Power Wave Observer User Manual

Version 3.2f Y50021-09

July 25, 2004

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Power Wave Observer

Power Wave Observer is an application that is used for two main purposes: View the current status of the Power Wave Configure the non-volatile memory of the Power Wave DeviceNet module. The application will connect to an ArcLink based Power Wave family machine1 via direct serial cable2 or network connection3. 1 Connection to Power Wave The connection dialog will automatically open when the application is started and may also be accessed from the File | Connect to machine menu.

Select TCP and enter localhost in the IP Address edit box to allow multiple applications to communicate with the Power Wave4. Set the Communications Port field to match the computer port in use. Select Serial when the computer is connected directly to the machine via RS232 serial cable and the serial port is not being shared with other applications. Select TCP or UDP and enter an IP address if your machine is ethernet compatible. Click OK and Observer will create a connection to the Power Wave.

Observer is not compatible with Power Wave 450 or LincNet PW455/STT/PF10 semi-automatic systems. Typical computer to Power Wave serial connection requires a 9 pin female to 25 pin male adapter cable (Radio Shack cat no. 26-269). 3 Ethernet module (G3894) is required to connect Power Wave to network. 4 The LEAL Server application (LealSrv.exe) is required to share a serial port connection and should be in the same working directory as Observer. Power Wave Observer User Manual Page 2
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Basic Screen

Power Wave Observers basic screen is used to view the current status of the Power Wave machine that is connected. The Basic Screen is shown below:

The Basic Power Wave Observer screen can be broken down into five major sections: Welding Feedback, Graphing Utilities, LEAL connection status, System Status, and Weld Schedule Variables.

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2.1 Welding Feedback The Welding feedback section has three major components: Current, Voltage, and Wire Feed Speed charts. The graph for each feedback is auto scaled5 to fit the feedback values. This chart automatically pauses when the Weld Sequencer is not active (IDLE). The three components of the graph are described below.

2.1.1 Current This chart recorder component displays the Average Welding Current that the Power Wave sees. 2.1.2 Voltage This chart recorder component displays the Average Welding Voltage that the Power Wave sees. 2.1.3 Wire Feed Speed (WFS) This chart recorder component displays the Wire Feed Speed that the PF10/R Control Board sees. This value is not the actual Wire Feed Speed, but a Wire Feed Speed that is calculated from the Actual Motor Speed using known values such as the gear box ratio and drive roll diameter.

Double-clicking on a graph section will bring up a dialog box to set minimum/maximum values displayed in each graphing window. This allows the user to increase resolution around a particular range of values. Selecting Auto-scale will display the full range of values collected. Power Wave Observer User Manual Page 4

2.2 Graphing Utilities The graphing utilities include Window Size Control, Start/Stop Graphing, Clear Graphs, and Save Data from the graph. With the exception of window size control all utilities are found under the Graphs heading at the main menu. 2.2.1 Window Size Control The graphing area can be enlarged by using the boxes located in the upper right and lower left of the graphing area. When these boxes are clicked on they will convert to and hide the components that were on the side or bottom of the Observer window. To restore the components click on the boxes and the components will be restored. 2.2.2 Start/Stop Graphing The Start/Stop Graphing option under the Graphs heading of the main menu is used as a toggle selection to control the logging of all three chart components. The default causes Observer to start graphing when the weld sequencer becomes active. Select Stop Graphing to prevent Observer form logging data. 2.2.3 Clear Graphs This selection clears the data on the graphs. 2.2.4 Save Data This selection saves the data that is stored in the graphs in a comma delimited text file to allow import into a data analysis or a spreadsheet program. It will store all data values since the starting of the application or since the previous time that the graphs were cleared. 2.3 LEAL Connection Status The upper right side of the Observer window contains the connection status display. When a serial connection to a Power Wave is made the name LOCALHOST will appear in the window. If LOCALHOST does not appear, follow the steps in section 1 Connecting to a Power Wave.

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2.4 System Status The system status is on the right side of the Observer window. The System Status section contains the current value of critical system status attributes. The status of these attributes are portrayed as virtual lights on the user interface. The convention that is used is as follows: Light is not illuminated: Condition is not present Light is blinking RED: Fault Condition is present Light is illuminated GREEN: Normal or expected Status is present The following status conditions are reported in the System Status section: Sequencer State, Arc Detect, DeviceNet Connection, Sequencer Fault, Power Source Fault, Water Fault, DeviceNet Fault, and DeviceNet Limit Error. NOTE: The System Status is not intended as an exhaustive system diagnostic, but as a general overview of system health. 2.4.1 Sequencer State This line displays the current state of the Sequencer. Its state is displayed in blue. The Weld Sequencer Object is a state machine responsible for synchronizing the actions of the weld cell components. The value of Sequencer State reflects the current state of the state machine. States names that may be displayed are: IDLE, PREFLOW, STRIKE, WELD, POSTFLOW, RESTRIKE, and FAULTED. 2.4.2 Arc Detect Status This light is enabled when sufficient Arc Voltage and Arc Current are present to establish a welding arc. The actual values that determine the presence of an arc are dependent on the current Weld Mode. Typically these values are 10 Volts and 20 Amps. 2.4.3 DeviceNet Connection Indicates that a DeviceNet polled connection has been established and is in good health.

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2.4.4 Sequencer Fault Indicates that the Weld Sequencer Object has entered the FAULTED state. Some reasons the Weld Sequencer Object may enter the FAULTED state are but are not limited to: An unexpected error on the Power Waves internal network A fault in a device that is under the Weld Sequencers control such as the Wire Drive or Weld Controller Objects The trigger was asserted prior to the system being Ready to Weld A necessary state machine condition was not met The Weld Sequencer Object was forced to the FAULTED state An external shutdown such as a Water Fault 2.4.5 Power Source Fault Indicates that an inverter fault has been detected. Some causes of an inverter fault are, but are not limited to: CAP under/over voltage CAP imbalance Primary overcurrent Failure to complete inverter softstart If these errors persist or reoccur regularly, please contact Lincoln Electric service personnel for assistance. 2.4.6 Water Fault Indicates that the fault line that is typically assigned to the assigned to the water fault is open. These fault lines are accessed through a green Phoenix Terminal Connector on the front of the Power Wave. An open fault line indicates a fault. In the case of water flow, a flow sensor that is normally open will cause a fault when there is no water flow. If a water cooler is not connected to the Power Wave, verify that the fault jumper is in place in the Phoenix Terminal Connector. Consult the Power Wave Instruction Manual for the pinout of the Phoenix terminal connector. 2.4.7 DeviceNet Fault Indicates that a fault has occurred in the DeviceNet connection. Some causes of a DeviceNet fault are, but are not limited to: Attempt to select an invalid schedule Schedule select timeout

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2.4.8 DeviceNet Limit Error Indicates that a commanded value that is being passed on at least one of the three analog DeviceNet channels is out of limit for the schedule that is currently selected. Verify the values that are being sent to make certain that they are within the operating limits. The Power Wave rejects any value that is out of limit. When a limit error is encountered, the Power Wave will continue to use the most recent value that was within limit. 2.5 Weld Schedule Variables The Weld Variables Section contains the current value of critical system attributes. These attributes are: Weld Mode, Set Wire Feed Speed, Workpoint, Trim, Wave 1, Wave 2, Wave 3, and Wave 4. There is a tab at the bottom to switch from Schedule 1A to Schedule 1B. To switch from on schedule to another, select the appropriate tab and if a make active line appears next to the tabs click on it and that selected schedule will have the active name next to it. The attributes in these schedules are described below.

2.5.1 Weld Mode Displays the value of the Weld Schedules Weld Mode attribute. The Weld Mode attribute is used to select one of the possible welding procedure programs that are stored in the Power Wave. A Weld Mode can be categorized based on process type, wire type, wire size, and gas type. Weld Modes may be further sub-categorized based on process variations such as pulse, or STT. A mode number can be directly entered into this field. It holds the value of the Weld Mode that will be used when the schedule becomes active.

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Clicking on the table browser.

button next to the Weld Mode will bring up the weld

From above it can be seen that Weld Mode 22 is a Pulse-GMAW Procedure for .045 Steel Wire. The mode is intended to be used with an Ar/CO2 Gas mixture. There is also a Sort By selection that will arrange the present Weld Modes into numerical order or grouping by process type. NOTE: The Weld Mode of an active schedule is not allowed to change. To prevent this, the Mode Memory field and Weld Table Browser button are disabled while the Power Wave is active. 2.5.2 Workpoint Displays the current commanded value of the Workpoint attribute. The Workpoint attribute is a primary control variable. The properties of the Workpoint attribute such as units or high/low limits vary with the active Weld Mode. Typically, in a synergic Weld Mode, Workpoint is the commanded wire feed speed. The units of Workpoint are shown to the right of the current value. The name or function assigned to Workpoint is shown to the left. Consult the Power Wave Instruction Manual for more detailed information concerning the effects of Workpoint. 2.5.3 Trim Displays the current commanded value of the Trim attribute. The Trim attribute is a secondary control variable of the Weld Controller object. The value displayed will be in engineering units if Display Scaled Trim/Wave Controls is checked or raw machine units otherwise.

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2.5.4 Wave Controls 1,2,3,4 Displays the current commanded value of the Wave Control attributes. Wave Controls are optional secondary control variables of the Weld Controller object. Only active Wave Controls will be displayed. The value displayed will be in engineering units if Display Scaled Trim/Wave Controls is checked or raw machine units otherwise. Consult the Power Wave Instruction Manual for more detailed information concerning the effects of Trim and Wave Control on the welding waveform.

NOTE: User may override the current value for Workpoint, Trim, and Wave Control by typing a new value in the associated edit box and pressing the Enter key6. This value will remain valid until a new value is received through the DeviceNet Network or entered into the variable field. 2.5.5 Names/Units The units for all the Weld Schedule Variables will be displayed to the right of the entry box for that variable. The name to left of the entry box reflects the function of the variable in the weld table. The names and units will change depending on the weld mode selected. If the Weld Schedule Variable does not require units, no units will be displayed. NOTE: Trim and Wave Controls are stored in the machine as a signed number between 32767 and +32767. The Trim and Wave Control attributes of the Weld Controller do not change their limits or units. However, the user has the option of providing a Trim or Wave command as an engineering value. When Trim or Wave Control is commanded as an engineering value, its limits may be dependent on the value of Workpoint. 2.5.6 Schedule Select Selects the schedule that will be configured by the Schedule Configuration parameters. Currently, the Power Wave supports two unique schedules. It is important to note that although only two preset schedules are available, this does not restrict the welding parameters that are passed to the system. For example, a single schedule will support any number of analog commands that are passed to the system over the polled DeviceNet connection and will alter the machine output on-the-fly. A schedule selection is not required to alter welding parameters. NOTE: When changing from one schedule to another there will be a slight delay for the PC to read the values. This delay will be approximately 3 seconds.

Workpoint and Trim/Wave Controls are write-enabled based on the settings in the Observer Preferences dialog box accessible from the File|Preferences menu. Power Wave Observer User Manual Page 10

2.6 Additional Weld Schedule Variables7 The Power Wave has the capability of storing multiple schedule configurations. This creates a large matrix of sequence steps that the Power Wave goes through during a weld. Observer provides the ability to modify a minimal subset these schedule parameters. The Schedule Configuration section includes the following parameters: Strike Wire Feed Speed, Preflow Time, Burnback Time, and Postflow Time. 2.6.1 Strike Wire Feed Speed (inches per minute) Configures the Wire Feed Speed for the STRIKE state. STRIKE is the time period between the end of the PREFLOW state and the establishment of a welding arc. This is also known as run-in WFS. Configuring a STRIKE Wire Feed Speed prevents the welding wire from running full-speed into the part before an arc has been established. This is especially useful for electrode types that are sensitive to starting- i.e. large gauge Aluminum. A valid Strike Wire Feed Speed MUST be configured in order for the system to feed wire to strike an arc. 2.6.2 Preflow Time (milliseconds)8 Sets the time that the Weld Sequencer object will remain in the PREFLOW state. PREFLOW is the time period between assertion of the trigger and enabling of the welding output. A value of zero disables the PREFLOW state. 2.6.3 Burnback Time (milliseconds) Sets the time that the Weld Sequencer object will remain in the BURNBACK state prior to moving to the POSTFLOW state. BURNBACK is the time following the de-assertion of the trigger that the welding output will remain on while the wire feeding is stopped. The configuration of the BURNBACK time is highly application specific and is dependent on welding wire feed speed and stickout. A value of zero disables the BURNBACK state. 2.6.4 Postflow time (milliseconds) Sets the time that the Weld Sequencer object will remain in the POSTFLOW state. POSTFLOW is the time period between the Welding Output being disabled by the Weld Sequencer Object and returning to the IDLE state. A value of zero disables the POSTFLOW state.

Strike WFS, Preflow, Postflow and Burnback are hidden/displayed based on the settings in the Observer Preferences dialog box accessible from the File|Preferences menu. 8 The DeviceNet module will automatically enable sequencer states when non-zero values for preflow, burnback and postflow times are commanded. Observer will set the appropriate times but will make no attempt to enable/disable states if a DeviceNet module is not present. Power Wave Observer User Manual Page 11

DeviceNet

3.1 DeviceNet Configuration The DeviceNet Configuration parameters are used to configure the Power Waves critical DeviceNet network parameters and define how it responds to changes in command values that are passed to it. The DeviceNet Configuration dialog is accessible from the DeviceNet | Configuration menu and is only available when a DeviceNet module is detected9.

3.1.1 DeviceNet Communication - MAC ID This field indicates the current configuration of the Power Waves DeviceNet MAC ID. This value will only change if the DIP switches on the Power Waves DeviceNet interface boards are configured to allow retrieval of the MAC ID from EEPROM memory. If this value is altered, the Power Wave must be reset (cycle power) in order for the change to become effective.
See Power Wave instruction manual or DeviceNet Interface Specification (Y50031) for configuration details. Power Wave Observer User Manual Page 12
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3.1.2 DeviceNet Communication - Baud Rate This field indicates the current configuration of the Power Waves DeviceNet Baud Rate. This value will only change if the DIP switches on the Power Waves DeviceNet interface boards are configured to allow retrieval of the Baud Rate from EEPROM memory. If this value is altered, the Power Wave must be reset (cycle power) in order for the change to become effective. 3.1.3 Analog Input Channels/Hysteresis These values indicate the magnitude of change that must occur on the first three analog DeviceNet channels before the Power Wave will respond to the change. In the case of a command value that is sourced from an A/D whose output may dither slightly, this configuration prevents unintended parameter changes. This attribute is not useful for command values whose source is completely digital and should be set to 0. One exception is when the Power Wave has an Analog Interface module, in this case set these values to a 30. Input channels will be ignored if their Active boxes are unchecked in which case the Power Wave will assign default values to the associated parameters10. 3.1.4 Analog Output Configure AN2 output channel to report actual (default) or commanded WFS. Note: This control is for AC/DC systems only. 3.1.5 System Control Enable passive mode operation If checked, then the DeviceNet polled inputs will have no effect on the system except for the Weld Output disable bit and the Production Monitoring Fault Reset bit.. Enable this when the DeviceNet connection is used only to monitor system operation. 3.1.6 System Control Restore settings from memory on reset The DeviceNet board will automatically restore weld schedule values on powerup that are not accessible from a polled connection. These include Weld Mode, strike, restrike and cold inch wire feed speeds, and times for preflow, postflow and burnback. If the system contains an UI with memory a memory panel or a robot/PLC that restore settings on power up, do not check this box. 3.1.7 System Control Fault if no polled connection detected Disables welding if a polled DeviceNet connection is not present. Check this when a DeviceNet master controls machine. 3.1.8 Workpoint Input This indicates whether the values passed to the system through the analog DeviceNet channels for the Workpoint parameter are raw values or scaled
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Analog Input Masking and Analog Output configuration are available in DN Vendor Rev 1.008 and later. Power Wave Observer User Manual Page 13

engineering values. Selecting the Engineering Units option indicates that scaled engineering values for Workpoint will be passed across the analog DeviceNet channel. For example when the workpoint is in Inches/per Minute and scaled engineering units are used, then a value of 50 to 800 might be expected to be commanded on the DeviceNet analog input for the workpoint. This would represent a value of 50 to 800 inches/per minute. When the Unscaled Values option is selected, the commands for Workpoint range from 0 to 32767 corresponding to the minimum and maximum workpoint of the selected weld mode. For most applications, Engineering Units is normally selected. 3.1.9 Trim/Wave Control Input This indicates whether the values passed to the system through the analog DeviceNet channels for the Trim and Wave Control parameters are raw values or scaled engineering values. Selecting the Engineering Units option indicates that scaled engineering value for Trim or Wave Control 1 will be passed across the analog DeviceNet channels. For example when the Trim is in volts and scaled engineering units are used, then a value of 75 to 520 might be expected to be commanded on the DeviceNet analog input for the trim. This would represent a value of 7.5 to 52.0 volts. When the Unscaled Values option is selected, the commands range for Trim and Wave Control 1, 2, 3, 4 range from 32768 to 32767 with 0 representing a nominal value. A great majority of applications will require Trim and Wave Control command values to be set near the nominal value. 3.1.10 Report Trim/ Wave Outer Process Limits When the Trim and Wave are being reported in Engineering Units and these inputs are depended on the workpoint, then this item is used to determine how to report back the trim and wave high and low limits. If the above conditions are meet, then checking this box will have the absolute high and low limit always be returned, unchecking the box will have the returned limits be based on the workpoint. As the workpoint changes, the acceptable range that the trim and waves can be in will change as well, unchecking this box will have the limits report back what this range is. Normally this item is checked. 3.1.11 TAST Update Frequency This parameter is used for Through the Arc Seam Tracking. The lower the number the more often the feedback is updated, but higher the system load on the boards. If Through the Arc Seam tracking is being used, then this is usually set to a value of 10 to 20, else a value of 100 is usually acceptable. 3.1.12 Metering Time Constant This parameter sets the filtering of the feedback data. The default value of 400 is usually used unless Through the Arc Seam Tracking is being done, then this item is usually set to a value of around 75.

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3.1.13 Analog Scans Between Updates This determines how often the analog input channels (workpoint, trim, and wave control) update the system in terms of Polled I/O scans. For example a value of 50 means that every 50th I/O scan will be accepted. The setting of this item depends on how often the Power Wave is scanned. For systems with a scan rate of 200 or more, then the default of 50 is usually acceptable. For systems with very low scan rates, such as 10hz then the setting as low as 2 might be needed. Once a DeviceNet connection has been established, see IO Scans/Sec item in the DeviceNet monitor screen in Observer for the current scan rate. Note that this setting does not affect the digital I/O bits updating rate. 3.1.14 Cold Inch Wire Feed Speed This parameter sets the feed speed of the wire while cold inching or jogging the wire. This value is used for either cold inching forward (Jog +) or cold inching reverse (Jog -). This value is in units of IPM. A value of 0 will cause the wire to inch at 0 IPM, or in other words, not at all. 3.1.15 DN Event Logging The DeviceNet module keeps a running history of system in an on-board event log. These events may be generated during normal operation when power is applied to or removed from the system. These boxes should be left unchecked unless troubleshooting the system.

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3.2 DeviceNet Monitor The DeviceNet Monitor interprets command input and feedback passing through the DeviceNet module. This is a troubleshooting tool for those customers implementing a DeviceNet connection to the Power Wave. This dialog is accessed from the DeviceNet | Monitor menu and is only available when a DeviceNet module is detected. Refer to Y50031-xx Device Net Interface Specification for more information on these items.

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3.3 DeviceNet Trace The DeviceNet Trace displays low-level communication passing through the DeviceNet module. This is a troubleshooting tool for those customers implementing a DeviceNet connection to the Power Wave. This dialog is accessed from the DeviceNet | Trace menu and is only available when a DeviceNet module is detected.

4 Observer Preferences Observer operation is determined by the settings in the Preferences dialog accessible from the File | Preferences menu. The default settings (shown below) assume the machine will be controlled via a DeviceNet module. Only those controls that cannot be set with a polled DeviceNet connection are displayed.

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4.1

Observer Preferences - General

4.1.1 General Period between attribute updates Enter the time (in milliseconds) to refresh machine attributes read by Observer. 4.1.2 General Display Strike/Burnback/Postflow When checked, the associated controls will be visible on the main Observer screen. These controls configure sequence memory not available through a polled DeviceNet connection. See Additional Weld Schedule Variables for details.

4.1.3 General Show Trigger Button When checked, a Trigger control is visible on the main screen. This button allows triggering the machine through the Observer program. To turn on welding output, hold the CTRL key while clicking the button while the output is off. Clicking the button when output is on will turn the trigger off. 4.1.4 General Show Weld Statistics When checked, arc statistics for the last weld become visible on the main screen. Total Arc Time and the history of welds since Observer was started is available from the View menu. NOTE: The heat calculation (Joules) is based on average current and voltage readings and should be used for reference only.

4.1.5 General Enable Workpoint/Trim Controls When checked, the edit boxes for Workpoint, Trim and Wave Controls become active so that new values may be entered from the main Observer screen. To override a value, type a new value in the associated control and press the Enter key. This value will remain valid until a new value is received through the DeviceNet Network or entered into the variable field. NOTE: This box must be checked to activate Weld Control screen in the Preferences dialog.

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4.2

Observer Preferences Weld Control 4.2.1 Weld Control This screen determines which sequence states are updated when a new value is entered in the associated edit box. Typically, all states shown in red should be be set11. Checking Use Strike WFS for Restrike WFS will update the Restrike state when new values for Strike WFS are entered. NOTE: Hovering over each control will display the associated sequencer state in a tool-tip window.

Observer displays the value of the Weld1 state for Workpoint, Trim and Wave Controls. Right-clicking on the Workpoint, Trim or Wave Control edit box in the main Observer screen will allow you to view all sequencer state values and the active limits for a control at the selected workpoint. Power Wave Observer User Manual Page 19

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4.3

Observer Preferences Graphs 4.3.1 Observer may connect to several machines simultaneously. Current from each machine may be displayed graphically as individual waveforms and/or as a composite sum. Volts and Wire Feed Speed graphs display waveforms from all machines. 4.3.2 Select whether the AMPS readout shows the composite current from all machines or the individual contribution of the highlighted connection. Voltage and WFS readouts always display values from the selected machine connection. 4.3.3 Click on a color square to customize graph colors.

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Help

Observer includes an About Box that lists program revision particulars. The System Info dialog provides details about the Power Wave hardware and software. If problems arise, this information will be crucial to help solve them.

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