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Lincoln arc welding and cutting
equipment is designed and built
with safety in mind. However, your
overall safety can be increased by
proper installation ... and thought-
ful operation on your part. DO
NOT INSTALL, OPERATE OR
REPAIR THIS EQUIPMENT
WITHOUT
READING
MANUAL AND THE SAFETY
PRECAUTIONS CONTAINED
THROUGHOUT.
And,
importantly, think before you act
and be careful.
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THIS
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40
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21
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33.4
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SOFTWARE OPERATOR'S MANUAL
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Summary of Contents for Lincoln Electric WAVE DESIGNER IM649
- Page 1 Wave Designer Safety Depends on You Lincoln arc welding and cutting equipment is designed and built with safety in mind. However, your overall safety can be increased by proper installation ... and thought- ful operation on your part. DO NOT INSTALL, OPERATE OR REPAIR THIS EQUIPMENT WITHOUT READING...
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Page 3: Table Of Contents
License Information ... ii Introduction ... Section 1 1.1 Product Overview ... 1-1 1.2 User Responsibility ... 1-1 1.3 Computer System Requirements ... 1-1 1.4 Software Release Data ... 1-2 1.5 Welding Equipment Requirements ... 1-2 Software Installation ... Section 2 2.1 File Storage Locations ... -
Page 4: License Information
NON-DISCLOSURE: You agree that the Software is and shall remain the property of Lincoln Electric, and that you will hold the Software in confidence for Lincoln. You agree to make reasonable efforts to prevent unauthorized use of the Software, and to prevent disclosure to third parties. - Page 5 JAVA RUNTIME ENVIRONMENT, VERSION 1.1.6, BINARY CODE LICENSE This binary code license ("License") contains rights and restrictions associated with use of the accompanying Java Runtime Environment software and documentation ("Software"). Read the License carefully before using the Software. By using the Software you agree to the terms and conditions of this License.
- Page 6 LICENSE INFORMATION WAVE DESIGNER...
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Page 7: Introduction
Section 1 KEY TOPICS This symbol indicates the location of key concepts throughout this manual. 1.1 PRODUCT OVERVIEW Wave Designer is a visual, interactive software application used to modify wave shapes for use with programmable waveform-controlled welding machines such as the Power Wave 455. The Wave Designer software package includes a standard set of waveforms commonly used in commercial and industrial welding applications. -
Page 8: Software Release Data
Wave Designer Editor Screens. 1.4 SOFTWARE RELEASE DATA Wave Designer is a product of The Lincoln Electric Company. Please send your comments, questions, suggestions, and problem reports to wavedesigner@lincolnelectric.com. Refer to the Wave Designer Welcome screen for the applicable release version of the Wave Designer software package. -
Page 9: Software Installation
SOFTWARE INSTALLATION Section 2 2.1 FILE STORAGE LOCATIONS The Wave Designer default home directory is C:\Program Files\WaveDesigner. Subdirectories included with Wave Designer are as follows: • arcScope - user data file for ArcScope traces (Wave Designer Pro option only) • bin - system executables and support files, do not tamper with these files •... -
Page 10: Equipment Interface Connections
Figure 2-3. FIGURE 2-1. WAVE DESIGNER STARTUP SCREEN. Welcome to Wave Designer Lincoln Electric Wave Designer Version 1.0 Copyright © 1998 The Lincoln Electric Company All Rights Reserved Wave Designer United States Patent Pending Comments? Write to wavedesigner@lincolnelectric.com... - Page 11 SOFTWARE INSTALLATION Section 2 PLEASE NOTE: Some IBM ThinkPads® by default have the serial port disabled and instead the port is used for infrared. The following information describes the procedure to disable the infrared feature and enable the serial port. Follow the instructions below to use COM1 to communicate with the PowerWave.
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Page 12: Equipment/Software Startup
SOFTWARE INSTALLATION 2.4 EQUIPMENT/SOFTWARE STARTUP When the Wave Designer software installation is complete, Wave Designer is listed among the programs you can start up from the Windows startup screen. Click on START, point to the programs option, then click on the Wave Designer option. The Wave Designer Welcome screen is displayed followed by the Pulse Waveform Editor screen. -
Page 13: Software Operation
Section 3 3.1 SYNERGIC WELDING AND WORKPOINTS Prior to using Wave Designer it is important to have a good understanding of the concepts of synergic welding and workpoints. Synergic welding is basically “one knob control” of a welding process; all other variables of the process are adjusted by the power source based on the single controlling variable. -
Page 14: Working In Wave Designer
3.2 WORKING IN WAVE DESIGNER 3.2.1 WAVEFORM EDITOR WINDOW Refer to the Waveform Editor window in Figure 3-2 and the related usage instructions. File Tools Print Pulse Waveform Editor Wire Feed Speed Ramp Up Rate Ramp Overshoot % Peak Amps Peak Time ms Tailout Time Tailout Speed... - Page 15 Section 3 5. Optional Windows The optional window buttons open additional windows used during wave shaping. Optional windows in the pulse Waveform Editor include Start, Adapt, Short, End, and About. Details about the use of most optional windows is covered in the applicable appendix (i.e.
- Page 16 (Wire Feed Speed) workpoints. Export to HTML Web Pages Use the Export to Web Pages option to copy a custom waveform to a web page for transmission of the waveform to Lincoln Electric for review. Quit Ctrl+Q Use the Quit option to exit the Wave Designer program.
- Page 17 Section 3 3.2.2.2 TOOLS MENU The Tools menu includes waveform display options and other tools required to operate Wave Designer. The Tools menu options include the following: Pulse Editor Ctrl+P Display the Pulse Waveform Editor screen. STT Editor Ctrl+E Display the STT Waveform Editor screen. Simplify Editor Display the primary wave shaping parameters only.
- Page 18 3.2.2.3 PRINT MENU Print menu options enable you to print out a waveform display, ArcScope screen, or tabular waveform data listing as shown below. The Print menu options include the following: Wave Designer Pro Waveform Editor Printed on Thu Jul 09 07:24:50 EDT 1998 ..\systemWeldFile\pulse.swf For Wire Feed Speed 150 inch / min Ramp Up Rate...
- Page 19 Section 3 3.2.3 EDITING AND SELECTING WORKPOINTS For each custom welding application, unique wave shapes are developed for specific workpoints within the range of workpoints defined for the application. In Wave Designer the range of workpoints and the specific workpoint values are defined in a Workpoint Editor window. After the workpoints are defined, we use a workpoint pulldown menu to select a specific workpoint for wave shaping.
- Page 20 3.2.3.1 EDITING WORKPOINTS Clicking on the Edit button in the waveform Editor window opens a Workpoint Editor window. The Workpoint Editor window displays a listing of workpoints for the selected standard waveform. Use the Workpoint Editor window according to the following descriptions and guidelines: •...
- Page 21 Section 3 3.2.3.2 SELECTING WORKPOINTS Clicking on the workpoint display box in the waveform Editor window opens a Workpoint pulldown menu. The pulldown menu displays the listing of workpoints defined for the active waveform. Use the pulldown menu according to the following descriptions and guidelines: •...
- Page 22 3-10 3.2.4 EDITING VARIABLE PARAMETERS The following is a summary of the different methods available for changing (editing) parameter values on the Waveform Editor screen and other display screens accessible through Wave Designer. Read the following information carefully before making parameter changes on the Waveform Editor screen.
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Page 23: Wave Design Process
Section 3 3.3 WAVE DESIGN PROCESS The wave design process is a series of operations that allows you to quickly modify a standard waveform to fit your specific welding application. The following process flowchart applies to a pulse waveform, but is similar to the process used to modify STT and other waveforms. Examples of each process step can be found in the listed reference paragraphs. -
Page 24: Downloading Wave Shapes
Wave Designer software may be out of date, but needed for use with older welding machines. Save the old factory default files in a new, “old weld files” directory and access the latest factory default files from the Lincoln Electric web site for use on the newer Power Wave machine(s). -
Page 25: Autosave
Section 3 2. Select a blank Mode or a defined Mode for overwrite by clicking on a box to the left of the Modes listing. When the Mode is selected, a checkmark appears in the Mode box. 3. Enter the file name of the desired waveform in the box to the right of the selected Mode number. - Page 26 SOFTWARE OPERATION 3-14 Section 3 WAVE DESIGNER...
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Page 27: Arcscope
Section 4 4.1 INTRODUCTION The following describes the ArcScope application included with Wave Designer Pro. The ArcScope application provides oscilloscope type displays of power source output waveforms on your computer monitor. 4.1.1 USING THE ARC SCOPE WINDOW Refer to the ArcScope window in Figure 4-1 and the related window usage instructions. File Tools Print... - Page 28 ArcScope window. Wave Designer counts the elapsed time between the start of this state to calculate the frequency. The Waveform Start State is set to 8 by default. Call Lincoln Electric for more details. ARCSCOPE...
- Page 29 Section 4 File | Save Scope: Use the Save Scope option to save the scope trace data in ASCII text format for use in a word editor or spreadsheet data processing application. File | Open Scope Trace: Use the Open Scope Trace option to open a saved scope trace data file.
- Page 30 ARCSCOPE Section 4 WAVE DESIGNER...
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Page 31: Troubleshooting
Section 5 5.1 OVERVIEW Wave Designer troubleshooting is limited to the software application. If the welding machine does not respond, recheck the interface connection and communication setup requirements in section 2 of this manual. Refer to the welding machine service manuals for troubleshooting suspected equipment malfunctions. - Page 32 TROUBLESHOOTING Section 5 WAVE DESIGNER...
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Page 33: Pulse Wave Shaping Principles
PULSE WAVE SHAPING PRINCIPLES Appendix A A.1 APPENDIX OVERVIEW This appendix provides a series of discussions on pulse wave shaping principles and the development of custom GMAW pulse waveforms. The contents of this appendix are arranged as follows: Paragraph No./Title GMAW Pulse Overview Adaptive and Non-Adaptive Mode... - Page 34 PULSE WAVE SHAPING PRINCIPLES A.2 GMAW PULSE OVERVIEW Figure A-1 illustrates the variables of the GMAW-P welding process. Each of these variables can be programmed into a weld table using the Wave Designer software. Figure A-2 shows how the pulse waveform and the primary variables shape, detach and propel a weld droplet across the arc.
- Page 35 PULSE WAVE SHAPING PRINCIPLES Appendix A BACKGROUND AMPS WELD DROPLET TRANSFER • From time T1 to T2: • From time T2 to T3: • From time T3 to T4: • From time T4 to T5: • After time T5: EACH PULSE DELIVERS ONE DROPLET OF WELD MATERIAL FIGURE A-2.
- Page 36 PULSE WAVE SHAPING PRINCIPLES A.3 ADAPTIVE AND NON-ADAPTIVE MODE To proficiently develop welding procedures using Wave Designer, the key concept of Adaptive versus Non-Adaptive welding must be understood. Wave Designer allows the user to set the machine into either adaptive or non-adaptive mode. During the wave design process both modes will be used depending upon the step.
- Page 37 PULSE WAVE SHAPING PRINCIPLES Appendix A A.4 PULSE WAVE DESIGN PROCESS The Wave Designer software interfaces with the welding machine controller to permit real time communication of pulse wave design changes. Refer to paragraph 2.3 for equipment interface connections. Use the following wave design process to customize a standard wave shape. The process is summarized in the following flowchart.
- Page 38 PULSE WAVE SHAPING PRINCIPLES A.4.1 SELECTING A STARTING WAVE SHAPE When customizing a waveform for a specific welding application, we recommend that you use a waveform in an existing weld file. An existing weld file can be selected from the systemWeldFiles folder in the Wave Designer directory as follows: a.
- Page 39 PULSE WAVE SHAPING PRINCIPLES Appendix A A.4.2 CUSTOMIZING THE WAVE SHAPE If customizing your first wave shape, perform the wave shaping exercises provided at the back of this section to get thoroughly acquainted with wave shaping. Thereafter, refer to the following wave shaping procedure.
- Page 40 Set the PowerFeed Trim control for a readout of 1.00. This will ensure that the wave shape is designed at the midrange of the trim adjustment capability. The welding machine’s trim control allows the welder to adjust the arc length between 0.5 to 1.5 (50% to 150%) times the established arc length adjustment factor.
- Page 41 PULSE WAVE SHAPING PRINCIPLES Appendix A 3. Close the Adaptive Loop / Adjust the Peak Voltage a. If the adaptive stickout window is not open, click on the window. Select the adaptive option to close the adaptive loop. Verify that the adaptive button lights up.
- Page 42 PULSE WAVE SHAPING PRINCIPLES A-10 5. Adjust the Start Control Parameters (Optional) The start control parameters can be adjusted to define how the welding machine will respond when the arc is struck. To view the start control window, click on the Adjust the start control parameters to accommodate your welding application and per the following parameter descriptions.
- Page 43 PULSE WAVE SHAPING PRINCIPLES Appendix A 6. Adjust the Shorting Control Parameters (Optional) The shorting control parameters can be adjusted to define how the welding machine will respond when the arc shorts to the weld puddle. To view the shorting control window, click on the Adjust the shorting control parameters to accommodate your welding application and per the following parameter descriptions.
- Page 44 PULSE WAVE SHAPING PRINCIPLES A-12 7. Adjust the End Condition Parameters (Optional) The end condition parameters can be adjusted to define how the welding machine will respond at the end of a weld application. To view the end condition window, click on the Adjust the end condition parameters to accommodate your welding application and per the following parameter descriptions.
- Page 45 PULSE WAVE SHAPING PRINCIPLES Appendix A 8. “Go Figure” / Make the Waveform Synergic Weld synergy is established by shaping the 2nd and all subsequent workpoints. Being synergic, the waveform parameters automatically adjust to programmed data table values. The data table values are unique for selected wire feed speeds.
- Page 46 PULSE WAVE SHAPING PRINCIPLES A-14 A.5 PRIMARY PULSE WAVEFORM COMPONENTS The following paragraphs describe how peak current, peak time, frequency, and background current effect weld droplet transfer. A.5.1 PEAK CURRENT AND PEAK TIME A combination of peak current and peak time, Figure A-6, applies a force to detach the weld droplet from the electrode and propel it across the arc.
- Page 47 PULSE WAVE SHAPING PRINCIPLES Appendix A A.5.2 FREQUENCY Frequency, Figure A-7, is the number of pulses per second or, in theory, the number of weld droplets per second. Since increasing the frequency generates more pulses in a given time period, higher frequencies generate higher average current levels. BACKGROUND CURRENT AVERAGE...
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Page 48: Secondary Waveform Parameters
PULSE WAVE SHAPING PRINCIPLES A-16 A.6 SECONDARY WAVEFORM PARAMETERS A.6.1 RAMP-UP RATE The ramp-up rate is the speed of current climb from the background current level to the peak current level. Faster ramp-up rates tend to produce a plasma plume that quickly surrounds the end of the next droplet. -
Page 49: Application Exercise
Before starting the waveshape development process, confirm that the consumables are working properly with the welder. We recommend using a standard waveshape such as mode 5 to confirm that the welding system performs under normal conditions before attempting to develop waveshapes. - Page 50 PULSE WAVE SHAPING PRINCIPLES A-18 3. Using the adaptive stickout window or the green adaptive button on the status bar, select ‘No Adapt’ . The status bar at the bottom of the screen should read: . Close the “adapt” window (if opened).
- Page 51 PULSE WAVE SHAPING PRINCIPLES Appendix A 6. The “Start”, “Short”, and “End” windows can be adjusted at this time to optimize the starting, shorting, and ending routines. Our Experiment: We needed to adjust the starting variables. With the feeder’s run-in WFS set at 65 in/min, we set the starting variables to control the starting routine.
- Page 52 PULSE WAVE SHAPING PRINCIPLES A-20 8. For a second workpoint we went to 300 in/min. Select the 300 in/min. wire feed speed from the pulldown menu in Waveform Editor window. Reset the PowerFeed for 300 in/min. with a 1.00 trim. 9.
- Page 53 PULSE WAVE SHAPING PRINCIPLES Appendix A 12. Open the “Edit” screen and select only those workpoints that have been developed (150 and 300 in/min.). Select the interpolate the remaining workpoints. The function gives a estimation of the values needed for the other wire feed speeds. Each useable workpoint should be developed separately.
- Page 54 PULSE WAVE SHAPING PRINCIPLES A-22 Appendix A WAVE DESIGNER...
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Page 55: Stt Wave Shaping Principles
STT WAVE SHAPING PRINCIPLES Appendix B B.1 APPENDIX OVERVIEW This appendix provides a series of discussions on STT wave shaping principles and the development of custom STT waveforms. The contents of this appendix are arranged as follows: Paragraph No./Title STT Overview STT (Surface Tension Transfer) STT Wave Design Process Primary STT Waveform... - Page 56 STT WAVE SHAPING PRINCIPLES B.2 STT OVERVIEW Figure B-1 illustrates the variables of the STT welding process. Each of these variables can be programmed into a weld table using the Wave Designer software. Figure B-2 shows how the STT waveform and the primary variables produce a weld. For more details on each of these variables, refer to Primary STT Waveform Components and Secondary STT Waveform Components in paragraphs B.5 and B.6 of this appendix.
- Page 57 STT WAVE SHAPING PRINCIPLES Appendix B BACKGROUND AMPS • From time T (Background Current) 100 Amps that maintains an arc to form a weld bead. • From time T (Ball Time) • From time T (Pinch) • Time T (Fuse Separation) •...
- Page 58 STT WAVE SHAPING PRINCIPLES B.3 STT (SURFACE TENSION TRANSFER) The Invertec STT power source is a high-frequency, current-controlled machine that delivers power to the arc based on immediate arc requirements. The Invertec STT produces large electrode current changes within microseconds. It operates in the short-circuiting welding mode. The electrode current supplied by the power source is guided by the arc voltage state.
- Page 59 STT WAVE SHAPING PRINCIPLES Appendix B – T The pinch mode applies an increasing, dual-slope ramp of current to the shorted electrode. The dual slope ramp of current accelerates the transfer of molten metal by the electric pinch forces. The pinch force is directly proportional to the square of the pinch current.
- Page 60 STT WAVE SHAPING PRINCIPLES B.4 STT WAVE DESIGN PROCESS The Wave Designer software interfaces with the welding machine controller to permit real time communication of STT wave design changes. Refer to paragraph 2.3 for equipment interface connections. Use the wave design process to customize a standard wave shape. The process is summarized in Figure B-4.
- Page 61 STT WAVE SHAPING PRINCIPLES Appendix B B.4.1 SELECTING A STARTING WAVE SHAPE When customizing a waveform for a specific welding application, we recommend that you use a waveform in an existing weld file. An existing weld file can be selected from the systemWeldFiles folder in the Wave Designer directory as follows: a.
- Page 62 STT WAVE SHAPING PRINCIPLES B.4.2 CUSTOMIZING THE WAVE SHAPE If customizing your first wave shape, perform the wave shaping exercises provided at the back of this section to get thoroughly acquainted with wave shaping. Thereafter, refer the following wave shaping procedure. 1.
- Page 63 Set the Invertec Trim control for a readout of 1.00. This will ensure that the wave shape is designed at the midrange of the trim adjustment capability. The welding machine’s trim control allows the welder to adjust the arc length between 0.5 to 1.5 (50% to 150%) times the established arc length adjustment factor.
- Page 64 STT WAVE SHAPING PRINCIPLES B-10 3. Adjust the Start Control Parameters (Optional) The start control parameters can be adjusted to define how the welding machine will respond when the arc is struck. To view the start control window, click on the Adjust the start control parameters to accommodate your welding application and per the following parameter descriptions.
- Page 65 STT WAVE SHAPING PRINCIPLES Appendix B 4. “Go Figure” / Make the Waveform Synergic Weld synergy is established by shaping the 2nd and all subsequent workpoints. Being synergic, the waveform parameters automatically adjust to programmed data table values. The data table values are unique for selected wire feed speeds.
- Page 66 STT WAVE SHAPING PRINCIPLES B-12 B.5 PRIMARY STT WAVEFORM COMPONENTS The following paragraphs describe how peak current, background current, and tailout effect weld droplet transfer. B.5.1 PEAK CURRENT The peak current control acts similar to an “arc pinch” control. Peak current serves to establish the arc length and promote good fusion.
- Page 67 STT WAVE SHAPING PRINCIPLES Appendix B B-13 B.5.2 BACKGROUND CURRENT The Background current controls the overall heat input to the weld. Adjusting this level too high will form a large droplet resulting in globular type transfer and increased spatter. Adjusting this level too low will cause wire stubbing and poor wetting of the weld metal.
- Page 68 STT WAVE SHAPING PRINCIPLES B-14 B.6 SECONDARY STT WAVEFORM COMPONENTS NOTE: The Invertec STT power source circuitry automatically establishes proper values for most primary and secondary waveform components. The values can be adjusted, but should not be set far from their automatically set values. B.6.1 PINCH START The pinch start is the amperage setting that begins the ramp up to the maximum pinch current.
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Page 69: Application Exercise
Before starting the waveshape development process, confirm that the consumables are working properly with the welder. We recommend using a standard waveshape such as mode 5 to confirm that the welding system performs under normal conditions before attempting to develop waveshapes. - Page 70 STT WAVE SHAPING PRINCIPLES B-16 2. Pick a wire feed speed from the Wire Feed Speed pulldown menu. We wanted to start with a 130 in/min. WFS. But 130 is not a workpoint in the selected wave shape application. Use the Workpoint Editor window to change the second workpoint (170 in/min.) to 130.
- Page 71 Adaptive Loop ... Adaptive Types ... Adaptive and Non-Adaptive Mode ... Amp • Time ... A-12 Application Exercise, STT ... B-15 Application Exercise, Wave Shaping, Pulse ... A-17 Arc Length (Pulse) ... Arc Reestablish Volts ... A-11 ArcScope ... Background Current, Pulse ... A-15 Background Current, STT ...
- Page 72 Index-2 Making the Waveform Synergic ... A-13 Open Circuit Voltage ... A-10 Operation, Software ... Peak Current ... A-14, B-5, B-12 Peak Current and Time (Pulse) ... A-14 Peak Time ... A-14 Peak Voltage... Pinch Current Rise Rate ... A-14 Pinch Mode ...
- Page 73 Upgrade Firmware ... User Responsibility ... Voltage, Arc Reestablish ... A-11 Open Circuit ... A-10 Peak ... Short Detect ... A-11 Start ... A-10 Wave Design Process, Pulse ... 3-11 Wave Design Process, STT ... Wave Shaping, Pulse ... Wave Shaping, STT ... Wave Designer Operation...
- Page 74 Index-4 INDEX WAVEDESIGNER...