production monitoring

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Table of Contents

1 General Information .............................................................................................................. 2 1.1 Introduction to Production Monitoring...................................................................... 2

2 Getting Started ....................................................................................................................... 5

2.1 System Requirements ................................................................................................... 5 2.2 Launching Production Monitoring ............................................................................. 5 2.3 Establishing a Connection............................................................................................ 6

3 Production Monitoring Configuration Wizard ................................................................... 8 3.1 Introduction................................................................................................................... 8

4 Main Window ......................................................................................................................... 9 4.1 Basic View...................................................................................................................... 9 4.2 Advanced View............................................................................................................ 13 4.3 Miscellaneous Functions............................................................................................. 19

5 Weld Profile Training.......................................................................................................... 20 5.1 Introduction................................................................................................................. 20

5.2 Using the Training Window....................................................................................... 20 6 Email Setup........................................................................................................................... 23 6.1 Server Settings............................................................................................................. 23 6.2 Address Book............................................................................................................... 24 6.3 Sending a Test Message.............................................................................................. 25 6.4 Saving / Restoring Email Settings ............................................................................. 25

7 Wire Package Tracking ....................................................................................................... 26 7.1 Configure Wire Package ............................................................................................ 26 7.2 Replenish Current Package ....................................................................................... 26

8 Production Shift Time Setup............................................................................................... 27 9 Support Applications ........................................................................................................... 28

9.1 Diagnostic Utility......................................................................................................... 28 9.2 Send Software.............................................................................................................. 28 9.3 Power Wave Report.................................................................................................... 29 9.4 SnapShot Utility .......................................................................................................... 29 9.5 Sync Real Time Clocks ............................................................................................... 30

10 Program Options............................................................................................................... 31 10.1 Preferences................................................................................................................... 31 10.2 Display Options........................................................................................................... 32 10.3 Training Options......................................................................................................... 33

11 Additional Information .................................................................................................... 34 11.1 DeviceNet I/O for Production Monitoring............................................................ 34

11.2 Using Production Monitoring in a FANUC Robotic Application .......................... 35 Glossary ....................................................................................................................................... 40


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1 General Information

1.1

Introduction to Production MonitoringProduction Monitoring is a new technology that is available for the latest models of the Lincoln Electrics PowerWave family of power sources.

The term Production Monitoring does not refer to any single feature. Instead, it refers to the entire collection of features and functionality included with the Power Wave. These features include, but are not limited to:

Collecting short- and long-term welding logs complete with statistics for each recorded weld. Setting logical limits upon arc current, arc voltage, and wire feed speed, and reporting welds that violate the

specified limits. Allowing thirty-two (32) distinct weld profiles, with separate limit settings for each profile. (See 1.1.1) Email functionality, with the Power Wave able to send email containing per-shift welding summaries,

reports of weld errors, and other information. Tracking wire usage and providing low package warnings for each Power Wave.

1.1.1 Weld Profiles

One of the principal goals of Production Monitoring is to detect and log welds that are outside of user-defined limitswith respect to voltage, current, wire feed speed, and duration. This goal would be fairly simple to implement if thePower Wave were to perform only one type of weld over and over. However, in practical applications, this is notthe case. The assembly of many different industrial components requires welds of varying type and length. Theconcept of Weld Profiles allows the Power Wave to apply different limit settings for each weld that is performed ona certain part. Before the Power Wave begins a new weld, it switches to the corresponding Weld Profile. The usercan, therefore, assign one Weld Profile to each weld required for the part assembly. Production Monitoring provides

up to 32 such profiles.

As an example, consider a part that requires 10 different welds for proper assembly. The user will begin byconfiguring 10 of the 32 programmable Weld Profiles, with proper limit settings for each of the different welds. Theuser can then begin welding the part, selecting the proper profile for each of the 10 welds.

There are several ways of selecting the Weld Profile: based on welding set point, through DeviceNet (using a PLC),through Robotic/PLC I/O, through an ArcLink compatible controller, and through User Interface memory buttons.The next sections outline the details of each of these methods.

1.1.1.1 Weld Profile Selection based on Welding Set Point

The Power Wave can be configured to determine the current Weld Profile based on the Power Waves welding setpoint. The last digit of the welding set point becomes the Weld Profile number currently in use. For example, if thewelding set point is set to 125, the Power Wave will use Weld Profile 5 for the given weld. If the last digit of welding set point is zero (0), the Power Wave will use Weld Profile 10. With this method, it is clear that the usercan access only 10 of the 32 possible Profiles. Despite this limitation, this method is simple and effective, and maybe the preferred choice for many applications.


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1.1.1.2 Weld Profile Selection through DeviceNet

The Weld Profile number can be selected by an external controller that can communicate with the Power Wave overa DeviceNet network. The controller has direct access to the Weld Profile number. Consequently, an externalDeviceNet controller (such as a PLC) would be able to access all of the 32 Weld Profile numbers, unlike the methodof selection based on welding set point. Refer to 11.1 for information on Production Monitoring features

configurable over DeviceNet.

1.1.1.3 Weld Profile Selection through Digital I/O

The Weld Profile number can be selected by an external controller that has five available digital outputs. This isdone through the use of the Weld Profile Selection kit (M18456-50). The kit will connect Fanuc Robotic digitaloutputs to the usable inputs on the Power Waves External I/O Connector. This method allows selection of all 32weld profiles. When this method is used the I/O available through the robotic feeder that is normally used forTrigger, Dual Process Input, 4-step input, Cold Inch Forward, Cold Inch Reverse, and Gas Purge will be rerouted toselect the Weld Profile.

1.1.1.4 Weld Profile Selection through an ArcLink-compatible ControllerThis method can select all 32 Weld Profiles, since an ArcLink-compatible controller can communicate directly withthe Power Wave using its native ArcLink protocol. An example of such a controller is the Fanuc RJ3iB (V6.4). See11.2 for reference on programming the RJ3iB for use with Production Monitoring.

1.1.1.5 Weld Profile Selection through User Interface memory buttons

Production Monitoring can be configured so that the Weld Profile is selected by pressing the memory buttons foundon the Power Feed user interfaces (PF10M, PF-10A). This method offers ease of use and straightforwardness inselecting the Profile, but, since there are six memory buttons on the user interface, it limits the selection to sixProfiles.

1.1.2 Weld Logging

Production Monitoring also has the ability to record large quantities of weld statistics. The Power Wave has enoughmemory to store summary data on approximately 12,000 welds, referred to as Weld History (See 4.2.6). Each logentry contains the following welding statistics:

For current, voltage and wire feed speed:o minimumo maximumo averageo percent above limito percent below limit

date and time the weld was made duration of the weld weld status after limit checking

In addition to storing data about each individual weld, the Power Wave stores information about all of the welds as awhole, referred to as Weld Totals (See 4.2.5). This information is stored on a per-Profile basis. For each WeldProfile, the Power Wave stores the total number of welds, and the number of welds that exceeded the Profiles limitsettings.


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1.1.3 Email Capability

When a Power Wave with Production Monitoring installed is connected to a network with an available email server,it can send email notifications to multiple addresses. Each email address can be configured to receive messagesfrom the Power Wave upon any of several event conditions (See 6).

1.1.4 Shift Times

Production Monitoring introduces six user-configurable shift times that can be set to match the starting and endingtimes of actual production shifts. When enabled, Production Monitoring will report per-shift statistics via email,such as the total arc time for the given shift, and weld statistics (See 8).


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2 Getting Started

2.1 System Requirements

Hardware Requirements: 64MB system RAM. 300MHz processor speed. 800600 display resolution with 256 colors or higher. Approximately 16 MB free disk space. (Additional disk space may be needed for saving files) Connection to the network to which Lincoln Electric Power Waves are connected.

Production Monitoring may be run within any of the following versions of Microsoft Windows: Windows NT, Service Pack 6 Windows 2000 Windows XP

2.2 Launching Production Monitoring

Select Production Monitoring fromthe Start Menu to launch theapplication. The main programwindow will appear, as well as theEstablish Connection window.Before any actions can be performedin Production Monitoring, aconnection to at least one PowerWave must be made.

Figure 2.1: Newly-started Production Monitoring.


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2.3 Establishing a Connection

When Production Monitoring is started, the Establish Connection window is automatically shown. This windowprovides a way to connect to a single Power Wave on the network, or search for Power Waves automatically by

scanning portions of the network.

This guide assumes that the operators manual has already been completed for installation. If this is not the case,please complete the installation process outlined in the operators manual (IM840).

2.3.1 Connecting to a Single Power Wave

To connect to a single Power Wave, in the Address field enter the IP address of the Power Wave, and click Addor press Enter. For example, suppose a Power Wave exists at address10.23.8.18. To connect to this power source type 10.23.8.18 into theAddress field, and click the Add button.

The address that was specified will be added immediately to the list in themain window (See 4.1). Thisallows the addition of IPaddresses of Power Waves thathave not yet been configured orconnected to the network.

In this manner, the EstablishConnection window allows the

connection of an indefinite number of Power Waves based on eachindividual IP address.

2.3.2 Searching for Power WavesThe Establish Connection window also allows searching for Power Waves onthe network by scanning segments of the network. In the Address field,enter the first three octets (numbers) of the network segment that are to bescanned. For example, entering 10.23.8 into the field will cause theEstablish Connection window to scan all IP addresses from 10.23.8.1 to10.23.8.254.

Note: exactly three octets are required to be entered to search a Subnet.

After entering the desired subnet, click the Scan button or press Enter.The subnet will then be scanned by the Establish Connection window.

When a subnet is being scanned, the Status Bar at thebottom of the main window displays the progress of thesubnet scanning.

Figure 2.2: Connecting to a singlePower Wave.

Figure 2.3: A Power Wave added to the Main Window list.

Figure 2.4: Searching for Power Waves ona subnet.

Figure 2.5: Main Window status bar while scanninga subnet.


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2.3.3 Closing and Restoring the Establish Connection window

When it is no longer needed, the Establish Connection window can be closed by clicking the X button at the top-right corner of its window, or by pressing the Escape key. To connect to a different Power Wave at a later time, the

Establish Connection window can be brought back using either of the following ways:

From the menu of the main window, select View, then Establish Connection. Right-click anywhere within the area of the main window, and select Establish Connection. Double-click on the status bar at the bottom of the main window.

2.3.4 Connection Files

To quickly connect to more than one Power Wave, a connection file can be generated. This file will contain all of the Power Waves that are currently connected. To save a file, select the File menu in the main window and thenselect Save Connection File.

To restore a connection file, select Open Connection File from the File menu.From there, select the correct connection file. The Power Waves from the file will beadded automatically. Multiple connection files can be opened, allowing the differentnetwork sections to be saved in different connection files.

Figure 2.7: Saving a Connection File

Figure 2.6: Restoring the Establish Connection window.


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3 Production Monitoring Configuration Wizard

3.1

IntroductionThe Production Monitoring Configuration Wizardsimplifies the task of configuring Production Monitoringparameters and settings, especially for first-time users.

The wizard allows the user to take a step-by-stepapproach to configure the essential components of thePower Wave, with descriptions and instructions on everypage.

To start the Production Monitoring Wizard, right-click ona Power Wave and select Configuration Wizard. Thewizard can also be started by double-clicking on theProduction Monitoring icon in the Basic View whenProduction Monitoring has not yet been configured on agiven Power Wave (See 4.1.1.5).

Follow the on-screen instructions when the wizard starts.Click the Next button to move to the next page in thewizard, applying the changes made in the current page. Click the Back button to go back to the previous page,discarding changes made in the current page. The wizard can be exited at any time by clicking the Cancel buttonat the bottom-right corner, or pressing the Escape key.

In the bottom-left corner of the wizard there is a progress bar that indicates how much of the wizard is complete.When the wizard is complete, click the Finish button to close it and return to the main window.

Figure 3.1: The Production MonitoringConfiguration Wizard.


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4 Main WindowThe Main Window of Production Monitoring is the window from which most of the applications functions areperformed. The window contains two tabs: Basic View and Advanced View. The Power Waves that arecurrently connected are organized in a listformat, as seen in Figure 4.1.

4.1 Basic View

The Basic View is the preferred way of monitoring Power Waves when all that isneeded is a quick overview of what PowerWaves are on the network, as well as a brief status indication for each Power Wave.

The Basic View presents all of the PowerWaves in a list format, where the PowerWaves are sorted initially by the order inwhich they were added to the list. To reorderthe Power Waves, right-click on the BasicView List, select Sort Machines, then eitherSort by Address or Sort by Name.

As Power Waves are added to the Basic Viewthey will fill up the window. Once thewindow is full the list can be scrolled throughusing the scroll bar on the far right.

4.1.1 Basic View List Items

Each item in the Basic View List contains information about the Power Wave which it represents. Figure 4.2demonstrates the layout of information for each list item. The next several sections describe each bit of informationincluded in the layout.

Power Wave AddressPower Wave NamePower Wave Status

Production Monitoring StatusPower Wave Status Description

Figure 4.2: Layout of each Power Wave in the Basic View List.

Figure 4.1: The Basic View of the Main Window, after connecting to several Power Waves.


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4.1.1.1 Power Wave Icon

This shows an icon (picture) that most closely resembles the power source that is present at the given IP address.The following are all possible icons that can be displayed, and their corresponding Power Wave models:

In addition to the icon of the Power Wave, the image will also display the status of the Power Wave using icons thatare displayed on top of the Power Wave icon. The following are the possible status icons that may be displayed ontop of the Power Wave icon:

Indicates that the Power Wave is currently welding. (See 4.1.1.4)

Indicates that the Power Wave is currently in a faulted state. (See 4.1.1.4)

Indicates that the Power Wave is currently in System Safety mode. (See 4.1.1.4)

Indicates that Production Monitoring has lost or cannot establish a connection to the Power Wave. (See4.1.1.4)

Indicates that the wire package that the Power Wave is using is running low. (See 7)

Indicates that a Robot is attached to the system via ArcLink.

For example, in Figure 4.4, the Power Wave called SPWelder is a Power Wave F355i, with an ArcLink capableRobot attached, and is currently welding.

Power Wave455/655

Power Wave455M

Power WaveF355i

Power Wave AC/DC 1000

System Interface

Standalone Board

Figure 4.3: Power Wave icons with corresponding model name.

Figure 4.4: Example Power Wave image.


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4.1.1.2 Power Wave Address

This is the original IP address that was entered into the Establish Connection window prior to connecting to thisPower Wave. This may also be an IP address that was found while scanning a particular subnet using the Establish

Connection window.

4.1.1.3 Power Wave Name

If the Power Wave has Production Monitoring installed, this displays the name of the Power Wave as configured inthe Production Monitoring Configuration Wizard or in the email Setup window. (See 3 and 6.1)

If the Power Wave does not have Production Monitoring installed or has not been configured, this displays themodel number of the Power Wave.

4.1.1.4 Power Wave Status / Status Description

This gives a brief text description of the status of the current Power Wave. The following is a list of all possiblestatus messages, and a description for each message:

Power Wave is Idle : Indicates that the Power Wave is in an idle state (not welding). Welding : Indicates that the Power Wave is currently welding. Power Wave is Faulted : Indicates that the Power Wave has recently experienced an event that may

prevent it from welding. (See 9.1) Latched Fault : Indicates that the Power Wave has a latched fault caused by Production Monitoring. This

fault can be reset by double-clicking the Production Monitoring Status icon (See 4.1.1.5). System Safety Mode : Indicates that the Power Wave is either currently being reprogrammed, or has

experienced an event that may prevent it form welding. This event should be diagnosed. (See 9.1) Recognition Failure: Connection Broken : Indicates that Production Monitoring cannot establish a

connection to the Power Wave. This may be caused by the Power Wave is turned off, an unpluggednetwork cable, very high network traffic, a poor (noisy) network connection, or an invalid IP address.

System Interface : Indicates that the Power Wave at the given IP address is a Lincoln Electric SystemInterface device, used for controlling phase relationships in synchronized mult i-arc systems.

Standalone Board (advanced): Indicates that the given IP address points to a single Ethernet Module. Thismay indicate a misconfiguration of the Power Wave.

The Status Description message (as shown in Figure 4.2) will display a description similar to those outlinedabove.


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4.1.1.5 Production Monitoring Status

To the right of the Power Wave image, and below the Power Wave name, there is another icon that indicates thestatus of the Production Monitoring features in the current Power Wave. This icon can look like any of the

following:

[No icon] Production Monitoring is not installed on the power source.

Indicates that Production Monitoring is installed and enabled.

Indicates that Production Monitoring is installed, but not enabled. To enable Production Monitoring,run the Configuration Wizard (See 3).

Indicates that Production Monitoring is installed, but has not yet been configured. To configureProduction Monitoring, double click on the icon to run the Configuration Wizard. (See 3)

Indicates that the Power Wave has a latched fault caused by Production Monitoring. This may occurwhen the Alarm Latch option is selected for any one of the Limit Actions defined in the GeneralSettings of the Production Monitoring Setup (See 4.2.7.1). To clear the fault, double-click on the icon.

4.1.2 Status Color

The status color of each item in the Basic View List can change based on the current state of the Power Wave. Thefollowing list defines the default color each state is:

White Unselected Blue Idle Red Faulted

Light Blue WeldingThese colors, as well as the fonts used to display the text information, are fully configurable. (See 10.2)

4.1.3 Removing Power Waves

To disconnect from a Power Wave, right-click on the Power Wave, and selectRemove.

To disconnect from all of the Power Waves in the list, right-click and selectRemove All.

4.1.4 Status Bar - Machine StatusThe status bar includes a general overview of the number of machines thatProduction Monitoring is currently connected to. This status also includes thenumber of machines that are currently welding.

Figure 4.5: Removing a Power Wave from the Basic View List.

Figure 4.6: Number of machines and their welding status


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4.2 Advanced View

4.2.1 Introduction

The Advanced View delivers a more sophisticated,compact, and structured presentation of each PowerWave. This view is preferred over the Basic Viewwhen the user requires more detailed informationabout the Power Waves being monitored.

In addition, the Advanced View provides access tomany of the features of Production Monitoring thatare installed in the Power Wave. If the selectedPower Wave has Production Monitoring installed,the lower half of the Advanced View window willbe dedicated to exposing much of the ProductionMonitoring functionality, including Weld Totals,Weld History, and access to Weld Profile limit

settings.

4.2.2 Power Wave List

In the Advanced View, the Power Waves areorganized in a list format, much like in the Basic View, except with more information. The next several sectionsdescribe each of the columns that are seen in the Advanced View List.

4.2.2.1 Address

This is the original IP address that was entered into the Establish Connection window prior to connecting to thePower Wave. This may also be an IP address that was found while scanning a particular subnet using the EstablishConnection window.

4.2.2.2 Name

If the Power Wave has Production Monitoring installed, this displays the name of the Power Wave as configured inthe Production Monitoring Configuration Wizard or in the email Setup window. (See 3, 6.1)

If the Power Wave does not have Production Monitoring installed, or if the Power Wave name has not beenconfigured, this displays the model number of the Power Wave.

4.2.2.3 Shift Usage

This displays the amount of arc time (in hours:minutes:seconds) for the Power Wave during the current shift,followed by the corresponding percentage of arc time to total shift time. If shift times have not been set up, shiftusage will not be displayed. (See 8)

Figure 4.7: The Advanced View of the Main Window, after connecting to several Power Waves..


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4.2.2.4 Wire Remaining

This displays the amount of wire (in pounds) remaining in the current wire package, followed by the percentage of the wire package remaining. (See 7)

4.2.2.5 Time Since Last WeldThis displays the amount of time (in hours:minutes:seconds) that has elapsed since the end of the last weld that thePower Wave performed.

4.2.2.6 Total Arc Hours

This displays the total number of hours that the Power Wave has ever spent in a welding state. This number isanalogous to an automobile odometer. It always increases, and cannot be modified by the user from ProductionMonitoring.

4.2.3 Status IconsThe icons that appear to the left of each Power Wave in the Advanced View List are not as detailed or descriptive asthose found in the Basic View, but they nevertheless indicate the status of the Power Wave in a minimal way. Thefollowing are the possible icons that can appear for each Power Wave, and their interpretations:

The Power Wave is currently in an idle state. (See 4.1.1.4)

The Power Wave is currently welding.

The Power Wave is currently in a faulted state.

The Power Wave is currently in System Safety mode.

Production Monitoring has lost, or cannot establish, a connection to the Power Wave.

4.2.4 Process Details

Double-clicking on one of the Power Waves in the Advanced Viewwill bring up a window, as in Figure 4.8, containing informationabout the process under which the Power Wave last operated. If no welds have been made since the Power Wave was powered onthen the first weld mode in the process table will be displayed.

It displays the name of the process, gas type, wire type, and wirediameter, as specified in the Power Waves process table.

Figure 4.8: Double-clicking on a Power Wave brings up Process Details.


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4.2.5 Weld Totals

The Weld Totals tab displays long-term welding statisticsfor the Power Wave currently selected in the Advanced

View list.

These statistics appear on a per-Profile basis. For eachWeld Profile, the list displays the following information:

Counts : Total number of welds performed inthis Profile.

Runts : Number of welds that were runts. T Limit : Number of welds that were outside of

the time limits. I Limit : Number of welds that were outside of

the arc current limits. V Limit : Number of welds that were outside of the arc voltage limits. WFS Limit : Number of welds that were outside of the wire feed speed limits.

The number of Weld Profiles shown in the Weld Totals list depends on the Power Waves Weld Profile selectionmethod. If the Weld Profile selection is based on welding set point, only 10 Profiles are shown. Otherwise, all 32Profiles are shown.

The Total row contains the sum of the values of each column in the list.

4.2.6 Weld History

The Weld History tab displays detailedstatistics about each weld performed by the

Power Wave currently selected in theAdvanced View List.

The welds are grouped by Weld Profile. Thereis a tab that segregates the welds for eachProfile. Profiles that have not been used arenot displayed. For example, in Figure 4.10, thePower Wave has performed welds only inProfiles 5 and 10.

The welds in each Profile tab are listed in the order in which they were performed (oldest to most recent). For eachweld, the following information is listed in the columns of the Weld History section:

#: An index number for the weld. This number always starts at 1, and increases with each weld. Items inthis column also contain an icon that indicates the status of the given weld. The icon may be one of thefollowing:

The weld remained within all limits. The weld was outside one or more limits. The weld was a runt . (See 4.2.5)

Date : The date on which the weld was started. Time : The time at which this weld was started. Duration : The duration of the weld (seconds).

Figure 4.9: Weld Totals section of the Advanced View.

Figure 4.10: Weld History section of the Advanced View.


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Status : Gives a text description of the status of this weld. The following is the list of possible statuses.o High I or Low I Current out of limito High V or Low V Voltage out of limito High WFS or Low WFS Wire Feed Speed out of limito Time Duration of the weld was out of limito Runt Duration of the weld was less than the sum of the start and end delay.o In Limit

All measured variables were within limit.For example, if the weld went above the arc current limit and below the wire feed speed limit, the textwould be, High I, Low WFS.

I max : Maximum arc current (Amps) measured during this weld. I min : Minimum arc current measured during this weld. I avg : Average arc current measured during this weld. I % High : Percent of the weld that was above the arc current limit. I % Low : Percent of the weld that was below the arc current limit. V max : Maximum arc voltage (Volts) measured during this weld. V min : Minimum arc voltage measured during this weld. V avg : Average arc voltage measured during this weld. V % High : Percent of the that was above the arc voltage limit. V % Low : Percent of the weld that was below the arc voltage limit. WFS max : Maximum wire feed speed (IPM) measured during this weld. WFS min : Minimum wire feed speed measured during this weld. WFS avg : Average wire feed speed measured during this weld. WFS % High : Percent of the weld above the wire feed speed limit. WFS % Low : Percent of the weld that was below the wire feed speed limit. Wire Deposited : Amount of wire (lbs) that was deposited during this weld. This amount depends on the

density and diameter settings of the Wire Package (See 7).

Production Monitoring provides an option to display or hide some of the columns listed above. (See 10.2)

Due to the number of Weld History records stored in the Power Wave, itmay take several minutes to download and display all of the records inProduction Monitoring. When displaying the Weld History section, the

status bar of the main window shows the progress of downloading theWeld History records. If there are a significant number of Weld Historyrecords to be downloaded, a progress bar will appear and give the statusof the downloading data. When all of the History has been downloaded,the progress bar disappears.

4.2.6.1 Saving Weld History

The Weld History can be saved from Production Monitoring to a tab-delimited text file.This file can then be used in most spreadsheet applications. The file will contain theinformation in the Weld History section, as well as the Weld Totals information(See 4.2.5). To save the Weld History, right-click inside the Weld History or Weld

Totals section, and select Save Weld History. This will open a standard save-filedialog where a file name is specified and a file location is selected. Note: If thehistory is not completely downloaded when the save operation is done, a warning will appear about savingincomplete weld history contents.

Figure 4.11: A progress bar indicates thedownload progress of Weld History.

Figure 4.12: Saving Weld History.


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4.2.6.2 Clearing Weld History and Weld Totals

The Weld History can be cleared by right-clicking inside the Weld History or Weld Totals sections and selectingClear Weld History. This will eliminate all Weld History information from the Power Wave, and will also resetthe Weld Totals counters.

4.2.7 Production Monitoring Setup

The Production Monitoring Setup section of the Advanced View allows the control of many of the settings providedby Production Monitoring. These settings will apply to the Power Wave that is currently selected in the AdvancedView list.

4.2.7.1 General Settings

The General Settings portion of ProductionMonitoring Setup contains options thatglobally affect Production Monitoring, and are

independent of Weld Profiles. These optionsare accessible by clicking on the GeneralSettings item in the list on the left side of thewindow. Any of these options can be changedby double-clicking on them. The availableoptions are as follows:

Enable Production Monitoring : This enables ordisables the Production Monitoring features in thePower Wave. When disabled (when the value is No), the Power Wave will no longer record WeldHistory for each weld, check the limits of welds based on Profile settings, or track wire usage.

Weld Profile Selection Method: Weld Profile selection based on welding set point, Robotic Feeder I/O,external controller, or User Interface memory buttons.

The next options represent the action that the Power Wave will take when a weld exceeds the Production Monitroinglimits for weld duration, arc current, arc voltage, or wire feed speed. The possible actions for an out-of-limit weldare:

No Action : The Power Wave will take no action, and will not mark the weld as out-of-limits. Log Alarm : The Power Wave will mark the weld as out-of-limits. Fault System : The Power Wave will stop welding when an out-of-limit condition is detected. Alarm Latch : The Power Wave will enter into a faulted state when the weld ends, and remain faulted until

the fault is reset by the operator (a so-called latched fault). To reset a latched fault, see 4.1.1.5.

Production Monitoring can also allow arc current, arc voltage, and wire feed speed to go outside of limits for a shorttime before any of the above actions are performed. This value is represented in seconds and has a 20 millisecondresolution. The following are the options listed in General Settings that set up the actions and tolerances mentionedabove:

Action on Time Limit : This indicates which action the Power Wave performs when a weld goes out of limits with respect to duration (i.e. if a weld is shorter or longer than the minimum or maximum durationlimit, respectively).

Action on Current Limit : Action that the Power Wave performs when a weld goes out of limits withrespect to arc current.

Seconds Until Current Limit : This specifies the duration that the weld can exceed arc current limits untilthe selected action is taken.

Action on Voltage Limit : Action that the Power Wave performs when a weld goes out of limits withrespect to arc voltage.

Figure 4.13: General Settings portion of Production Monitoring Setup.


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Seconds Until Voltage Limit : This specifies the duration that the weld can exceed arc voltage limits untilthe selected action is taken.

Action on WFS Limit : Action that the Power Wave performs when a weld goes out of limits with respectto wire feed speed.

Seconds Until WFS Limit : This specifies the duration that the weld can exceed wire feed speed limitsuntil the selected action is taken.

4.2.7.2 Weld Profile Settings

Below the General Settings item in thelist, the available Weld Profiles can beconfigured. If the Weld Profile selectionmethod is based on welding set point (See4.2.7.1), only Weld Profiles 1 through 10will be displayed. Otherwise, all 32 Profileswill be displayed.

Select a Weld Profile from the list to

configure its limit settings. Once a Profile isselected, the window to the right of theProfile list will display the limitconfiguration.

To change any of the limit values, click inside the corresponding field, type in thenew value, and press Enter. The following is a brief explanation of each of the settings:

Enable Limits for this Profile : If this option is checked, Production Monitoring will apply the specifiedlimits to this Weld Profile. Otherwise, this Profile will not be monitored for limit errors.

Start Delay : Amount of time (seconds) that Production Monitoring will wait, directly after the start of aweld, until the limits for this Profile begin to be applied. This option is necessary because the start of aweld is often unpredictable and may fall out of limits easily.

End Delay : Amount of time (seconds), directly before the end of the weld, when Production Monitoringwill stop applying the limits for this Profile. This option is necessary because, at the end of a weld, thePower Waves set points are often different than the rest of the weld (e.g. if the Power Wave is in aburnback state).

Low / High Time Limit : Specifies the minimum and maximum duration of any weld for this Profile. Low / High Current Limit : Specifies the minimum and maximum arc current for any weld that utilizes

this Profile. Low / High Voltage Limit : Specifies the minimum and maximum arc voltage for any weld that utilizes

this Profile. Low / High Wire Feed Speed Limit : Specifies the minimum and maximum wire feed speed for any weld

that utilizes this Profile.

4.2.8 Save / Restore / Reset Weld Profiles

Production Monitoring makes it possible to save the limit settings for all profiles, aswell as the general settings, to a file. To save the settings, right-click anywhereinside the Production Monitoring Setup section, and select Save Settings from thepopup menu.

To restore these settings from a file that has been previously saved, right-click within the Production Monitoring Setup section, and select

Figure 4.14: Weld Profile Settings portion of Production Monitoring Setup.

Figure 4.15: Saving Weld Profile settings.


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Restore Settings from the popup menu. All Production Monitoring settings for this machine will then be restoredfrom the file.

It is also possible to reset these settings to the factory defaults. To reset the settings, right-click within theProduction Monitoring Setup section, and select Reset Profiles. This resets the following settings:

All limits are reset to 0.

All profiles are enabled. All out-of-limit conditions are set to No Action. All seconds until limit error are set to 0.10.

4.3 Miscellaneous Functions

4.3.1 About Box

Selecting Help, then About from the menu of the main window will cause Production Monitoring to display anAbout box that contains technical information about this program, as well as the computer it is running on. Thisinformation will be necessary when requesting technical support.

The About box contains the following information: application build date application version number network name of computer available amount of memory on the computer computers CPU information

Figure 4.1: Production Monitoring About Box.


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5 Weld Profile Training

5.1 Introduction

Weld Profile Training is another one of the features of Production Monitoring. Essentially, this feature removes thenecessity of setting up limits manually for each of the Weld Profiles.

This feature allows the operator to make several training welds in the same manner as they would be done innormal production. Then, based on the training welds, Production Monitoring automatically generates limits for arccurrent, voltage, wire feed speed, and time. The operator can remove any welds made during the training that areconsidered bad welds.

5.2 Using the Training Window

To enter Training Mode, activate the Training Window

from Production Monitoring. To bring up this window,go to the Production Monitoring Setup section in theAdvanced View, right-click anywhere within theProduction Monitoring Setup section, and select TrainWeld Profiles.

The Training Window can also be activated from theProduction Monitoring Configuration Wizard.

Note: When Production Monitoring enters the trainingmode, all Weld History will be lost.

At first, the Training Window will be blank. Now

begin to make training welds, switching betweendifferent Weld Profiles as necessary. Make sure thatthe welds made during Training are the same as thosethat would be made during normal production.

It is recommended to make at least 5 welds per Profileto generate a reasonable sample of the welding.

As welds are made, they will be recorded in the Training Window, grouped by Weld Profile, as shown in Figure5.1. If more than one weld in a particular Profile is made, the welds will be grouped in tabbed format in theirrespective Profile group, also as shown in Figure 5.1.

To exit the Training Window click on the X button at the top right corner of the window, or press the Escape key.

5.2.1 Weld Profile Groups

Each Weld Profile group displays three charts thatrepresent arc current, arc voltage, and wire feedspeed for a particular weld.

If there is more than one weld in the Weld Profile

Figure 5.1: Training Window, with severalcompleted welds.

Figure 5.2: Weld Profile group for Profile 7, with 16 completed welds.


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group, selecting the corresponding tab for the desired weld will display the selected weld into the charts.

If a certain weld turns out to be undesirable (for example, if the operator is certain that a mistake was made), theweld can be removed from the Weld Profile group by right-clicking within the charts of the weld, and selectingDelete Weld from the popup menu. If a certain weld is particularly undesirable (enough so that the statisticalanalysis cannot be performed), the weld will be marked as Rejected in its corresponding tab, and will not beincluded in the computation of limits for its Weld Profile.

5.2.2 Chart Options

These options apply to all three charts that display arc current, arc voltage, and wire feed speed for each WeldProfile group.

The separators between the three charts are drag-able using the mouse, so that the width of any chart can beincreased or decreased. The height of the charts, however, cannot be modified.

Right-clicking on any of the charts will pop up a menu containing the following options:

Zoom In : Causes the chart to zoom in on the data by a factor of 2. Zoom Out : Causes the chart to zoom out from the data by a factor of 2.

Set Maximum : Enables the user to set the maximum value on the verticalaxis of the chart.

Set Minimum : Enables the user to set the minimum value on the verticalaxis of the chart.

Automatic Scale : If any of the minimum or maximum display optionshave been changed then selecting the Automatic Scale will switch thedisplay back to automatic scaling.

Delete Weld : Eliminates the weld that is currently selected from the Weld Profile group. If a certain weldturns out to be undesirable (for example, if the operator is certain that a mistake was made), the weld can beremoved from the Weld Profile group by right-clicking within the charts of the weld, and selecting DeleteWeld.

Double-clicking anywhere within the chart area will bring up a green tool-tip that will follow the mouse. The tool-tip will contain the value of the vertical axis at the location of the mouse. Double-clicking a second time willchange the tool-tip to a blue color and now contain the time offset form the beginning of the weld (in seconds).Double-clicking a third time will hide the tool-tip.

Holding down the Shift key while clicking and dragging within the chart area will change the line width of thecharts so that the lime may be more visible.

Figure 5.3: Double-clickinginside the chart area.


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5.2.3 Applying New Limits

When all of the training welds have been completed, the calculated limits are ready to be applied to the WeldProfiles stored in the Power Wave. These changes can be applied in two ways:

Each Profile Group has a button in the bottom left corner which can be used to apply the new limits:Clicking this button will apply the limits to this Profile only. This method can be used if only some of theProfiles need limits applied but not all of the Profiles shown in the Training window.

At the top left corner of the Training Window, there is an Apply All Settings button. Click this button toupdate all trained Weld Profiles with their new limit settings.

5.2.4 Modifying Values Manually

Each Weld Profile group has two vertical tabs on the left side,labeled Graphs and Parameters. The Graphs tab is selectedby default, and displays the charts discussed above. TheParameters tab contains the actual list of limit values that werecalculated based on the acquired welds.

To alter any of these limits, double-click on the value to bemodified, then type the new value into the dialog box.

Note: The units for these parameters are in seconds, amps, volts, or inches per minute .

Figure 5.4: Manually modifying limit values.


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6 Email SetupThe following section covers the email setup of the Power Wave. Before setting up the Power Waves emailsystem, collect the following information:

List of email users who will receive email messages. IP address (or host name) of the SMTP email server and DNS server to be used by the email system. Port number on which the email server receives email.

The Email Setup window provides access to all of theconfiguration options of the email feature of ProductionMonitoring. From this window, email recipients can be added orremoved from the Power Waves address book, and the emailserver that the Power Wave will send email to can beconfigured.

To begin configuring email, in the Basic View or AdvancedView, right-click on the Power Wave. From the popup menu,select Email, then select Configure Email. This will bringup the Email Setup window.

To enable or disable the email system in the Power Wave, click on the bottom-most check box labeled Enable EmailFunctionality. Un-checking this check box will prevent thePower Wave from sending email messages. It will also nolonger show the email configuration options in the email Setupwindow.

To close the Email Setup window, click the Close button, or click the X button at the top right corner of thewindow.

6.1 Server Settings

Before the Power Wave can send email, it must be configured to use theproper email (SMTP) server located on the network. Contact a network administrator for assistance on obtaining information about the email serverand other settings included in this section.

The email server configuration is located in the lower half of the emailSetup window. To modify this configuration, click the Modify Settingsbutton, or double-click on any item in the Mail Server Information list.

This will bring up the Email Server Information window, shown in Figure6.2, in which the following information must be provided:

Sender Email Address : This will be the address that appears as the reply address in email messages sentby the Power Wave. Since email cannot be sent back to the Power Wave, this address can be anycombination of characters, as long as it is the format of a standard email address. This address is notmeaningful with respect to Production Monitoring. It is only necessary to satisfy the SMTP protocol.

Email Server Name : Host name of the email (SMTP) server on the network, if available. If the emailserver does not have an associated host name, the email server IP address (below) is required.

Figure 6.1: Email Setup window.

Figure 6.2: Email Server

Information window.


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PW Machine Name : This is a descriptive name that is assigned to the Power Wave. This is the name thatappears as the Power Wave Name in the Basic View and Advanced View (See 4.1.1.3and 4.2.2.2). Thisname will also appear in the From field of email messages sent from the Power Wave.

Email Server IP : This is the IP address of the email server on the network. If a host name of the emailserver has already been entered, entering the IP address is not necessary. However, if the host name hasnot been entered, the IP address is required.

Port : This is the port number of the SMTP service on the email server. The standard port number forSMTP servers is 25. This number should only be changed if recommended by a network administrator.

DNS Server IP : This is the IP address of the DNS server on the network. This is necessary only if a hostname has been specified ( not an IP address) for the email server. If an IP address has been specified for theemail server, the DNS Server IP is not necessary.

Company ID : This is your company name that is associated with this Power Wave. It can be anycombination of characters. This name will appear in the body of email messages sent from the PowerWave.

Note: the items discussed above can also be set up from the Production Monitoring Configuration Wizard .

6.2 Address Book

The Power Wave contains an internal address book, capable of storing upto twelve different email recipients. Each recipient can choose to receiveemail upon one or more events that occur within the Power Wave.

Configuration of the Address Book takes place in the upper half of theEmail Setup window. The Address Book is also accessible from theProduction Monitoring Configuration Wizard (See 3).

To add an email recipient to the Address Book, click the Add button.This will bring up the Email Configuration window, shown in Figure 6.3.

Type the email address of the recipient in the box next to Email Address.

Then, select any of the events upon which the recipient would like to receivean email notification by clicking the appropriate check box associated witheach event. The following are possible events that can be selected:

Software/Hardware Change : The Power Wave will send an email message when it is reprogrammed withnew software, or when one of i ts hardware components is replaced, removed, or added.

System Event : The Power Wave will send an email message when a System Event occurs within thePower Wave (e.g. a thermostat fault).

Lincoln Service Event : The Power Wave will send an email message when a miscellaneous event occurswithin the Power Wave. These events are used for specific troubleshooting and are reported during generaloperation.

Production Weld Data : The Power Wave will send an email message when 100 welds have been made, orwhen 5 minutes of Power Wave idle time have elapsed and there are less than 100 new welds. The

message will contain a Weld History record of the welds, similar to the information shown in the WeldHistory section of the Advanced View (See 4.2.6). Weld Limit Exceeded : The Power Wave will send an email message when a weld has exceeded one or

more of the limits defined in a given Weld Profile. Consumable Warning : The Power Wave will send an email message when the consumable package

begins to run low (See 7). Power On: This causes the Power Wave to send out an email when the Power Wave is turned on or reset.

The recipient can also choose to receive a special email message upon any of the six Shift Times as defined in ShiftTime Setup (See 8). This message is referred to as a Production Monitoring Report, and contains information

Figure 6.3: Email Recipient

Configuration window.


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about Production Monitoring activity during the specified shift. Click on the appropriate check box for each shifttime that the recipient wants to receive this report.

Click the OK button to add the address to the address book, or Cancel to discard.

To modify a recipient in the Address Book, select the desired recipient, and click Modify, or double-click on thedesired recipient. To remove a recipient from the Address Book, select the desired recipient, and click Remove,or press the Delete key.

6.3 Sending a Test Message

The Power Wave can send a test email message to any of the recipients in the AddressBook. This is useful for testing if the email system has been set up correctly. To send atest message, right-click on the recipient that will receive the message, and select SendTest Email from the popup menu.

It may take a few moments for the Power Wave to send the message. When themessage is sent, Production Monitoring will post a message confirming the delivery of

the mail to the email server. Open the email client and check that the message has been received successfully. If theemail fails, or if Production Monitoring does not display the pop-up notification within 5 minutes, there may be anerror in the Power Waves email settings.

6.4 Saving / Restoring Email Settings

Production Monitoring allows the email configuration, to be saved to a file. This can be used to set up multiplePower Waves with similar email settings once an initial configuration has been completed.

To save email configuration to a file, go to the Basic View or Advanced View in the main window, and right-click on the desired Power Wave. From the popup menu, select Email, then Save Email Settings. Select the name of the file that will store the email configuration.

To restore email configuration to a Power Wave, go to the Basic View or Advanced View in the main window, andright-click on the desired Power Wave. From the popup menu, select Email, then Restore Email Settings.Select the file that will be restored to the Power Wave. After the file has been loaded, the Power Waves addressbook can bee verified by bringing up the email Setup window.

Figure 6.4: Sending a test email message.


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7 Wire Package Tracking

7.1

Configure Wire PackageProduction Monitoring allows the configuration of the Wire Package usedfor welding, so that its usage can be tracked by the Power Wave, and theuser notified when the package begins to run low.

To set up the wire package, right-click on the Power Wave, and selectConfigure Wire Package. This will bring up the Update Wire Packagewindow, shown in Figure 7.1.

In this window, the following settings must be configured:

Initial Package Weight : This is the original weight of the wirepackage, as indicated on the container.

Current Weight of Package : If the package has already beenused, the current weight of the package can be entered. However, if the package is new, this weight shouldbe the same as the initial weight.

Warning Package Weight : Production Monitoring will issue a wire package low warning when the wirereaches this amount(See 4.1.1.5 and 6.2).

Wire Diameter : Indicates the diameter of the wire in the package. Metal Density : Indicates the density of the metal from which the

wire is composed. The choices are:o Steelo Stainless Steelo Aluminum 4043o Aluminum 5356o User Defined Density This is selected when none of the

above metals match what is currently being used. When this is selected, another field will appear,in which the actual density (in pounds per cubic inch) can be entered.

Click OK to accept the new Wire Package settings, or Cancel to discard the changes.

7.2 Replenish Current Package

To set the current package weight back to the initial packageweight, right-click on the Power Wave, from the Popupmenu and select Replenish Current Package. This willreset the current package weight to the initial package

weight.

Figure 7.1: Update Wire Packagewindow.

Figure 7.2: Selecting a user-defined metal density.


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8 Production Shift Time SetupProduction Monitoring allows the configuration of up to six ProductionShift Times. These times can be set to match the actual times of theproduction shifts, or any other time interval.

These configurable times are used by Production Monitoring to segregatearc usage and weld totals among different shifts. These times are alsoused by the email feature to send production reports (See 6.2).

To configure Shift Times, right-click on the Power Wave, from the popupmenu, select Setup Shift Times. This will bring up the Production ShiftTime Setup window, shown in Figure 8.1. Setting up the Shift Times isalso possible from the Production Monitoring Configuration Wizard (See3.1).

Each of the six possible Shift Times appears as a dropdown box of times,

arranged by 15 minute increments. Select the dropdown item that bestmatches the desired time.

The graphical clock icons to the right of the drop-down boxes reflect the timethat was selected. It is also possible to click and drag over each clock icon,and select the appropriate time using the mouse.

Each of the six Shift Times has two check boxes next to it, labeled Reset Shift Usage, and Reset Weld Totals. Reset Shift Usage The Power Wave will reset the per-shift arc usage at the specified time (this is the

same per-shift usage that is displayed in the Advanced View list (See 4.2.2.3). Reset Weld Totals The Power Wave will reset the Weld Totals (See 4.2.5) for all Weld Profiles at the

specified time.

Figure 8.1: Production Shift TimeSetup window.


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9 Support ApplicationsThe distribution package that contains Production Monitoring also contains several other software applications fromLincoln Electric. The following sections describe the usefulness of these applications, and the way in which theyare related to Production Monitoring.

9.1 Diagnostic Utility

The Lincoln Electric Diagnostic Utility is a software tool used for maintenance anddiagnostics of Lincoln Electric welding equipment utilizing the new common digitalcontrols platform. For full details, refer to the manual for the Diagnostic Utility.

The Diagnostic Utility can be activated from within Production Monitoring to diagnose aPower Wave that is in a faulted state (See 4.1.1.4). To activate this utility, right-click on thePower Wave and select Diagnose from the popup menu. This will launch the DiagnosticUtility for the given Power Wave.

9.2 Send Software

Production Monitoring can send software updates to the Power Wave(s) byindirect use of the System Update utility. To begin sending new software,from the menu of the main window, select Tools, then Send Software.

This will launch a window that contains a list of available Power Waves.From this list, select the Power Waves to send the software update to. Click the Select All button to automatically select all Power Waves. Click theSelect None button to unselect all Power Waves.

When all Power Waves that should receive software have been selected, click the Send Software button. Next, select the appropriate INI file thatrepresents the software files that will be sent. After selecting the proper INIfile, Production Monitoring will launch an instance of the System Updateutility for each Power Wave to which the new software is to be sent. SystemUpdate will then be responsible for successfully sending the updatedsoftware.

For more details, refer to the manual for the System Update application.

Note: Software updates should not be performed while the Power Wave is welding .

Figure 9.1: Activating the DiagnosticUtility from Production Monitoring.

Figure 9.2: Preparing to send softwareto multiple Power Waves.


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9.3 Power Wave Report

Production Monitoring is capable of generating a Power Wave Report,

which contains technical information about the internal configuration of thePower Wave.

Power Wave Reports are useful for verifying and maintaining Weld Tableversions, firmware versions, hardware versions, as well as installed options.

For each hardware module that is part of the Power Wave, the report willstate information such as the module number, software version, boardserial number, etc. The Power Wave Report can be in either Text orHTML format. Figure 9.3 shows a Power Wave Report as viewed from Internet Explorer.

To create a Power Wave Report for one or more Power Waves, go to the menu in the main window, and selectTools, then Power Wave Report. This will bring up a window of available Power Waves. From this list, select

the Power Waves to generate a report about. Click the Select All button to automatically select all Power Waves.Click the Select None button to unselect all Power Waves. Check the Advanced check box to include additionaltechnical information in the report.

To generate the report click Start. The report generation may take a few moments. Once the report is complete itwill need to be saved to a file.

9.4 SnapShot Utility

The SnapShot Utility is a diagnostic tool for Power Waves that is designed to require minimal effort from theoperator. Essentially, its sole function is to dump the contents and the internal configuration of the Power Wave in effect taking a snap shot of all relevant Power Wave functions. The operator can then send the file containing

the Power Wave information to Lincoln Electric technical support forexamination and diagnosis. For full details, refer to the manual for theSnapShot Utility.

This utility can be launched from Production Monitoring, so that SnapShots of multiple Power Waves can be taken at once. To acquire SnapShots for one or more Power Waves, go to the menu in the main window,and select Tools, then SnapShot Utility.

This will launch a window that contains a list of available Power Waves.Select the Power Waves that a snapshot should be acquired from.Click the Select All button to automatically select all Power Waves.Click the Select None button to unselect all Power Waves.

Click the Start button to start acquiring the Snap Shots. You will first be prompted to find a directory on the harddrive where the snapshot files will be stored. After a directory has been specified, Production Monitoring willlaunch an instance of the SnapShot utility for each Power Wave that was checked. The SnapShot utility will then beresponsible for completing the snapshot of each selected Power Wave.

Figure 9.3: An example Power Wave Report.

Figure 9.4: The SnapShot Utility in action.


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10 Program OptionsProduction Monitoring has numerous configurable program options that can be accessed by selecting File, thenOptions. The Options window is divided into three tabs: Preferences, Display Options, and TrainingOptions. The following sections describe each of these tabs. When finished modifying the options, click OK toaccept and store the options, or Cancel to discard the changes.

10.1 Preferences

The following options are available in the Preferences tab of the Options window:

Disable Screen Saver : Check this box to preventWindows from activating the screen saver after aperiod of inactivity. Leave it unchecked to allowWindows to run the screen saver normally.

Power Wave Connection File Directory : This is thedefault directory to which Power Wave Connectionfiles are saved (See 2.3.4). To set this directory, click the Browse button next to this field.

Production Monitoring Directory : This is thedefault directory to which Production Monitoringconfiguration files are saved. These files includeconfiguration files saved from the ConfigurationWizard, as well as Weld History files (See 4.2.6.1).To set this directory, click the Browse button nextto this field.

Email Configuration Directory : This is the default directory to which email configuration files are saved(See 6.4). To set this directory, click the Browse button next to this field.

Machine Report Format : This allows the selection of the format in which Production Monitoringgenerates Power Wave Reports (See 9.3). If you select Text, then Power Wave Reports will be generatedin a plain text format, viewable with any text editor like Notepad. If you select HTML, then PowerWave Reports will be generated in HTML format, viewable with an Internet browser like Internet Explorer.

Units Style : This allows Production Monitoring to display numbers in either English or Metric units. Forexample, under English units, wire feed speed quantities are shown in inches per minute, while underMetric units, wire feed speed is shown in meters per minute.

Use TCP Connections Only : By default, Production Monitoring connects to all Power Waves using theUDP protocol. This protocol is faster and more lightweight than TCP, but it can be unreliable under heavynetwork stress. Check this box to force Production Monitoring to use only the TCP protocol whenconnecting to Power Waves.

Retries Before Connection Error : When Production Monitoring fails to read data from a Power Wave,this indicates the number of times that the program is allowed to retry reading data from the Power Wave,until Production Monitoring declares a lost connection to the Power Wave.

Time Between UDP Retries : When Production Monitoring fails to read data from a Power Wave, this isthe amount of time (in milliseconds) that Production Monitoring will wait until sending a retry to thePower Wave.

Local Connection Timeout : This is the amount of time (in milliseconds) that Production Monitoring isallowed to wait until it declares that it has failed to read data from a Power Wave.

Figure 10.1: Production Monitoring preferences.


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10.2 Display Options

The following options are available in the Display Optionstab of the Options window:

Colors: Unselected Color : This is the color of a Basic View

item, when the item is unselected. Selected Color : This is the color of a Basic View

item, when the item is selected. Faulted Color : This is the color of a Basic View

item, when the Power Wave that the item represents isfaulted.

Welding Color : This is the color of a Basic Viewitem, when the Power Wave that the item represents iswelding.

Selected Text : This is the color of the text that isdisplayed inside a Basic View item when the item isselected.

Unselected Text : This is the color of the text that isdisplayed inside a Basic View item when the item isunselected.

Fonts : Power Wave Name : This is the font that is used to display the Power Wave Address and Power Wave

Name in Basic View items (See 4.1.1.1). To change any of the fonts, click the corresponding button,or double-click on the corresponding AaBbCc label.

Status : This is the font that is used to display the Power Wave Status in Basic View items. (See 4.1.1.4). Overview : This is the font that is used to display the Power Wave Status Description in Basic View items.

(See 4.1.1.4). Advanced View : This is the font that is used to display the items in the Advanced View list (See 4.2.2). Totals/History : This is the font that is used in the Weld Totals and Weld History lists.

Restore Defaults : Click this button to restore the default (original) values for the Colors and Fonts shown above.

History Columns: Current Information : Check or uncheck this box to show or hide the columns related to arc current in the

Weld History section (See 4.2.6), for example, average current, max current, min current, etc. Voltage Information : Check or uncheck this box to show or hide the columns related to arc voltage in the

Weld History section. WFS Information : Check or uncheck this box to show or hide the columns related to wire feed speed in

the Weld History section. Include % High and Low : Check or uncheck this box to show or hide the columns that state the Percent

High and Low values for arc current, arc voltage, and wire feed speed. Include Date : Check or uncheck this box to show or hide the Date column in the Weld History section. Include Wire Deposited : Check or uncheck this box to show or hide the Wire Deposited column in the

Weld History section.

Figure 10.2: Production Monitoring Display Options.


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10.3 Training Options

These options give the user partial control over the algorithmused in the Weld Profile Training section of ProductionMonitoring (See 5.1).

The following are the options, and their interpretations:

Minimum Start Delay : This is the minimum StartDelay to which the Training algorithm will beconstrained during its calculation. That is, if theTraining algorithm produces a Start Delay that is lessthan this value, then the Start Delay willautomatically default to this value.

Minimum End Delay : This is the minimum EndDelay to which the Training algorithm will beconstrained during its calculation.

Minimum Tolerance for Weld Time : This is theminimum range (in the form of a percent) for total

weld duration to which the Training algorithm willbe constrained during its calculation. Minimum Tolerance for Current : This is the

minimum range (in the form of a percent) for arc current to which the Training algorithm will beconstrained during its calculation. The percentage is an offset (plus/minus) from the mean.

Minimum Tolerance for Voltage : This is the minimum range (in the form of a percent) for arc voltage towhich the Training algorithm will be constrained during its calculation. The percentage is an offset(plus/minus) from the mean.

Minimum Tolerance for Wire Feed Speed : This is the minimum range (in the form of a percent) for wirefeed speed to which the Training algorithm will be constrained during its calculation. The percentage is anoffset (plus/minus) from the mean.

Figure 10.3: Production Monitoring Training Options.


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11 Additional Information

11.1 DeviceNet I/O for Production Monitoring

This section outlines the features of Production Monitoring that are accessible and controllable using a DeviceNetinterface (for a complete description of the Power Wave DeviceNet interface, refer to the document entit led Y50031-

xx_DeviceNetInterfaceSpecification.pdf ).

The DeviceNet interface allows access to the Production Monitoring attributes WStats Weld Select and SelectWeld Based on welding set point. The Wstats Weld Select attribute contains the number of the Weld Profilecurrently in use (See 1.1.1). The Select Weld Based on welding set point attribute contains a boolean (yes/no)value that specifies whether the Weld Profile selection is based on the welding set point setting (See 1.1.1.1 and4.2.7.1).

To access these attributes, use the following DeviceNet class/attributes:

WStats Weld Select : DN Class 100, Instance 1, Attribute 70DN Class 15, Instance 165

Select Weld Based on welding set point: DN Class 100, Instance 1, Attribute 71DN Class 15, Instance 166

The DeviceNet I/O also includes a feedback bit for when there is a Production Monitoring Fault, as well as aProduction Monitoring Fault Reset Bit to clear the Production Monitoring Fault:

Produced Assembly (Perspective of DeviceNet Master):

Byte Bit 7 Bit 6 Bit 5 Bit 4 Bit 3 Bit 2 Bit 1 Bit 00 Fault Reset

(Arc Obj)WeldOutputDisable

Cold InchRev

Cold InchFwd

TouchSenseCmd

GasPurge

Trigger

1 Prod. Mon.Fault Reset

AttributeRequest

ProcessSelectReady

ScheduleSelect(Bit 2)



Consumed Assembly (Perspective of DeviceNet Master):

Byte Bit 7 Bit 6 Bit 5 Bit 4 Bit 3 Bit 2 Bit 1 Bit 00 DN Fault

(Sys Fault)WireStick

InverterFault

WaterFault

WireFault

Gas Fault TouchSensed

ArcDetect

1 AttributeResponse

ToggleBit (ArcObj)

ActiveFeedHead

GasPurge On

Prod.Mon.Fault

WeldCmplete

LimitError

ProcessSelectAck.

The Production Monitoring Fault Bit will become set when a Production Fault or Alarm is detected.

It will go off either when the Production Monitoring Fault Reset on the Incoming DeviceNet I/O is asserted, or whenthe Production Monitoring Alarm Reset Attribute is written to, or when the DeviceNet trigger is reasserted. WhenAlarm Latch is used, asserting the Production Monitoring Fault Reset will turn off the Production Monitoring Faultbit on the DeviceNet I/O and it will call Alarm Reset for Production Monitoring. Note: this bit is active even whenthe DeviceNet interface is in Passive Mode.


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11.2.4 Adding Production Monitoring To Welding Programs

1. Two programs, also already installed in the robot, will be run at the time of the weld, one to collect datatitled PM_SEL and one to compare data titled PM_VER . They will be listed in the Select key programlisting along with all other programs. Through the use of a CALL instruction, PM_SEL will be taught andrun just before the Arc Start point is recorded. After the Arc End point is taught, PM_VER will be taught

and run. When these two instructions are taught, a desired Weld Profile number (1-32) will be taught aspart of the instruction. A sample weld program is shown below:

1: J P[1] 100% CNT1002: J P[2] 100% CNT1003: CALL PM_SEL(1)4: J P[3] 100% FINEARC START[1]5: L P[4] 40 in/min FINEARC END[1]6: CALL PM_VER(1)7: J P[5] 100% CNT1008: J P[1] 100% CNT100END

2. To teach the Production Monitoring instructions, press F1-INST, cursor to line CALL , Enter. At newsubmenu, cursor to line Call Program, Enter. A list of programs will now appear; cursor to PM_SEL orPM_VER , Enter. With cursor now just past the PM_SEL or PM_VER , press F4-Choice, cursor to Constant,Enter. The word Constant will now appear on the line; key in desired Weld Profile number, Enter.Instruction is now complete and should appear similar to example program above.

3. Now, whenever this program is run, that weld profile will be monitored.

11.2.5 Alarm/Alert Programs

1. Whenever a weld goes out of limits, an alarm is posted to the top of the teach pendant screen. It may be

desirable for additional actions to take place such as a warning light to illuminate. Six additional programsare installed in the robot for ease of adding additional actions to take place. These programs are titledALERT_1 through ALERT_5 , and ALERT_10 . They would be used as follows:

ALERT_1 Weld Profile Runt occurredALERT_2 Weld Profile Time Limit occurredALERT_3 Weld Profile I (current) Limit occurredALERT_4 Weld Profile V (voltage) Limit occurredALERT_5 Weld Profile WFS (wire feed speed) occurredALERT_10 Invalid Profile has been selected

The program names will have already been created but it is the end users responsibility to set theseprograms up as desired and to install the necessary electrical and mechanical interfaces necessary to allow

these programs to work. Refer to the Fanuc Controller Electrical Connection and Maintenance Manual forinterfacing instructions. An example program is shown below:

ALERT_41: DO[1] = ON2: WAIT UI[6] = ON3: DO[1] = OFFEND


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This program turns on Digital Output [1] if a Voltage Limit occurs. DO[1] may be wired to an indicatorlight to alert the operator if a Voltage Limit has occurred. The light will remain on until User Input [6] isreceived, which may be triggered by a reset switch located near the indicator light. Then Digital Output[1] turns off, turning off the indicator light.

11.2.6 Erroneous Runt Alarms1. A Runt is a weld that was less than the sum of the start and end delays as set by the user during the setup of

Production Monitoring. These times are set in the same screen that the other limits are set. When theTorchMate and Touch Sensing options are used, the momentary touch the wire makes at the part or theTorchMate block is enough to cause a Runt alert to be generated. If these Runt alerts are becoming anuisance, it is possible to turn off Production Monitoring prior to running a Touch Sensing routine orrunning TorchMate Adjust and then turn it back on again prior to making a weld.

2. Two programs are installed in the robot to turn Production Monitoring on or off, PM_OFF and PM_ON .These are taught as a CALL instruction similar to 11.2.4, step 2.

3. To avoid tampering with the original TorchMate Adjust program, it may be desirable to create a newprogram titled TorchMate, for example, that begins with a line to turn off Production Monitoring, followedby the TorchMate Adjust instruction, and finishing with a line that turns Production Monitoring on again,

ready for the next weld. A sample program is shown below:

TORCHMATE1: CALL PM_OFF2: Torchmate Adjust3: CALL PM_ONEND

4. Teach the two CALL instructions as shown above. To teach the TorchMate Adjust instruction, press F1-INST, cursor to line Macro, Enter. At new submenu, cursor to line TorchMate Adjust, Enter.

11.2.7 Reference

1. Programs Installed To Operate Production Monitoring

WR_AL_AT.PCRD_AL_AT.PCPM_SELPM_VERPM_OFFPM_ONALERT_1, ALERT_2, ALERT_3, ALERT_4, ALERT_5, ALERT_10

2. Listing of program PM_SEL

1: R[1] = AR[1] - 1;2: IF R[1]31, CALL ALERT(10);3: LBL[1];4: ! set profile selection5: CALL WR_AL_AT(1,17,1008,R[1],3,4);6: ! verify that the write was ok7: IF R[3]0,JMP LBL[1];8: IF R[4]0,JMP LBL[1];9: ! read limit counts

10: R[1] = R[1] * 25;


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11: R[1] = R[1] + 2013;12: ! Get runt counts13: LBL[3];14: CALL RD_AL_AT(1,17,R[1]);15: IF $ARCLINK_ATR.$STATUS0 JMP LBL[3];16: R[5] = $ARCLINK_ATR.$INT_VALUE;17: R[1] = R[1] + 1;18: ! Get Time Limit counts19: LBL[4];20: CALL RD_AL_AT(1,17,R[1]);21: IF $ARCLINK_ATR.$STATUS0 JMP LBL[4];22: R[6] = $ARCLINK_ATR.$INT_VALUE;23: R[1] = R[1] + 1;24: ! Get I Limit counts25: LBL[5];26: CALL RD_AL_AT(1,17,R[1]);27: IF $ARCLINK_ATR.$STATUS0 JMP LBL[5];28: R[7] = $ARCLINK_ATR.$INT_VALUE;29: R[1] = R[1] + 1;30: ! Get V Limit counts

31: LBL[6];32: CALL RD_AL_AT(1,17,R[1]);33: IF $ARCLINK_ATR.$STATUS0 JMP LBL[6];34: R[8] = $ARCLINK_ATR.$INT_VALUE;35: R[1] = R[1] + 1;35: ! Get WFS limit counts37: LBL[7];38: CALL RD_AL_AT(1,17,R[1]);39: IF $ARCLINK_ATR.$STATUS0 JMP LBL[7];40: R[9] = $ARCLINK_ATR.$INT_VALUE;END

3. Listing of program PM_VER

1: R[1] = AR[1] - 1;2: IF R[1]31, CALL ALERT(10);3: R[1] = R[1] * 25;4: R[1] = R[1] + 2013;5: ! Get runt counts6: LBL[3];7: CALL RD_AL_AT(1,17,R[1]);8: IF $ARCLINK_ATR.$STATUS0 JMP LBL[3];9: IF R[5] $ARCLINK_ATR.$INT_VALUE, CALL ALERT(1)

10: R[1] = R[1] + 1;11: ! Get Time Limit counts12: LBL[4];13: CALL RD_AL_AT(1,17,R[1]);

14: IF $ARCLINK_ATR.$STATUS0 JMP LBL[4];15: IF R[6] $ARCLINK_ATR.$INT_VALUE, CALL ALERT(2)16: R[1] = R[1] + 1;17: ! Get I Limit counts18: LBL[5];19: CALL RD_AL_AT(1,17,R[1]);20: IF $ARCLINK_ATR.$STATUS0 JMP LBL[5];21: IF R[7] $ARCLINK_ATR.$INT_VALUE, CALL ALERT(3)22: R[1] = R[1] + 1;23: ! Get V Limit counts


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24: LBL[6];25: CALL RD_AL_AT(1,17,R[1]);26: IF $ARCLINK_ATR.$STATUS0 JMP LBL[6];27: IF R[8] $ARCLINK_ATR.$INT_VALUE, CALL ALERT(4)28: R[1] = R[1] + 1;29: ! Get WFS limit counts30: LBL[7];31: CALL RD_AL_AT(1,17,R[1]);32: IF $ARCLINK_ATR.$STATUS0 JMP LBL[7];33: IF R[8] $ARCLINK_ATR.$INT_VALUE, CALL ALERT(5)END

4. Listing of program PM_OFF

1: CALL WR_AL_AT(1, 17, 999, 0, 0, 0)END

5. Listing of program PM_ON

1: CALL WR_AL_AT(1, 17, 999, 1, 0, 0)

END


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Glossary

ArcLink A communications protocol developed by Lincoln Electric for use in a welding system. This protocoltakes into account specific needs of a welding system and the interaction of the multiple components that make upthe network to greatly improve reliability and robustness.

Board Serial Number Each component in an ArcLink system has a unique number that allows it to be identifiedfrom the other components. In Lincoln Electric systems, this is used to verify what component is being referencedin software.

DeviceNet A standard industrial networking protocol usually used by a PLC to control networked devices in aMaster/Slave relationship.

DNS Domain Name Service used for translating host names to an IP address so that networked equipment can begiven an alphanumeric name instead of a number. See Host Name for an example of what a DNS server does.

Email Electronic Mail, an electronic message that is transferred over a communications network, or the Internet.

Host Name Alphanumeric name that is used to represent networked equipment at a specific IP address. Anexample would be www.google.com instead of 216.239.37.99.

HTML Hyper Text Markup Language, the document format used for web pages on the Internet.

IP address A number that identifies a device on the network. This number is a 32-bit numeric address written asfour octets separated by periods also referred to as dots. The numbers range from zero to 255. An example wouldbe 192.168.1.45.

Latched Alarm Prevents the Power Wave from making another weld until the alarm has been acknowledged.

This setting can be utilized for verifying a welding setup before making another weld.

Module Number The Power Wave consists of modules that communicate with each other to create a weldingsystem. The module number is the name given to each one of these devices.

Octet A number ranging from zero to 255 used in IP addresses.

PLC Programmable Logic Controller; a specialized device used in the control of industrial processes.

Port In a specific network such as a TCP or a UDP network, a port is an endpoint to a logical connection. The portnumber defines what type of information will be transmitted. An example would be port 80 for HTML data or port25 for email data.

Power Wave Name A name given to a Power Wave for easy reference of where the machine is located and/orwhat the machine welds together.

Production Report Summary of Weld History that shows all Weld Profiles and their totals. The report alsoincludes the total time the Power Wave has welded during the given shift, and the amount of wire left in the wirepackage.

Rejected Weld A weld that was either not consistent enough or long enough to apply statistical equations togenerate reasonable limit information.


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Robotic Feeder I/O The PF10R feed head comes with an External I/O Connector that can be reconfigured throughProduction Monitoring to reroute the I/O from its normal operation to be utilized as a Weld Profile Selection.

Runt A weld that has a shorter duration than the sum of the start delay and the end delay settings.

Shift Times A Production Monitoring feature used to trigger events at a specific time of day that will allow thetracking of usage and clearing out of Weld Totals and Weld History. There are a total of 6 shift times that can beutilized on a daily basis.

Shift Usage The amount of arc time since the last Shift Timer that was selected to clear the Shift Usage.

SMTP Simple Mail Transfer Protocol, the standard protocol used for sending email through an email server.

Spreadsheet application A PC tool such as Microsoft Excel that arranges values into rows and columns.

Subnet A section of a network. Subnets are used to divide up large networks into small sections for ease of management, increased performance and increased security.

Tab-delimited text file Generic text file format that is used for arranging data in a spreadsheet. Most spreadsheetapplications can import this file format with little or no conversion by the user.

TCP Transmission Control Protocol, used in the transmission of data between two devices. It is a more reliableprotocol than UDP since it controls the delivery of data and verifies the order in which the data is sent.

UDP User Datagram Protocol, used in the transmission of data between two or more devices. It is a faster protocolthan TCP, but it does not guarantee data delivery or the order in which the data is sent.

Weld History Data on welds that the Power Wave has made. This statistical data includes information on duration,voltage, current, wire feed speed, an

production monitoring

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