIN SELECT SIGNAL IT IS RECOMMENDED THAT THE BIN SELECT LINES ARE SET BEFORE THE WELD AND HOLD STATE UNTIL AFTER THE WELD HAS BEEN COMPLETED MINIMUM REQUIREMENTS BIN SELECT LINES MUST BE STABLE 80ms BEFORE THE ONSET OF WELD CURRENT AND REMAIN STABLE UNTIL 80ms A
84. Rev E Introduction to Resistance Weld Monitoring Introduction As discussed in the last chapter what you see is not always what you get Although a constant current control may indicate that there is sufficient weld current to create a quality weld unless the measurement is taken at the electrodes the actual amount of heat generated is only speculation In view of the fact that the generation of sufficient weld heat is a function of current density it could logically be argued that the primary cause of bad welds is inadequate current density Many factors affect current density poorly maintained worn or improperly sized electrodes dirty materials lack of sufficient force at the tips and lack of sufficient weld current at the tips are just a few examples This being the case how can a production person or weld engineer catch these or other potential problems before they lead to bad welds How do you make sure that what you see is what you get The answer lies in the subject of this chapter resistance weld monitoring Why Monitor When Professor Elihu Thompson developed the concept of resistance welding the idea of weld monitoring most likely didn t exist At that time the only means available of differentiating a good weld from a bad weld was through destructive testing Even today destructive testing is regularly used to provide a reliable answer good weld or bad weld depending on how the weld reacts during its destruction
85. UA E SE Ss S CA SAE KE ES 2e AS S f A X C at g a a S PM SI Ka S f S L Y E RY SES ESI ELSES ELE ESV ESI Weld Force Too High Weld Current Too High x x x x x Weld Time Too Long x x _ p i xX 1xp I x I Weld Force Too Low So _ X X Weld Current Too Low Eo EI II spp es 8 Weld Time Too Short X l Llx Electrode Face Too Small x X xix x Electrode Face Too Large S X Insufficient Electrode Cooling T GT i Electrode Allow Too Soft pne Electrodes Not Flat amp Parallel L oL X x x j ee Electrodes Misaligned Eae ee ee Poor Fit Up X x X J X Poor Heat Balance S xx o fi Weld Spacing Too Close En Sx J ST S IEEE IA Weld Too Close To Edge of Part X jxj J X Dirty Material S X X Metallurgy of Material ip q s fx Squeeze Time Too Short _ _ S _ i Poor Follow Up S S eee 00 ax px s No Speed Regulator On Cylinder X T J T Poor Pressure Regulation 5 sas tu sms o Hold Time Too Short pul STS f ee Transformer Tap Set To Off jj S No Weld Switch es InNoWeld x Pressure Switch Open E o cw cc T fx Temperature Limit Switch Open JT T J J X Electrodes Do Not Contact Work j JT J IX Ins
86. a weld signature Simply put a weld signature is the distinct characteristics of any particular weld From either one or a collection of high quality weld signatures a master signature is made Throughout this text a master signature and its related tolerances see below will be referred to simply as a master A high quality weld signature is the signature of any production weld made that was proven to be high quality through destructive testing A master is a set of values representing those conditions that make for a high quality weld A master is created in the WMS program by making a high quality production weld and using its corresponding signature The master is what defines the acceptable range for individual weld parameters through tolerances which are initially drawn from a set of default values installed when the master is made Once a master is created tolerances can be individually modified by the user and depending on the application can be loosely or strictly defined Once tolerances are defined for a master every subsequent weld made will be compared with the stored master tolerance limits 1f the weld does not fall within the master tolerance limits of that master the monitor will record a reject signal and display it as a rejected weld Using a PLC this signal can also be set to trigger a variety of rejected weld responses such as lights buzzers and reset reliant restrictions the electrodes will 0430 INS 400 Rev D 3 1 re
87. able failure Disconnect the sensor from the cable if still pegged Disconnect cable from the weld monitor If the A D reading changes to a value within 100 from 0 the sensor cable should be repaired or replaced If the A D reading remains at maximum value refer to Section 8 Trouble With Hardware FROZEN A D READING DISPLACEMENT ONLY The Input Monitor indicates a constant static A D reading for the displacement sensor This value never changes the other sensor channels appear to be working and the A D values for these channels are changing updating Sensor failure A static reading may indicate a problem with the sensor sensor cable or weld monitor Disconnect the sensor from the sensor cable If the A D reading changes to a value of less than 100 the sensor may be malfunctioning Repair or replace the sensor If the A D reading remains at the same value or does not change to a value of less than 100 the sensor may be OK and the sensor cable or weld monitor may be malfunctioning Refer to Section 6 Possible Sensor Cable Failure Sensor cable failure Disconnect the sensor from the cable if value remains the same Disconnect cable from the weld monitor If the A D reading changes to a value within 100 from 0 the sensor cable should be repaired or replaced If the A D reading remains at maximum value refer to Section 8 Trouble With Hardware 0 01 ASNOOP SNI SSVO PRO
88. age Leads Voltage leads should be as short as possible do not be afraid to cut them They should be connected as close as possible to the electrodes ideally on a permanent fixture so that the leads will not have to be re attached during electrode maintenance Typically a small hole 10 32 is recommended is drilled and tapped near the electrode tip and a ring terminal installed on the voltage lead Affixing the voltage leads is a process that requires working both from front to back as well as back to front It is a balance between keeping the cable qam connector as close to the leads as possible while B a leaving sufficient excess to accommodate head motion Keeping the leads short and twisting the wire Secure the ring terminals whenever possible will greatly reduce unwanted noise 45 close as possible to the and help ensure the integrity of the sensor readings You may also choose to protect the leads with a flame resistant spiral wrap or a miniature flexible conduit to protect wires from damage If you are installing on a Servo Gun or have reason to believe you may have 5 noise from a Servo motor you should install a Gym Voltage Lead Noise Suppression Filter Make sure that the contact surfaces on the ring terminals and the electrodes are free of dirt grease Or corrosion Figure 7 4 Mounting the Voltage leads The cable connector should be out of the way of moving parts or current carrying pieces The leads sh
89. ainst Force On your spreadsheet click once on the column letter in this example it should be N containing currentrms to highlight the entire column While holding down the Control key on your keyboard click once on the column letter in this example it should be R containing force to highlight that entire column as well I3 6 7 X 6 Be Prompt o 38 252224 1 05336797 1 57008195 38 252224 1 05336797 1 57008195 38 252224 1 05336797 1 57008195 38 252224 1 05336797 1 57008195 38 252224 1 05336797 1 57008195 33 2679024 065659013 1 01673445 4 n cccnna4 89478485 99 8 56 89478485 99 8 56 89478485 99 8 53 59470485 99 8 53 89475485 89478485 imnec4 on4zodoc 22 c7nn 4 12 18 0454 APP 121 Rev A 26 Go to the top toolbar under Insert and select Chart or you can click on the chart icon in the standard toolbar Note This screen shot has been cropped to show the selected columns Chart Icon cel Insert Format Tools Data Window Help Cells LO 0 9 45 oo ia gt Prompt ili 4 2 Worksheet Page Break i ee OE a ee esie et zx alfcycle cyclel acceptstatu xl currentpeal voltagerms voltagepeak t Name 18 2799 8 57 89478485 38252224 105336787 1 57008195 0 cs Comment 18 2 99 8 56 89478485 38 252224 1 05336797 1 57008195 0 18 2 99 8 56 8947
90. alfcycles prior to the trigger the Pre weld segment and a number of halfcycles after the current has ceased the Post weld segment depending on the importance of this data to weld analysis For example a weld schedule may have 8 cycles 16 halfcycles of Squeeze 12 cycles 24 halfcycles of Weld and 8 cycles 16 halfcycles of Hold In this particular process the force during the last six halfcycles of the Squeeze period and the first eight halfcycles of the Hold are especially important Accordingly the segment length can be set to include only those specific halfcycles All additional data before and after the indicated number of halfcycles would consequently be discarded by the monitor 3 4 0430 INS 400 Rev D Getting Familiar With The WeldWise 2400 This chapter will review the external features of the WeldWise 2400 hereafter referred to as 2400 as well as the various menus and options of the Weld Monitoring Software WMS program including the proper shutdown procedure for all Livingston equipment The Weld Wise 2400 Front Panel LIVINGSTON Master 07 03 2000 10 24 55 M01 Weld 1 Weld Status 6 341 Current Rms 10 00 1201 98 Voltage Rms 0 000 5 000 0 222 Va Initial Thickness 0 200 0 200 8 Hcycle On Cnt 0 000 100 WELDWISE 24400 RESISTANCE WELD MONITOR Figure 4 1 Front panel of the WeldWise 2400 The WMS program can be fully controlled from the front panel touch
91. alibration Factor 319 and then click the Update Configuration button Figure 8 5 8 4 0435 INS 400 Rev D Calibrating Displacement Livingston strongly recommends fabricating two different gauge blocks that fit into the welding electrodes for displacement calibration Typically these blocks are made of hardened steel The first block should be equal to the stack up thickness of the parts to be welded The second block should have a known thickness that is not more than 4 5 of the overall stroke of the sensor For example a gauge block for a sensor with a 4 inch stroke should be of a thickness generally around half and no greater than 0 180 inches These blocks can be chained to the machine for easy access To calibrate the displacement 1 From the Utilities Menu choose the Calibrate Displacement option 2 Place a gauge block equaling the stack up thickness of the parts to be welded between the weld head electrodes Close the weld head electrodes on the gauge block 3 Enter O for the Point 1 value and press ENTER This does exactly the same thing as the Zero Displacement Button Refer to the section below for more details Figure 8 6 Calibrate Displacement screen 4 Open the weld head electrodes and add a second gauge block of known thickness on top of the first block Close the weld electrodes onto the blocks and enter the known thickness of the gauge block as the Point 2 value and press ENTER 5 Select ESCAP
92. and Hcycle On Cnt are shown Your screen may look different if other parameters have been selected There are multiple parameters recorded by the monitor Current Rms Current Peak Voltage Rms Voltage Peak Force Conduction Angle Cond Angle Setdown Expansion Initial Thickness Final Thickness Resistance Energy and Halfcycle On Count Hcycle On Cnt These parameters are explained in detail in Chapter 6 WMS Reference Guide In each parameter display window is the weld summary value for that parameter To the right of each value is a bar graph To adjust the high and low settings see Graph Setup in Section 6 WMS Reference Guide You can select the bar graph to view a trend of the last 30 welds taken as shown in figures 5 3 and 5 4 below Use ESCAPE to return to the main screen 0432 INS 400 Rev E Master No Master Trend Graph for Current Rms Last 3 welds through Weld 3 0 000 1 500 Hcycle On Cnt 0 000 Figure 5 3 Select the bar graph to the right of a parameter shown here with an outline around Figure 5 4 The Trend Graph for the selected it by touching the graph on the screen parameter will display information for up to 30 welds e POD ID Select Pod ID indicates which WeldWise 2400 ID is currently selected The factory setting is 60 e Weld Status Indicators Indicates the status of the displayed weld If a check mark is displayed then the weld was accepted If a flashing up or down arrow is displayed th
93. and what factors are contributing to the problem Potential problems can also be detected before they occur parameters such as resistance or force can be trended to ultimately predict electrode wear and improve preventive maintenance schedules 0429 INS 400 Rev C 2 3 Effects of Different Factors Each of the four main parameters Current Voltage Force and Displacement affect the properties of a weld Current measured in KA is typically set and expressed as a percentage of heat on weld controls used by a number of manufacturers although some of the more modern equipment allows a current setting in KA instead of a percentage Throughout the industry the majority of welds are performed using single phase AC current but there are other sources of welding current used as well These include e Single and Three phase rectified DC Mid frequency DC 600 1 200 Hz e High frequency DC 2 000 25 000 Hz e Capacitive Discharge DC Whatever type of current is used control of current density during welding is the most important factor involved in making a quality weld Without proper current density too much heat can be generated leading to expulsion and or part deformation Conversely there may be too little heat generated causing cold welds and or incomplete weld nugget formation Some people uphold the bake it longer theory which prescribes lower weld heat for a longer time While this reduces expulsion the longer weld time mak
94. aper on a regular basis removing any foreign materials 11 Perform dressing of electrodes on a regular basis to maintain the correct contour 12 Use a rubber mallet to align holder and tips rather than a metallic tool Avoid these potential sources of weld problems Never weld using unidentified electrodes or electrode materials Avoid using special purpose or offset tips if the job can be handled with a standard straight tip Do not use a small tip for welding heavy gauge materials or a large tip on small piece Do not overlook turning on the cooling water to the appropriate force when beginning to weld Never use a water hose that does not firmly fit the water connection nipples Avoid leaky clogged or broken water connections Do not use holders that have leaking or deformed tapers Do not use electrode holders without an adjustable internal water cooling tube 4271909 S abe Avoid leaving the electrodes unused in tapered holder seats for long periods 10 Do not use pipe wrenches or similar tools when removing electrodes 11 Never dress an electrode using a coarse file These recommendations can help improve the quality and consistency of your welds For more information you can contact the RWMA Resistance Welding Manufacturing Alliance or AWS American Welding Society directly 550 NW LeJeune Road Miami FL 33126 Tel 800 443 9353 Intl 305 443 9353 URL www aws org 1 10 0428 INS 400
95. as stacked on a 1mm 0 03937 thick plate the total thickness to be measured would be 6 08mm or 0 240 Since the stack up height 0 240 is greater than the half window 0 180 if you zeroed the monitor with the electrodes closed together without the part Then when the part stack up is added the sensor travel would be outside the measurement window Fabricate a zeroing gauge block that represents the stack up height of the parts being welded Use the block to zero the sensor this way the window can be moved to the appropriate location for the weld If you re doing flat plate welds e g sheet metals the chances are pretty good that the stack up will already be within the half window However for any type of projection or nut welding the stack up is likely to fall out of range It is possible to use actual parts for zeroing on instead of a gauge block however nuts vary plates vary and the tip force used to hold the part in place may cause deformation of the metal With a gauge block the sensor is zeroed in the same place every time regardless of part variances 0443 INS 400 Rev C 9 1 Livingston strongly recommends fabricating a calibration block as well typically sized 3 4 of the stroke length Such a block provides a known thickness for sensor calibration By using both a zeroing gauge block and calibration gauge block you can be assured of a consistent zero and a proper calibration Hardening of gauge blocks is recommend
96. ase contact Livingston if you choose to install different network protocols on the Livingston monitor e The proper passwords IP addresses and workgroup settings will need to be set Refer to the recommendations below for further information e Ifthe computer you are using is running Windows 95 98 you will need to follow the procedure in application note 0454 APP 124 How to create a new user account on a 2400 or Pod Server prior to networking Recommendations e If your company has an existing network that is not controlled by a Server your systems administrator or IT person should set up the Livingston weld monitor as if it were a new computer on the network The monitor should be assigned a unique IP address that is similar to other local IP addresses The first three numeric groups must be identical and the last group must be 454 APP 299 Rev B 12 21 12 22 unique For example if the IP address of your computer was 10 43 5 23 a similar address would be 10 43 5 67 Subnet Mask should be identical to other local Subnet Masks If your company has an existing network that is controlled by a Server your systems administrator or IT person may want to change the IP address of the Livingston weld monitor to your local IP address The default IP address of the 2400 Pod Server is 192 168 2 xxx where xxx is the last 3 digits of the monitor s serial number If your local IP address does not use these numbe
97. aster Select Current Master Selec Note Calculated weld Current values are not Figure 8 1 Input Monitor screen displayed on the Input Monitor The values in this screen change as the monitor continuously updates each channel If the monitor sensor cable is attached to the unit and the A D values appear frozen there may be a problem with the monitor Refer to Chapter 10 Troubleshooting Guide for more information e External Master Select This value indicates the binary select Master select number that the weld monitor is receiving from the External inputs located at the rear of the WeldWise 2400 e Current Master Select This value indicates the master that is in use whether from an external or internal selection If the binary select master select value does not correspond to an existing master then the Current Master Select will be 0 No Master For more information about binary selects please refer to the General Setup section of Chapter 6 of the users manual WMS Reference Guide e Zero Displacement This button is used to re establish the range in which the displacement readings are being taken For more information about this feature please refer to Displacement Channel Overview in Chapter 11 Appendices 8 2 0435 INS 400 Rev D Installing Swapping Toroids Each toroid has its own properties The Toroid Calibration Factor established when the toroid was manufactured is clearly labeled on a sticker
98. c bat Eil Dic C Temp boot ini lo st 50 objectis 45 8MB 2 12 8 0454 121 Rev 7 Right click on the file named WeldData mdb WeldData may or may not be capitalized and select Copy S 42400_0172 c livcosetup CE XI File Edit View Help E liveosetup El e ESEE x Jd Fsetup mdb e Mstrdown bat FI Shutdown bat XL ivco ldb Mtmaster mdb mi Shutdown exe V Livco mdb Ntsync exe Pe Srvstart bat livcolog t t E Remdown bat FI Srvstop bat S Livcopy mdb Setup mdb Weldcopy mdb tl Livcoset exe 51 Setupexp bat 98 W elddata ldb S Masters mdb FI Setupimp bat W elddata mdb pen Scan with Norton AntiVirus Copies the selected items to the Clipboard Use Paste to put tt eSjAdd to Zip to Welddata zip Send Cut Create Shortcut Delete Rename Properties 8 Go back to the open window containing the new folder that you created named 2400 xxxx MMDDY Y Open the folder and paste WeldData mdb amp D My Weld Data 2400_0172 xi File Edit View Help 1 object s 3 63MB 2 9 Return to the livcosetup window and close it You now have a copy of the Livingston database on your computer 0454 APP 121 Rev A 12 9 TO CREATE A SIMPLE MS EXCEL CHART OR GRAPH FROM THE LIVINGSTON DATABASE 1 Open a new spreadsheet in MS Excel 2 Goto Data gt Get External Data gt Create New
99. cannot be recorded and welds cannot be monitored during any database operations Typically weld accept reject status will be unavailable depending on system configuration Database Management Utilities ERES Export Compact Database Repair Database Delete All Welds Figure 6 18 Database Management options E ELIT ELA e Import This option displays the import menu which allows data and setup information to be retrieved from backup databases e Export This option displays the export menu which allows data and setup information to be stored to backup databases 0433 INS 400 Rev E 6 13 e Compact Database Database Management Utilities System data records are constantly added to and deleted from the database during normal WARNING This command will operation When certain data records are Inger compact the current database deleted from the database e g Delete System Log or Delete Master is performed Export 1 minute s to complete space for these records is not automatically reclaimed The Compact Database option removes all unused records from the database files If you copy databases to an archive over the network the Compact Database command will reduce the archive space Delete All welds continue or lt Escape required This compact option is basically the same compact tool that is provided with Microsoft Access WARNING Welds cannot be monitored while the Compa
100. cepted 3 2 0430 INS 400 Rev D Every factor involved in making a weld has its own weld lobe and set of unique tolerances There are multiple parameters that can be measured and toleranced using a Livingston monitor The WMS program makes it easy to define track and record tolerances for each parameter critical to the weld process For maximum flexibility acceptable tolerances can be specified by absolute or relative values when comparing weld data in real time against a master Measured Parameters Livingston monitors capture measurements from up to four sensors attached to a welder From these four measurements the monitors then calculate and record the following parameters e Current Rms e Part Expansion e Current Peak e Electrode Setdown e Voltage Rms e Conduction Angle e Voltage Peak e Energy e Force e Resistance Dynamic e Initial Part Thickness e Number of Halfcycles e Final Part Thickness For a complete definition of each of these measured parameters please refer to section 6 the WMS Reference Guide Segments Since there are many different weld processes users may be more interested in observing and analyzing certain time periods during a weld To accommodate these differences and needs Livingston devised the concept of segments A segment is simply a collection of halfcycles before during and after the firing of weld current By default there are three segments created when a master is made the Pre Weld Sque
101. changed ESCAPE to the main screen and make a weld If the weld passes go to the Halfcycle Summary screen Your Halfcycle Summary screen should look similar to figure 5 20 Notice that the Current Rms line is within the set tolerances Now we ll lower the heat for the next weld so you can see what happens 5 10 0432 INS 400 Rev E 7 Decrease the heat on your weld schedule by 20 If your schedule is set for 45 heat lower it to 25 heat ESCAPE to the main screen and make a weld 8 The Weld Status box should display flashing arrows indicating a REJECTED weld as shown in figure 5 21 Go to the Halfcycle Summary screen It should look similar to figure 5 22 Notice that the Current Rms line is below the lower tolerance boundary causing a REJECTED weld Summary Remember this guide is intended as an example only the creation of masters and tolerances for individual weld processes will vary Please refer to Chapter 6 WMS Reference Guide for a complete description of all functions in the WMS program or use Chapter 10 Troubleshooting Guide for more information about mastering 0432 INS 400 Rev E Master 3 13 01 3 50 40 PM M01 er 009 T o b weld Current Rms Yoltage Rms 0 000 20 Cnt 0 000 100 Figure 5 21 Main program screen displaying a REJECTED weld Current Rms etc too low Master 3 13 01 3 50 40 PM M01 Figure 5 22 Halfcycle Summary for REJECTED weld 5 11
102. connections to both database files must be closed Note Weld data should be deleted periodically to avoid filling the weld database to capacity refer to FAQ Chapter 9 0433 INS 400 Rev E 6 15 Database Import Screen Database Import iNING This command will lace all of the data in Livco mdb and Welddata mdb with data from Livcopy mdb and W eldcopy mdb It will take about 1 minute s to complete e Import This option deletes the current databases and reverts to archive databases that have been saved by a previous Export All command The current and archive database file names are Duel This command requires exclusive FIGppy 5 CO equires EXCIUSIVE Current Database Archive Database so all other external i gt connections to both database Livco mdb Livcopy mdb Import Setup files must be closed Welddata mdb Weldcopy mdb REO zm Press Import All gt to continue or Import Setup trom Escape to eyit Note You can only perform an Import if an Floppy Export All command has been previousl y Figure 6 23 Import All performed WARNING Welds cannot be monitored while the Import All option is in use Any remote user interface windows must also be closed WARNING This command wil It may take more than ten minutes to complete Import All merge masters previously saved Database Import Utilities 1 an Import command If the Cancel button Ms
103. corded using the adjusted weld schedule or work pieces The new weld is then used to replace the original weld in the copied Master while keeping the tolerances and segment structure of the copied Master Note Copy Replace will work only for a new weld with the same number of halfcycles in the weld segment Can I Copy Replace between bin selects No When a Master is Copied Replaced it will always be in the same bin select as the existing Master Note You can Copy Replace a Master then use the Edit Master Screen to change the Bin Select 9 2 0443 INS 400 Rev C Can I make than one Master at a time Yes if multiple binary selects are used For example if the New button is pressed in the Mastering screen then three different welds on three different bin selects are made with the welder in auto mode as the welds are made the binary selects are sent by the PLC When the Done button is pressed there will be three new Masters made one for each bin select in the weld sequence If you only wanted to make 1 Master on a specific bin select just delete the other two Masters Why does the weld monitor display a single weld as several welds If you re using a pulsed weld then the post delay may not be set high enough to account for the time between pulses In this case the weld monitor will consider each pulse as an individual weld Refer to General Setup in Chapter 6 WMS reference Guide Another possibility is that the weld sche
104. ct Database option is in use Any Uperalion is being etc remote user interface windows must also be Import is emng Y ou have to shutdown and closed A large database may take over an This command requires exclusive so all other external connections to both database files must be closed Press lt Compact Database gt to to exit Figure 6 19 Compact Database restart the system hour to compact If the Cancel button is used Export the weld monitor must be shut down and restarted DO NOT shutdown the monitor during this operation Press lt Exit gt or lt Escape gt to exit Eompact Database Database Exit Delete All Welds Figure 6 20 If a database operation is cancelled the monitor must be shut down and restarted 6 14 0433 INS 400 Rev E e Repair Database Database Management Utilities If a database file is open by the weld monitor ST aT ia WAnNINU 115 command Wi software or an external application such as repair the current database files Microsoft Access and an improper shutdown Livco mdb and Welddata mdb occurs the database may become damaged Export e minute s to This repair option is basically the same repair tool that is provided with Microsoft Access 1 command requires exclusive This option should only be executed if connections Io boih F e recommended by a Livingston service as must Be closed technician It i
105. cturers 3 Not all manufacturers use the same math to calculate the current measurement To compensate for these differences Livingston offers a feature called Percentage Adjustment The percent adjustment option takes whatever value was received from the channel and adjusts it by whatever percentage you specify The adjustment applies both to Current Peak and to Current Rms This means that if the current reading from a Livingston monitor absolutely needs to match the current reading from another current measuring device the Livingston monitor can be easily adjusted so that the readings are the same To obtain the correct Percentage Adjustment 1 Make a weld then return to the toroid settings screen The last weld s Current RMS value is displayed 2 Take the reading from your weld control or Plant standard current meter and enter the value into the Desired Current RMS field Press Enter on your keyboard or click the Enter button on the virtual Keypad You will see the Percent adjusted display see Figure 8 4 3 Click the Update Configuration Button This Figure 8 4 Percent change After Entering will save the percentage change Now escape Toroid Calibration out to the main screen make another weld and return to the Toroid Settings screen The two current RMS fields will now match as shown in figure 8 5 103 01 4 If you would like to return to 100 simply edit the Percent field back to 100 and press enter Toroid C
106. d The current and archive database file names are Current Database Archive Database Livco mdb Livcopy mdb Welddata mdb Weldcopy mdb WARNING Welds cannot be monitored while the Export All option is in use Any remote user interface windows must also be closed It may take more than an hour to complete an Export command If the Cancel button is used the weld monitor must be shut down and restarted DO NOT shutdown the weld monitor during this operation e Export Masters This option saves the current masters to an archive database backing up all current masters An Export Masters command should be executed periodically as masters are developed The masters archive database file name is masters mdb This command will overwrite any masters written by a previous Export Masters command Database Export Utilities WARNING This command will Export All compact and export all data to Livcopy and Weldcopy mdb It nou will overwrite any data previously Export Masters stored there t will take about 1 minute s to complete Export Masters to Floppy This command requires exclusive so all other external connections to both database files must be closed Export Setup to continue or Press Export All Escape gt to exit Export Setup to Floppy Figure 6 28 Export All Database Export Utilities WARNING This command will export all masters to Masters mdb It will overwrite an
107. d and to help dissipate heat from the area being welded To ensure that all three of these functions are executed properly it is important to regularly maintain the electrodes keeping them clean and in good condition A reprint of an RWMA chart describing various types of electrode materials and their different uses may be found in Chapter 11 APPENDICES of this manual Conducting Current The first of these functions is purely electrical fire weld current through the workpiece Taking into account the relationship among current voltage and resistance it becomes important to pay attention to the type of electrodes used For example it wouldn t be wise to select electrodes made entirely froma high resistance material since they would get so hot they d melt before the current even had a chance to flow to the workpiece It is also important to make sure that the electrodes are the right size for the application proper electrode sizing is largely dependent on the amount of force being used on the workpieces Transmitting Force The second function of the electrodes is mechanical The amount of force needed to make a good weld varies depending on the type of metal being welded and other factors but a general figure would be about 600 800 Ibs Because electrodes are typically on the small side roughly from about the size of 1 4 0428 INS 400 Rev E an acorn to the size of a plum it is also important to choose electrodes that are able to
108. d or replaced at the discretion of the Company free of charge as per the conditions set forth in Obtaining Service Under Warranty provided that the Customer a provides written notice to the Company of such defect within fourteen 14 days of Customer s discovery of such defect and b establishes that the product has been properly installed maintained and operated within the rated limits of normal usage Repaired or replaced parts the warranty is effective ninety 90 days from date of shipment by the Company or the remainder of the original warranty whichever is longer THIS WARRANTY SET FORTH HEREIN IS THE CUSTOMER S SOLE AND EXCLUSIVE REMEDY AND WILL STATISFY ALL OBLIGATIONS OF THE COMPANY WHETHER BASED ON CONTRACT STRICT LIABILITY TORT INCLUDING NEGLIGENCE OR OTHERWISE IN NO EVENT SHALL THE COMPANY BE LIABLE FOR ANY CONSEQUENTIAL INDIRECT SPECIAL INCIDENTAL EXEMPLARY OR PUNITIVE DAMAGES INCLUDING BUT NOT LIMITED TO ANY LOSS OF PROFITS HARM TO BUSINESS HARM TO REPUTATION OR PROCUREMENT OF SUBSTITUTE GOODS OR SERVICES LOSS OF USE OR DATA OR BUSINESS INTERRUPTION HOWEVER CAUSED AND ON ANY THEORY OF LIABILITY WHETHER IN CONTRACT STRICT LIABILTY OR TORT INCLUDING NEGLIGENCE OR OTHERWISE ARISING IN ANY WAY OUT OF THE USE OF FAILURE OF OR DEFECT IN MISUSE OF OR IN CONNECTION WITH ANY COMPANY PRODUCT EVEN IF THE COMPANY HAS BEEN OR IS ADVISED OF THE POSSIBILITY OF SUCH DAMAGE THIS EXPRESS WARRANTY IS MADE IN L
109. d to as tolerance and is implemented by high and low limits relative to the master Default tolerances set in the Tolerance Defaults screen are installed when a master is made and are set to be very forgiving The default tolerances can be changed new default tolerances will only be applied to masters made after the adjustment It is up to the weld process engineer to document the weld process and adjust tolerance limits to the proper values The WMS supports Halfcycle and Segment Tolerancing Halfcycle Tolerancing compares the data from each halfcycle in a segment to halfcycle limits specified for that segment All of the halfcycles in a segment are compared to the same halfcycle limits for that segment If you move the cursor to any halfcycle in a segment and set the halfcycle tolerance this sets the limits for all of the halfcycles in that segment If you want to impose different limits on halfcycles in the same weld you can divide the weld up into more segments and tolerance the halfcycles in each segment differently Segment Tolerancing calculates an average value for all of the halfcycles in each segment and then compares that value to separate segment limits specified for that segment To switch between the Halfcycle Tolerancing and Segment Tolerancing screens touch anywhere on the graph using touch screen to highlight it and press the SELECT button The display will shift between HALFCYCLE TOLERANCES and SEGMENT TOLERANCES
110. ds have the same record type 2 Weld summary data records are also shown in the Halfcycle Summary table 0433 INS 400 Rev E 6 11 System Log Screen e System Log This screen displays a table of recorded system information It is an event log with date time stamps intended for diagnostic purposes It is recommend that the system log be deleted periodically as it does add to the size of the livco mdb database It is also recommend that a Compact Database be performed following the deletion of system log entries 6 12 System Log Delete Log Entries Figure 6 17 System Log 0433 INS 400 Rev E Database Management The WMS software running on the WeldWise 2400 uses Microsoft Access database files for storing configuration calibration masters master tolerance limits and weld data This section describes all of the database operations available in the Database Management Utilities screen Recommendations for maintaining your WeldWise 2400 databases can be found in the Recommended Database Management section in Chapter 11 APPENDICES Before performing any database functions all remote user interfaces and applications accessing the database should be closed Database functions should be performed from the WeldWise 2400 weld monitor only Some options will allow you to cancel the action being performed If the action is cancelled you will need to shutdown and restart the weld monitor Note Weld data
111. dule has changed since a master was created i e The on time of the weld has increased The solution in this case is to return the weld schedule to it s previous weld length create a new master so that the monitor will accommodate the length of the weld For additional possibilities refer to Chapter 10 Trouble Shooting Guide 0443 INS 400 Rev C 9 3 9 4 INDEX TROUBLESHOOTING GUIDE INTRODUCTION 10 3 1 SOME OR ALL WELDS ARE REJECTED NOT CATCHING FAULTY WELDS 10 6 WELD COUNT IS NOT INCREASING EVERY WELD IS REJECTED FOR ALMOST EVERY PARAMETER EVERY WELD IS REJECTED FOR HALFCYCLE COUNT EVERY WELD IS REJECTED FOR DISPLACEMENT PARAMETERS EVERY WELD IS REJECTED FOR FORCE PARAMETERS EVERY WELD IS REJECTED FOR CURRENT VOLTAGE ENERGY RESISTANCE OR CONDUCTION ANGLE PARAMETERS SOME WELDS ARE REJECTED FOR ALMOST EVERY PARAMETER SOME WELDS ARE REJECTED FOR HALFCYCLE COUNT WELDS THAT SHOULD BE REJECTED ARE NOT BEING REJECTED WELD COUNT DOES NOT INCREASE 2 TROUBLE WITH FORCE SENSOR READINGS OR CHANNEL 10 14 CALIBRATED FORCE SIGNAL IS READING HIGHER OR LOWER THAN NORMAL CALIBRATED FORCE SIGNAL IS INDICATING A FROZEN STATIC READING WHEN A WELD IS MADE THERE IS LITTLE OR NO FORCE REPORTED A D READING IS FROZEN A D READING IS PEGGED 32767 INACCURATE A D READINGS 4 32767 3 TROUBLE WITH DISPLACEMENT SENSOR READINGS OR CHANNEL 10 17 CALIBRATED DISPLACEMENT SIGNAL IS READING HIGHER OR LOWER T
112. e if the sensor cable is properly connected to the weld monitor Toroid disconnected or damaged Inspect the toroid for poor connections and or physical damage or abrasion Reconnect replace and or relocate toroid if necessary A D Threshold setting is too high incorrect In the General Setup Menu decrease setting until a weld is detected Hardware Software failure Call Livingston Service vI Ol ASNOOP SNI SSPO 2 TROUBLE WITH FORCE SENSOR READINGS OR CHANNEL PROBLEM CALIBRATED FORCE SIGNAL IS READINGS HIGHER OR LOWER THAN NORMAL POSSIBLE CAUSE OR SYMPTOM Calibration has changed or is incorrect POSSIBLE FIX Inspect and recalibrate sensor if necessary Refer to Chapter 8 Calibrating the Sensors Note If an Export Setup was performed the last time this sensor was properly calibrated an Import Setup may be performed to reload the saved calibration settings Refer to Chapter 6 WMS Reference Guide CALIBRATED FORCE SIGNAL IS INDICATING A FROZEN static READING The force sensor is not connected properly Inspect electrical connections for poor connections or corrosion The force sensor sensor cable or weld monitor is malfunctioning Use the Input Monitor to observe the force channel readings With the sensor disconnected an A D value of 32767 may indicate a failed sensor cable or weld monitor hardware problem Refer to Section 8 of this c
113. e this button or ESCAPE to leave the Shutdown Menu Quit all Livingston programs but don t shutdown Windows e Yes Pm sure Shutdown Windows Close this User Interface Window too but don t quit Weld Monitor This option closes all programs and shuts down Windows Figure 6 64 Shutdown menu e Quit All Livingston programs but don t shutdown Windows This option closes the Livingston programs but doesn t shutdown Windows System administrators who need to access Windows or to gain exclusive access to the Livingston databases would use this option e Close this User Interface Window but don t quit Weld Monitor This option closes the WMS graphical user interface livcoset exe but does not stop the WMS weld monitor service Doit exe The weld monitor will continue to collect weld data and all I O will continue to function Note If option 2 has been selected both the WMS program and Windows will shutdown The Shutdown Computer message box will appear with the following text It is now safe to turn off your computer Below the text is a Restart button DO NOT use the Restart button to restart the weld monitor If this button is used the WMS program will reboot without video the monitor s screen will be blank When the Shutdown Computer message appears use the switch located on the back of the weld monitor to turn off and restart the program 6 46 0433 INS 400 Rev E If a database operation has failed the shutd
114. e to the WMS program in the event of a sudden 11 14 0438 INS 400 Rev C power loss APC manufactured Back UPS Pro 280 Model BP280S or a Back UPS 650 Model BK650M are two recommended and approved models which may be used with the WeldWise 2400 If your WeldWise 2400 has been shipped with an optional UPS the necessary UPS software is pre installed You will however need to calibrate the UPS once you have set up your weld monitor and UPS Additionally if you would like to your WeldWise 2400 to remotely shut down other WeldWise 2400s or devices in the event of a power loss you will need to re configure the UPS settings Note Please be aware that once the UPS shutdown sequence has been initiated it will not stop until the cycle is complete even if power has been restored midway To prevent improper shutdowns and possible resulting damage to your unit s please allow your WeldWise 2400 s to fully complete the shutdown sequence before initiating any changes The following sections review how to calibrate the UPS and how to set your WeldWise 2400 for remote shutdown 0438 INS 400 Rev C 11 15 Calibrating the UPS The following prerequisites must be met before initiating runtime calibration An approved UPS must be connected to the WeldWise 2400 via the COM 2 port using the gray serial cable included in the UPS package Power must be connected from one of the three battery backup power connections on the UPS
115. eat the workpiece metal begins to melt A good analogy to this process is a child eating a popsicle on a hot summer day When the popsicle melts it doesn t remain on the stick it drips everywhere When metal melts it wants to do the same thing however because it s molten metal and not a runny popsicle it doesn t simply drip It explodes out of the workpiece This is why proper weld force is so important it literally forces the molten metal to stay put so it can then cool to form a weld nugget Without sufficient force the metal will do what it wants to do which is what causes expulsion Expulsion is nothing more than little pieces of molten metal exploding out of the weld because they re not being properly held in The problem with expulsion is that all the metal flying out of the weld is metal that s not going in to the weld a weld cannot be made stronger by removing metal from it Determining the proper amount of force is entirely application dependent The RMWA can be contacted for additional recommendations and guidelines Cooling the Workpiece Electrodes get considerably hot with 10 20 KA or more repeatedly flowing under hundreds of pounds of force Although most welders have an internal water cooling system that allows water to circulate through the tips of the electrodes while welds are being made a common problem is a lost damaged or improperly sized cooling water tube Without Deflector tube adjusted so that cold water str
116. eatures allow the user to immediately identify and correct faulty parameters or conditions that can produce poor quality welds Different parameters that can be monitored using Livingston equipment will be identified in addition to some of the ways that monitoring can be used to simplify and refine the weld process Livingston Weld Wise Monitor The WeldWise 2400 Dynamic Resistance Weld Monitor is a portable bench top unit that when connected to the appropriate sensors can be used to monitor a single weld head in a fixed location or rotated on your factory floor to monitor different weld heads one at a time If a weld is not within master tolerance limits the WeldWise 2400 sends a reject signal to a PLC or similar controller which is then displayed on the monitor as a rejected weld If the weld is within tolerances the WeldWise 2400 sends an accept signal which is displayed as an accepted weld The WeldWise 2400 performs real time monitoring on a halfcycle by halfcycle basis for AC welds A halfcycle is exactly what the name implies one half of a weld cycle based on a 50 or 60 Hz sine wave Signatures and Masters Once a Livingston weld monitor and sensors have been installed and the WMS Weld Monitoring Software program is running the monitor continually collects data from the sensors When a weld is made information about that weld is captured analyzed displayed and stored by the monitor This information is called
117. ed during calibration Take the voltage reading of a battery using a multimeter while it is still connected With the leads still connected to the battery set the entry for Point 2 to the known value This value must be entered to proceed Press ENTER to input the value Figure 8 8 Calibrate Voltage screen Note The Maximum input for voltage channel is 9 5V channel will saturate at 10V 6 Use the ESCAPE button to exit 7 Go back to the Input Monitor screen and compare the incoming values on the voltage channel with the leads shorted together as well as with the battery connected To calibrate the voltage using a Livingston Voltage Calibrator Follow the instructions that came with the Voltage Calibrator 8 8 0435 INS 400 Rev D Frequently Asked Questions When I change my electrodes why do I have to zero displacement Do I have to re calibrate Any time minor changes to the tooling are made electrodes ware or mushroom beyond tolerance limits or when work piece material thickness changes e g a new lot or batch of parts the displacement should be zeroed The reason for this is that all measurements having to do with displacement are calculated based on where the zero point is set Masters are also made and toleranced based on the zero point When electrodes are changed the size of the tips may be significantly different especially if the old tips are mushroomed and worn This difference may be enough to cause a weld to e
118. ed so blocks remain the same thickness through repeated calibrations Why do I have to delete weld data Refer to the Recommended Database Management section of Chapter 11 Appendices I was working with a Master in the tolerancing screen and I selected another Master to work with When the new Master came up the tolerancing bands disappeared A Master must be updated for use to display tolerance bands Select the Master and click UPDATE to load the Master for use If I did an Export but I only want to retrieve setup information can I just do an Import Setup No An Import Setup will only work if an Export Setup has been performed likewise with an Import and Export If I use the Copy Replace feature will the Master I m copying replacing be deleted No Whether you are copying or replacing the selected Master is always copied first When would I use the Copy Replace feature This feature is useful in a situation where the tolerances for a particular Master have been carefully refined and adjusted but a slight adjustment needs to be made to the weld schedule For example it may be determined that more current or less force is needed or perhaps the material thickness has changed slightly In such a case a new Master will be needed but you may wish to keep the tolerances and segment structure of the old Master Using the Copy Replace feature a copy of the original toleranced Master is made and then a new weld 15 re
119. een indicates that almost every parameter is rejecting CONT D EVERY WELD IS REJECTED The Weld Summary screen indicates that the HalfCycle Hcycle Count is incorrect EVERY WELD IS REJECTED The Weld Summary screen indicates that any or all Displacement parameters Initial Thickness Final Thickness Setdown Expansion are out of tolerance Weld Schedule changed Electrodes were changed dressed and the displacement was not zeroed Electrodes worn or mushroomed deformed severed partially severed shredded abraded and or has bare wires showing may be suspect Disconnect sensor cable from weld monitor and replace Try to reposition new cable to avoid recurring damage Spiral wrap or guards will also help to protect cable Inspect electrical connections for damage poor connections and or corrosion Replace connectors and or cable Change weld schedule back to what it was when the Master was created create a new Master or adjust the Master Tolerance Limits to accommodate the new schedule Zero the displacement Refer to Chapter 8 Calibrating the Sensors or Supplementary Procedure if applicable Calibration has changed Check calibration and recalibrate sensor if necessary Refer to Chapter 8 Calibrating the Sensors Note If an Export Setup was performed the last time this sensor was properly calibrated an Import Setup may be performed to reload the saved calibration settings Refer to Chapter 6
120. emote user interface windows must also be closed If the Cancel button is used the weld monitor software must be shut down and restarted DO NOT shutdown the weld monitor during this operation e Export Setup To Floppy This option is the same as the Export Setup command above except that the archive database is compressed and stored to a floppy disk This command will over write any setup information written by a previous Export Setup To Floppy command Only one setup archive can be stored on a floppy disk WARNING Welds cannot be monitored while the Import Setup From Floppy option is in use Any remote user interface windows must also be closed If the Cancel button is used the weld monitor software must be shut down and restarted DO NOT shutdown the weld monitor during this operation 0433 INS 400 Rev E 6 19 Scope Data Screen NOTE The scope data feature is intended for use as a diagnostic tool by Livingston Please contact Livingston if you need the ability to record scope data e Scope Data This option displays the raw and filtered data from the external sensors The scope feature must be enabled in the General Setup in order to view Scope data For more information refer to the Scope Enable and related settings in the General Setup Figure 6 33 shows the raw A D toroid signal pre integration The left y axis represents the A D counts The graph heading shows which weld the waveform is for as well as how many samples
121. en the graph is selected in zoom view it can be scrolled left or right using the arrow buttons The Beginning Segment Beg Sg defines which segment the cursor arrow is in The second Weld Halfcycle Count WHC shows which halfcycle the cursor is on see figure 6 9 If Status you are working in zoom view and new weld 0 0 is made the screen will not automatically 0 0 2 0 update 0 0 3 0 0 0 0 e Weld Number Select Display 0 0 0 0 D fi 0 Use the arrow buttons to select a weld If 0 0 8 0 graph is selected the most recent weld is l 0 9 0 displayed and the graph screen updates l l automaticallv e Table Graph Button Figure 6 12 Halfcycle Summary table Switches the display to either graph or table format Each row of the table shows a data record from the selected weld as shown in figure 6 12 Segment and weld summary records are also shown in this table Use the scroll bars or the arrow buttons to move through the table display The Halfcycle Summary Table contains the following parameters e Segment A weld is divided into segments The segment field indicates which segment the data record is from By default 0 Pre weld 1 Weld 2 Post weld The segment field of a weld summary record shows the number of segments in the weld e Rtype Record type indicates what type of data is in the row data record 0 Halfcycle Summary 1 Segment Summary average
122. en the weld was rejected e Job Status Indicators Indicate whether any weld made in a series of welds has been rejected If all of the welds have accepted a check mark is displayed If any one of them has rejected either one or both of the arrows will flash the same as in the Weld Status box By selecting the Weld Summary option in the Data Menu you can find out which weld s were rejected See Chapter 6 WMS Reference Guide for more details Smaller arrows are displayed to the right of the bar graphs for each parameter display While the big arrows in the both the Weld Status and Job Status boxes tell you if any of the multiple parameters are over or under limit these smaller arrows will show up next to the failed parameter If the arrow points up the parameter was over the tolerance limit down signifies it was under the tolerance limit Remember if no master has been updated or masters are not enabled all weld parameters will fail by default and the arrows will flash e Clear Indicator Button This button at the bottom of the Job Status box will clear all flashing arrows from the screen and display check marks 0432 INS 400 Rev E 5 3 2 Make a few welds using weld settings and parts customary for the application After each weld is made notice the weld number increase by one e Use the MENU key to go to the Main Menu Select Data then Halfcycle Summary The screen should look similar to figure 5 5 At the top of the
123. ents e Line Frequency Default Setting 60 Hz Line Frequency should be set to the frequency of the AC line power feeding power to the primary of the welder s transformer It can be set to either 50 or 60 Hz e Relay Mode Default Setting ACC REJ see also Relay Out 0 and Relay Out 1 Relay 0 and Relay 1 will remain in their current states energized unenergized when the weld monitor software is shut down ACC REJ Relay 1 momentarily changes state for approximately 200ms after the completion of an ACCEPTED weld Relay 0 momentarily changes state as soon as a REJECTED halfcycle is recorded and is asserted for approximately 200ms following the completion of a REJECTED weld BUSY STAT Relay 1 remains in its unenergized state while the 2400 is NOT busy Relay 0 changes to and holds its unenergized state after the completion of an ACCEPTED weld Relay 0 changes to and holds its energized state after the completion of a REJECTED weld Relay 0 remains in its current state until another weld is processed All other Relay Mode settings are for use with a POD weld monitor and should not by used for WeldWise 2400 monitor operation Note Once the Relay Mode setting has been toggled the change does not take effect until the next weld has been processed e Relay Out 0 Default Setting N O N O The unenergized state of the Relay 0 contacts is normally open N C The unenergized state of the Relay 0 contacts is normally closed Note
124. er set change the binary select or 3 15 01 10 48 51 AM M01 rename a master Update 3 15 01 10 53 42 AM MUT 3 15 01 11 19 45 MDI 3 15 01 11 25 51 AM MOI e Copv Replace Delete Master 3 15 01 11 39 26 AM 01 This button has two functions The first is to copy a selected master COPY if the Figure 6 37 Select Master Copy Replace button is pressed and then the Done button is pressed without any new welds being made the selected master will be copied and named with the current date and time The SER second is to create a new master with the same Select Master tolerances as the selected master but with new master data REPLACE if the Copy Replace Edit Master button is pressed and new welds are recorded before the Done button is pressed the original welds that were used to create the selected master are deleted from the copy and the new weld data is used instead The segment Delete Master structure and tolerance settings of the original master are preserved To replace a master the source master must first be Updated and the new welds recorded must contain the same number of half cycles Figure 6 38 Copy Replace Note Masters cannot be copied replaced between binary selects however the binary select associated with the master can be edited using the edit master feature Note Copy Replace should be used only if the replacing weld new weld contains the same number of halfcycles as the existing master being copied
125. erage force at the electrode tips during the halfcycle segment or weld average of Pre Weld and Post segment half cycles Set Down Set Down is the decrease in thickness as a part is welded relative to initial thickness Halfcycle Set Down is the lowest thickness during the halfcycle minus the Initial Thickness value at the beginning of the weld halfcycle 0 from segment 1 Segment Set Down for a segment is lowest Set Down reported for a halfcycle within the segment Weld Set Down is the difference between the initial thickness at the beginning of the weld segment halfcycle 0 from segment 1 and the Final Thickness at the end of the Post segment Expansion Expansion is the increase in thickness as a part is welded relative to initial thickness Halfcycle Expansion is the highest thickness during the halfcycle minus from the Initial Thickness value at the beginning of the weld halfcycle 0 from segment 1 Segment Expansion for a segment is the highest Expansion value for a halfcycle within the segment Weld Expansion is the highest Expansion value from all of the segments excludes PRE Initial Thickness The thickness of the workpiece at the start of a halfcycle segment or weld Initial Thickness from the first halfcycle in segment 1 the first weld segment Final Thickness The thickness of the workpiece at the end of a halfcycle segment or weld final thickness from the POST segment CondAngle Conduction angle
126. erance except for Half Cycle count Internal Bin Select is working intermittently Refer to Section 7 Trouble With Bin Select or Accept Reject Weld Timer is malfunctioning or the logic controlling the Weld Timer is incorrect Check weld timer operation firing boards and SCRs Call your resident logic programmer and have the logic inspected SOME WELDS ARE REJECTED The weld summary screen indicates that some welds are rejecting due to incorrect Half Cycle Count Weld Timer is malfunctioning or the logic controlling the Weld Timer is incorrect Check Weld Timer operation Firings boards and SCRs Call your resident logic programmer and have him her inspect the logic Toroid failure or loose buckle Inspect the Toroid for physical damage or abrasion Replace and or relocate Toroid if necessary Inspect for loose buckle AD Threshold settings require adjustment Refer to the General Setup Section in Chapter 6 WMS Reference Guide for rule of thumb settings and overview on these settings Try increasing the settings Call Livingston Service for support The transformer secondary is not properly grounded Check the transformer for grounding issues The transformer secondary should be grounded either directly or through a grounding inductor A ImegaOhm resistor in parallel to a O1 microFarad 600V capacitor may also be used 101 QOr SNI SSPO PROBLEM POSSI
127. ers and periods Press the Enter key to accept the new entry s and exit the window Microsoft TCP IP Properties Cancel 12 4 0454 APP 118 Rev A 8 If you are using a mouse close all open windows and then press the key combination Ctrl Alt Del This will bring up the Windows NT Security window Windows NT Security x Logon Information You are logged on as 2400_Oxxx Administrator Logon Date 3 7 01 9 59 01 AM Oxxx will be the serial number of your 2400 or POD Server Use the Task Manager to close an application that is not responding 9 Without a mouse press Alt S to select the Shutdown option or simply click on the Shutdown button 10 The Shutdown Computer window will appear Press Alt S again to shut down the monitor or select the Shutdown option and click OK 11 Reboot the weld monitor END 0454 APP 118 Rev A 12 5 12 6 0454 APP 118 Rev Document 0454 APP 121 Author E Barbiero LI INGS TON Date 04 26 01 COMPANY c Revision A APPLICATION NOTE Category Procedure Applies to 2400 or POD Server Subject Copy weld data amp create a MS Excel chart HOW TO COPY WELD DATA FROM A 2400 OR POD SERVER amp CREATE EXCEL CHARTS WITH THE COPIED WELD DATA Objective This procedure will first explain how to copy stored weld data from your 2400 or POD Server and then show how to use that copied data to create simple MS Excel charts and graphs Please note that all o
128. es it much less efficient Others think that in order to have good welds expulsion is necessary as an indicator that a weld is being made However tiny pieces of molten metal exploding out of a weld cause the weld itself to be weaker than it would be without expulsion Voltage measured in Volts is also a key indicator during the weld process As discussed earlier voltage is a relative measure in that the location of the measurement is important The voltage in the secondary of a welder can vary during operation due to a variety of factors including e variances in the part fit up e loose connections e line load variations within the plant e differences in power factor throughout the day Voltage variations at the tips due to worn or pitted electrodes dirty materials or insufficient surface contact with the workpiece can also affect resistance and current density As a partial solution many of today s controllers are equipped with an Automatic Voltage Compensation AVC If a voltage drop in the factory line is detected the control will adjust in an attempt to provide the same amount of energy to the weld Despite the adjustment what comes out of the transformer is not necessarily what comes out of the electrodes The same conditions apply to constant current controls Even though the amount of current coming out of the transformer secondary is regulated the amount at the tips may be variable Force measured in pounds per square inch
129. etup This option displays the Setup Menu which provides setup options to help you configure the system and to calibrate sensors e Shutdown This option displays a list of shutdown choices 6 4 0433 INS 400 Rev E Data Menu Options Data Menu e Halfcycle Summary This option displays Halfcycle Segment and Weld Summary Weld Summary data in a graphical or tabular format System Log e Weld Summary Database This option displays Weld Summary data in a tabular format Scope Data e System Log i Figure 6 7 Data Menu screen This option displays System Log information for different system events This information is used by Livingston technicians for system diagnostics e Database Displays sub menus and commands which backup restore or delete information from the weld databases e Scope Data Displays raw data from the external sensors The Scope Data feature is used for diagnostic purposes and must be enabled in the Setup Menu to operate It should not be enabled during normal production Please contact Livingston for more details 0433 INS 400 Rev E 6 5 Halfcycle Summary Screen The WMS software displays weld data on a halfcycle segment and weld basis If the system is set up to record halfcycle information data records are stored in a database for each halfcycle of the weld Each stored weld data record contains data values for all parameters as well as other system information Weld Master ID
130. eze Weld and Post Weld Hold segments Different tolerances can be set for each segment segment lengths can be increased or decreased and new segments can easily be created Using segments each weld can be divided into as many parts as necessary to focus on the data that is critical to the weld process Consider the following example Coated steel is being welded with the following weld schedule 8 cycles of Squeeze 10 cycles of Weld and 12 cycles of Hold The objective is to monitor the current density during the Weld time to ensure sufficient concentration for high quality welds According to the factory weld lobe the current at the electrodes during the weld must be 12 KA with an allowable difference of only 0 5 Amp After examining preliminary weld data it is discovered that the current during the first few halfcycles of the Weld period is much less than 12 KA The reason for the decrease is that the coating must first be burned off before the weld current actually reaches the steel at the faying surfaces and makes the weld How can tolerances be properly set to accommodate the weld lobe specification of 12 KA 0 5 Amp without automatically rejecting welds during the time it takes for the coating to burn off 0430 INS 400 Rev D 3 3 To resolve this issue the exact time in halfcycles needed for the weld current to burn through the coating could be determined by examining collected weld data Using this information a segment could
131. f physical overview of navigating with the software e WMS Quick Start A basic how to guide to weld monitoring with Livingston equipment e WMS Reference Guide A complete software reference to the Livingston Weld Monitoring Software WMS program e Installing the Sensors Describes the various types of sensors available for use with Livingston weld monitors and installation guidelines e Calibrating the Sensors Explains how to calibrate sensors using the WMS program e FAQ Includes answers to frequently asked questions e Troubleshooting Guide A beginner s guide to basic troubleshooting for Livingston systems e Appendices Includes information reprinted from the RWMA and various subject matter pertaining to both Livingston equipment and software e Application Notes Includes general how to procedures and notes relating to software and or hardware issues e Contact Information How to reach Livingston il 0452 INS 400 Rev C Table of Contents OVERVIEW OF RESISTANCE WELDING INTRODUCTION VARIABLES IN THE WELDING PROCESS THE WELD CYCLE CRITICAL FACTORS IN WELDING CURRENT VOLTAGE POWER RESISTANCE ELECTRODES SURFACE CONTACT CURRENT DENSITY OHM S LAW AND JOULE S LAWS IDENTIFYING AND CORRECTING WELD PROBLEMS RECOMMENDATIONS FOR PRODUCING QUALITY WELDS AVOID THESE POTENTIAL SOURCES OF WELD PROBLEMS INTRODUCTION TO RESISTANCE WELD MONITORING INTRODUCTION WHY MONITOR WELD LOBES AND THE WELD PROCESS STYLES OF MONITORING B
132. f the screen shots in the procedure are using MS Excel 97 with Windows NT If you are using another system version the procedure may be different TO COPY THE LIVCO DATABASE USING WINDOWS 95 98 NT 1 Make sure that the computer you are using has a network connection to the Livingston monitor for further information please refer to the procedure on How to Establish a Network Connection 2 On your computer s desktop or on another drive Inf xi which the collected weld data will be transferred Edit View Help right click and create a new folder named 2400 xxxx r MMDDYY where is the four digit serial 3 s ti tal number found on the back of the Livingston unit and 12400 0172 112000 MMDDYY is the current date In the example at right the serial number is 0172 and the date is 11 20 00 Leave this window open while vou proceed with the following steps 1 objeetis D bytes 2 ees dini 3 Go to Start gt Find gt Computer In the Find Computer window B New Office Document type in the 9 character name of the 2400 POD Server in the format 2400 xxxx where xxxx is the four digit serial number found on the back of the Livingston unit Nec EE Open Office Document Programs Note If you have changed the name of your Livingston unit type in the Documents name that you have changed it to Type in the name of the 2400 POD Server in this f
133. ference Guide for a description of these functions It is recommended that system settings be periodically exported and stored in a safe place Note It is recommended that all Export operations be performed any time it is necessary to perform any one of the Export operations This will ensure that all of the exported information located in the database files is in synch Following the steps below will provide the best means of recovery 1 Delete all welds Delete System Log and then Compact Database as described in the Recommended Database Maintenance section of this document This will clean out and minimize the size of the databases 2 Export Setup This makes a backup of calibration general setup as well as the tolerance defaults and graph setup and stores the information in the setup mdb file 3 Export Masters This makes a backup of each of the masters includes master tolerance limits and stores the information in the masters mdb file 4 Export All This makes a backup all of the system information to the livcopy mdb and weldcopy mdb files The exported files exist on the WeldWise 2400 hard drive in the livcosetup folder If possible these files should be copied and stored on a separate computer If an Ethernet connection with the WeldWise 2400 is not possible then the following additional steps are also recommended Place a blank formatted 3 1 2 floppy disk in
134. figure the UPS settings on your weld monitor s Before reconfiguring the following prerequisites must be met An approved UPS must be connected to the WeldWise 2400 via the COM 2 port using the gray serial cable included in the UPS package Power must be connected from one of the three battery backup power connections on the UPS to the WeldWise 2400 s You will need to attach a keyboard video monitor and mouse to complete this procedure You will also need a crossover cable to network your WeldWise 2400 s To purchase this item directly from Livingston please contact your Livingston representative Procedure for Configuring a WeldWise 2400 Master To Shutdown Remote Computers Slaves 1 Power up the WeldWise 2400 you wish to designate as Master and allow to boot If prompted log on as Administrator password 2400 2 If Livco software starts running select MENU Select SHUTDOWN Select Quit Livco program but don t shutdown Windows NT 3 Click Start on the task bar Select Programs gt Windows NT Explorer 4 In the root directory c right click on the file upsdown bat and select Edit 5 There is a line that looks similar to 2400_XXXX c livcosetup rshutdown bat orders the 2400 unit serial XXXX to shutdown Remove the rem from the beginning of this line Modify the line text to perform the shutdown of a remote WeldWise 2400 by replacing XXXX with the last 4 digits of the serial n
135. ge A cable that is REJECTED The Weld Summary screen indicates that Current Voltage Energy Resistance or Conduction Angle Parameters are out of tolerance CONT D deformed severed partially severed shredded abraded and or has bare wires showing may be suspect Disconnect sensor cable from the weld monitor and replace Try to reposition new cable to avoid recurring damage Spiral wrap or guards will also help to protect cable Refer to Section 6 Possible Sensor Cable Failure Inspect electrical connections for damage poor connections and or corrosion Replace connectors and or cable Using the cable pinout documentation for your system check the continuity of all connections relating to this sensor Repair or replace cable as necessary Disconnect the sensor cable from the weld monitor amp sensor and then using Livingston sensor cable documentation check continuity of all connections within the cable Repair or replace cable as necessary Toroid failure Inspect the toroid for physical damage or abrasion Inspect for loose buckle Replace and or relocate toroid if necessary ASNOOr SNI SSPO Il 01 PROBLEM POSSIBLE CAUSE OR POSSIBLE FIX SYMPTOM SOME WELDS ARE External Bin Select is working Refer to Section 7 Trouble With Bin Select or Accept Reject REJECTED The weld intermittently summary screen indicates that some welds are Rejected Almost every parameter is out of tol
136. ged Verify calibration by disconnecting leads from electrodes and connecting to a 1 5V flashlight battery also connect a DMM the reading on the multimeter should match the calibrated reading on the Input Monitor screen Recalibrate voltage if necessary Refer to Chapter 8 Calibrating the Sensors Voltage leads are not connected properly Inspect electrical connections for poor connections or corrosion Sensor Cable or weld monitor failure Weld monitor has a problem with the voltage channel Inspect sensor cable for physical damage A cable that is deformed severed partially severed shredded abraded and or has bare wires showing may be suspect With the flashlight battery connected flex and manipulate leads to see if the calibrated readings jump or change If so disconnect sensor cable from the weld monitor and replace with a spare sensor cable Try to reposition the new cable to avoid recurring damage Spiral wrap or guards will also help to protect cable A static reading may indicate a problem with the weld monitor voltage channel Refer to Section 8 Trouble With Hardware 00 0 c Ol PROBLEM PEGGED A D READING The Input Monitor momentarily indicates a voltage channel A D reading of 32767 during a weld POSSIBLE CAUSE OR SYMPTOM Voltage applied to leads is above 9 9 volts Weld monitor has a problem with the voltage channel POSSIBLE FIX A
137. greater length of the cable and not in one small area Spiral wrap or guards will also help to protect cable Refer to Section 6 Possible Sensor Cable Failure In the General Setup menu check the A D Threshold settings Adjust these settings as necessary until the problem is resolved Refer to General Setup Section in Chapter 6 WMS Reference guide Toroid needs relocating Calibration factor not entered correctly Reposition toroid to avoid other sources of current or noise Re enter cal factor located on cylindrical housing Remember to enter the cal factor without the decimal point Example 0 356 356 cc Ol QOr SNI SSPO 5 TROUBLE WITH VOLTAGE LEADS READINGS OR CHANNEL PROBLEM CALIBRATED VOLTAGE SIGNAL IS READING HIGHER OR LOWER THAN NORMAL OR CALIBRATED VOLTAGE SIGNAL IS INDICATING A FROZEN static READING FROZEN A D READING VOLTAGE ONLY The Input Monitor indicates a constant static A D reading for voltage This value never changes the other sensor channels appear to be working and the A D values for these channels are changing updating SYMPTOM OR POSSIBLE CAUSE Voltage leads are broken POSSIBLE FIX Inspect for damage use an ohmmeter to check for high resistance flex and manipulate leads to see if readings change indicating an intermittent connection Replace leads if necessary Refer to Chapter 7 Installing the Sensors Calibration has chan
138. hanges the other sensor channels appear to be working and the A D values for these channels are changing updating The air pressure was adjusted or system pressure has changed POSSIBLE FIX Check air pressure setting Check the force at the electrodes Process timing has changed Weld head is extending later or retracting sooner than it was when Master or tolerance limits were set Intensification timing has changed Check for mechanical binding Check for PLC program changes Mechanical binding Problem with Weld monitor Sensor failure Check for mechanical binding of the weld head If other channel readings are not changing the data may not be updating Shutdown and Restart the weld monitor If problem persists contact Livingston Service A reading of 32767 indicates that the input channel is reading its maximum value and is saturated There may be problem with the sensor sensor cable or weld monitor hardware Disconnect the sensor from the sensor cable If the A D reading changes to a value within 100 from 0 the sensor may be malfunctioning Repair or replace the sensor If the A D reading remains at maximum value then the sensor may be OK and the sensor cable may be malfunctioning Refer to Section 6 Possible Sensor Cable Failure Sensor cable failure Disconnect the sensor from the cable if still pegged Disconnect cable from the weld monitor If the A D reading changes to a value w
139. hapter Trouble With Hardware Use the Input Monitor to observe the force channel readings Apply and remove pressure If the A D value does not change this may indicate a failed sensor sensor cable see below or weld monitor hardware problem Refer to Section 8 of this chapter Trouble With Hardware Use the Input Monitor to observe the force channel readings and compare the readings to those of another similar weld head adjusted to the same pressure Apply and remove pressure If the A D values are not similar to those displayed on a different weld monitor that is functioning properly this may indicate a failed sensor sensor cable or weld monitor hardware problem Use the Input Monitor to observe the force channel readings Apply and remove pressure If the A D values are not close to expected values this may indicate a failed sensor sensor cable see below or weld monitor problem If sensor and cable are ok refer to Section 8 of this chapter Trouble With Hardware QOr SNI SSPO lt 1 01 PROBLEM POSSIBLE CAUSE OR SYMPTOM WHEN A WELD IS MADE THERE IS LITTLE OR NO FORCE REPORTED FROZEN A D READING The Input Monitor indicates a constant static A D reading for the force sensor This value never changes the other sensor channels do not change or update either PEGGED A D READING The Input Monitor indicates a force channel A D reading of 32767 This value never c
140. haracteristics of the weld process and transmit this data to the weld monitor Toroids are used for measuring current and pressure sensors or load cells are used for measuring force Relative movement of the electrodes during welding is measured using displacement sensors while voltage leads measure voltage at the weld head Data is collected from all or a combination of these sensors and displayed by the halfcycle cycle or average for the entire weld depending on the type of monitor used The more weld parameters monitored the harder it is to unknowingly make a bad weld Using a Dynamic monitor factors that may adversely affect the quality of a weld can be easily tracked and identified and the exact moment when a problem occurs can be isolated down to the halfcycle A weld monitor will not control the weld process nor will it inform the user what the process parameters are supposed to be It will confirm if welds are made within the limits set by the user and a monitor can be used to simplify methods of refining process parameters It s important to understand that the user first needs to define the weld lobe and proper weld schedule Once a weld lobe and schedule are established according to internal standards or through trial and error monitoring can begin More Benefits Below are additional benefits of weld monitoring e Optimize weld schedules for individual parts and conditions e Ensure a 100 inspection level every single par
141. he measured window 11 10 0442 INS 400 Rev C Sensor Calibration Utilities Overview Sensors such as toroids slide potentiometers and force gauges are used by Livingston weld monitors to get information about the weld process as welds are taking place The relationship between the output of a particular sensor and a standard unit of measure such as inches is defined during the calibration process Many factors can influence the relationship between the output of a sensor and a defined unit of measure such as variations between sensors and different application techniques A good sensor will provide an output with a linear relationship to what the sensor is intended to measure During the calibration process two known reference points are provided From these points the Livingston weld monitor records the linear relationship between the installed sensor and standard units of measure e The toroid current sensor channel is calibrated at the factory and does not require further calibration e The voltage channel has no sensor readings are picked up via lead wires attached close to the electrode tips and therefore does not require calibration after leaving the factory e The remaining two channels force and displacement must be calibrated only when a new sensor or slide potentiometer is installed e Under normal operating conditions the only continuing procedure that is required is to zero the displacement sensor when changing
142. he weld summary screen indicates that weld data is being recorded with the wrong Binary Select POSSIBLE CAUSE OR SYMPTOM Binary Select Mode is not set to External POSSIBLE FIX Go to the General Setup menu and set Binary Select Mode to External Device controlling the Binary Select signals is not working correctly The timing of the bin select logic is not working properly Typically the Binary Select is controlled by a PLC and or switches on a panel Check all connections and programming logic Check the programming logic Weld Monitor Malfunction Interlock wiring is not correct Shutdown and restart the weld monitor If the problem persists contact Livingston Service Check all wiring for correctness Check that all I O voltages are correct WELD MONITOR ACCEPT REJECT SIGNALS NOT WORKING PROPERLY PLC programming is flawed Call your resident PLC programmer ANOOr SNI SSPO Lc 01 8 TROUBLE WITH HARDWARE PROBLEM SYMPTOM OR POSSIBLE CAUSE POSSIBLE FIX THE TRIGGER LED IS YELLOW The weld monitor in the middle of processing a weld Wait for the monitor to finish processing If scope mode is enabled the processing may take several minutes THE READY LED IS OFF The weld monitor is not ready to process welds The monitor may be still be initializing If after several minutes the LED is still OFF then shutdown and restart the weld monitor
143. ical axis 915 is Force measured in lbs Although 910 this particular graph only shows force and current all weld parameters be force toleranced using a Livingston monitor The locations of the diamonds show 895 exactly how much force was used at a 890 905 900 Force in Lbs particular current for the displayed weld 0 2 4 6 8 10 12 set For example the circled diamond in Current Rms KA figure 3 1 indicates a weld made with approximately 9 5 KA of weld current at Figure 3 2 Example of a Weld Lobe for Force 895 Ibs of force To determine the lobe for this particular data set each part associated with these welds would be destructively tested Suppose that testing revealed that the welds made within a range of about 908 to 914 165 of force with a range of about 7 11 KA of current were all good If a box is drawn to isolate these ranges as shown in figure 3 2 the area within that box is the weld lobe The box itself represents the tolerance limits or the limits of the range in which good high quality welds can be made A master is what provides the monitor with a weld signature that is within the weld lobe Tolerances are what define the boundaries of that box Once a master is created and toleranced Livingston monitors will reject any welds that have fallen outside of the box out of tolerance while any welds inside the box within tolerance will be ac
144. ieces missing from the tips of the electrodes pitting will result in an increased current density due to the decreased surface area The same amount of current fired through a smaller surface area may cause little hot spots that expel molten metal expulsion and or may result in undersized weld nuggets Conversely if the electrode tips mushroom and get bigger the current density is lower For example suppose that there are 6 mm round tips on a welder The area of each tip is about 28 mm The area of a circle is nr 3 3 14 28 Suppose the tips deliver 10 KA to a workpiece Current density equals the amperage divided by the surface area so the current density will be 0 36 KA or 36 Amps for every millimeter squared of surface 10 KA 28 mm 0 36 KA mm What happens if the tips mushroom to measure 7 mm about 0 040 inches greater in diameter Although one millimeter doesn t seem like a significant increase consider what happens to the current density The 7 mm tips now have a surface area of about 38 mm 3 5 3 14 38 Dividing the amperage by the surface area results in 0 26 KA or 26 Amps for every millimeter squared of surface The difference between 36 Amps per and 26 Amps per mm is a rather significant 28 reduction in current density 36 Amps 26 Amps 10 Amps difference 10 Amps is 27 78 of 36 Amps By allowing the electrodes to mushroom only one millimeter bigger over a quarter of the current density has been lo
145. ikes the hottest part of the tip first anything to cool off the tips heat can quickly build up to the point where the electrodes will eventually Water outlet weld to the workpieces To correct this problem the 4 Water inlet water tube should be placed so that the incoming cold water strikes the hottest part of the tip first as shown in figure 1 2 Figure 1 2 Example of an electrode cooling channel 0428 INS 400 Rev E 1 5 Surface Contact The ultimate goal of the weld process is for the weld current to generate sufficient heat between the workpieces being welded so that the metal will melt fuse together and form a weld nugget For this to happen the surface contact must be maximized The following experiment may sound silly but proves an important point take a piece of Scotch tape and stick it to a clean piece of paper Assuming that the tape was clean beforehand it probably sticks very well Now sprinkle some salt on the piece of paper Stick another piece of tape to the paper with the salt on it Depending on how much salt is there the tape probably sticks somewhat to not at all Lastly stick a third piece of tape to some carpeting then pull it off Now try to stick that same tape to the paper The third piece probably doesn t stick at all Compare the electrodes to the tape and the workpiece to the paper The clean tape sticks best to the clean paper just like well maintained clean electrodes have the best co
146. ing be extremely stiff since any mounting bracket that can be deflected a few thousandths of an inch can result in erratic and inaccurate displacement readings The displacement sensor window is approximately 9 of the range of the stroke of the displacement sensor For example a 4 inch sensor has a 354 inch range 0 177 inches from the zero point For additional info on displacement window and sensor sizing please contact your Livingston representative The displacement sensor can be zeroed electronically at any point on its stroke For more information on zeroing the displacement sensor please refer to Chapter 8 Calibrating the Sensors General mounting guidelines m Affix the mounting bracket to the welder If possible avoid locating the mounting on an electrical bus especially the transformer secondary bus Mount the sensor to the bracket use a service removable thread locking compound on rod end bolts and all other bracket fasteners to keep parts from loosening m Locate the blue displacement cable and plug it into the sensor The Livingston Monitor Sensor cable may be modified to work with qualified third party sensors Please contact your Livingston representative for further information 0434 INS 400 Rev C 7 7 Testing Sensor Installation This quick test will verify if all sensors have been properly installed by confirming that the weld monitor is receiving incoming sensor readings To test the sensor installation
147. ing of approximately 0 to 40 When full force is applied the reading should be from 50 to 75 of full scale 50 of 32767 16383 A D counts These numbers will vary based on sensor millivolt per volt output and load range verses actual load The point is that if A D readings with sensor loaded are similar to the sensor with no load this generally indicates a failure of the sensor or sensor cable Remember when checking a displacement sensor you must be within the measurement window to get meaningful A D readings If you are not within e g gun is retracted the reading will be pegged 32767 channel input range has been exceeded Refer to Chapter 8 Calibrating the sensors Chapter 9 FAQ and the Displacement Channel Over view Section of Chapter 11 for additional Information on displacement 10 4 0455 INS 400 Rev C QOr SNI SSPO S 01 1 SOME OR ALL WELDS ARE REJECTED NOT CATCHING FAULTY WELDS WELD COUNT NOT INCREASING PROBLEM POSSIBLE CAUSE OR SYMPTOM POSSIBLE FIX EVERY WELD IS REJECTED The weld summary screen indicates that almost every parameter is rejecting No Master or Master tolerance limits have been created It is possible that they were made but not updated Check to see if No Master is displayed on the Main Program screen If so create anew Master or new Master tolerance limits Refer to Chapter 5 WMS Quick Start Guide or Supplementary Procedure if applicable
148. ion data Import Masters from Eloppy Import Setup fram Floppy WARNING This command wil replace the current setup and related info in the database with the data previously saved in Fsetup cmp on floppy Press Import Setup from Floppy to continue or WARNING Welds cannot be monitored while the Import Setup option is in use Any Import Setup remote user interface windows must also be closed If the Cancel button is used the weld j monitor must be shut down and restarted DO NOT shutdown the weld monitor during this Figure 6 27 Import Setup From Floppy operation e Import Setup From Floppy This option is the same as the Import Setup command above except that the archive database has been compressed and stored to a floppy disk previously by an Export Setup To Floppy command Only one setup archive can be stored on a floppy disk WARNING Welds cannot be monitored while the Import Setup From Floppy option is in use Any remote user interface windows must also be closed If the Cancel button 15 used the weld monitor software must be shut down and restarted DO NOT shutdown the weld monitor during this operation 0433 INS 400 Rev E 6 17 Database Export Screen e Export All This option saves the current databases to archive databases backing up all system and weld data An Export All command should be executed periodically as system settings are changed and masters are develope
149. is called Expansion before sinking down into the workpiece this movement is called Setdown The expansion setdown process is very much like a pot of water boiling over before it s removed from the heat as the metal is heated it expands and then quickly contracts as it cools to form the weld A subsequent measurement of the nut workpiece after the weld is made is called the Final Thickness All these different measurements of electrode movement are measures of what s commonly called Electrode Displacement or simply Displacement Measuring displacement provides a good indication of whether or not the resulting weld was formed properly If the nut sinks too far into the workpiece it may be a sign of excessive heat which could render the weld no good It could also indicate that too much force was applied the weld time was too long or a number of other things Conversely if the nut doesn t sink far enough it may mean that not enough heat was generated for the materials to weld properly the force was insufficient etc Problems with displacement can be problematic in many applications such as welding hydraulic fittings If the setdown is too much too little chances are that the welded fitting will leak When taken into account that displacement is only one of many factors that when measured provide valuable information about the formation of the weld and its overall quality it becomes clear that weld monitoring is indeed a valuable tool Weld moni
150. is point on if you are not using a video monitor you will not be able to see everything you are doing on the weld monitor screen It is critical that you follow each step exactly so that the settings are properly entered If at any time you need to exit a screen use the ESCAPE key on the keyboard or using the monitor s touch screen select the Close option under the File tab All images here are displayed as they would be on a Livingston weld monitor Press the S key this will open the Settings menu which will not be visible then press the C key this will open the Control Panel window Use the up down arrow keys to highlight Network then press the Enter key 12 2 B a Computer Shortcut to livcoset exe l wa Network Neighborhood Recycle Bin Shortcut to livcosetup Shortcut to Shutdown bat Control Panel File Edit E Help View EJ Modems Mouse wi Multimedia im Add Remove Programs Console BE Date Time a Devices Pr PC Card PCMCIA Ports Fi Printers 0454 APP 118 Rev A 3 The Network window will appear with the Identification tab in the foreground If you do not wish to change the Identification skip to the step 5 Otherwise click the Change button or press Alt C to bring up the Identification Changes window Enter the desired Computer Name and or Workgroup or Domain Press Alt W then the right arrow key to change the Workgroup Pre
151. ithin 100 from 0 the sensor cable should be repaired or replaced If the A D reading remains at maximum value refer to Section 8 Trouble With Hardware 91 01 QOr SNI SSPO PROBLEM POSSIBLE CAUSE OR POSSIBLE FIX SYMPTOM INACCURATE A D Sensor failure A damaged force sensor may result in an offset or inaccurate READINGS The Input Monitor indicates the force sensor A D readings are changing but the readings may not be correct readings Use the Input Monitor to observe the force channel readings then refer to the force sensor manufacturer specifications and determine what the mV output of the sensor should be at a given force 32767 A D readings are equivalent to 20mV Apply and remove force and see if the A D input readings compare to what the sensor readings should be If the values seem to be incorrect there may a problem with the sensor sensor cable or weld monitor hardware Try using a known good spare sensor cable and or weld monitor If the readings still appear to be incorrect replace the sensor Sensor cable failure Try using a spare sensor cable Apply and remove force and see if the A D input readings compare to what the sensor readings should be If the values are still incorrect there may be a problem with the sensor or weld monitor Weld Monitor failure Try using a spare weld monitor Apply and remove force and see if the A D input readings compare to what the senso
152. ition The cursor is the thin arrow on the tolerancing screen that is slightly taller than the others The cursor may be moved by the Arrow Keys or by touching the graph The units and value of the selected data parameter at the cursor are displayed as the Cursor Halfcycle Value The Cursor Halfcycle Position is displayed just above the graph The segment halfcycle count within the segment and halfcycle count of the weld are displayed e Update After the tolerance limits of a master are edited the master must be updated in order for the weld monitor to begin comparing welds with the new tolerances limits After the master has been updated the current limits are displayed graphically along with the master The limit traces are displayed as dimmer lines on the display e Low High Limit Boxes The high and low limits for the selected parameter are displayed edited in these boxes The displayed limits correspond to the segment where the cursor is The Tolerance Limit Mode is displayed next to the parameter pickbox and cannot be changed in this menu Tolerance Limit Mode is set in the Tolerance Defaults screen There are two Tolerance Limit Modes REL Relative Limits All tolerance limits are set relative to the master signature data For example for a given master the high tolerance limit for Current Rms in Segment 1 is set to 5 If the Cursor Halfcycle Value for hcycle 10 is 9 03 and the Cursor Halfcycle Value for hcycle 11 is
153. ks to complete this procedure To copy export the default toroid calibration tables Database Export Utilities WARNING This command will export the current setup and related info to Fsetup mdb then LOTES s the file and store it to 2 Select Database Esport Masters It wi overwrite any data previously 1 From the Main Menu screen select Data Export All 3 Select Export Export Masters to stored there Mal the diskett sure the diskette 15 no 4 Select Export Setup to Floppy Insert the P write protected and insert it into floppy disk into the drive on the front of your Saip the drive Livingston monitor Follow the instructions to Press lt Export Setup to Floppy the right of the screen to continue 5 Use the ESCAPE button to exit this window Figure 11 1 Export Setup To Floppy Label this disk LDCT Livco Default Calibration Tables and keep it with the rest of your Livingston files To make a copy of the adjusted calibrations perform the same steps after all your sensors have been calibrated Use a new disk to capture this information Label this disk ACT Adjusted Calibration Tables and note the current date and welder being monitored on the label Should you ever need to return your Livingston monitor for repair it will be returned to you with the factory default calibration table You will need the ACT disk to reload your adjusted calib
154. l are joined by applying heat and pressure Back in the good old days blacksmiths and other crafty people would heat metals in a furnace and then weld them by hammering the red hot metals together By hammering the metals as they cooled the weld would be made stronger This heating and hammering method is known as forge welding While forge welding worked quite well for most of the welding done back then today s welding requirements are a bit more advanced After all it would be pretty difficult to heat all the metal needed to build an automobile in a big factory furnace and expect workers to hammer together each specific part used in the manufacturing process We d all still be riding horses to work Fortunately there are always a handful of brilliant people throughout history who are kind enough to invent newer faster and better ways of doing things One of these people was a professor by the name of Elihu Thompson Sometime in the year 1885 Professor Thompson invented a process called electric resistance welding He discovered that to weld metals together one could fire an electric current through the metals while they were tightly clamped together When the current passed through the metals it would create such a high heat that the metals would melt and run together and a weld would be made Many times the welded metal would be even stronger than the original metals used in the welding process Today s resistance welders work almost exactly
155. like pitting or mushrooming of the electrodes dirty workpieces changes in force etc all have an effect on the surface area the area of contact between the electrode and the workpiece Since changes in the surface area affect the contact resistance resistance of the surface area it is reasonable to say that the resistance at the workpiece is not constant but rather a factor that can change depending on a number of other conditions If Resistance is not constant then according to Ohm s 0428 INS 400 Rev E 1 7 Law Current is not constant either This means that the I squared version Joule s Law will not reveal the amount of heat generated at the workpiece unless the resistance at the tips is known Simply put to determine how much heat is being generated at the workpiece using Joule s Law current voltage or resistance must be measured at the workpiece Although a weld controller may be programmed to deliver 20 KA at 10 Volts if there is significant resistance in the secondary weld loop the heat will go there and not to the workpiece Likewise if the electrodes are worn or the workpiece is dirty resistance and current density will be affected In such a situation a controller might indicate 10 Volts at the secondary however there might actually be only 5 Volts at the weld tips Such a disparity could easily cause bad welds Identifying and Correcting Weld Problems A simple rule to remember is that quality usually equals consistency
156. ll the choice is up to the user 7 2 0434 INS 400 Rev C Displacement Double Rod End This type of sensor is an industrial linear potentiometer utilizing rod ends to connect it to weld head tooling The rod end s spherical bearings take up any minor misalignment in tooling or brackets making installation a little more forgiving than a spring return type This type of displacement sensor is a very robust unit and is highly recommended by Livingston for most applications Spring Return This type of sensor is also an industrial linear potentiometer and is typically used in situations when the space surrounding the weld force cylinder is limited When the potentiometer pot is retracted by the weld head tooling an internal spring allows the pot to extend with the tooling without actually being connected to it Special care must be taken to keep the rod perpendicular to the tooling or side loading may occur Rotary Some applications using a rotating pin or pivot may require the use of a rotary potentiometer This type of sensor is a small can with a rotating shaft The shaft can be coupled to the pivot transmitting the rotary motion from the pivot to the pot A rotary sensor is a good choice when tooling design makes it difficult to mount a linear potentiometer 0434 INS 400 Rev C 7 3 Installing the Current Toroid Before installing the toroid make a note of the three digit calibration factor that appears on a Livingston sticker on
157. ll incorrect then there may be a problem with the sensor or the sensor cable Refer to Section 6 Possible Sensor Cable Failure ASNOOr SNI SSPO 4 TROUBLE WITH PROBLEM INTERMITTENT LOW HALFCYCLE COUNT HCYCLES ON WELDS ARE RECORDED WHEN THE WELDER IS NOT WELDING WELDS ARE RECORDED BUT THE CURRENT IS NOT READING CORRECTLY POSSIBLE CAUSE OR SYMPTOM Weld control failure POSSIBLE FIX Check the weld controller Toroid settings not properly adjusted In the General Setup menu check the A D Threshold settings Set the A D Threshold to 750 and A D Hysteresis to 250 Higher settings may be required for higher weld currents Call Livingston Service if this does not solve the problem Toroid failure Check to be sure the buckle fastened on the toroid Check the placement of the toroid Inspect the toroid for physical damage Also inspect connector pins for contaminants or corrosion A toroid that is deformed severed partially severed shredded abraded and or has bare wires showing may be suspect If any damage is found replace the toroid Sensor cable failure Toroid settings not properly adjusted Inspect sensor cable for physical damage A cable that is deformed severed partially severed shredded abraded and or has bare wires showing may be suspect Disconnect sensor cable from the weld monitor and replace Try to reposition cable so that any flexing is over a
158. llectively in order to avoid false triggering due to electrical noise This noise may be caused by nearby contactors other secondary shunts in multi head applications servo drives etc The sum of the AD Threshold and AD Hysteresis settings determines the minimum amount of Current that must flow before the weld monitor begins capturing weld data If the AD Threshold is set too high the monitor may record inaccurate halfcycle counts and produce inaccurate information Too low a setting may cause false triggering leading to rejected welds and possible loss of data during a weld For maximum accuracy the AD Threshold should be set to a value higher than random noise spikes in the toroid signal Generally the AD Threshold is adjusted to a value twice the noise floor in the toroid signal The following graph should be used to determine an initial setting for these values However since each welding application and environment is unique these settings may need further adjustments Scope Mode can be used to help determine an appropriate setting if the initial settings do not work Call Livingston amp Co for technical support or for more information 0433 INS 400 Rev E 6 35 e AD Hysteresis Adjustment be required Recommended initial setting 250 AD Hysteresis is used in conjunction with AD Threshold and should generally be set to 25 to 40 of the AD Threshold value Higher AD Hysteresis settings may be required in noisy environm
159. made by the welder during a part cycle Note A binary select of 16 may appear if a master was created while an external binary select of 0 was selected This is intended as a diagnostic aide for those trouble shooting external binary select timing problems 6 10 0433 INS 400 Rev E Weld Summary Screen The Weld Summary displays a table of stored weld summary data records Rtype 2 with the most current record at the top Use the arrow keys to scroll through the rows data records and columns data parameters To determine the parameters that were out of tolerance in a given row weld data record pick that row and press the SELECT key A pop up window will display the offending parameters as shown in figure 6 16 Use ESCAPE to close the pop up window To view the weld tolerance limits for a specific parameter navigate to the data for that parameter and press the SELECT key A pop up window will display the weld tolerance limits Use ESCAPE to close the pop up window In addition to many of the Halfcycle Summary parameters described in the previous section the Weld Summary parameters also include the following e Weld The weld number with the most recent at the top e Hcycles On r lirnit Over limit Figure 6 16 Pop up window displaying all parameters that were out of tolerance Number of halfcycles in the weld that actually had current flow Note The Rtype field is omitted because all weld summary recor
160. main clamped until the ladder logic has been reset Parts with rejected welds can then be immediately identified and isolated from parts with accepted welds Selecting a Master A Livingston weld monitor can store a number of masters contains master tolerance limits that are selectable using the binary select inputs Selecting different masters is desirable for weld heads that make more than one weld perhaps with a different weld schedule or different part stack up Please refer to the General Setup Menu section in this manual for more information on binary select modes The WeldWise 2400 Binary Select inputs are 24V discrete connections located on the rear of the monitor Tolerances Weld Data Current vs Force Understanding tolerances requires an understanding of the weld lobe Restated 915 a cael 910 4 5 simply a weld lobe is the range for any welding parameter in which a high 5 bg quality weld can be made A weld lobe f force is typically defined by destructively 5 testing welds and then examining the corresponding weld data to determine 890 0 2 4 6 8 10 12 Current Rms in KA quality limits An example of collected weld data is shown in figure 3 1 In this graph the Figure 3 1 Weld data showing Force and Current diamond shapes represent welds made Example of a Weld Lobe The horizontal axis is the weld Current measured in KA and the vert
161. mpared to a master if one exists Depending on tolerance settings each weld is accepted or rejected based on this comparison No Masters are disabled and the WeldWise 2400 monitors without comparing welds to masters Note All welds will be rejected for all parameters when masters are disabled e Halfcycle Data Mode Default Setting None All halfcycle data records record type 0 will be recorded and stored in the database If a halfcycle is stored in the database then the associated weld record must be stored also If Halfcycle Data Mode is set to All Weld Data Mode is also automatically set to Failed If a weld is rejected halfcycle data is recorded only for those halfcycles that were out of tolerances failed If Halfcycle Data Mode is set to Failed Weld Data Mode cannot be set to None Note When viewing the halfcycle data graph halfcycles that did NOT fail are filled in with data points from the master and displayed along with the failed halfcycles None No halfcycle data records will be recorded For most high volume applications storing all of the halfcycle data records is not practical during normal production 20 cycle weld will produce 60 halfcycle data records including 10 halfcycles of pre weld data and 10 halfcycles of post weld data For this reason the default settings have Halfcycle Data Mode in None 0433 INS 400 Rev E 6 33 Segment Data Mode Default Setting None
162. n press the MENU key to display the Main Menu options 2 Select Mastering 3 Select New from the options The message displayed reads Initializing master memory then Creating new master Ready to accept welds The New button changes to Done 4 Make one weld using weld settings and standard parts customary for the application 5 Press the Done button to end the data capture The screen will say Updating master weld Pod 60 Creating new master Ready to acc weld Update Delete Master Figure 5 12 Mastering screen ready to accept welds set The date time stamp of the new master is displayed at the top left of the screen 6 Your screen should now look similar to figure 5 13 Press the Update button to save the newly created master into the monitor s memory Note Anytime you create a new master change the name of a master or change tolerances for a master yu MUST use the Update button for the new master tolerance changes to take effect The MOT after the date time stamp of a master refers to the Master Select binary select number For more information about Bin Selects please refer to Chapter 6 WMS Reference Guide 0432 INS 400 Rev E 1 50 40 PM M01 Select Master Edit Master Copy Replace Delete Master Figure 5 13 Mastering screen with new master date time stamp displayed at the top left Press Update to update master for use by the monitor 5 7 Accepti
163. nce once a week is a suggested and conservative starting point The following steps should be performed in order to clean out and minimize the size of the databases If weld data is being archived it should be archived prior to performing these steps 1 Delete All Welds It is recommended that weld data be deleted so that the welddata mdb database is kept to less than 600Mbytes in size This will make it easier for those who wish to make a copy of the data prior to deleting weld data A file size of 600Mbytes is still manageable when copying data across the company network querying the data and archiving the database files to a CD R 2 Delete System Log The System Log records system events such as starting up shutting down errors on the network general diagnostic events certain configuration events database upgrades etc Although this log does not fill up quickly it is recommended that the log entries be deleted any time weld data is deleted 3 Compact Database When information is deleted from a database database records are only marked for deletion but still take up space in the database For example deleting the system log does not make the livco mdb file any smaller Even if the system log were deleted every day livco mdb would continue to grow To recover this space and reduce the size of the database file the Compact Database operation should be performed periodically 11 4 0614 INS
164. nd Trigger Post settings will increase the time needed for this processing Trigger Mode Applies only when Scope Mode is Enabled Repeat Each weld is captured in Scope Mode Due to the amount of data recorded in Scope Mode the 2400 may be busy for a considerable period of time after the weld has been completed Use the LEDs on the front panel to determine when the monitor is finished recording the waveform Single Shot Data for the first weld following the Scope Enable setting of 1 is captured in Scope Mode The Scope Enable parameter is then automatically reset to a value of 0 First Failure Data for the first Rejected weld following the Scope Enable setting of 1 1s captured in Scope Mode The Scope Enable parameter is then automatically reset to a value of 0 This mode is useful for catching intermittent elusive failures however the monitor will be busy for an indeterminate amount of time while recording a waveform This means that any welds following the failure will not be monitored until the 2400 has finished recording and is not busy 6 34 0433 INS 400 Rev E e Trigger Hcycle Applies only when Scope Mode is Enabled Trigger Hcycle determines the halfcycle within the Trigger Segment that will be the start of data gathering in Scope Mode This halfcycle is the trigger point for Scope Mode e Trigger Segment Applies only when Scope Mode is Enabled Trigger Segment determines the weld segment in which data gathering start
165. ng SELECT The SELECT button is used to select an item This either performs the action associated with that item or puts you into Editing mode A selected item is usually highlighted shown with a highlighted border or indicated with a flashing cursor Once an item has been chosen shown by a highlighted or enhanced border in the touch screen press the SELECT button to highlight shown by a different fill color that item for use or change For example if the item is a menu option the program opens to the next appropriate display If the item is parameter you can cycle through a list of additional choices using the Arrow Buttons If the choices show a 4 2 043 1 INS 400 Rev D ENTER Other Buttons HELP PRINT 043 1 INS 400 Rev D number you can increase or decrease it by using the arrow buttons or if you have a keyboard you can simply type in the desired number The SELECT button takes you to the next level or the next set of choices You can also double click the item with a mouse or press Enter on an external keyboard When you have changed a value or completed some type of operation in the program use the ENTER button to confirm the change and store the new value For example if you change the value of a tolerance using the Arrow Buttons use the ENTER button to confirm the change and save the new tolerance setting You can do this using the ENTER button on the touch pad or by pressing the Enter button on a keyboard Pressi
166. ng Rejecting Welds Once a master has been created and updated the monitor has a basis on which to compare subsequent welds If all parameters fall within the master tolerance limits the weld is accepted by the monitor If any of the parameters fall outside of the master tolerance limits the weld is rejected by the monitor This section will demonstrate an accepted weld and a rejected weld 3 0 40 PM MOT Weld Making an accepted weld 1 ESCAPE to the main program screen 2 Make another weld Notice that the newly Voltage Rms 0 000 5 000 created master is displayed in the top left indicating that the weld was compared against this master as shown in figure 5 14 Ideally 0 000 1 500 this weld should have accepted and a check mark should be displayed in the Weld Status 20 box If there are flashing arrows in the Weld Hcycle On Cnt 0 000 Status box then weld rejected for some reason Either the weld was rejected because Figure 5 14 Main program screen with new master the master tolerances are set too tightly or date time stamp displayed either the master weld or the last weld made was not characteristic of a typical weld for this process 3 Goto the Weld Summary screen and look at the Accept Status for the weld you just made the most recent weld will be at the top An Accept Status of 0 indicates that the weld was accepted If the weld was rejected highlight the Accept Status number and press the SELECT key to see what pa
167. ng the ENTER button will return you to navigation mode Note Once you have selected and highlighted a value to be changed you must use the ENTER button to exit the highlighted item even if the value has not changed This button accesses the built in help features of the WMS program Although new help features are continually being incorporated into the program you may find that in some windows the HELP button does not activate If you are having difficulties with a particular feature please consult this manual or your Livingston representative for further information This button will print the contents of the WMS touch screen window using the built in thermal printer Printing can take place from most of the screens that appear in the display window NOTE The printer will only print what is visible in the display window to the left of the virtual keypad Printing can be configuration for use with an external printer or network printer The WeldWise 2400 Back Panel AC power switch here eee COM 1 MOUSE Video monitor here LIVINGSTON West Lebanon NH 03784 Model WW2400 Serial No m AC power cable here Keyboard here Mouse here Ethernet cable here Numbers used for Figure 4 3 Back panel of a 2400 IP address and computer name The back panel features connectors for attaching peripherals such as an external keyboard monitor printer UPS or other device 4 4 0431 INS 400 Rev D Proper Shutdown
168. nging the value of it There are four directional arrows on the keypad In the middle of the arrow is a SELECT button and an ENTER ESCAPE MENU HELP button on the bottom right On the top are three other buttons ESCAPE MENU and HELP The PRINT button is on the bottom left A If you are using an external keyboard these options may be quickly accessed with the hot keys represented by the SELECT underlined letters ALT letter You can also use the keyboard arrows instead of the arrows on the touch pad PRINT ENTER Figure 4 2 Keypad buttons Navigation Generally anytime you move within a screen or from screen to screen the location of the cursor is shown by a highlighted or enhanced border ESCAPE This button reverses your path through the program For example if you selected the Data option from the Main Menu you can use the ESCAPE button to return to the Main Menu ESCAPE always takes you back one level at a time towards the Main Menu of the program or cancels your previous action If you press ESCAPE enough times from anywhere in the program you will always end up at the opening program screen This button accesses the Main Menu from many but not all points in the program Use it to return to the Main Menu options Arrow Use the arrow buttons to move up down left or right on the touch screen The arrows will also allow you to change options once an item has been selected Editi
169. nitor This option displays the input monitor screen which shows the data values from external sensors and inputs A Zero Displacement utility is also provided Toroid Settings Calibrate Voltage Calibrate Force e Toroid Settings This utility is used adjust the toroid Calibrate calibration The calibration is set at the Displacement factory for use with a toroid that has a CF of 0 400 calibration factor of 400 When Figure 6 51 Setup Utilities installing a toroid the CF setting labeled on the toroid should be entered as a whole number in this screen Example CF of 0 354 should be entered as 354 e Calibrate Voltage This utility is used to calibrate the voltage sensor input channel The voltage calibration values are set at the factory and therefore do not require calibration e Calibrate Force This utility is used to calibrate the force sensor input channel The Force channel must be calibrated when a new force or pressure sensor is installed e Calibrate Displacement This utility is used to calibrate the displacement sensor input channel This channel should be calibrated when a new displacement sensor is installed 6 38 0433 INS 400 Rev E Input Monitor A D Values Input Unit The Input Monitor display allows you to see the raw data readings from the sensor input channels A D values as well as the calibrated readings for Voltage Force and Displacement are also shown Value Calculated
170. ntact with a clean workpiece The tape sticks so so to the paper with the salt on it just like electrodes will have a so so contact with the workpiece if it s dirty greasy etc Lastly the tape that has been stuck to the carpet and then re stuck to the paper probably doesn t stick well at all just like worn or pitted electrodes don t have very good contact with the workpiece By maximizing the surface contact current density is increased Both of these factors play key roles in ensuring that enough heat is generated to reach that ultimate goal of forming a weld nugget Current Density Current density describes how much current is being delivered to a specific area In other words it describes the concentration of the current in a small area of the workpiece namely the area where the weld is To calculate current density the amperage how much current is divided by the surface area area of contact between the electrode and the workpiece As a rule the smaller the surface area the denser the current When the current is denser the surface area gets hotter and the metal melts faster Consequently a current density that is too high for the application may cause expulsion In contrast a larger surface area delivers a less dense current If the current density is too low for the application there may be cold welds or perhaps no welds at all The size shape and overall condition of the electrodes affect the surface area in contact Small p
171. ny rejected welds including the parameters that were out of tolerance according to the limits defined by the current signature For each Accept Status code the weld monitor can display a text description indicating the parameters that were not within master tolerance limits You can track and interpret this information from the stored database values that are logged during weld monitoring Advanced users can convert the Accept Status decimal numeric value into a binary value that signifies the parameters that failed and whether the failure was higher or lower than the tolerance threshold To convert an Accept Status code 1 Enter the value of the code into a calculator that can handle decimal to binary conversion such as_ the Windows calculator application For example figure 11 3 shows a decimal value of 260 for the status code 2 Change the display view from decimal to binary The equivalent binary value appears 100000100 as shown in figure 11 4 3 Counting from the right starting at 0 bit positions 2 and 9 indicate failures Consult the table on the following page to identify the failed parameter The following table maps bit positions to failures A binary 1 will appear in each position where there is an associated failure From the previous example bit positions 2 9 indicate CURRENTPEAK HI and FORCE HI failures In other words peak current and force were outside of their master tolerance limits 11 12
172. o Chapter 8 Calibrating the Sensors for additional information Update Cal Factor Sends the calibration to the weld monitor This button must be used for any new settings to take effect 6 40 0433 INS 400 Rev E Voltage Calibration Utility WARNING The voltage Voltage is calibrated at the factory and does not Jut settings have been need to be re calibrated If however there is an calibrated at the factory extenuating circumstance requiring re calibration of and do not need to be l re calibrated under the voltage use the following procedure You will normal conditions need a battery and a multimeter to calibrate voltage n Refer to Chapter 8 Calibrating the Sensors for lo Con ae cE additional information tees to exit Figure 6 55 Voltage calibration warning Setup Utilities Figure 6 56 Voltage calibration fields 0433 INS 400 Rev E 6 41 Force Calibration Utility Force sensor calibration is required when a new i Set low force sensor is installed An external hand held force gauge will be required to determine the exact amount of force that is being applied during this calibration Refer to Chapter 8 Calibrating the Sensors for additional information Figure 6 57 Force calibration fields 6 42 0433 INS 400 Rev E Displacement Calibration Utility Displacement sensor calibration is required when a new sensor is installed The displacement channel calibration
173. od or bad Together they can answer what is perhaps the most important question of all is the welding process consistently within the defined weld lobe 0429 INS 400 Rev C 2 1 Weld Lobes and the Weld Process Each of the factors involved in the creation of a weld Current Voltage Resistance etc has a specific range in which good welds can be made This range is commonly known as the weld lobe Bad welds are made when the weld process falls outside of the lobe so the simple answer to making consistently good welds is to keep the process inside the lobe It is not so simple however to ensure that this happens for each weld made This is where resistance weld monitoring is most valuable The following example uses a weld nut and the relative movement of the electrodes during the weld to examine what goes on during the weld process Livingston terminology in italics is used to describe various measurements The nut itself has a number of little metal feet or projections on the bottom of it These projections sit on top of the workpiece to which they ll be welded A measurement of the nut sitting on top of the workpiece with the electrodes clamped on it before the weld is made is called the nitial Thickness When the proper electrode force is applied and weld current is fired the projections melt into the workpiece and create a weld When the projections melt the molten metal expands for a moment pushing the electrodes apart this movement
174. omer s expense Repaired products shipped ground to the Customer shall be at the Customer s expense Expedited shipment at the Customer s request shall be at the Customer s expense Products should be shipped to the Customer Service Department c o the Company 415 Waterman Road South Royalton VT 05068 The Company will evaluate the Product and will contact the Customer with a repair cost estimate and will require a Purchase Order for the repair from the Customer before proceeding An initial evaluation charge of 80 00 will be assessed Repaired parts the warranty is effective ninety 90 days from date of shipment by the Company SPECIAL CIRCUMSTANCES The Company may ship pre paid or COD to some Customers depending on credit status and or location Customers will be notified in advance of any such action UNCLAIMED PRODUCTS Any unclaimed products will become the property of the Company after a period of 90 days 11 24 0079 PRD ADM Rev D Document 0454 118 LIVINGSTON E s amp COMPAN Y INC Revision A APPLICATION NOTE Category Procedure Applies to WeldWise 2400 or POD Server Subject Change IP Address HOW TO CHANGE THE IDENTIFICATION AND OR IP ADDRESS OF A 2400 OR POD SERVER USING THE 2400 OR POD SERVER WITH OR WITHOUT A MOUSE Objective This procedure will allow you to change the Identification and or IP address of your WeldWise 2400 weld monitor or POD Server using a keyboard with or
175. ommand will current setup and ated info to Setup mdb It will overwrite any data previously tored there It may take up to 1 minute s to complete Press Export Setup ti continue or Escape to exit Note A floppy disk can typically hold 1 4MB If the data you are trying to export exceeds that i H Export Setup ta size it should be transferred via a networked Floppy computer Call Livingston Service for additional information Figure 6 31 Export Setup WARNING Welds cannot be monitored while mar the Export Masters to Floppv option is in use Anv remote user interface windows must also be closed If the Cancel button is EX Mat jalap i used the weld monitor must be shut down and related info to Fsetup mdb then restarted DO NOT shutdown the weld sport Masters a monitor during this operation any data previously asters to ored there e Export Setup Make sure the diskette is not write protected and insert it into This option saves the current general setup and ine drive sensor calibration information to an archive 4 Press Export Setup to Floppy database The setup archive database file name i continue or Escape to exit is setup mdb This command will overwrite the existing setup and calibration data Figure 6 32 Export Setup to Floppy WARNING Welds cannot be monitored while the Export Masters to Floppy option is in use Any r
176. or dressing electrodes or when using workpieces of significantly different thickness This can be done via the Zero Displacement button in the Input Monitor display Force sensor note If it is not possible to obtain two distinct readings at different levels the monitoring program can work from a single value For example suppose you open the welder tips but cannot completely remove the force from a transducer because of the weight of connected mechanics Suppose you also can t easily determine how much force is on the sensor because it s not practical to get a calibrated force gauge into the mechanics In this case the weld monitor can perform a single point calibration by assuming that a zero output from the force transducer corresponds to a force of zero PSI When the weld tips are closed and a known force is provided as the second high reference point the linear relationship is established Note It is strongly recommended that whenever possible you use two calibration values to ensure more accurate calibration and more precise monitoring operations For more information about calibrating sensors please refer to chapter 8 Calibrating the Sensors 0445 INS 400 Rev D 11 11 Identifying and Interpreting Accept Status Codes The main operating display for the weld monitor provides a quick view of the ongoing status of the welding operation The Accept Status codes displayed at several points in the program indicate the nature of a
177. ore cylinder with a 70 psi line pressure Surface area of the bore Radius of an 8 bore 4 4 16 16 3 14 50 24 50 24 70 psi 3516 8 psi electrode force Enter 3516 8 in the Point 2 value field Note Many tandem or multiple piston cylinder manufacturers supply force inlet pressure specification charts 0435 INS 400 Rev D 8 7 Calibrating Voltage Voltage is calibrated at the factory and does not need to be re calibrated If there is an extenuating circumstance requiring re calibration of the voltage use the following procedure You will need a set of Livingston voltage leads a battery and a multimeter to calibrate voltage A Livingston Voltage Calibrator may also be used Note Do not insert paper clips or wire into the connectors The connector pins may be damaged resulting in intermittent readings on the voltage channel To calibrate the voltage using a set of voltage leads a battery and multimeter 1 Disconnect the green Voltage sensor cable from the voltage leads installed on your welder 2 Connect the calibration leads to the green cable connector 3 From the Utilities Menu select Calibrate Voltage 4 Short the voltage leads together and set the value to 0 This reading is listed as optional but is highly recommended Click ENTER to confirm the entry 5 Connect a 1 5V or 9V battery to the leads The red lead is positive the black lead is negative Make sure the DC voltage polarity is observ
178. ormat 1 Find Computer File Edit View Help gt MG Files or Folders Computer Name Named 2400 0172 z tu On the Internet 89 Using Microsoft Outlook kem New Search Windows NT Workstation 0454 APP 121 Rev A 12 7 4 Once the unit is found double click on it to open it this may take a minute or two If you are using Windows NT you may be prompted for a password Type in Administrator in the Connect As box and 2400 in the Password box 1 Find Computer Iof x File Edit View Help Computer Name Named 24000172 y Stop New Search a Enter Network Password Ed Incorrect password or unknown username for OK 2400 0172 Heb E2400 0172 Network Neighbor Connect As Administrator Help 1 computers found Password 2400 5 Ifthe unit is a 2400 open the folder If the unit is a POD Server open the d folder 2400 0172 L IDIX 2400 0170 oO x File Edit View Help File Edit View Help 2400 0172 t 2400 0170 Nc qni gt 3 Printers C pwrchute pwrchute 8 Printers 3 objects Z 4 objects 7 6 Open the file named livcosetup fin 2400_0172 Bife Es Apc5 1 1ed Pod Es Batch C Program Files C Touch a Boo Chips C Reonsole Sg Tscdrv E Sme E winnt E Di3 Cd 5 5 Advpack dil amp Di5 20 Sst S Autoexe
179. ould be attached as close to the tips of the electrodes as possible without interfering with the weld process Ideally you will want to select a location on a permanent piece of tooling to prevent re mounting the leads Once you have selected a location drill and tap a hole for a 10 32 screw taking care not to tap into an area where the electrode s cooling channels are located The Noise Suppression Filter should be attached close to the connector and should be wrapped 13 times with the leads Do not twist the leads while wrapping them around the filter The filter itself should then be secured using cable ties Run the voltage lead wire from the connector up to the point of connection near the electrode tips Open and close the tips to see exactly how much excess lead wire is needed to accommodate the motion Secure the voltage wires back along the bus using cable ties or some type of hold down clamps Attach 10 ring terminals to the ends of the voltage leads 0434 INS 400 Rev C 7 5 Installing the Force Sensor The mounting of the force transducer is completely dependent on the configuration of the equipment and the type of sensor in use In the case of a load cell an equipment integrator may have already installed the transducer or special tooling may be needed to accommodate it An inline pressure transducer can be integrated with the air oil hydraulic cylinder via the inlet port or pressure port on a modified air over oil cylinde
180. ow Leave item 4 blank and click OK Create New Data Source What name do you want to give your data source y first query Select a driver for the type of database you want to access 2 Microsoft Access Driver mdb Click Connect and enter any information requested by the driver D My Weld Data 2400_0172 112000 WeldData Select a default table for your data source optional 4 Y Save my user ID and password in the data source definition Cancel 13 The Choose Data Source window will reappear with the new data source you named highlighted Click OK 0454 APP 121 Rev A 12 13 14 15 The Query Wizard Choose Columns window will appear Under the Available tables and columns should be posteddata with a small checkbox next to it Click the gt button between the two windows This will transfer the contents of posteddata into the Columns in your query window Click Next gt Query Wizard Choose Columns 24x What columns of data do you want to include in your query Available tables and columns Columns in your query Bact Cancel The Query Wizard Filter window will appear This window allows you to filter or sort the weld data in a number of different ways Note In this procedure we ll use the pod recordtype and weld fields as examples Once you are familiar with this process you can filter the data however you like
181. own menu will appear slightly different as shown in figure 6 65 Likewise if a database function has been cancelled the shutdown menu will feature only one option as shown in figure 6 66 Database Missing or Beyond Repair DB Maintenance Operation Failed Import All and shutdown Windows too Import All and shutdown but don t shutdown Windows i Shutdown Shutdown Windows Shutdown without Import All Shutdown Windows too Shutdown without Import All but don t shutdown Windows Figure 6 65 Alternate shutdown options Figure 6 66 Shutdown monitor 0433 INS 400 Rev E 6 47 6 48 Installing the Sensors The Monitor Sensor cable included with a WeldWise 2400 routes input from four possible external signal sources Current Voltage Force and Displacement sensors to the weld monitor Each sensor must be attached to the appropriate cable lead as indicated by the color coding It is not necessary to have a sensor attached to every lead however a Livingston current toroid must always be used Note Any sensor lead not in use should have its connector protected to prevent contamination of internal pins RED Figure 7 1 Color coding on the Monitor Sensor cable Q EE current Red Current sensor SE vonc H n Green Voltage sensor E YELLOW l SAN Yellow Force sensor The Monitor Sensor cable attaches to the weld monitor as shown below BLUE DISPLACEMENT Blue
182. r General mounting guidelines Be sure to avoid mounting the sensor on or too close to an electrical bus Take precautions to isolate the load cell from the welding ground Do not mount the sensor within the loop formed by the weld head secondary bus The sensor should be tightly secured at its mounting point and should be isolated as best as possible from sources of magnetic fields The yellow force cable connector couples with the force sensor The Livingston Monitor Sensor cable may be modified to work with qualified third party sensors Please contact your Livingston representative for further information 7 6 0434 INS 400 Rev C Installing the Displacement Sensor Livingston recommends the use of a double rod end displacement sensor The size of this sensor will depend on the stroke of weld cylinder the sensor s stroke must always be greater than the full stroke of the cylinder to prevent over travel of the sensor It is important to leave at least 1 4 of travel on either end of the sensor stroke as the resistive element inside the sensor has a small dead band on each end Try to position the sensor so readings are being taken in the middle range of the full stroke because scaling resistors are tuned to work best with readings being taken in the area that is centered between 25 of travel on each end The sensor itself should be mounted on a non flexible aluminum or other non magnetic bracket It is essential that the mount
183. r readings should be If the values are still incorrect then there may be a problem with the sensor or the sensor cable Refer to Section 6 Possible Sensor Cable Failure QOr SNI SSPO 1701 3 TROUBLE WITH DISPLACEMENT SENSOR READINGS OR CHANNEL PROBLEM CALIBRATED DISPLACEMENT SIGNAL IS READING HIGHER OR LOWER THAN NORMAL CALIBRATED DISPLACEMENT SIGNAL IS INDICATING A FROZEN static READING POSSIBLE CAUSE OR SYMPTOM The sensor was not zeroed Calibration has changed POSSIBLE FIX Zero the displacement sensor Inspect and recalibrate sensor if necessary Refer to Chapter 8 Calibrating the Sensors Note If an Export Setup was performed the last time this sensor was properly calibrated an Import Setup may be performed to reload the saved calibration settings Refer to Chapter 6 WMS Reference Guide Sensor failure Inspect sensor for physical damage Inspect electrical connections for poor connections or corrosion Try recalibrating sensor if the sensor will not calibrate or A D readings don t look right Test the sensor Independent of the Livingston system Test the sensor independent of the Livingston System by using an Oscilloscope Different model sensors may require different methods of testing Call Livingston amp Co for details regarding the testing of your sensor Sensor Cable or weld monitor failure Inspect sensor cable for physical damage
184. r a definition of relative and absolute tolerances As weld data is recorded and compared to the master tolerance limits the monitor flags values that are out of tolerance In this section we ll change the tolerances for the master that was just made and then accept reject welds based on those master tolerance limits 1 From the Main Menu select Tolerancing x eTTETTTTIZ ET If nothing comes up press the Select Master button and highlight the master we Current Rms Limits REL Select Master just made Press SELECT Your screen Low High Cursor Unit should look similar to figure 5 18 10 10 0 75 Update HALFCYCLE TOLERAHCES Segment 1 Hcycle 6 WHC 16 Touch anywhere in the Weld segment middle of the screen so that the pointer thinnest vertical arrow is in Segment 1 Weld segment Under HALFCYCLE TOLERANCES the screen should say Segment 1 Figure 5 18 Tolerancing screen Select the parameter Current Rms Tolerancing Master 3 13 01 3 50 40 PM M01 Current Rms Limits REL Select Master Low High Cursor Unit Select the Low number and change it to 1 i 8 15 KA Select the High number and change it to 1 HALFCYCLE TOLERAHCES Segment 1 Hevcle 7 17 Press the Update button After a few 4 mm moments the screen should now look F m aa similar to figure 5 19 Notice that the 8 tolerance bands have adjusted accordingly Figure 5 19 Master with Low High tolerances
185. r groupings you may type a to indicate a space You may want to select the Obtain IP address from a DHCP server option from the TCP IP Properties window if you are using DHCP If you are using a personal laptop or do not have a company network you may want to change the IP address of your computer to the 2400 Pod Server s IP address The default IP address of the 2400 Pod Server is 192 168 2 xxx where xxx is the last 3 digits of the monitor s serial number The 2400 Pod Server s default User Name is Administrator The default Password is 2400 The default Workgroup is Livingston 454 APP 299 Rev B Contact Information Livingston amp Company Inc Administration Engineering and Manufacturing 415 Waterman Road South Royalton VT 05068 Telephone 802 763 2934 Fax 802 763 2746 Email info livco com URL www livco com Livingston amp Company Inc Michigan Office Sales and Service Suite 250 1100 North Opdyke Road Auburn Hills MI 48326 Tel 248 377 1782 Fax 248 377 2196 Technical Support Telephone 802 763 2934 Email support livco com Sales Telephone 248 377 1782 Email sales livco com 0450 INS 400 Rev E 13 1 13 2 UPDATES THE WELDWISE USER S MANUAL Revision C The WeldWise M 2400 User s Manual Revision C is intended for use with Version 8 software starting with the following versions released April 2005 User Interface livcoset exe 8 008 8 8 0
186. r supply is recommended to avoid a hard shutdown of the computer due to sudden loss of power This kind of shutdown may result in corrupt databases and in some cases damage to Windows system files leaving the computer inoperable If your weld monitor was purchased with the UPS option the necessary software was installed and configured at the factory The pre loaded software will either activate the startup or shutdown procedure in the WMS program For information about how to install a UPS for use with a Livingston monitor please refer to Attaching Peripherals in Chapter 11 Appendices The following actions should never be taken e NEVER shut off your Livingston monitor using the power switch on the back panel without having gone through the proper shutdown procedure e NEVER disturb the Livingston monitor or UPS if equipped while it is cycling through the shutdown sequence Failure to comply with these guidelines may irreparably damage the Livingston database Livingston will not be responsible for damage to any monitor incurred through failure to comply with these guidelines For additional information about using or obtaining a UPS please refer to the APC UPS manual 0431 INS 400 Rev D 4 5 4 6 WMS Quick Start Guide This chapter is a quick how to guide to begin using a Livingston weld monitor The provided example describes the necessary steps to collect and view data create a master and set tolerances Note Since thi
187. rameters failed 4 Go to the Halfcycle Summary Screen to graphically compare the halfcycle data with the master tolerance limits Change the parameter in the top left box to Current Rms and the parameter in the top right box to Hcycle Limits Your screen maempr EP TIECTETUETET should now look similar to figure 5 15 The thin vertical arrows pointing down separate the three default segments Pre weld Weld and Post weld of the weld process The upper and lower horizontal lines represent the default tolerances assigned to the master The middle line represents the weld signature for the weld number at the bottom of the screen As you can see the parameter Current Rms was within the tolerance defaults of this master For the weld to be accepted all parameters must be within the master tolerance limits Figure 5 15 Halfcycle Summary Current Rms shown with Halfcycle Limits Selecting different parameters in the upper left box will allow you to compare all parameters with the master tolerance limits 5 8 0432 INS 400 Rev E 5 Making rejected weld Now we will deliberately reject a weld and see If for some reason your weld rejected try making more welds to see if any accept If the welds continue to reject review the failed parameters and skip ahead to the tolerancing section of the WMS quick start guide Adjust master tolerances until welds are accepted and continue with the following steps to make a rejected weld
188. rations In this situation follow the import procedure below To import the default calibration tables WARNING This command will Import All 1 From the Main Menu screen select Data eus va C it ee eiated info in the database with the data previously saved in 2 Select Database Import Masters Festus creo Hane 3 Select Import ae ee Import Masters from Press Import Setup from 4 Select Import Setup From Floppy Insert Floppy or either the LDCT or ACT floppy disk l UST containing the exported files Follow the 5 directions to the right of the screen 5 Use ESCAPE to exit this window a Figure 11 2 Import Setup From Floppy 11 8 0437 INS 400 Rev D You will want to keep LDCT disk in safe place should you ever need it for future use Should your calibration settings change you should update the ACT disk Calibration settings weld data and masters can also be imported exported to an archive in the monitor itself Refer to chapter 6 WMS Reference Guide for additional information 0437 INS 400 Rev D 11 9 Displacement Channel Overview The displacement channel is used to measure the thickness of a part before during and after the weld process This channel is designed to work with a potentiometer type sensor which is a variable resistor with three terminals one on each end of the resistor and one wiper which contacts the resistor to indicate
189. rd electrodes and fixtures They can also be used for seam welder bearings and other current carrying structural parts Class 20 Good electrical and thermal Welding of metallic coated metal such as Medium Conductivity properties with heat and galvanized steel terne plate mild steel low alloy Medium Hard temperature resistance steel etc They are used for welding highly conductive materials like copper or silvers projection Class 10 14 l High heat high pressure and welding cross wire welding electro forming Low Conductivity H mechanical wear resistance electroforging and upsetting Also used for low High Hardness conductors like stainless where high pressures are needed Figure Il 8 Common Uses of RWMA Material reprinted with permission 0447 INS 400 Rev Il 21 11 22 Warranty amp Repair Policy Livingston amp Company Inc shall herein be referred to as the Company and any customer Purchasing goods or services from the Company shall herein be referred to as Purchaser In the case that the Purchaser and the Warrantee are not the same entity for purposes of the following warranty provisions they shall be referred to collectively as the Customer LIMITED WARRANTY Any Company manufactured product which under normal operating conditions proves defective in material or in workmanship within one 1 year from the date of shipment by the Company will be repaire
190. replace the sensor FROZEN A D READING ALL The Input Monitor indicates a constant static A D reading for the displacement sensor This value never changes the other sensor channels do not change or update either Weld Monitor problem If other channel readings are not changing the data may not be updating Shutdown and Restart the weld monitor If problem persists contact Livingston Service ASNOOr SNI SSPO 61 01 PROBLEM POSSIBLE CAUSE OR POSSIBLE FIX SYMPTOM PEGGED A D READING The sensor was not zeroed displacement Zero the displacement sensor If the sensor will not zero the The Input Monitor only sensor sensor cable or weld monitor may be malfunctioning indicates a displacement Sensor failure A reading of 32767 indicates that the input channel is channel A D reading of saturated and reading its maximum value There may be a 32767 This value never changes the other sensor channels appear to be working and the A D values for these channels are changing updating problem with the sensor sensor cable or weld monitor Disconnect the sensor from the sensor cable If the A D reading changes to a value of less than 100 the sensor may be malfunctioning Repair or replace the sensor If the A D reading remains at maximum value then the sensor may be OK and the sensor cable or weld monitor may be malfunctioning Refer to Section 6 Possible Sensor Cable Failure Sensor c
191. rface contact and current density Current Current usually measured in Kilo Amperes KA one Kilo Amp is equal to 1 000 Amps is one of the most important factors A resistance weld cannot be made unless there is sufficient weld current According to the RWMA the typical amount of current needed to weld low carbon steel for example is about 10 000 Amps 10 KA at about 5 Volts To put this in perspective a normal household or office outlet provides a maximum of 15 20 Amps 0 015 0 020 KA at 120 Volts while a power circuit in a factory may only be capable of providing 200 Amps 0 200 KA at 500 Volts to a welder The factory s 200 Amps is then converted to the 10 000 Amps needed to weld by means of a welding transformer A transformer consists of two coils of wire called the primary and the secondary wound around an iron core Power is transferred from primary to secondary via the magnetic properties of the iron The factor by which the current and voltage is stepped up or down is equal to the ratio between the number of turns of wire in the coils forming the primary and secondary windings of the transformer Consider the steel that needs 10 000 Amps 10 KA of current to be welded in a factory that can only provide 200 Amps 0 200 KA If the welding transformer had 100 turns on the primary and 2 turns on the secondary the turns ratio would be 100 to 2 or more simply 50 to 1 The 200 Amp current in the primary would then be converted
192. rities in the force during the weld process Mass monitoring is also relatively insensitive to changes in the weld schedule and weld current Aspects such as upslope and downslope are recorded but are delivered as averages rather than by the cycle or halfcycle Although the average current for a 10 cycle weld could be the same as for a 20 cycle weld there would probably be a great deal of expulsion in the 20 cycle weld A Mass monitor would not be able to detect anything amiss in this situation because the average would likely be an acceptable figure While Mass monitoring is a more thorough method of observation than BA monitoring it s still not the most effective method of monitoring the resistance weld process Dynamic Monitoring Dynamic monitoring is currently the most comprehensive method of observing and recording the weld process A Dynamic resistance weld monitor measures weld parameters in real time while the weld process is happening More detailed than a before after picture and more accurate than an average of each parameter a Dynamic monitor provides a complete view of the weld process as the weld is being made measured in either halfcycles or cycles based on a 50 or 60 Hz sine wave Because the weld process is observed so closely events such as Expansion and Setdown can be pinpointed down to the halfcycle If weld irregularities are suspected recorded weld data can be analyzed to determine where in the process they re occurring
193. s in Scope Mode e Trigger Pre Applies only when Scope Mode is Enabled Trigger Pre determines the amount of time in halfcycles that data is gathered before the trigger point in Scope Mode e Trigger Post Applies only when Scope Mode is Enabled Trigger Post determines the amount of time in halfcycles that data 1s gathered after the trigger point in Scope Mode e Max Bad Hcycles Default Setting 0 Max Bad Hcycles is the number of rejected halfcycles that the weld monitor ignores when determining whether the weld is rejected or accepted based on a halfcycle fault The number of rejected halfcycles includes the number of halfcycles that rejected due to a parameter fault not within master tolerance limits plus the number of halfcycles where there was conduction angle 70 current flow where the master weld did not have a conduction angle 70 no current flow plus the number of halfcycles where the conduction angle 0 no current flow where the master weld did have a conduction angle 70 current flow Although the weld may be Accepted the rejected halfcycle data is still recorded in the database and displayed in the Halfcycle and Weld Summaries e AD Threshold adjustment may be required Recommended initial setting 750 The weld monitor determines that a weld is occurring by using a toroid to monitor the flow of weld current in the secondary weld loop of the transformer AD Threshold and AD Hysteresis are adjusted co
194. s is only an example it assumes the following All hardware has been properly installed all sensors have been properly calibrated and the 2400 is turned on and ready to monitor You familiar with how to navigate and edit functions within the WMS program see Chapter 4 Getting Familiar With The WeldWise 2400 Due to the variety of welding processes and schedules throughout the welding industry the following example steps may not be applicable to every welding process For a complete description of all functions in the WMS program refer to Chapter 6 WMS Reference Guide General Setup The first step is to confirm that the general configuration settings are appropriate for this procedure 1 With the equipment set up for monitoring and the WMS program running go to the Main Menu Select Setup then General Setup 2 Current ID should be set to 60 3 For the purposes of this example set the General Setup parameters to the following values parameters not mentioned here can be left at their default settings Refer to the General Setup Menu in Section 6 WMS Reference Guide for parameter Current ID Update Configuration specifics Pre Size 10 Halfcycle Data Mode All Post Size 10 Segment Data Mode All Post Delay 0 Weld Data Mode All Masters Enabled Yes Segment Tolerance Mode Average Segment Size 100 4 Once these changes have been made use the Update Configuration button
195. s made the welder during a part cycle Internal The binary select is set to the Internal Binary Select setting in the General Setup Menu see below External The Binary Select is determined by the status of the Binary Select inputs located at the rear panel of the 2400 A Binary Select of 0 is invalid e Internal Binary Select Default Setting 1 The Internal Binary Select value is only used if the Binary Select Mode is set to Internal The Internal Binary Select should be set to a number from 1 to 15 In internal mode all masters created will be associated with this Binary Select e Pre Size Default Setting 10 see figure 6 50 This setting determines the amount of time in halfcycles that data is recorded before the weld current begins It is recommended that the Pre be set to less than the Squeeze time used for the weld schedule e Post Size Default Setting 10 see figure 6 50 This setting determines the amount of time in halfcycles that data is recorded after the weld current ends It is recommended that the Post be set to slightly less than the Hold time used for the weld schedule yet long enough for the weld to have solidified e Segment Size Default Setting 620 see figure 6 50 The Segment Size setting determines the maximum number of halfcycles amount of time that data is recorded after weld current begins until the weld current ends This setting should be set to a number higher than the expected n
196. s recommended that a Compact o Database be performed after the database is NA continue or Escape to exi repaired Delete All Welds Repair Database WARNING Welds cannot be monitored while Figure 6 21 Repair Database the Repair Database option is in use Any remote user interface windows must also be closed The program will not let you leave this screen or monitor welds until the repair operation is complete DO NOT shutdown the weld monitor during this operation e Delete All Welds H t Utiliti This option will delete all weld data records but will not compact the database Master data will JARNING This command eal not be deleted It is recommended that the Import delete all of the System Log be deleted at this time Refer to welds in Welddata mdb file It N will not delete any masters It will System Log section in this Chapter ake about 1 minute s to his command requires WARNING Welds cannot be monitored while p exclusive access so all other the Delete Welds option is in use Any remote user interface windows must also be closed If the Cancel button is used the weld slept Uaiteitt 22 Press lt Delete All Welds monitor must be shut down and restarted DO of lt Escape NOT shutdown the weld monitor during this operation The database must be compacted after all welds are deleted Figure 6 22 Delete Welds screen external
197. screen is the name of the master to which the weld number at the bottom of the screen was compared If there was no master in use when the weld was 7 made it will sav No Master Below the 40 1500 master name are two parameter boxes The parameter on the left is represented by the axis on the left the parameter on the right is represented by the axis on the right You can select either box and scroll through the list to change which two parameters are displayed The parameter in the left box will be displayed as a non bold line The parameter in the right box will show up as a bold bright solid line If you have trouble differentiating between the Figure 5 5 Halfcycle Summary graph two select the same parameter in both boxes The horizontal axis is measured in halfcycles 1200 If the graph extends vertically off the screen you can change the graph display range by doing the following 1 ESCAPE to the Main Menu Select Setup then Graph Setup 2 Select the value in the Graph Low or Graph High boxes that correspond with the parameter displayed in the Halfcycle Summary screen and scroll through or type in the desired high low value When you return to the Halfcycle Summary screen the changes will take effect immediately Parameter Cond n Angi e 0 05 0 0 0 05 60 VoltageRms V 0 Figure 5 6 By changing the Low High values fora Figure 5 7 you can alter the graph display on the displayed parameter in the Graph
198. should you be inclined to use them Attaching an External Keyboard Attaching an external keyboard is simply a matter of plugging the keyboard connector into the port labeled AT KEYBOARD on the back panel of your WeldWise 2400 Attaching a Mouse To attach a mouse plug the mouse connector into the port labeled COM1 on the back panel of your WeldWise 2400 Attaching a Video Monitor To attach an external video monitor plug in the monitor connector to the port labeled VIDEO VGA on the back panel of your WeldWise 2400 Attaching an External Printer Your Livingston monitor comes with a built in thermal printer that may be used to print most screens To use an external printer plug the printer cable into the port labeled PRINTER on the back panel of your WeldWise 2400 An external printer may require the installation of a specific driver on Windows NT Follow the installation instructions for the printer manufacturer on Windows NT Follow the installation instructions for the printer manufacturer You may need to attach a video monitor mouse and keyboard to install the necessary driver Note It is only possible to print what is displayed on the touch screen monitor of the WeldWise 2400 even if a full size video monitor and external printer have been connected Attaching a UPS Livingston amp Company recommends that an Uninterruptable Power Source UPS be used with Livingston weld monitors to prevent possible damag
199. ss Alt D then the right arrow key to change the Domain omputer on the i juter and tk appear in Computer Name 2400 0182 Workgroup LIVINGSTON Domain 4 Click OK or press Enter on the keyboard to accept the changes and close the window 5 To change the IP Address using a mouse select the Protocols tab otherwise use the Ctrl Tab key combination to select the Protocols tab 6 Double click on TCP IP Protocol or use the up down arrows to highlight TCP IP Protocol and press Alt P this will select the Properties button to open the Microsoft TCP IP Properties window Microsoft TCP IP Properties Protocols Y NetBEUI Proto ol Remove 2 0454 APP 118 Rev 12 3 7 Ifyou are using a mouse click on the radio button next to Specify an IP Address and enter the desired IP address You may also enter a different Subnet Mask and or Default Gateway Click OK to confirm the new entry Without a mouse press Alt S to select the Specify an IP Address option then press Alt I to go to the IP Address entry field If you wish to change the Subnet Mask and or Default Gateway press Alt U for Subnet Mask and Alt G for Default Gateway Begin typing the new IP or other address entering periods where appropriate For example if the new address was 129 57 8 2 you would enter the numbers 1 2 9 then a then 5 7 then a then 8 then a then 2 with no spaces or commas in between or after the numb
200. st even though the same amount of current is passing through the tips Imagine the 1 6 0428 INS 400 Rev E size of the loss if they ve mushroomed 2 3 even 4 millimeters A constant current control a weld stepper may be used to regulate the amount of current used but a controller or stepper does not track the change in surface area So even though the current is regulated the current density is overlooked Unfortunately inadequate current density usually produces inadequate welds Following proper preventive maintenance schedules can help ensure sufficient current density by ensuring that the electrodes remain in good condition As proven in the example above it is crucial to have the proper current density at the area where the weld is to be made Depending on the materials being welded however proper current density is actually a range rather than one specific amount Welding engineers call this range the weld lobe Each parameter involved in making the weld current voltage resistance etc has its own range or lobe Quality welds are made when the weld process stays within the lobe The next chapter will discuss weld lobes and tolerancing which is a way to ensure that the weld process does not fall outside of the lobe Ohm s Law and Joule s Laws The following laws are widely thought to be what make or break resistance welding While it is true that these laws are very important to resistance welding there are a few details
201. stepped up to 10 000 Amps 200 Amps x 50 turns 10 000 Amps in the secondary which would yield enough amperage to make a weld Voltage If current is the amount of electricity flowing then Voltage measured in Volts is the pressure or force that s causing the flow A good analogy is water flowing through a pipe A larger voltage will result in greater water pressure which will cause more water current to flow through the pipe Using the transformer example above after the 200 Amps at 500 Volts on the primary passes through the transformer coils the secondary amperage increases to 10 000 Amps but the voltage actually drops to 10 Volts This decrease in voltage occurs because the amount of power coming out of a transformer isn t actually increased but more accurately exchanged 0428 INS 400 Rev E 1 3 Power Power is Voltage multiplied by Current and is measured in Watts or KVA KVA stands for Kilo Volt Amperes Watts and KVA will be used interchangeably in this text This means that the amount of current flowing times the pressure that s causing it to flow equals the amount of power generated A basic law to bear in mind is that the power going into a transformer will always equal the power coming out of it Returning to the transformer example 200 Amps coming in at 500 Volts 200 x 500 100 000 on the primary with a 50 to 1 turns ratio in the transformer will be converted into 10 000 Amps at 10 Volts 10 000 x 10 100 000
202. sters Had is used the weld monitor must be shut down Import Masters eating masters Ed masters must be deleted first in order to be replaced with the data from imported file It may take up to 1 minute s to complete and restarted DO NOT shutdown the weld monitor during this operation Import Masters from Elappy e Import Masters Import Setup Press Import Masters to This option imports masters previously stored ROT EU RUE continue or Escape to exit Import Setup from in an archive database by an Export Masters Floppy command The masters archive database file name is masters mdb This command will not Figure 6 24 Import Masters overwrite any existing masters If an Import Masters command is executed and one of the Database Import Utilities current masters has the same name as one of the masters in the archive the import of that master WARNING This command wil will be skipped To delete a master use the Import Ail merge masters previously saved Delete Master command in the Mastering in Flopmast cmp file on floppy into the database It will NOT replace existing masters Existing masters must be deleted first in order to be replaced with the data from imported file screen Import Masters WARNING Welds cannot be monitored while the Import Masters option is in use Any remote user interface windows must also be l Press lt Import Masters from closed If the Cancel b
203. t being produced can be monitored in seconds and the resulting weld data compared to known good values e Detect weld setup problems and maintenance issues before they cause bad welds e Provide traceability of welded components the recorded hard copy or electronically stored weld history helps ensure regulatory compliance in specialized industries e Minimize production downtime if a welder isn t working properly the problem can quickly be tracked down and repaired faster Less downtime means more money 0429 INS 400 Rev C 2 5 Both quality improvements and efficiency be gained through weld process monitoring For example by demonstrating and tracking the consistent high quality of primary welds the need for additional safety or delta welds can be reduced or even eliminated The ability to quantify what constitutes a known good weld makes it possible to achieve consistent results even in high volume situations Productivity gains can also be achieved by replicating and tracking those conditions that have been shown to result in ideal welds In a high volume automated factory line environment the resulting gain in productivity can be substantial 2 6 0429 INS 400 Rev C Tolerancing and Monitoring Introduction This chapter will introduce Livingston s concept of dynamic resistance weld monitoring The definitions of tolerances and segments as they pertain to a WeldWise 2400 will be discussed as well as how these f
204. t were used to create the current master Edit Master 9 16 01 9 57 08 AMMOL e Add Delete Button PO Use this button to add delete welds to from the master set If a weld is accidentally deleted E Man D vapeur ll from the master set it re added using Master Binary Select e g M01 in your entry the Add button New welds cannot be added mE You hit lt Escape gt at time to abort the to_an existing master set Refer to Chapter 10 entry and return to the Edit screen FAQ for further information NOTE Please use the keyboard keys exclusively including lt Enter gt and lt Escape gt keys e Edit Pod ID Edit Bin Sel buttons Use these buttons to edit the Pod ID and binary select associated with this master Figure 6 40 Rename Master screen Note The master name by default a date time stamp can be changed by using the Alt R key combination via an external keyboard attached to the monitor Use the ENTER key to save the new name and ESCAPE to return to the Edit Master screen See page Attaching Peripherals in Chapter 11 Appendices for more information about connecting an external keyboard to your monitor 6 24 0433 INS 400 Rev E Tolerancing Screen When new welds are compared to the master they are given a certain amount of forgiveness relative to the values in the master This is because even good welds aren t exactly alike The amount of forgiveness is referre
205. tatus Button When the Clear button is pressed both Job Status and Weld Status are cleared and a Check Mark is displayed Parameter Displays All of the different weld summary parameters are available from the main screen Each parameter display can show data for one of these parameters A parameter display section of the main screen is shown in figure 6 2 below Bar Graph and Trend Parameter Value Y Y Graph Display Button lt Parameter High Limit indicator not shown lt Parameter Low Limit indicator Parameter Graph Low High Limits Figure 6 2 Parameter display Parameter Name Each parameter display can show data for one of these parameters Current RMS Current Peak Voltage RMS Voltage Peak Force Conduction Angle Setdown Part Expansion Initial Thickness Energy Final Thickness Resistance Power Factor Halfcycle On Count Note Power Factor is not yet implemented and will display zero To select a different parameter in a parameter display touch 4 055 the parameter name on the touch screen or navigate to the parameter name with the arrow keys so that the parameter name is outlined and use the SELECT button to highlight it Figure 6 3 Touch on the parameter as shown in figure 6 3 Once the parameter box is display and use the SELECT button to highlighted the up down arrows will scroll through the highlight it parameter list 6 2 0433 INS 400 Rev E e Parameter Value
206. ter is complete by default it will be broken up into three segments Eqit Master opy t ICI Update Delete Master Figure 6 36 Creating a master Segment 0 Pre Weld before current starts Segment 1 Weld portion of weld with current Segment 2 Post Weld after current stops 0433 INS 400 Rev E 6 21 Each segment will have the tolerances specified in the Tolerance Defaults Screen The weld can be divided up into more segments in the Tolerancing Screen The binary select value when the master was made is indicated at the end of the master name by Mxx where xx is the binary select number A master will be created for each unique binary select received during mastering Note Livingston weld monitors are initially set with forgiving default tolerances Tolerances usually need to be tightened by the customer for most applications Refer to the Tolerancing section in Chapter 6 for more information e Select Master This option displays a list of stored masters and NUS 22723701 6 44 51 PM MUI allows one to be picked for editing or update i 2 26 01 3 39 38 PM MOT 2 26 01 4 39 50 PM M01 Select Master 2 27 01 9 17 19 MOT e Edit Master 3 13 01 3 32 26 PM M01 E Edit Master 3 13 01 3 50 40 PM The edit master option selects the Edit Master 3 14 01 10 00 13 M01 i 3 14 01 10 04 07 AM M01 screen This can be used to add remove welds 2 14 01 8 10 33 PM NOI from a mast
207. the WeldWise 2400 must be installed and the WMS program running Note Incoming sensor readings will not be accurate if the sensors have not been calibrated In line Pressure Transducer Mounting Bracket Double Rod End Displacement Sensor Voltage Noise Suppression Filter Current Toroid Voltage Leads Figure 7 5 Example of a welder with all four sensors attached 7 8 0434 INS 400 Rev C To perform a quick test of the sensor installation 1 With the sensors connected and WeldWise 2400 turned on set up the welder as usual to perform a weld The monitoring of weld events is triggered by current detection and is preset so no further setup is required to begin recording values during welding Make a few welds Note the values that appear on the monitor s main program screen If the parameters CurrentRms and VoltageRms are not already displayed on the weld monitor s screen click any parameter box on the screen itself click the SELECT key on the Virtual Key pad and then use the Arrow Keys to scroll through the various parameters until CurrentRms is displayed Press ENTER to show incoming readings for that parameter Do the same with another parameter box and select VoltageRms The graphic display indicates the levels of the sensor readings for these factors and these values are recorded for the weld Note Readings will be uncalibrated as the sensors have not been calibrated yet Calibration is co
208. the WeldWise 2400 floppy drive A 5 Export Setup to Floppy This makes a backup of calibration general setup as well as the tolerance defaults and graph setup and stores the information in the setup cmp file compressed version of setup mdb 6 Export Masters to Floppy This makes a backup of each of the masters includes master tolerance limits and stores the information in the masters cmp file compressed version of masters mdb The exported files on the floppy disk are compressed database files that contain necessary information required to recover the WeldWise 2400 settings The floppy should be stored in a safe place until needed It is also recommended that a copy of livco mdb and welddata mdb in the livcosetup folder be stored on a computer other than the WeldWise 2400 in case something happens that physically damages the unit 11 6 0614 INS 400 Rev D What If What if someone made changes to some settings and then forgot the known good settings or changed sensor calibration and then realized that they had made a mistake and wanted to put these things back to the way they were prior to the mishap gt Use either the Import or the Import Setup utility to recover the known good settings OR gt Ifa floppy was created with the Export Setup from Floppy then insert the floppy and use the Import Setup from Floppy option What if someone accidentally deleted a master or master
209. the readings jump the bracket or rod ends may be loose To avoid inaccurate readings it is important that the displacement sensor mounting brackets have no mechanical slop are rigid and do not move e Ifthe displacement reading saturates in the Input Monitor 32767 channel input range has been exceeded while attempting to calibrate with a gauge block the gauge block is too thick Refer to Chapter 9 FAQ for more information about using a gauge blocks to zero and calibrate the displacement Understanding A D Readings This chapter utilizes the Input Monitor screen for troubleshooting the various sensors There are two different values reported for each sensor calibrated values not reported for current and A D values The A D values represent the analog sensor signals that have been converted to digital readings The calibrated values displayed are the incoming readings after the sensor has been calibrated The A D values can help determine the electrical integrity of the sensor and or sensor cable Always take note of the A D readings if a sensor does not calibrate properly If a sensor and or 0455 INS 400 Rev C 10 3 cable are shorted or open an inaccurate calibration will result Check for frozen or pegged A D readings Plug in a known good sensor and cable check the A D values and compare them with the suspect sensor and cable As an example a properly sized force sensor with no load on it will have an A D read
210. the same way they did when Thompson invented the process The current is generated by a transformer and is fired through electrodes which hold the metal pieces in place These electrodes also apply force to the metal pieces usually before during and after the firing of the electric current This method is called resistance welding because it is the resistance between the contact surfaces of the metals being welded that generates the heat to fuse them together Resistance is the opposition that a substance offers to the flow of electric current The less resistance a metal has the less heat is generated when current passes through it Conversely the higher the resistance of a metal the more heat is generated when that same current passes through it This behavior can be paraphrased as follows the heat is where the resistance is and the resistance is where the heat will be Obtaining the best results in resistance welding requires a thorough understanding of the materials being welded careful control of the heat and pressure at the weld point and consideration of numerous other factors This chapter will deal with the basics of resistance welding the variables involved and why they re so important to the welding process 0428 INS 400 Rev E 1 1 Variables in the Welding Process The many variables involved in welding can be broadly categorized into two basic sections process variables and material variables Process variables include
211. the segment after current flow stops Tolerances can be placed on force and thickness after current flow Add Segment Line Tolerancing Master 3 13 01 3 50 40 PM 01 Move the cursor to a section of the weld other Current Rms Limits REL Select Master than the pre weld segment and use the Down Low High Cursor Unit 5 E 9 03 KA Update Arrow Key to add a segment line The new segment line will divide the existing segment into two at the location of the cursor The new HALFCYCLE TOLERANCES segments will have the same tolerance limits Segment 2 Hicycle 0 WHC 20 which can then be adjusted separately Use the Update button to record any segment line or i tolerancing changes i CE In figure 6 42 a segment line was added in the middle of segment 1 Segment 1 was divided in two to become segment 1 and segment 2 There Figure 6 42 A new segment line was added to this are now four segments total master Tolerance limits are the same for the each t Segment 0 Pre Weld segmen Segment 1 Beginning of weld Tolerancing Master 3 13 01 3 50 40 PM M01 Segment 2 Remainder of weld Segment 3 Post Weld Current Rms Limits REL Select Master Low High Cursor Unit In figure 6 43 the tolerance limits for Current 3 3 8 81 KA Update Rms in segment 2 were changed from 5 KA UELEGUULE TUI ERRNCES to 3 KA relative to the master The limits for a Segment 2 Heycle 5 WHC 25 segment are still 5 KA Refer to Chapter 9
212. the toroid for example 388 this value will be used later to enter the toroid calibration factor 1 7 4 Shut down the welder to be monitored Install the current toroid Unhook the clasp on the toroid ring and place it around a stationary secondary welding cable or bus If there is no stationary cable or bus place it around the secondary with the least movement Be sure that the clasp is at least 34 inch away from the framework of the machine or any ferrous metal Reconnect the clasp on the toroid and route the cable Toroid centered on tool arm away from current carrying tooling Best results are achieved with the toroid centered on the cable or bus This may accomplished by using a piece of plastic or a similar non conductive material Toroid raised off tool arm with non conductive block Secure the toroid in its location using cable ties The toroid should not be able to move around after being secured The clasp should also be secured so that it cannot accidentally come undone Keep the toroid as round as possible avoid doubling it over or securing it in such a way so that it resembles a figure 8 as this will result in inaccurate readings and Less reliable data Best Arrangement Better Arrangement Toroid hanging off tool arm i Good Arrangement Toroid hanging off tool arm Bad Arrangement Figure 7 3 Different ways to mount a toroid 0434 INS 400 Rev C Installing the Volt
213. then be added that would effectively divide the Weld segment into two The first Weld segment would start when the weld current fires and would end when the coating had been burned off The weld current tolerances in this particular segment could be widened to accommodate the change in current density when burning through the coating The second Weld segment would begin at that point when the weld current had reached the metal to be welded and would end when the weld current ceases In this segment the weld current tolerances could be tightened to ensure the necessary amount of current in the example 12 KA 0 5 amps to make a good weld Segments provide a useful means for organizing the weld data and comparing changes over time The ability to specify different tolerances within several different segments allows the user to precisely isolate weld factors that may be critically important to weld integrity and include these factors when accepting or rejecting welds Data Collection Data can be collected for each halfcycle segment and or weld Please refer to the General Setup Menu in section 6 WMS Reference Guide Weld data is continuously recorded whenever the weld monitor is operating however only a pre specified amount of data is stored The monitor is triggered at the instant that weld current is fired this moment is referred to as the trigger The quantity of data stored is based on the trigger The user can choose a number of h
214. tion will affect the data reported for Current RMS Current Peak Energy and Resistance Note WeldWise 2400 s and Toroids are calibrated at the factory The only setting that requires adjustment is the Toroid Calibration Factor Toroid Calibration Factor Update Cal Factor Last Weld s Current RMS This is the weld summary Current RMS recorded for the last weld Desired Current RMS Percent Figure 6 53 Toroid Calibration Desired Current RMS or Percent maybe adjusted to match the reported current to a desired current from a weld timer weld controller or other weld meter etc Once the desired settings have been entered the calibration must be updated to the weld monitor by using the Update Configuration button To return to the factory calibration simply enter 100 for a percentage Update Configuration Sends the calibration to the weld monitor This button must be used for any new settings to take effect Toroid Calibration Factor Each Livingston toroid has proprietary conditioning circuitry in an inline cylindrical housing The Toroid Serial Number and Calibration Factor are printed on the cylindrical housing When a new toroid is installed the Toroid Calibration Factor should be entered in this field as a whole number without decimals For example a CF of 0 354 should be entered as 354 Once the calibration factor has been entered the calibration must be updated by using the Update Cal Factor button Refer t
215. to your WeldWise 2400 s You will need to attach a keyboard video monitor and mouse to complete this procedure Note This calibration may be time consuming For additional information please consult the APC manual included in the original packaging Procedure for Initiating Runtime Calibration 1 Power up the WeldWise 2400 and allow to boot If prompted log on as Administrator password 2400 2 If Livco software starts running select MENU Select SHUTDOWN Select Quit Livco program but don t shutdown Windows Click Start on the task bar Select Programs gt PowerChute Plus gt PowerChute Plus Click on the UPS to highlight and then click Attach Connect to the UPS all units that will draw power from the UPS during a power failure Quo P Select the Diagnostics pull down menu Select Initiate Runtime Calibration Allow the unit to calibrate This may be time consuming Should you gave any questions or concerns related to the UPS please contact a support technician at APC at the telephone number given in the original packaging If you have questions concerning your Livingston products please contact your Livingston representative 11 16 0438 INS 400 Rev C Configuration for Remote Shutdown In the event of a power outage you may wish to have your WeldWise 2400 act as a master and remotely shutdown any number of slave devices also connected to the UPS To do this you will need to recon
216. toring provides the user with an easy way to access a wealth of information about the welding process information that can actually help improve the process itself as well as alert the user to any number of potential problems Styles of Monitoring There are many different types of monitoring systems on the market nowadays These systems can be broadly categorized into three different styles which for educational purposes are nicknamed as follows Before amp After monitoring Mass monitoring and Dynamic monitoring Before amp After Monitoring As the name suggests Before amp After monitoring hereafter referred to as BA monitoring focuses on only two phases of the weld process before the weld is made and after the weld is made This type of monitoring is typically used to measure displacement only As mentioned above measuring 2 2 0429 INS 400 Rev C displacement can indicate whether the resulting weld was formed properly BA monitoring measures the displacement before the weld is made Initial Thickness and then again after the weld is made Final Thickness However if it is determined that the displacement is consistently below where it should be e g the nut is not sinking far down enough into the workpiece to make a good weld BA monitoring cannot identify exactly where in the process the problem is occurring Similarly the BA monitor may indicate a normal setdown yet the nut may be sinking down much too quickly due to
217. ulated Electrodes Holders Eu po qp dp pq cq SX Shunt Path In Secondary SxS T S T x i Tx T STS T eee Excess Ferrous Material In Throat Emergency Stop Switch Open S umo 1 T Sx If Weld Force is too low excess heating of the material surface may cause excess indentation Figure 1 3 Chart of weld defects and possible causes Recommendations for Producing Quality Welds To produce high quality welds consistently follow these tips 1 Be sure that the electrodes you are using are suitable for the job 2 Use standard electrodes whenever possible 3 Select an electrode tip diameter suited to the thickness of the stock being welded 4 Make use of flow indicators for viewing and assuring proper cooling water flow through the electrodes typically 1 5 gallons per minute 5 Ensure that the internal water cooling tube of the holder projects into the tip water hole to within 1 4 inch of the bottom of the tip hole 6 Adjust the internal water cooling tube of the holder to the appropriate height when switching to a different length tip 0428 INS 400 Rev E 1 9 7 Ensure that the top of the adjustable water cooling tube in the holders is the proper height when changing to a different tip length 8 Coat the tip with a thin film of cup grease before placing it in the holder to simplify removal 9 Use ejector type holders for easy tip removal that won t damage the tip walls 10 Clean the tip taper and holder t
218. umber of halfcycles in the weld Note that Weld Segment data is truncated to Setdown the actual number of halfcycles in the weld The Segment Size is the maximum number of halfcycles that will be recorded in the weld segment when making a master If a master is being used and masters are enabled then the master s segment size data will override this setting Halfcycle axis 6 32 0433 INS 400 Rev E Figure 6 50 Segment Size sets the maximum weld segment size e Post Delay Default Setting 0 Once weld current has ended the weld monitor waits for a period of time to see if weld current begins again This amount of waiting time can be specified in halfcycles using the Post Delay setting If weld current does not begin again after the Post Delay the weld monitor considers the weld finished If weld current resumes within the Post Delay time period the weld monitor continues data collection This is particularly useful for pulsed or seam welding applications For example if the weld process included a pulsed weld 5 cycles on 2 cycles off 5 cycles on the Post Delay would need to be increased to at least 4 halfcycles in order to bridge the 2 cycle gap between the pulses If the Post Delay were set to 0 then the weld monitor would incorrectly consider this process as two separate welds Note The Post Delay should be set to the same value used during mastering e Masters Enabled Default Setting Yes Yes Each weld is co
219. umber of the remote unit found on the back panel of the Livingston monitor Repeat this line for additional remote units 6 Save and close when finished editing the file Exit the text editor window 7 Click Start on the task bar Select Settings gt Control Panel Double click Services 8 Scroll down and find UPS APC PowerChute Plus and highlight Click Startup button 9 Startup Type should be set to automatic In the log on as box select the radio button for This Account Type in administrator and enter 2400 for password and 2400 to confirm password Note All slaves must have the same logon and password as the master 10 Click OK close all windows and reboot system for changes to take effect Repeat steps 7 10 for all slave units 0438 INS 400 Rev C 11 17 WELDWISE 2400 BINARY SELECT INPUTS BINARY SELECT 0 2 BINARY SELECT 1 a BINARY SELECT 2 eZ BINARY SELECT 3 BINARY SELECT COMMON RELAY 1 RELAY 1 RELAY 0 RELAY 0 RELAY OUTPUTS oO ON DO oa 2 C Binary selects nominal 24 volts AC or DC Common can be tied either high or low Inputs are optically isolated Binary Select 0 is invalid all inputs off INTERLOCK INPUTS NOTE 1 Range 12 to 50 volts NOTE 2 NOTE 3 INTERLOCK CONNECTION ON BACK NOTE 4 OF WELDWISE 2400 BROWN 1 RED 2 RANGE 3 O
220. utton is used the weld Inport Saip Floppy to continue or monitor software must be shut down and Sepe restarted DO NOT shutdown the weld monitor during this operation Impart Setup from Floppy Figure 6 25 Import Masters From Floppy 6 16 0433 INS 400 Rev E e Import Masters From Floppy Database Import Utilities This option is the same as the Import Masters anneal m WARNING 15 Command Wi command above except that the archive zi Ihe curent set rion database has been compressed and stored to a the database with the data previously saved in Setup mdb It may take up to 1 minute s to co mplete floppy disk previously by an Export Masters mport Masters To Floppy command Import Masters from Floppy Press lt Import Setup gt to continue or lt Escape gt to exit WARNING Welds cannot be monitored while the Import Masters From Floppy option is in use Any remote user interface windows must also be closed If the Cancel button 15 used the weld monitor must be shut down and restarted DO NOT shutdown the weld monitor during this operation Figure 6 26 Import Setup e Import Setup Database Import Utilities This option imports general setup and sensor calibration data previously stored in an archive Import Ail database by an Export Setup command The setup archive database file name is setup mdb Import Masters This command will overwrite the existing setup and calibrat
221. vered in Chapter 8 Calibrating the Sensors 4 Click the MENU button on the Key pad 5 Select the Data option from the Main Menu 6 Select Weld Summary The program displays the data collected for the welds organized by weld number as shown in figure 7 7 For each weld made the Halfcycle count should be twice the amount of cycles in the weld For example a schedule with 5 cycles of Squeeze 10 cycles of Weld and 8 cycles of Hold would have 46 total halfcycles 5 10 8 23 23 times 2 46 Use the Arrow Keys to scroll through the various headings to view readings for Current Voltage Force and Setdown Expansion Displacement Figure 7 6 Weld Summary screen If any of these operations don t work as described recheck the setup instructions in this chapter or consult Chapter 6 WMS Reference Guide 0434 INS 400 Rev C 7 9 7 10 Calibrating the Sensors All sensors must be properly calibrated to obtain maximum accuracy from the weld monitor The WMS program includes calibration screens that simplify this process by guiding the user through the necessary steps Both raw A D and calibrated sensor readings can be viewed using the Input Monitor a screen that displays incoming values for all input channels Important Notes KS Units of measure should be set prior to calibrating the sensors These units are set in the tolerance defaults screen Calibrating and Zeroing the displacement sensor are not the same
222. w labeled Drives Select from the pull down list the drive on which you created the folder named 2400 xxxx MMDDY Y See example below 9 Inthe window labeled Directories find the 2400 xxxx MMDDY Y folder and double click it to open it The file WeldData mdb should appear in the left side window labeled Database Name See example below 10 Click once on WeldData mdb to highlight it and then click OK Find the 2400_xxxx MMDDYY folder and open it Select Database Highlight WeldData mdb Database Name Directories W eldD ata mdb d 2400 0172 112000 Cancel c a __ E gt My Weld Data 2400 0172 1120 __ Read Only zi Exclusive List Files of Type Drives Network Access Databases rm d Select the drive on which you created the 2400_xxxx MMDDYY folder 12 12 0454 APP 121 Rev A 11 You will be returned to the ODBC Microsoft Access Setup window Under Database the file path of WeldData mdb will be displayed Click OK ODBC Microsoft Access 97 Setup Data Source c m Description Database Database D 2400 0172 112000 WeldD ata mdb Create Repair Compact System Database None C Database Sustem Database Advanced 1 Options gt gt Cancel Help 12 You will now be returned to the Create New Data Source wind
223. without a mouse You may want to connect a video monitor to the weld monitor for easier viewing but this is not strictly necessary JF YOU HAVE ANY QUESTIONS ABOUT THE IDENTIFICATION AND OR IP ADDRESS OF YOUR MONITOR PLEASE CONTACT YOUR SYSTEM ADMINISTRATOR BEFORE STARTING THIS PROCEDURE 1 From the main program screen of the weld monitor press MENU Select Shutdown Select the option Quit all Livingston programs but don t shutdown Windows NT A Windows NT desktop will appear on the screen Are you sure you want to shut me down ta i Shortcut to livcoset exe Network Shortcut to Neighborhood livcosetup Recycle Bin Shortcut to Shutdown bat 0454 APP 118 Rev A 12 1 2 A Ifa video monitor and mouse are connected go to gt Start gt Settings gt Control Panel gt Network e Windows NT Explorer New Office Document a Open Office Document Control Panel 3 Printers A Taskbar aj Shut Down Windows NT Workstation Control Panel Iof x File Edit View Help 5 Control Panel v pe Network SP ODBC PC Card PCMCIA gF Potts oil Configures network hardware and sc B If there is no video monitor and or mouse press the Windows flag button located between the Ctrl and Alt key to the left of the spacebar on the keyboard or if you are using a keyboard without a flag button press Alt S or Ctrl ESC NOTE From th
224. withstand the force needed to make a good weld A key point to understand is that force and resistance have an inverse relationship more force will result in less resistance and vice versa The equation has to do with surface contact which refers to the specific area on the workpieces touched by the electrodes Surface contact will be covered further in the next section but the following example will begin to illustrate this relationship if you examine your fingertip under a magnifying glass what first appears to be a smooth surface is actually a mass of rough looking ridges and bumps The same is true of electrodes and workpieces The tips of the electrodes and the surfaces of the workpieces may look to be smooth and in good condition but in reality their surfaces are quite rough especially if the electrodes are old and worn or if the workpieces are dirty By applying pressure to these rough surfaces any microscopic inconsistencies e g dirt or grease on the workpiece and or pits and cracks in the electrodes are compressed and the surface actually evens out This results in improved increased surface contact between the electrode tips and the workpiece and between the workpieces themselves When the surface contact is increased current can flow more readily from the tips through the workpieces which means that the resistance has been lowered Force also is what helps to keep the weld intact as it s being formed As the current generates h
225. xceed its tolerances and consequently be Rejected This difference may also lead to inaccurate displacement measurement By zeroing the displacement sensor the zero point is adjusted to accommodate the new tip size or work piece material variation Zeroing the displacement should be incorporated into the daily maintenance schedule for the welder Calibration on the other hand typically only needs to be done once unless the sensor itself is replaced Why does the gauge block for zeroing displacement have to be the same size as my part stack up Why do I even need to make a gauge block can t I just zero with the electrodes closed together The answer to both of these questions has to do with a the resolution quality of the displacement sensor versus the cost of that sensor b the stackup height of the parts being welded and c consistency A high cost displacement sensor can measure to four places 0 0001 using the full stroke length A low cost displacement sensor can accomplish the same resolution however it can only be attained using about 9 of the stroke length That 9 window can be anywhere along the stroke of the sensor but the measurement must be within half of that window because zeroing occurs in the middle of the window For example using a 100mm sensor 9 of the stroke is 9mm or approx 0 354 inches The half window is then 4 5mm or 0 180 If you were welding a nut with a thickness of 5 08mm 0 200 that w
226. y master data previously stored there It may take up to 1 minute s to complete Export All Export Masters Export Masters to Floppy Press lt Export Masters gt to continue or lt Escape gt to exit Export Setup Export Setup to Floppy Figure 6 29 Export Masters Database Export Utilities WARNING This command will Export All WARNING Welds cannot be monitored while the Export Masters option is in use Any remote user interface windows must also be closed If the Cancel button is used the weld monitor software must be shut down and restarted DO NOT shutdown the weld monitor during this operation 6 18 export all masters Fmasters mdb then compress the file and store i any master data p there Make sure the dis Flopmast cmp It to floppy as will overwrite eviously stored ette is not write protected and insert it into Export Setup the drive Export Setup to Press lt Export Masters to Floppy Floppy to continue or Escape to exit Figure 6 30 Export Masters to Floppy 0433 INS 400 Rev E e Export Masters To Floppy Database Export Utilities This option is the same as the Export Masters command above except that the archive database is compressed and stored to a floppy disk This command will overwrite any masters written by a previous Export Masters To Floppy command Only one masters archive can be stored on a floppy disk ARNING This c

Dr. Livingstone, I Presume 2400 Welding System User Manual

Contents

Download Pdf Manuals

Related Search

Related Contents