1. Manuals
  2. Brands
  3. Lincoln Electric Manuals
  4. Software
  5. POWER WAVE MANAGER IM8002
  6. Operator's manual

Lincoln Electric POWER WAVE MANAGER IM8002 Operator's Manual

Hide thumbs
Table of Contents

Advertisement

Quick Links

Download this manual
Operator's Manual
POWER WAVE
Register your machine:
www.lincolnelectric.com/register
Authorized Service and Distributor Locator:
www.lincolnelectric.com/locator
Save for future reference
Date Purchased
Code: (ex: 10859)
Serial: (ex: U1060512345)
IM8002
| Issue Date Jul-13
© Lincoln Global, Inc. All Rights Reserved.
®
MANAGER
Need Help? Call 1.888.935.3877
to talk to a Service Representative
Hours of Operation:
8:00 AM to 6:00 PM (ET) Mon. thru Fri.
After hours?
Use "Ask the Experts" at lincolnelectric.com
A Lincoln Service Representative will contact you
no later than the following business day.
For Service outside the USA:
Email: globalservice@lincolnelectric.com

Advertisement

Table of Contents
loading

Related Manuals for Lincoln Electric POWER WAVE MANAGER IM8002

Summary of Contents for Lincoln Electric POWER WAVE MANAGER IM8002

  • Page 1 Operator’s Manual ® POWER WAVE MANAGER Need Help? Call 1.888.935.3877 Register your machine: to talk to a Service Representative www.lincolnelectric.com/register Authorized Service and Distributor Locator: Hours of Operation: www.lincolnelectric.com/locator 8:00 AM to 6:00 PM (ET) Mon. thru Fri. Save for future reference After hours? Use “Ask the Experts”...
  • Page 2 THANK YOU FOR SELECTING KeeP your head out oF the Fumes. A QUALITY PRODUCT BY DON’T get too close to the arc. Use LINCOLN ELECTRIC. corrective lenses if necessary to stay a reasonable distance away from the arc. READ and obey the Material Safety...

  • Page 3: California Proposition 65 Warnings

    American Welding Society, P.O. Box 351040, Miami, Florida 33135 or ELECTRIC AND CSA Standard W117.2-1974. A Free copy of “Arc Welding Safety” MAGNETIC FIELDS MAY booklet E205 is available from the Lincoln Electric Company, 22801 St. Clair Avenue, Cleveland, Ohio 44117-1199. BE DANGEROUS BE SURE THAT ALL INSTALLATION, OPERATION, 2.a.

  • Page 4: Electric Shock Can Kill

    S FETY ELECTRIC SHOCK ARC RAYS CAN BURN. CAN KILL. 3.a. The electrode and work (or ground) circuits are 4.a. Use a shield with the proper filter and cover plates to protect your electrically “hot” when the welder is on. Do eyes from sparks and the rays of the arc when welding or not touch these “hot”...
  • Page 5 S FETY WELDING AND CUTTING CYLINDER MAY EXPLODE IF SPARKS CAN CAUSE DAMAGED. FIRE OR EXPLOSION. 7.a. Use only compressed gas cylinders containing the correct shielding gas for the process used 6.a. Remove fire hazards from the welding area. If and properly operating regulators designed for this is not possible, cover them to prevent the the gas and pressure used.
  • Page 6 NOTES...

  • Page 7: Table Of Contents

    Table of Contents Preface Typographical Conventions Used ......................1 Cross-References ........................1 Text You Type Using the Keyboard .................... 1 Keys You Press and Buttons You Click ..................1 Menus You Select ........................1 Dialog Box, Application Window Titles, and Field Names ............1 Notes, Warnings, and Tips ........................
  • Page 8 Table of Contents Power Source Settings Calibration ............................6.1 Cable Settings and Tests ........................6.3 Sense Lead Settings Tab ......................6.3 Weld Cable Test Tab ....................... 6.4 Sense Lead Diagnostics Tab ....................6.5 Miscellaneous ........................... 6.7 Time Settings on the Power Source ..................6.8 Total Welding Lifetime ......................
  • Page 9 Table of Contents Weld Data Tab ........................9.5 Charts Tab ..........................9.5 Backup/Restore ..........................9.6 Backing Up a Power Source ....................9.6 Restoring a Backup ......................... 9.7 Observer ............................9.9 Charts Tab ..........................9.9 Logged Welds Tab ......................... 9.10 Settings Tab .......................... 9.11 Production Monitoring Register............................
  • Page 10 Table of Contents FANUC Robots FANUC Systems and IP Addresses ....................B.1 FANUC® Robot Application (Prior to v7.70P/21) ................B.1 Requirements .........................B.2 Setting Limits ..........................B.3 Adding Production Monitoring™/CheckPoint™ to Welding Programs ........B.3 Alarm/Alert Programs ......................B.4 Erroneous Low Time Limit Alarms ..................B.5 FANUC Program References (Prior to v7.70P/21) ..............B.5 FANUC®...

  • Page 11: Preface

    Preface Typographical Conventions Used Before using this guide, it is important to understand the typographical conventions used to identify and describe information. Cross-References Cross-references to chapters, sections, page numbers, headings, etc. are shown in an italic typeface. e.g., Refer to Text You Type Using the Keyboard on page 1. Text You Type Using the Keyboard Text that you type using the keyboard is shown in a Courier typeface.

  • Page 12: Notes, Warnings, And Tips

    Preface Notes, Warnings, and Tips Notes, Warnings, and Tips Notes, stops and tips appear throughout the manual. They provide additional information that is important for you to know about the topic. NOTE | A note is an important piece of information. STOP | You should definitely read the information in a stop table.

  • Page 13: Revision History

    Revision History Date Change Description July 2013 Initial Release as IM8002 IM8002 Power Wave® Manager User Manual REV.1...
  • Page 14 Revision History REV.2 Power Wave® Manager User Manual IM8002...

  • Page 15: Introduction

    Power Wave® Manager is an application that allows you to configure and manage a multitude of settings and configuration options within the full range of the Lincoln Electric Power Wave® line of Welding Power Sources. It also provides in-depth diagnostics of the welding power source’s hardware and firmware to help identify and eliminate issues with welding or configuration.
  • Page 16 Not all Welding Power Source models have an Ethernet port. However, you can upgrade some models to utilize Ethernet by adding the Communication Interface module, available from Lincoln Electric as K2207-2 or K2436-1 (depending on the Power Wave® model). Connecting to robotic applications could vary from the information in this manual.

  • Page 17: Connecting The Power Source

    Not all Welding Power Source models have an Ethernet port. However, you can upgrade some models to utilize Ethernet by adding the Communication Interface module, available from Lincoln Electric as K2207-2 or K2436-1 (depending on the Power Wave® model). Connecting to robotic applications could vary from the information in this manual.

  • Page 18: Serial Cable Connection

    Source is a DB-25 female connector (25 pins). Figure 2.1 Serial Cable Connection This cable is available at Lincoln Electric automation division as part number AD1207-2. It is also available at various electronics retailers and online stores by searching for the keywords “DB9 to DB25 modem cable”.

  • Page 19: Update Welding Power Source Firmware

    Chapter 3 Installing Power Wave® Manager Once you have physically connected the Welding Power Source and your computer, you must perform two main steps to install Power Wave® Manager: Update the firmware on each power source you connect to  Install the Power Wave®...
  • Page 20 Run or Allow to permit your system to launch the file. The system opens the Lincoln Electric System Update Utility window where you tell the utility how to find the Welding Power Source you want to update.
  • Page 21 Update Welding Power Source Firmware Chapter 3. Installing Power Wave® Manager Procedure Details the Troubleshooting section (Appendix A). The software scans the Welding Power Source to Click the Connect button once you have verify if the firmware currently on the machine entered the IP address for the power source is up to date.
  • Page 22 Wave® Manager is a software application that allows you to manage a multitude of settings and configuration options within the Lincoln Electric Power Wave® family of Welding Power Sources. It also provides in-depth diagnostics of the Welding Power Source’s hardware and firmware to help identify and eliminate issues with welding or configuration.
  • Page 23 Installing Power Wave® Manager Chapter 3. Installing Power Wave® Manager Procedure Details Click the Download Power Wave® Utilities NOTE | Depending on your Windows version, FREE button to run the update. you may have to click Run or Allow to permit your system to launch the file.
  • Page 24 Chapter 3. Installing Power Wave® Manager Installing Power Wave® Manager Procedure Details Congratulations! You have installed Power Wave® Click the Finish button to exit the installer. Manager and can now configure your Welding Power Source. Power Wave® Manager User Manual IM8002...

  • Page 25: Overview Of Power Wave® Manager

    Chapter 4 Overview of Power Wave® Manager Power Wave® Manager is a software application that allows you to configure and manage the Power Wave® family of Welding Power Sources. Once you connect to a Welding Power Source, you have a multitude of tools at your disposal.

  • Page 26: Ethernet Connection

    Procedure Details Generally, you can select Start > All Programs > Open Power Wave® Manager. Lincoln Electric > Power Wave® Manager from the computer’s main menu. When Power Wave® Manager opens, it automatically displays the Connect tab for you (Figure 4.2).

  • Page 27: Finding The Ip Address Of A Welder

    Connecting to the Welding Power Source Chapter 4. Overview of Power Wave® Manager Procedure Details An IP address is a numeric identifier for a device Choose I know the IP address of the welder (if on a network, similar to a phone number, and is you know the network address) and type the composed of four numbers (each ranging from 0 IP address in the text field.
  • Page 28 Chapter 4. Overview of Power Wave® Manager  Connecting to the Welding Power Source  STOP  |  When you click the OK button, the Welding Power Source  resets and stops welding.  Be sure to only click this button if  the power source is not currently welding.    STOP  |  If the Welding Power Source is currently part of a network,  contact your network administrator to verify you can make  changes to the Ethernet settings of the power source.  To change the network settings (including the IP address) on a power source:  Procedure  Details      On the Connect tab of Power Wave®  Manager, choose I do not know the IP address  of the welder and select the power source  from the list.  This helps you ensure you change the settings on    Verify the selected Welding Power Source has  the intended Welding Power Source.  a blinking green status light.  The Change Settings window opens.    Click the Configure button.    If your computer is directly connected to the    Make your changes.  Welding Power Source using an Ethernet cable,  you may click the Suggest Settings button.  This  will automatically generate the proper network  settings for the Welding Power Source that would  make it ready to communicate with your  computer.  The Welding Power Source then resets and ...

  • Page 29: Serial Connection

    Navigating Power Wave® Manager Chapter 4. Overview of Power Wave® Manager Serial Connection Once you have the computer and power source physically connected through a serial cable setup, simply choose the Connect through the serial port option on the Connect tab of Power Wave® Manager (Figure 4.1 on page 4.1).
  • Page 30 Chapter 4. Overview of Power Wave® Manager Language Selection THIS PAGE INTENTIONALLY LEFT BLANK. Power Wave® Manager User Manual IM8002...

  • Page 31: System Status

    SnapShot button: This button allows you to save a file that contains detailed configuration and  debugging information collected from each module in the Welding Power Source. This can help Lincoln Electric Support to troubleshoot any possible issues that cannot be easily resolved. See page 9.2 for more details. IM8002...

  • Page 32: System Status Tab

    Chapter 5. System Status System Status Tab System Status Tab The System status tab displays any problems that may be present in any of the components of the Welding Power Source, including hardware, firmware and software (e.g., DeviceNet module, wire drives, or user interfaces).

  • Page 33: Detailed Status Display

    System Status Tab Chapter 5. System Status Detailed Status Display If you see error icons and need to look into the problems further, you can select Detailed status from the Display drop-down and view additional information for each component connected to the Welding Power Source.

  • Page 34: Module Information Tab

    Chapter 5. System Status Module Information Tab Module Information Tab The Module information tab displays information about each hardware module attached to the Welding Power Source. This information includes versions of the hardware and firmware of each module, serial numbers, Weld Set name, and miscellaneous information such as firmware revision numbers and checksums.

  • Page 35: Power Source Settings

    Chapter 6 Power Source Settings The Power source settings section consists of various subsections that contain settings for the Welding Power Source component of the welding system. You will access the Power Source Settings when you first set up your Welding Power Source, but once you have your Welding Power Sources set up and welding, you will use this section infrequently.
  • Page 36 Chapter 6. Power Source Settings Calibration The following is the recommended procedure for calibrating your power source: Procedure Details Attach Welding Power Source output cables to a 300A/30V resistive grid load. Open Power Wave® Manager. Connect to the power source. Display the Calibration section.

  • Page 37: Cable Settings And Tests

    Cable Settings and Tests Chapter 6. Power Source Settings Cable Settings and Tests The Cable settings and tests section allows you to configure and test your welding cables and sense leads for the Welding Power Source to which you are connected. Sense Lead Settings Tab Use these settings to enable or disable automatic hardware sense lead selection or to modify the behavior through manual settings.

  • Page 38: Weld Cable Test Tab

    Chapter 6. Power Source Settings Cable Settings and Tests Enable Negative Welding Polarity If negative welding polarity is required for the Welding Power Source, such as in some Innershield™ applications, you may need to configure the correct voltage sense location manually. NOTE | If the system is already configured to sense arc voltage at the remote voltage sense leads, no changes are required.

  • Page 39: Sense Lead Diagnostics Tab

    Cable Settings and Tests Chapter 6. Power Source Settings Figure 6.3 Weld Cable Test Tab It is good practice to record the results of these tests when the welding system is operating well. You can then use those values to compare to values taken when there are welding problems on the same weld cell.
  • Page 40 Chapter 6. Power Source Settings Cable Settings and Tests Figure 6.4 Sense Lead Diagnostics NOTE | You cannot perform this test with ServoTorch. Automatic Test Power Wave® Manager can also help you troubleshoot sense lead issues. The software automatically attempts to detect the sense lead location by turning on the Welding Power Source’s output in an open circuit voltage (OCV) mode and reading back voltage.

  • Page 41: Miscellaneous

    Miscellaneous Chapter 6. Power Source Settings Manual Test If you know want to step through each sense lead manually, you can use Power Wave® Manager to test them individually and force the Welding Power Source to sense voltage from the location you choose.

  • Page 42: Time Settings On The Power Source

    Chapter 6. Power Source Settings Miscellaneous Time Settings on the Power Source The Power Source time section displays the current time on the Welding Power Source’s internal clock. The power source uses this when recording internal events, errors, and information that it sends to Production Monitoring™...

  • Page 43: Network Settings

    Chapter 7 Network Settings The Network settings section provides you with the flexibility to configure the connection of the Welding Power Source to other equipment. You can connect various components through the use of ArcLink technology, DeviceNet communications, and/or Ethernet connections. The Network settings section allows you to review and monitor these settings.

  • Page 44: Arclink

    Chapter 7. Network Settings ArcLink ArcLink The ArcLink section provides you with an overview of all the welding system components connected to this Welding Power Source using the ArcLink technology. This section of Power Wave® Manager also provides you with the opportunity to “pair” devices together if they haven’t automatically paired themselves. (See page 7.3 for more on pairing.) Mapping Status Tab The Mapping status tab provides you with the logical layout (or “mapping”) of the components connected...

  • Page 45: Pairing Setup

    Chapter 7. Network Settings Pairing Setup Certain Lincoln Electric components can be “paired” together, such as dual-head wire feeders and user interfaces. The system usually pairs these automatically for you. However, if there was a problem with pairing between two or more components, Power Wave® Manager displays the Pairing setup tab (Figure 7.3).

  • Page 46: Devicenet

    Modifying DeviceNet settings is highly technical. If you are uncomfortable with making changes, contact your local IT support for assistance. You should also consult the appropriate Lincoln Electric Operator Manual for the module you have installed. Multiple DeviceNet Modules If the system to which a Welding Power Source is connected contains more than one DeviceNet module (e.g., a Power Wave®...

  • Page 47: Configuration Tab

    DeviceNet Chapter 7. Network Settings Configuration Tab Use the Configuration tab to review and/or edit options for the DeviceNet interface connected to this Welding Power Source. Power Wave® Manager reads these options from the connected Welding Power Source and displays them here. The available fields depend on the DeviceNet module. Table 7.1 explains each of the fields in more detail.
  • Page 48 Chapter 7. Network Settings DeviceNet Field Description Power Wave® Manager to set the MAC ID of the DeviceNet interface. STOP | If you change the MAC ID, you must cycle the power to the Welding Power Source (off then back on) in order for the change to take effect. Be careful not to cycle the power while the power source is currently welding.
  • Page 49 DeviceNet Chapter 7. Network Settings Field Description TAST update This parameter is used for Through the Arc Seam Tracking (TAST). The lower frequency the number the more often the feedback is updated, but higher the system load on the boards. In general, if TAST is being used, this frequency is set to a value between 10 and 20.
  • Page 50 Actual WFS: This option reports the actual wire feed speed of the  feeder through the third analog feedback. Commanded WFS: Typically used for non-Lincoln Electric wire  feeders, this option sends the recommended wire feed speed through the third analog feedback.

  • Page 51: Monitor Tab

    DeviceNet Chapter 7. Network Settings Monitor Tab The Monitor tab contains detailed information about the polled input/output data coming to and from the Welding Power Source’s DeviceNet interface. This is a troubleshooting tool for those customers implementing a DeviceNet connection to the Welding Power Source. For detailed information about the data on this tab, refer to the DeviceNet Interface Specification Document (Y50031) included with the Power Wave®...

  • Page 52: Trace Tab

    This tab allows you to record the DeviceNet network traffic coming to and from the Welding Power Source’s DeviceNet interface and create a file you can send to Lincoln Electric support or keep for reference in the future. This is extremely useful for troubleshooting communication issues.

  • Page 53: Weld Limits Tab

    DeviceNet Chapter 7. Network Settings Table 7.2 Options on the Trace Tab Field Description Trace type This option helps you control how much data you collect with the trace.  Continuous: Choose this option if you want the trace to keep recording data until you click the Stop trace button, regardless how long the trace is.

  • Page 54: Weld Sequencer Tab

    Chapter 7. Network Settings DeviceNet Figure 7.9 Weld Limits Tab NOTE | Updating the firmware on the Welding Power Source may cause the limits of some procedures to change. Weld Sequencer Tab The Weld sequencer tab contains advanced configuration settings for the Weld Sequencer component of the system.

  • Page 55: Ethernet

    Ethernet Chapter 7. Network Settings Ethernet This section provides options for configuring the network settings for the modules connected to the Welding Power Source through an Ethernet connection. Multiple Ethernet Modules If the system to which a Welding Power Source is connected contains more than one Ethernet module (e.g., a Power Wave®...
  • Page 56 Chapter 7. Network Settings Ethernet Table 7.3 Fields under Current Settings Field Description IP Address This is the location of this Welding Power Source on the computer network. Any device on your network that wants to communicate with the Welding Power Source must use the power source’s address to make the connection.
  • Page 57 Ethernet Chapter 7. Network Settings Simply choose the Obtain an IP address automatically option if you want the Welding Power Source to assign the IP address automatically using a dynamic IP address. STOP | If you choose this option, the Welding Power Source obtains a different IP address every time it connects to a network.
  • Page 58 Chapter 7. Network Settings Ethernet For example, if the custom range is from 192.168.1.0 to 192.168.1.255, a computer whose IP address is 192.168.1.10 will be able to access this machine, but a computer whose IP address is 192.168.2.1 will not. Communications Setup Tab Network speed (how fast your network can transmit data) and the duplex setting (the two-way communication allowed on that network) dictate how effective the communication is between your...

  • Page 59: Wire Feeder

    Chapter 8 Wire Feeder The Wire Feeder section contains settings and diagnostic information for any wire feeders and user interfaces attached to the Welding Power Source to which you are currently connected with Power Wave® Manager. Feeder Settings In the Feeder Settings section, you can fine tune the behavior of the wire feeders connected to this Welding Power Source.

  • Page 60: Settings Tab

    Chapter 8. Wire Feeder Feeder Settings Settings Tab Under the Settings tab, you can change the stall factor and gun offset for push-pull operation, as well as change the feed head and gear type. Table 8.1 explains the fields in more detail. Figure 8.2 Wire Feeder Settings Tab Table 8.1...

  • Page 61: Diagnostics Tab

    Feeder Settings Chapter 8. Wire Feeder Diagnostics Tab You can use the Diagnostics tab to troubleshoot and verify the operational state of your wire feeder. If you have multiple wire feeders connected to this welding power source, you can select the wire feeder from the Select Wire Feeder module drop-down at the top of the window (Figure 8.1 on page 8.1).

  • Page 62: User Interface

    Chapter 8. Wire Feeder User Interface Table 8.2 Fields on the Diagnostics Tab Option Description WFS feedback The fields in the WFS feedback section displays the wire feed speed information coming from the wire feeder. This includes:  Set WFS: This is the wire feed speed that was set in the Weld Profile being used for the weld or that was set manually on the machine by the Weld Operator.

  • Page 63: Setup/Security Settings Tab

    User Interface Chapter 8. Wire Feeder Figure 8.4 Multiple User Interface Drop-down If you’re not sure the selection in the drop-down refers to the actual user interface you want to review, click the Blink status light button. This causes the green status light on the User Interface to start blinking rapidly, and you can verify you have the correct device selected in Power Wave®...

  • Page 64: Memory Settings Tab

    Chapter 8. Wire Feeder User Interface Memory Settings Tab The Memory Settings section allows you to configure any of the memory buttons that exist on the User Interface module(s) attached to your welding system. Memory buttons allow you to preset weld settings for those welds commonly performed using this power source.
  • Page 65 User Interface Chapter 8. Wire Feeder Memory Parameters To edit a parameter, double-click the entry. The parameter’s edit window opens (Figure 8.7). Simply enter a new value and click OK. The Weld Modes and parameters that are available for the memory buttons vary depending on the individual User Interface.
  • Page 66 Chapter 8. Wire Feeder User Interface THIS PAGE INTENTIONALLY LEFT BLANK. Power Wave® Manager User Manual IM8002...

  • Page 67: Lookup Error

    Chapter 9 Tools The Tools section of Power Wave® Manager provides you with the ability look up an error codes you receive from a Welding Power Source, create backup and troubleshooting files and view the weld as it is being made. Lookup Error The Lookup error section allows you to obtain information about any error code given by a Welding Power Source (Figure 9.1).

  • Page 68: Snapshot

    When a problem or issue occurs with the Welding Power Source, record a SnapShot of the Welding Power Source, clear the logs (in the System status section, page 5.1), and attempt to reproduce the issue. If you can reproduce the issue, record another SnapShot and send both files to Lincoln Electric Support for analysis.

  • Page 69: Weldview

    Lincoln Electric service personnel may request a weld trace to aid in resolving welding issues. Click the Save button to save a trace file that you can send to Lincoln Electric Support for evaluation. If the Acquire new weld trace and Read trace from power source buttons are disabled, the feature may not be supported by the connected Welding Power Source.

  • Page 70: Creating A Weld Trace

    Chapter 9. Tools WeldView Creating a Weld Trace The WeldView Wizard allows you to fully configure the trace before starting it, including the trace frequency, the event that begins the trace (i.e., the trigger event), and if you want to record an extra channel with the trace.

  • Page 71: Weld Data Tab

    WeldView Chapter 9. Tools Procedure Details You can skip to step 7 if you do not want to use a If you want the trace to begin only when a trigger. Make sure there is no check mark in the specific event occurs, place a check mark in Use trigger checkbox.

  • Page 72: Backup/Restore

    Chapter 9. Tools Backup/Restore data in smaller segments of time. The Zoom out icon ( ) condenses data and displays the time segments in larger segments. For example, if your chart currently displays one second of data segmented every millisecond and you click the Zoom in icon, the chart begins to expand that one second into parts of a second.

  • Page 73: Restoring A Backup

    Backup/Restore Chapter 9. Tools To create a backup of the Welding Power Source to which you are currently connected: Procedure Details Click the Backup/Restore menu item. The program prompts you for a location where On the Backup tab, click the Backup button. you would like to save the file.
  • Page 74 Chapter 9. Tools Backup/Restore To load a settings file and overwrite the existing settings on this Welding Power Source: Procedure Details Click the Backup/Restore menu item. The system displays the categories of settings you can Click the Restore tab. restore. The Open file dialog appears.

  • Page 75: Observer

    Observer Chapter 9. Tools Observer While WeldView gives a detailed view of a portion of a weld with a short duration, the Observer tool graphs welding feedback at a slower rate over the course of several entire welds. When you begin a weld, Power Wave®...

  • Page 76: Logged Welds Tab

    Chapter 9. Tools Observer To save the data in the charts to a tab-delimited text file, click the Save chart data button on the top toolbar. Click the Clear charts button to clear the data from the screen and start fresh. Click the plus icon ( ) at each corner of the chart to collapse the panel next to it (if available).

  • Page 77: Settings Tab

    Observer Chapter 9. Tools Field Description Average amps Hundreds of times per second, the Welding Power Source takes a measurement of the arc current being used while the welder is active for this weld. When the weld is complete, the power source averages those measurements together. The Average amps column displays that average value for this weld.
  • Page 78 Chapter 9. Tools Observer THIS PAGE INTENTIONALLY LEFT BLANK. 9.12 Power Wave® Manager User Manual IM8002...

  • Page 79: Production Monitoring

    Chapter 10 Production Monitoring You use the Production Monitoring section of Power Wave® Manager to help you configure the Production Monitoring™ or CheckPoint™ software on this Welding Power Source (whichever is applicable). You also use this section to configure Weld Profiles and create training models for the Welding Power Source. Figure 10.1 Installation Section NOTE | If you do not see the Production Monitoring section in the...

  • Page 80: Register

    Chapter 10. Production Monitoring Register Register The Register section in Power Wave® Manager allows you to perform some of the necessary installation procedures for the Production Monitoring™ and CheckPoint™ applications, as well as review the current welds in the memory of the Welding Power Source. For more information on either of these applications, refer to the Production Monitoring™...

  • Page 81: Diagnostics Tab

    Configuration Chapter 10. Production Monitoring Diagnostics Tab The Diagnostics tab provides you with a way to view a list of welds that the power source currently has in its memory since the last time it powered on (the Number of welds in memory field), as well as a way to reset the machine if there is an Alarm Latch detected from an out-of-limits condition (click the Reset fault button).

  • Page 82: Weld Profile Selection Tab

    Chapter 10. Production Monitoring Configuration Weld Profiles allows the Welding Power Source to apply different limit settings for each weld that is performed on a certain part. A Weld Engineer creates a Weld Profile for each weld needed to make a part. The Weld Profile configures the power source to complete a certain type of weld within certain limits needed to obtain a specified level of quality.

  • Page 83: Out-Of-Limit Actions Tab

    Configuration Chapter 10. Production Monitoring Table 10.1 Options on the Weld Profile Selection Tab Field Description Select Weld Profile When you choose this option, the last digit of the welding set point automatically based on the becomes the Weld Profile number currently in use. last digit of the Workpoint For example, if the welding set point is set to 125, the Power Wave®...
  • Page 84 Chapter 10. Production Monitoring Configuration When setting the Out-of-limit tolerance for WeldScore™, remember that the sample rate is 0.25 seconds. You should choose a tolerance value according to the fewest number of samples you want to include. For example, a value of 0.3 seconds in the Out-of-limit tolerance field only ensures one sample. A value of 0.6 seconds ensures two samples.

  • Page 85: Profile Limits Tab

    Configuration Chapter 10. Production Monitoring If the Action on WeldScore limit value field is grayed out, either the power source does not support WeldScore™ or the power source has older firmware that needs to be updated. See page 3.1 for details on upgrading the power source’s firmware.
  • Page 86 Chapter 10. Production Monitoring Configuration Figure 10.6 Profile Limits Tab To change settings in a particular Weld Profile, simply click the Weld Profile to select it and make changes to the fields on the right. Place a check mark in the Enable checkbox to tell the power source to use that limit for the profile.
  • Page 87 Configuration Chapter 10. Production Monitoring Table 10.3 Limits Available for Each Weld Profile Field Description Start delay This is the amount of delay the power source should use when applying limits at the beginning of this weld. The Start delay is the amount of time (in seconds) that the power source should wait, directly after the start of a weld, before it begins to apply the limits entered for this Weld Profile.
  • Page 88 Chapter 10. Production Monitoring Configuration Field Description for that Weld Profile) and displays the value in the system. NOTE | The default, as well as minimum, value for this setting is 80. If you need to set a minimum WeldScore™ limit of less than 80 to prevent your welds from triggering limit alerts, either the training was performed incorrectly or a variable has changed since the original training was done.

  • Page 89: Wire Package Tab

    Configuration Chapter 10. Production Monitoring Wire Package Tab In order for Power Wave® Manager, Production Monitoring™ or CheckPoint™ to notify you when the consumable on the Welding Power Source is running low or to allow the monitoring software to calculate a variety of values, you need to enter the details of the consumable into the power source.

  • Page 90: E-Mail Setup Tab

    Chapter 10. Production Monitoring Configuration E-mail Setup Tab The E-mail setup tab provides you with the ability to configuration e-mail alerts (such as system events and wire package warnings) for up to 12 e-mail addresses. This requires collecting a bit of information before you begin.
  • Page 91 Configuration Chapter 10. Production Monitoring Mail Server Configuration The following options allow you to configure the Welding Power Source to send e-mail notifications to the addresses in the Address Book (page 10.13). Table 10.5 explains these options in more detail. Table 10.5 Configuration Options on the E-mail Setup Tab Field Description...
  • Page 92 Chapter 10. Production Monitoring Configuration Figure 10.9 Address Book To add a user to the address book, click <empty> slot in the address list to activate a text field. Type the address and press Enter on the keyboard. To edit an address, simply click on the address and begin typing. Press Enter on the keyboard to commit your changes.

  • Page 93: Miscellaneous Tab

    Configuration Chapter 10. Production Monitoring power source will generate an e-mail. If the Weld Operator completes the next weld and the WeldScore™ is again below the minimum, the power source generates another e-mail. To assign an e-mail trigger to an e-mail address, simply make sure you have the e-mail address selected and place a check mark in the checkbox next to the appropriate options.
  • Page 94 Chapter 10. Production Monitoring Configuration Click inside the appropriate field and type the serial number. Click the Update button to commit your changes. Once you update with the new number, Power Wave® Manager displays it in the Current value field. (You can also click Apply settings to commit changes made to all serial numbers.) Figure 10.11 Miscellaneous Tab 10.16 Power Wave®...

  • Page 95: Training

    Chapter 11 Training For third-generation Welding Power Sources, you need to create training models in order to use WeldScore™. For second-generation power sources (which do not support WeldScore™), training models simply help you set limits for current, voltage and wire feed speed. You use both the Profile limits tab (page 10.7) and the Training section (this chapter) to maintain your Weld Profiles.

  • Page 96: Where To Use Weldscore

    Chapter 11. Training WeldScore™ addition to traditional current and voltage measurements, WeldScore™ also looks at 30 to 40 additional variables that help to make it more reliable and accurate than traditional weld monitoring systems. Consistency and repeatability are the keys to make your use of WeldScore™ effective. In order to assign a score, the Welding Power Source must first be taught what is considered to be an acceptable weld.

  • Page 97: Weld Profile Training

    Weld Profile Training Chapter 11. Training Weld Profile Training You use Weld Profile Training to create training files for the welds you consider acceptable when a Weld Operator uses that specific Weld Profile. Training helps you generate limits for current, voltage, wire feed speed and duration for a Weld Profile automatically.

  • Page 98: Training Profiles

    Chapter 11. Training Training Profiles Training Profiles Be sure you are connected to the Welding Power Source on which you want to train the welds and that all components are working properly. STOP | Be sure you have read Before You Begin Training a Weld on page 11.1 before you continue.
  • Page 99 Training Profiles Chapter 11. Training When a Weld Profile has one or more training files associated with it, the gray icon ( ) next to the Weld Profile number appears as a star icon ( ). Click the plus icon ( ) to expand the Weld Profile and view the training files created.
  • Page 100 Chapter 11. Training Training Profiles Procedure Details Power Wave® Manager adds a check mark next to Repeat steps 4 and 5 for each Weld Profile each profile you have trained during this session and you want to train during this session. changes the gray icon ( ) to a star icon ( ).

  • Page 101: Viewing The Calculated Limits For A Weld

    Viewing the Calculated Limits for a Weld Chapter 11. Training Viewing the Calculated Limits for a Weld If there are welds trained for a Weld Profile, you will see an arrow icon ( ) next to the Weld Profile in the Training section.

  • Page 102: Deleting A Trained Weld From A Weld Profile

    Chapter 11. Training Deleting a Trained Weld from a Weld Profile Deleting a Trained Weld from a Weld Profile When you perform welds to create training models, you may accidentally create a weld that is not an acceptable example. You may also have an existing trained weld in a Weld Profile that throws off the limits for that profile.

  • Page 103: Loading A Weld File

    Loading a Weld File Chapter 11. Training Loading a Weld File If you need to load an existing weld training file from the Preferences folder (page 4.1), you can easily do so with Power Wave® Manager. Procedure Details Right-click the Weld Profile to which you want to load the file.
  • Page 104 Chapter 11. Training Copying a Weld File THIS PAGE INTENTIONALLY LEFT BLANK. 11.10 Power Wave® Manager User Manual IM8002...

  • Page 105: Troubleshooting

    NOTE | If you continue to have trouble, please contact your local IT department or Lincoln Electric Production Monitoring support. For support in the USA or Canada, dial 1.800.691.5797. The direct dial number is 1.727.786.0121.

  • Page 106: Ethernet Settings Seem Valid But Still Cannot Connect

    Appendix A. Troubleshooting Cannot Connect to a Power Source Procedure Details On the Connect tab, choose I do not know the IP address of the welder. Only one IP address should appear. Click the Refresh List button. Select the welder and click Connect. TIP | When you select the power source, the green status light on the machine should begin to blink.

  • Page 107: Fanuc Robots

    Appendix B FANUC Robots FANUC Systems and IP Addresses When connecting to Welding Power Sources that provide welding power for FANUC robot controllers it is important to understand the connection path between the computer running Power Wave® Manager and the Power Wave® power source. The FANUC robot controller acts as a proxy server for messages between Power Wave®...

  • Page 108: Requirements

    Appendix B. FANUC Robots FANUC® Robot Application (Prior to v7.70P/21) Requirements When you want to implement Production Monitoring™/CheckPoint™ for the FANUC robot, you need to make sure you have met the following requirements: ArcTool® Software  The robot must have ArcTool® software version 6.40-1M or later installed. This version includes two programs, WR_AL_AT.VR and RD_AL_AT.VR that form the basis of Production Monitoring™/CheckPoint™...

  • Page 109: Setting Limits

    FANUC® Robot Application (Prior to v7.70P/21) Appendix B. FANUC Robots Production Monitoring™/CheckPoint™ Installed and/or Set up  For Production Monitoring™, the software from the Production Monitoring™ CD has been installed on a computer connected to the same network as the Welding Power Source or the robot.

  • Page 110: Alarm/Alert Programs

    Appendix B. FANUC Robots FANUC® Robot Application (Prior to v7.70P/21) Procedure Details Cursor to PM_SEL or PM_VER and press Enter. With the cursor now just past the PM_SEL or PM_VER, press F4-Choice. The word “Constant” now appears on the line. Cursor to Constant and press Enter.

  • Page 111: Erroneous Low Time Limit Alarms

    FANUC® Robot Application (Prior to v7.70P/21) Appendix B. FANUC Robots Erroneous Low Time Limit Alarms A low time limit can occur if the duration of the weld is less than the sum of the Start and End delays as set by someone like a Weld Engineer during the setup of Weld Profiles (page X).
  • Page 112 Appendix B. FANUC Robots FANUC® Robot Application (Prior to v7.70P/21) PM_ON  ALERT_1, ALERT_2, ALERT_3, ALERT_4, ALERT_5, ALERT_10  Listing of Program PM_SEL R[1] = AR[1] - 1; IF R[1]<0 OR R[1]>31, CALL ALERT(10); LBL[1]; ! set profile selection CALL WR_AL_AT(1,17,1008,R[1],3,4); ! verify that the write was ok IF R[3]<>0,JMP LBL[1];...
  • Page 113 FANUC® Robot Application (Prior to v7.70P/21) Appendix B. FANUC Robots Listing of Program PM_VER R[1] = AR[1] - 1; IF R[1]<0 OR R[1]>31, CALL ALERT(10); R[1] = R[1] * 25; R[1] = R[1] + 2013; ! Get runt counts LBL[3]; CALL RD_AL_AT(1,17,R[1]);...

  • Page 114: Fanuc® Robot Application (V7.70P/21 Or Later)

    Appendix B. FANUC Robots FANUC® Robot Application (v7.70P/21 or Later) FANUC® Robot Application (v7.70P/21 or Later) This section reviews FANUC support for Production Monitoring™/CheckPoint™ starting with the ArcTool v7.70P/21 release or later. See page B.1 for information on supporting Production Monitoring™/ CheckPoint™...

  • Page 115: Weld Profile Selection

    Procedure: Enabling Arc Production Monitor Appendix B. FANUC Robots Procedure Details Press Enter again to display the variables in this structure. Change the state of $PM_ENABLE from FALSE to TRUE. Weld Profile Selection The Arc Production Monitor option allows you to specify the Weld Profile for each weld in the TP program by calling a macro and passing the profile number as an argument.

  • Page 116: Production Monitoring™ Error Handling

    Appendix B. FANUC Robots  Procedure: Enabling Arc Production Monitor  SET_PM_PROF[1]; J P[2] 20 % FINE Weld Start [1,1]; L P[3] WELD SPEED CNT 100; etc.  Alternate serial number entry formats include:  SET_PM_PART(ABC1234567) ; SET_PM_PART(R[n]); SET_PM_PART(SR[n]); SET_PM_PART(GI[n]); If your robotic welding system includes the Multi‐Equipment feature, there will be four versions of the  Set_PM_PART macro as follows:  SET_PM_PART_E1 SET_PM_PART_E2 SET_PM_PART_E3 SET_PM_PART_E4 Select the appropriate macro for the weld equipment you are using to set the serial number.  You add the  serial number to the macro call by selecting F4 (CHOICE) and choosing the desired entry method from the  pop‐up list.  Production Monitoring™ Error Handling The Lincoln Production Monitoring™ feature allows you to specify three response actions when an out‐of‐ tolerance error is encountered:  Table B.1  Production Monitoring™ Error Handling ...

  • Page 117: Wire Monitor Setup Menu

    Procedure: Enabling Arc Production Monitor Appendix B. FANUC Robots You identify the Digital Output port number for an alarm (log event and alarm latch) by setting the system variable: $AWELEPM[equip].$ALARM_PNUM The Digital Output port number for a fault level alarm is set in: $AWELEPM[equip].$FAULT_PNUM Wire Monitor Setup Menu Another feature of Lincoln Production Monitoring™...

  • Page 118: Weldscore™ Display

    Appendix B. FANUC Robots Procedure: Enabling Arc Production Monitor At the top of the Wire menu, the Current weight of the wire supply is displayed. Each of the settings for this menu can be changed by moving the cursor to the respective line and entering the desired value. The Wire Material entry on line 5 allows you to select from the F4 (CHOICE) key as shown in Figure 11.4.

  • Page 119: Proxy Server Function For Checkpoint™ Cloud Server Data Storage

    Procedure: Enabling Arc Production Monitor Appendix B. FANUC Robots Figure 11.5 Arc Analog Meter While welding, these meters display the actual values of the selected parameters. At the end of the weld, the WeldScore™ meter displays the average value for the previous weld. Proxy Server Function for CheckPoint™...
  • Page 120 Appendix B. FANUC Robots Procedure: Enabling Arc Production Monitor Pressing ENTER yields Figure 11.7. Figure 11.7 Enable Proxy Server Enable the Proxy Server function by placing the cursor on the line labeled Enable and pressing F4 (TRUE). Move the cursor to the line labeled “Server” and enter the IP address of the Proxy Server in your local area network.

  • Page 121: Reference: $Awelepm System Variable

    The Host Name and IP address of the cloud server may be different than the values shown above. Please consult Lincoln Electric for details about this data. Upon completion of these entries, cycle power on the robot controller and Power Wave®.
  • Page 122 Appendix B. FANUC Robots Procedure: Enabling Arc Production Monitor 14 $WP_NUM_MAX 15 $ALARM 16 $LATCH_ALARM 17 $FAULT 18 $ALARM_PTYP 19 $ALARM_PNUM 20 $FAULT_PTYP 21 $FAULT_PNUM 22 $TRUE_ENERGY 21504.000 23 $WIR_LO_PTYP 24 $WIR_LO_PNUM 25 $WIRE_LOW FALSE 26 $WIRE_IN_KG FALSE 27 $PART_MAXLEN 28 $PREV_ENERGY 0.000 29 $WELD_ENERGY...

  • Page 123: Glossary

    Glossary ArcLink®: This is a communications protocol Ethernet: A telecommunications networking developed by Lincoln Electric for use in a welding protocol used to connect computers to each system. This protocol takes into account specific other. needs of a welding system and the interaction of...
  • Page 124 Glossary PLC through Welding Set Point PLC: Programmable Logic Controller, a Spreadsheet Application: A computer tool such specialized device used in the control of as Microsoft Excel that arranges values into rows industrial processes. and columns. Subnet: A section of a network. Subnets are Port: In a specific network such as a TCP or a UDP network, a port is an endpoint to a logical used to divide up large networks into small...
  • Page 125 NOTES...
  • Page 126 Do not touch electrically live parts or Keep flammable materials away. Wear eye, ear and body protection. WARNING electrode with skin or wet clothing. Insulate yourself from work and ground. Spanish No toque las partes o los electrodos Mantenga el material combustible Protéjase los ojos, los oídos y el AVISO DE bajo carga con la piel o ropa mojada.
  • Page 127 Keep your head out of fumes. Turn power off before servicing. Do not operate with panel open or WARNING Use ventilation or exhaust to remove guards off. fumes from breathing zone. Spanish Los humos fuera de la zona de res- Desconectar el cable de alimentación No operar con panel abierto o AVISO DE...
  • Page 128 Lincoln Electric for advice or information about their use of our products. We respond to our customers based on the best information in our possession at that time. Lincoln Electric is not in a position to warrant or guarantee such advice, and assumes no liability, with respect to such information or advice.

This manual is also suitable for:

Power wave 405m

Table of Contents