PowerWave Observer

7/30/2019 PowerWave Observer

1/21

Power Wave Observer User ManualPage 1

Power Wave ObserverUser Manual

Version 3.2f

Y50021-09

July 25, 2004


2/21


Power Wave ObserverPower 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 machine1via direct serial cable2 or network connection3.

1 Connection to Power WaveThe connection dialog will automatically open when the application is started andmay also be accessed from the File | Connect to machine menu.

Select TCP and enter localhost in the IP Address edit box to allow multipleapplications to communicate with the Power Wave4. Set the CommunicationsPort field to match the computer port in use.

Select Serial when the computer is connected directly to the machine via RS232serial 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 ethernetcompatible.

Click OK and Observer will create a connection to the Power Wave.

1Observer is not compatible with Power Wave 450 or LincNet PW455/STT/PF10 semi-automatic systems.

2Typical 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.


3/21


2 Basic Screen

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

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


4/21


2.1 Welding FeedbackThe Welding feedback section has three major components: Current, Voltage,and Wire Feed Speed charts. The graph for each feedback is auto scaled5 to fitthe feedback values. This chart automatically pauses when the Weld Sequenceris 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 thePower Wave sees.

2.1.2 Voltage

This chart recorder component displays the Average Welding Voltage that thePower Wave sees.

2.1.3 Wire Feed Speed (WFS)

This chart recorder component displays the Wire Feed Speed that the PF10/RControl Board sees. This value is notthe actual Wire Feed Speed, but a WireFeed Speed that is calculated from the Actual Motor Speed using known valuessuch as the gear box ratio and drive roll diameter.

5Double-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.


5/21


2.2 Graphing UtilitiesThe graphing utilities include Window Size Control, Start/Stop Graphing, ClearGraphs, and Save Data from the graph. With the exception of window sizecontrol all utilities are found under the Graphs heading at the main menu.

2.2.1 Window Size ControlThe graphing area can be enlarged by using the boxes located in the upperright and lower left of the graphing area. When these boxes are clicked on theywill 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 andthe components will be restored.

2.2.2 Start/Stop Graphing

The Start/Stop Graphing option under the Graphs heading of the main menu isused 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 delimitedtext file to allow import into a data analysis or a spreadsheet program. It willstore all data values since the starting of the application or since the previoustime that the graphs were cleared.

2.3 LEAL Connection StatusThe upper right side of the Observer window contains theconnection status display. When a serial connection to aPower Wave is made the name LOCALHOST will appear inthe window. If LOCALHOST does not appear, follow thesteps in section 1 Connecting to a Power Wave.


6/21


2.4 System StatusThe system status is on the right side of the Observer window. The SystemStatus section contains the current value of critical system status attributes. Thestatus of these attributes are portrayed as virtual lights on the user interface. Theconvention that is used is as follows:

Light is not illuminated: Condition is not presentLight is blinking RED: Fault Condition is presentLight is illuminated GREEN: Normal or expected Status is present

The following status conditions are reported in the SystemStatus section: Sequencer State, Arc Detect, DeviceNetConnection, Sequencer Fault, Power Source Fault, WaterFault, DeviceNet Fault, and DeviceNet Limit Error.

NOTE: The System Status is not intended as an exhaustivesystem 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 inblue. The Weld Sequencer Object is a state machine responsible forsynchronizing the actions of the weld cell components. The value of SequencerState reflects the current state of the state machine. States names that may bedisplayed are: IDLE, PREFLOW, STRIKE, WELD, POSTFLOW, RESTRIKE, andFAULTED.

2.4.2 Arc Detect Status

This light is enabled when sufficient Arc Voltage and Arc Current are present toestablish a welding arc. The actual values that determine the presence of an arcare dependent on the current Weld Mode. Typically these values are 10 Voltsand 20 Amps.

2.4.3 DeviceNet Connection

Indicates that a DeviceNet polled connection has been established and is in goodhealth.


7/21


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 arebut 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 theWire 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 inverterfault 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 servicepersonnel for assistance.

2.4.6 Water Fault

Indicates that the fault line that is typically assigned to the assigned to the waterfault is open. These fault lines are accessed through a green Phoenix TerminalConnector 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 faultwhen there is no water flow. If a water cooler is not connected to the PowerWave, verify that the fault jumper is in place in the Phoenix Terminal Connector.Consult the Power Wave Instruction Manual for the pinout of the Phoenixterminal connector.

2.4.7 DeviceNet Fault

Indicates that a fault has occurred in the DeviceNet connection. Some causes ofa DeviceNet fault are, but are not limited to:

Attempt to select an invalid schedule

Schedule select timeout


8/21


2.4.8 DeviceNet Limit Error

Indicates that a commanded value that is being passed on at least one of thethree analog DeviceNet channels is out of limit for the schedule that is currentlyselected. 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 mostrecent value that was within limit.

2.5 Weld Schedule VariablesThe Weld Variables Section contains the current value of critical systemattributes. 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 toswitch from Schedule 1A to Schedule 1B. To switch from on schedule toanother, select the appropriate tab and if a make active line appears next to thetabs 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 ModeDisplays the value of the Weld Schedules Weld Mode attribute. The Weld Modeattribute is used to select one of the possible welding procedure programs thatare stored in the Power Wave. A Weld Mode can be categorized based onprocess type, wire type, wire size, and gas type. Weld Modes may be furthersub-categorized based on process variations such as pulse, or STT. A modenumber can be directly entered into this field. It holds the value of the WeldMode that will be used when the schedule becomes active.


9/21


Clicking on the button next to the Weld Mode will bring up the weldtable browser.

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 intonumerical order or grouping by process type.

NOTE: The Weld Mode of an active schedule is not allowed to change. Toprevent this, the Mode Memory field and Weld Table Browser button are disabledwhile the Power Wave is active.

2.5.2 WorkpointDisplays the current commanded value of the Workpoint attribute. TheWorkpoint attribute is a primary control variable. The properties of the Workpointattribute such as units or high/low limits vary with the active Weld Mode.Typically, in a synergic Weld Mode, Workpoint is the commanded wire feedspeed. The units of Workpoint are shown to the right of the current value. Thename or function assigned to Workpoint is shown to the left. Consult the PowerWave Instruction Manual for more detailed information concerning the effects ofWorkpoint.

2.5.3 Trim

Displays the current commandedvalue of the Trim attribute. The Trim attribute isa secondary control variable of the Weld Controller object. The value displayedwill be in engineering units if Display Scaled Trim/Wave Controls is checked orraw machine units otherwise.


10/21


2.5.4 Wave Controls 1,2,3,4

Displays the current commanded value of the Wave Control attributes. WaveControls are optional secondary control variables of the Weld Controller object.Only active Wave Controls will be displayed. The value displayed will be inengineering units if Display Scaled Trim/Wave Controls is checked or raw

machine units otherwise.

Consult the Power Wave Instruction Manual for more detailed informationconcerning the effects of Trim and Wave Control on the welding waveform.

NOTE: User may override the current value for Workpoint, Trim, and WaveControl by typing a new value in the associated edit box and pressing the Enterkey6. This value will remain valid until a new value is received through theDeviceNet 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 theentry box for that variable. The name to left of the entry box reflects the functionof the variable in the weld table. The names and units will change depending onthe 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 numberbetween 32767 and +32767. The Trim and Wave Control attributes of the WeldController do not change their limits or units. However, the user has the option ofproviding a Trim or Wave command as an engineering value. When Trim orWave 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 Configurationparameters. Currently, the Power Wave supports two unique schedules. It isimportant to note that although only two preset schedules are available, this doesnot restrict the welding parameters that are passed to the system. For example,a single schedule will support any number of analog commands that are passedto the system over the polled DeviceNet connection and will alter the machineoutput on-the-fly. A schedule selection is not required to alter weldingparameters.

NOTE: When changing from one schedule to another there will be a slight delayfor the PC to read the values. This delay will be approximately 3 seconds.

6Workpoint and Trim/Wave Controls are write-enabled based on the settings in the Observer Preferences

dialog box accessible from the File|Preferences menu.


11/21


2.6 Additional Weld Schedule Variables7The Power Wave has the capability of storing multiple schedule configurations.This creates a large matrix of sequence steps that the Power Wave goes throughduring a weld. Observer provides the ability to modify a minimal subset theseschedule parameters. The Schedule Configuration section includes the following

parameters: Strike Wire Feed Speed, Preflow Time, Burnback Time, andPostflow Time.

2.6.1 Strike Wire Feed Speed (inches per minute)

Configures the Wire Feed Speed for the STRIKE state. STRIKE is the timeperiod between the end of the PREFLOW state and the establishment of awelding arc. This is also known as run-in WFS. Configuring a STRIKE WireFeed Speed prevents the welding wire from running full-speed into the partbefore an arc has been established. This is especially useful for electrode typesthat are sensitive to starting- i.e. large gauge Aluminum.

A valid Strike Wire Feed Speed MUST be configured in order for the system tofeed 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 thewelding 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 BURNBACKstate 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 thewire feeding is stopped. The configuration of the BURNBACK time is highlyapplication specific and is dependent on welding wire feed speed and stickout. Avalue of zero disables the BURNBACK state.

2.6.4 Postflow time (milliseconds)

Sets the time that the Weld Sequencer object will remain in the POSTFLOWstate. POSTFLOW is the time period between the Welding Output beingdisabled by the Weld Sequencer Object and returning to the IDLE state. A valueof zero disables the POSTFLOW state.

7Strike 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.


12/21


3 DeviceNet

3.1 DeviceNet ConfigurationThe DeviceNet Configuration parameters are used to configure the PowerWaves critical DeviceNet network parameters and define how it responds tochanges in command values that are passed to it. The DeviceNet Configurationdialog is accessible from the DeviceNet | Configuration menu and is onlyavailable when a DeviceNet module is detected9.

3.1.1 DeviceNet Communication - MAC ID

This field indicates the current configuration of the Power Waves DeviceNetMAC ID. This value will only change if the DIP switches on the Power WavesDeviceNet interface boards are configured to allow retrieval of the MAC ID fromEEPROM memory. If this value is altered, the Power Wave must be reset (cyclepower) in order for the change to become effective.

9See Power Wave instruction manual or DeviceNet Interface Specification (Y50031) for configuration

details.


13/21


3.1.2 DeviceNet Communication - Baud Rate

This field indicates the current configuration of the Power Waves DeviceNetBaud Rate. This value will only change if the DIP switches on the Power WavesDeviceNet interface boards are configured to allow retrieval of the Baud Ratefrom 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 threeanalog 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 maydither slightly, this configuration prevents unintended parameter changes. Thisattribute is not useful for command values whose source is completely digital andshould be set to 0. One exception is when the Power Wave has an AnalogInterface 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 willassign 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 systemexcept for the Weld Output disable bit and the Production Monitoring Fault Reset

bit.. Enable this when the DeviceNet connection is used only to monitor systemoperation.

3.1.6 System Control Restore settings from memory on reset

The DeviceNet board will automatically restore weld schedule values on power-up that are not accessible from a polled connection. These include Weld Mode,strike, restrike and cold inch wire feed speeds, and times for preflow, postflowand burnback. If the system contains an UI with memory a memory panel or arobot/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 thiswhen a DeviceNet master controls machine.

3.1.8 Workpoint Input

This indicates whether the values passed to the system through the analogDeviceNet channels for the Workpoint parameter are raw values or scaled

10Analog Input Masking and Analog Output configuration are available in DN Vendor Rev 1.008 and later.


14/21


engineering values. Selecting the Engineering Units option indicates thatscaled engineering values for Workpoint will be passed across the analogDeviceNet channel. For example when the workpoint is in Inches/per Minute andscaled engineering units are used, then a value of 50 to 800 might be expectedto 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 Valuesoption is selected, the commands for Workpoint range from 0 to 32767corresponding to the minimum and maximum workpoint of the selected weldmode. 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 analogDeviceNet channels for the Trim and Wave Control parameters are raw values orscaled engineering values. Selecting the Engineering Units option indicatesthat scaled engineering value for Trim or Wave Control 1 will be passed acrossthe 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 expectedto be commanded on the DeviceNet analog input for the trim. This wouldrepresent a value of 7.5 to 52.0 volts. When the Unscaled Values option isselected, 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 ofapplications will require Trim and Wave Control command values to be set nearthe nominal value.

3.1.10 Report Trim/ Wave Outer Process Limits

When the Trim and Wave are being reported in Engineering Units and theseinputs 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 aremeet, then checking this box will have the absolute high and low limit always bereturned, unchecking the box will have the returned limits be based on theworkpoint. As the workpoint changes, the acceptable range that the trim andwaves can be in will change as well, unchecking this box will have the limitsreport 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 thenumber the more often the feedback is updated, but higher the system load onthe 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 isusually used unless Through the Arc Seam Tracking is being done, then this itemis usually set to a value of around 75.


15/21


3.1.13 Analog Scans Between Updates

This determines how often the analog input channels (workpoint, trim, and wavecontrol) update the system in terms of Polled I/O scans. For example a value of50 means that every 50th I/O scan will be accepted. The setting of this itemdepends 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 systemswith very low scan rates, such as 10hz then the setting as low as 2 might beneeded. Once a DeviceNet connection has been established, see IO Scans/Secitem in the DeviceNet monitor screen in Observer for the current scan rate. Notethat 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 thewire. This value is used for either cold inching forward (Jog +) or cold inchingreverse (Jog -). This value is in units of IPM. A value of 0 will cause the wire toinch 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 eventlog. These events may be generated during normal operation when power isapplied to or removed from the system. These boxes should be left uncheckedunless troubleshooting the system.


16/21


3.2 DeviceNet MonitorThe DeviceNet Monitor interprets command input and feedback passing throughthe DeviceNet module. This is a troubleshooting tool for those customersimplementing a DeviceNet connection to the Power Wave. This dialog isaccessed from the DeviceNet | Monitor menu and is only available when a

DeviceNet module is detected. Refer to Y50031-xx Device Net InterfaceSpecification for more information on these items.


17/21


3.3 DeviceNet TraceThe DeviceNet Trace displays low-level communication passing through theDeviceNet module. This is a troubleshooting tool for those customersimplementing a DeviceNet connection to the Power Wave. This dialog isaccessed from the DeviceNet | Trace menu and is only available when a

DeviceNet module is detected.

4 Observer PreferencesObserver operation is determined by the settings in the Preferences dialogaccessible from the File | Preferences menu. The default settings (shown below)

assume the machine will be controlled via a DeviceNet module. Only thosecontrols that cannot be set with a polled DeviceNet connection are displayed.


18/21


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 themain Observer screen. These controls configure sequencememory not available through a polled DeviceNetconnection. See Additional Weld Schedule Variables fordetails.

4.1.3 General Show Trigger ButtonWhen checked, a Trigger control is visible on the mainscreen. This button allows triggering the machine throughthe Observer program. To turn on welding output, hold the

CTRL key while clicking the button while the output is off. Clicking the buttonwhen output is on will turn the trigger off.

4.1.4 General Show Weld Statistics

When checked, arc statistics for the last weld become visibleon 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 averagecurrent and voltage readings and should be used forreference only.

4.1.5 General Enable Workpoint/Trim Controls

When checked, the edit boxes for Workpoint, Trim and Wave Controls becomeactive 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 Enterkey. This value will remain valid until a new value is received through theDeviceNet Network or entered into the variable field.

NOTE: This box must be checked to activate Weld Control screen in thePreferences dialog.


19/21


4.2 Observer Preferences Weld Control

4.2.1 Weld Control

This screen determines which sequence

states are updated when a new value isentered in the associated edit box.Typically, all states shown in red shouldbe be set11. Checking Use Strike WFSfor Restrike WFS will update theRestrike state when new values for StrikeWFS are entered.

NOTE: Hovering over each control willdisplay the associated sequencer state ina tool-tip window.

11Observer 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.


20/21


4.3 Observer Preferences Graphs

4.3.1 Observer may connect to severalmachines simultaneously. Current fromeach machine may be displayed

graphically as individual waveformsand/or as a composite sum. Volts andWire Feed Speed graphs displaywaveforms from all machines.

4.3.2 Select whether the AMPSreadout shows the composite currentfrom all machines or the individualcontribution of the highlightedconnection. Voltage and WFS readoutsalways display values from the selected

machine connection.

4.3.3 Click on a color square tocustomize graph colors.


21/21


5 HelpObserver includes an About Box that lists program revisionparticulars. The System Info dialog provides details aboutthe Power Wave hardware and software. If problems arise,this information will be crucial to help solve them.

Documents

PowerWave Observer