Lincoln Electric IM649 manual

Wave Des igne r T M SOFTW ARE OPERA T OR’S MANU AL IM649 May, 1999 Safety Depends on You Lincoln arc welding and cutting equipment is designed and built with safety in mind. However, your overall safety can be increased by proper installation ... and thought- ful operation on your part. DO NOT INSTALL, OPERATE OR REPAIR THIS EQUIPMENT WITHOUT REA[...]

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WAVE DESIGNER i T ABLE OF CONTENTS Page License Information ..................................................................................................... ii Introduction .................................................................................................... Section 1 1.1 Product Overview ........................................[...]

By clicking the acceptance button or installing the software, you are consenting to be bound by and are becoming a party to this agreement. If you do not agree to all of the terms of this agreement, click the button that indicates you do not accept the terms and do not install the software. (If applicable, you may return the product to the place of[...]

JAVA RUNTIME ENVIRONMENT, VERSION 1.1.6, BINARY CODE LICENSE This binary code license ("License") contains rights and restrictions associated with use of the accompanying Java Runtime Environment software and documentation ("Software"). Read the License carefully before using the Software. By using the Software you agree to the [...]

iv iv LICENSE INFORMA TION WAVE DESIGNER[...]

1.1 PR ODUCT O VER VIEW Wave Designer is a visual, interactive software application used to modify wave shapes for use with programmable waveform-controlled welding machines such as the Power Wave 455. The Wave Designer software package includes a standard set of waveforms commonly used in commercial and industrial welding applications. The Wave De[...]

In Windows NT 4.0 log on as Administrator Start | Settings | Control Panel | System | Performance Virtual Memory Change... | Initial Size (MB): 100 | Set | OK Do you want to restart your computer now? Yes An RS-232 serial communication cable is required to use Wave Designer software with Power Wave power sources. The Power Wave requires an RS-232 D[...]

2.1 FILE ST ORA GE LOCA TIONS The Wave Designer default home directory is C:Program FilesWaveDesigner. Subdirectories included with Wave Designer are as follows: • arcScope - user data file for ArcScope traces ( Wave Designer Pro option only) • bin - system executables and support files, do not tamper with these files • export - user wavefo[...]

FIGURE 2-1. WAVE DES IGNER STARTUP SCREEN. 2-2 Section 2 SOFTW ARE INST ALLA TION WAVE DESIGNER Lincoln Electric Wave Designer Version 1.0 Copyright © 1998 The Lincoln Electric Company All Rights Reserved United States Patent Pending Comments? Write to wavedesigner@lincolnelectric.com Initializing ... Please wait 27850002 Wave Designer WARNING: Th[...]

Section 2 2-3 SOFTW ARE INST ALLA TION WAVE DESIGNER SW1 SW2 1 1 2 2 3 3 4 4 5 5 6 6 7 7 8 8 ON ON CONTROL BOX CONTROL BOARD 27850003 FRONT PA N E L POWER SOURCE RS232 CABLE COMPUTER SYSTEM 27850004 FIGURE 2-2. CONTROL BOARD DIP SWITCH SETTING. FIGURE2-3. INTERFACE CONNECTION. PLEASE NOTE: Some IBM ThinkPads® by default have the serial port disabl[...]

2.4 EQUIPMENT/SOFTW ARE ST ARTUP When the Wave Designer software installation is complete, Wave Designer is listed among the programs you can start up from the Windows startup screen. Click on START, point to the programs option, then click on the Wave Designer option. The Wave Designer Welcome screen is displayed followed by the Pulse Waveform Edi[...]

3.1 SYNERGIC WELDING AND WORKPOINTS Prior to using Wave Designer it is important to have a good understanding of the concepts of synergic welding and workpoints. Synergic welding is basically “one knob control” of a welding process; all other variables of the process are adjusted by the power source based on the single controlling variable. Thi[...]

3.2 W ORKING IN WAVE DESIGNE R 3.2.1 W A VEFORM EDIT OR WINDO W Refer to the Waveform Editor window in Figure 3-2 and the related usage instructions. FIGURE 3-2. WAVEFORM EDITOR WINDOW. 3-2 Section 3 SOFTW ARE OPERA TION WAVE DESIGNER Pulse Waveform Editor Wire Feed Speed Ramp Up Rate Peak Amps Peak Time ms Tailout Time Tailout Speed Stepoff Amps B[...]

Section 3 3-3 SOFTW ARE OPERA TION WAVE DESIGNER 5. Optional Windows The optional window buttons open additional windows used during wave shaping. Optional windows in the pulse Waveform Editor include Start, Adapt, Short, End, and About. Details about the use of most optional windows is covered in the applicable appendix (i.e. Appendix A for Pulse [...]

3-4 Section 3 SOFTW ARE OPERA TION WAVE DESIGNER 3.2.2 W A VEFORM EDIT OR T OOL BAR There are four menu selections available on the pulse waveform editor tool bar. The following describes how to use the File, Tools, and Print menus. The Help menu is self explanatory. 3.2.2.1 FILE MENU The File menu provides options for accessing and managing wavefo[...]

3.2.2.2 TOOLS MENU The Tools menu includes waveform display options and other tools required to operate Wave Designer . The Tools menu options include the following: Pulse Editor Ctrl+P Display the Pulse Waveform Editor screen. STT Editor Ctrl+E Display the STT Waveform Editor screen. Simplify Editor Display the primary wave shaping parameters only[...]

3.2.2.3 PRINT MENU Print menu options enable you to print out a waveform display, ArcScope screen, or tabular waveform data listing as shown below. The Print menu options include the following: 3-6 Section 3 SOFTW ARE OPERA TION WAVE DESIGNER Wave Designer Pro Waveform Editor Printed on Thu Jul 09 07:24:50 EDT 1998 ..systemWeldFilepulse.swf For W[...]

3.2.3 EDITING AND SELECTING W ORKPOINTS For each custom welding application, unique wave shapes are developed for specific workpoints within the range of workpoints defined for the application. In Wave Designer the range of workpoints and the specific workpoint values are defined in a Workpoint Editor window. After the workpoints are defined, we us[...]

3.2.3.1 EDITING W ORKPOINTS Clicking on the Edit button in the waveform Editor window opens a Workpoint Editor window. The Workpoint Editor window displays a listing of workpoints for the selected standard waveform. Use the Workpoint Editor window according to the following descriptions and guidelines: • Each workpoint value must be equal to or g[...]

3.2.3.2 SELECTING W ORKPOINTS Clicking on the workpoint display box in the waveform Editor window opens a Workpoint pulldown menu. The pulldown menu displays the listing of workpoints defined for the active waveform. Use the pulldown menu according to the following descriptions and guidelines: • Click on any one of the listed workpoints to access[...]

3.2.4 EDITING V ARIABLE P ARAMETERS The following is a summary of the different methods available for changing (editing) parameter values on the Waveform Editor screen and other display screens accessible through Wave Designer . Read the following information carefully before making parameter changes on the Waveform Editor screen. • The variable [...]

Section 3 3-11 SOFTW ARE OPERA TION WAVE DESIGNER 3.3 W A VE DESIGN PROCESS The wave design process is a series of operations that allows you to quickly modify a standard waveform to fit your specific welding application. The following process flowchart applies to a pulse waveform, but is similar to the process used to modify STT and other waveform[...]

3-12 Section 3 SOFTW ARE OPERA TION WAVE DESIGNER 3.4 DO WNLO ADING W A VE SHAPES The Power Wave stores wave shapes in the welding machine controller memory. The memory structure does not allow an upload or download of individual wave shapes. When downloading wave shapes to the welding machine, the entire welding machine memory must be overwritten.[...]

Section 3 3-13 SOFTW ARE OPERA TION WAVE DESIGNER 2. Select a blank Mode or a defined Mode for overwrite by clicking on a box to the left of the Modes listing. When the Mode is selected, a checkmark appears in the Mode box. 3. Enter the file name of the desired waveform in the box to the right of the selected Mode number. Click on the Choose button[...]

3-14 Section 3 SOFTW ARE OPERA TION WAVE DESIGNER[...]

4.1 INTR ODUCTION The following describes the ArcScope application included with Wave Designer Pro . The ArcScope application provides oscilloscope type displays of power source output waveforms on your computer monitor. 4.1.1 USING THE ARC SCOPE WINDO W Refer to the ArcScope window in Figure 4-1 and the related window usage instructions. FIGURE 4-[...]

6. Status Bar The status bar provides a scrolled listing of recent Wave Designer program operations, error conditions, etc., and three operational status indicators. The adaptive indicator is also a button that toggles between the Adaptive and Non-Adaptive mode. 7. Graphical Display Area The graphical display provides refreshed displays of the sele[...]

File | Save Scope: Use the Save Scope option to save the scope trace data in ASCII text format for use in a word editor or spreadsheet data processing application. File | Open Scope Trace: Use the Open Scope Trace option to open a saved scope trace data file. Section 4 4-3 ARCSCOPE WAVE DESIGNER File Open Waveform Ctrl+O Ctrl+S Ctrl+Q Save Waveform[...]

4-4 Section 4 ARCSCOPE WAVE DESIGNER[...]

5.1 O VER VIEW Wave Designer troubleshooting is limited to the software application. If the welding machine does not respond, recheck the interface connection and communication setup requirements in section 2 of this manual. Refer to the welding machine service manuals for troubleshooting suspected equipment malfunctions. 5.2 WAVE D ESIGNER TR OUBL[...]

5-2 Section 5 TR OUBLESHOO TING WAVE DESIGNER[...]

A.1 APPENDIX O VER VIEW This appendix provides a series of discussions on pulse wave shaping principles and the development of custom GMAW pulse waveforms. The contents of this appendix are arranged as follows: Paragraph No./Title Contents Description A.2 GMAW Pulse Overview How the pulse waveform transfers weld droplets to the weld surface A.3 Ada[...]

A-2 Appendix A PULSE W A VE SHAPING PRINCIPLES WAVE DESIGNER Pulse Waveform Editor Wire Feed Speed Ramp Up Rate Peak Amps Peak Time ms Tailout Time Tailout Speed Stepoff Amps Backgrd Amps Backgrd Time Frequency Ramp Overshoot % 26.4 33.4 21 40 .100 3.0 1.2 250 -20 600 Edit Start About Adapt Short End Wave Designer Pro Off Line - pulse.swf 700 600 5[...]

Appendix A A-3 PULSE W A VE SHAPING PRINCIPLES WAVE DESIGNER • From time T1 to T2: Background current maintains an arc, and a weld bead starts to form. • From time T2 to T3: Ramp-up current forms the weld droplet at the tip of the electrode. • From time T3 to T4: Peak current and peak time separate the droplet and propel it toward the weld su[...]

A.3 AD APTIVE AND NON-AD APTIVE MODE To proficiently develop welding procedures using Wave Designer , the key concept of Adaptive versus Non-Adaptive welding must be understood. Wave Designer allows the user to set the machine into either adaptive or non-adaptive mode. During the wave design process both modes will be used depending upon the step. [...]

A.4 PULSE W A VE DESIGN PROCESS The Wave Designer software interfaces with the welding machine controller to permit real time communication of pulse wave design changes. Refer to paragraph 2.3 for equipment interface connections. Use the following wave design process to customize a standard wave shape. The process is summarized in the following flo[...]

A.4.1 SELECTING A ST ARTING W A VE SHAPE When customizing a waveform for a specific welding application, we recommend that you use a waveform in an existing weld file. An existing weld file can be selected from the systemWeldFiles folder in the Wave Designer directory as follows: a. Click on a standard wave shape from the systemWeldFiles folder. Us[...]

NOTE: You can edit one or more workpoints to values other than the defaults. However, the listing of wire feed speeds displayed must be the same or increasing from top to bottom. All twelve wire feed speeds must be assigned values, but multiple workpoints can share the same value. The reason you would edit multiple workpoints to the same value woul[...]

2. Open the Adaptive Loop / Find the Optimal Ar c Characteristics Use the following weld trials and adjustment sequence to tune the selected waveform for your weld application at the designated workpoint (wire feed speed). Weld trials and adjustments are more easily performed with one person welding while you adjust the waveform parameters at the c[...]

3. Close the Adaptive Loop / Adjust the P eak V oltage a. If the adaptive stickout window is not open, click on the button to open the window. Select the adaptive option to close the adaptive loop. Verify that the adaptive button lights up. NOTE: When on-line with the adaptive loop closed, the wave shape parameters will be adapted (change) to maint[...]

5. Adjust the Start Control P arameters (Optional) The start control parameters can be adjusted to define how the welding machine will respond when the arc is struck. To view the start control window, click on the button on the Waveform Editor screen. Adjust the start control parameters to accommodate your welding application and per the following [...]

6. Adjust the Shorting Control P arameters (Optional) The shorting control parameters can be adjusted to define how the welding machine will respond when the arc shorts to the weld puddle. To view the shorting control window, click on the button on the Waveform Editor screen. Adjust the shorting control parameters to accommodate your welding applic[...]

7. Adjust the End Condition P arameters (Optional) The end condition parameters can be adjusted to define how the welding machine will respond at the end of a weld application. To view the end condition window, click on the button on the Waveform Editor screen. Adjust the end condition parameters to accommodate your welding application and per the [...]

8. “Go Figure” / Make the W avef orm Synergic Weld synergy is established by shaping the 2nd and all subsequent workpoints. Being synergic, the waveform parameters automatically adjust to programmed data table values. The data table values are unique for selected wire feed speeds. Thereby, the output of the power source changes in response to c[...]

A.5 PRIMAR Y PULSE W A VEFORM COMPONENTS The following paragraphs describe how peak current, peak time, frequency, and background current effect weld droplet transfer. A.5.1 PEAK CURRENT AND PEAK TIME A combination of peak current and peak time, Figure A-6, applies a force to detach the weld droplet from the electrode and propel it across the arc. [...]

A.5.2 FREQUENCY Frequency, Figure A-7, is the number of pulses per second or, in theory, the number of weld droplets per second. Since increasing the frequency generates more pulses in a given time period, higher frequencies generate higher average current levels. FIGURE A-7. FREQUENCY. Appendix A A-15 PULSE W A VE SHAPING PRINCIPLES WAVE DESIGNER [...]

A.6 SECOND AR Y W A VEFORM P ARAMETERS A.6.1 RAMP-UP RA TE The ramp-up rate is the speed of current climb from the background current level to the peak current level. Faster ramp-up rates tend to produce a plasma plume that quickly surrounds the end of the next droplet. A.6.2 RAMP O VERSHOO T % The ramp overshoot % can be set from -100% to +100% of[...]

A.7 APPLICA TION EXERCISE This application exercise steps the user through the development of a basic PowerWave welding program using Wave Designer . Your application most likely will vary from this example but the concepts outlined are recommended for all development work. If you would like to follow along with this example, use the following set [...]

Our Experiment: We found multiple droplet detachment with an arc length that was too long at these waveform settings. To attain the proper droplet detachment, we reduced the peak current value to 250 amps and found improved weld droplet transfer. But reducing the peak current also caused the arc to be shorter. Then we needed to lengthen the arc. We[...]

7. Click on the button to display the WorkPoint Editor window. Check only those wire feed speed points that have been developed (only 150 in/min. at this point). The WorkPoint Editor can also be used to change the wire feed speed value of a workpoint. Workpoints can have the same value but must be in numerical order. Select the button to set the wa[...]

A-20 Appendix A PULSE W A VE SHAPING PRINCIPLES WAVE DESIGNER 8. For a second workpoint we went to 300 in/min. Select the 300 in/min. wire feed speed from the pulldown menu in Waveform Editor window. Reset the PowerFeed for 300 in/min. with a 1.00 trim. 9. Open the adapting stickout window and select the ‘No Adapt’ mode; close the window. 10. A[...]

Appendix A A-21 PULSE W A VE SHAPING PRINCIPLES WAVE DESIGNER 12. Open the “Edit” screen and select only those workpoints that have been developed (150 and 300 in/min.). Select the button to interpolate the remaining workpoints. The function gives a estimation of the values needed for the other wire feed speeds. Each useable workpoint should be[...]

A-22 Appendix A PULSE W A VE SHAPING PRINCIPLES WAVE DESIGNER[...]

B.1 APPENDIX O VER VIEW This appendix provides a series of discussions on STT wave shaping principles and the development of custom STT waveforms. The contents of this appendix are arranged as follows: Paragraph No./Title Contents Description B.2 STT Overview How the STT waveform transfers weld droplets to the weld surface B.3 STT (Surface Tension [...]

B-2 Appendix B STT W A VE SHAPING PRINCIPLES WAVE DESIGNER STT Waveform Editor Wire Feed Speed Peak Amps Tailout Speed Pinch Start Pinch | Peak Peak Time dV | dt detect Backgrd Amps 14.00 1.0 .70 140 Edit Start About Explain Wave Designer Pro Off Line - stt.swf 500 400 300 200 100 0 012 3 4567891 0 File Tools Print Help      ?[...]

Appendix B B-3 STT W A VE SHAPING PRINCIPLES WAVE DESIGNER 27850060 BA CKGROUND AMPS PINCH AMPS PEAK AMPS TA I L O U T T 1 T 2 T 3 T 5 T 6 T 7 T 0 FIGURE B-2. WELD DROPLET TRANSFER. • From time T 0 to T 1 : Background current is a steady-state current level, between 50 and (Background Current) 100 Amps that maintains an arc to form a weld bead. ?[...]

B.3 STT (SURF A CE TENSION TRANSFER) The Invertec STT power source is a high-frequency, current-controlled machine that delivers power to the arc based on immediate arc requirements. The Invertec STT produces large electrode current changes within microseconds. It operates in the short-circuiting welding mode. The electrode current supplied by the [...]

T 2 – T 3 The pinch mode applies an increasing, dual-slope ramp of current to the shorted electrode. The dual slope ramp of current accelerates the transfer of molten metal by the electric pinch forces. The pinch force is directly proportional to the square of the pinch current. T 3 – T 5 dV/dt is the rate of shorted-electrode voltage change pe[...]

B.4 STT W A VE DESIGN PROCESS The Wave Designer software interfaces with the welding machine controller to permit real time communication of STT wave design changes. Refer to paragraph 2.3 for equipment interface connections. Use the wave design process to customize a standard wave shape. The process is summarized in Figure B-4. The flowchart is fo[...]

B.4.1 SELECTING A ST ARTING W A VE SHAPE When customizing a waveform for a specific welding application, we recommend that you use a waveform in an existing weld file. An existing weld file can be selected from the systemWeldFiles folder in the Wave Designer directory as follows: a. Click on a standard wave shape from the systemWeldFiles folder. Us[...]

NOTE: You can edit one or more workpoints to values other than the defaults. However, the listing of wire feed speeds displayed must be the same or increasing from top to bottom. All four wire feed speeds must be assigned values, but multiple workpoints can share the same value. The reason you would edit multiple workpoints to the same value would [...]

2. Find the Optimal Ar c Characteristics Use the following weld trials and adjustment sequence to tune the selected waveform for your weld application at the designated workpoint (wire feed speed). Weld trials and adjustments are more easily performed with one person welding while you adjust the waveform parameters at the computer terminal. a. Set [...]

3. Adjust the Start Control P arameters (Optional) The start control parameters can be adjusted to define how the welding machine will respond when the arc is struck. To view the start control window, click on the button on the Waveform Editor screen. Adjust the start control parameters to accommodate your welding application and per the following [...]

4. “Go Figure” / Make the W avef orm Synergic Weld synergy is established by shaping the 2nd and all subsequent workpoints. Being synergic, the waveform parameters automatically adjust to programmed data table values. The data table values are unique for selected wire feed speeds. Thereby, the output of the power source changes in response to c[...]

B.5 PRIMAR Y STT W A VEFORM COMPONENTS The following paragraphs describe how peak current, background current, and tailout effect weld droplet transfer. B.5.1 PEAK CURRENT The peak current control acts similar to an “arc pinch” control. Peak current serves to establish the arc length and promote good fusion. Higher peak current levels will caus[...]

B.5.3 T AILOUT The tailout provides additional heat without the molten droplet becoming too large. Increase tailout as needed to add heat to the arc without increasing arc length. (This will allow for faster travel speeds and improved wetting). As tailout is increased, the peal and/or background current is usually reduced. Appendix B B-13 STT W A V[...]

B.6 SECOND AR Y STT W A VEFORM COMPONENTS NOTE: The Invertec STT power source circuitry automatically establishes proper values for most primary and secondary waveform components. The values can be adjusted, but should not be set far from their automatically set values. B.6.1 PINCH ST ART The pinch start is the amperage setting that begins the ramp[...]

STT W A VE SHAPING PRINCIPLES WAVE DESIGNER B.7 APPLICA TION EXERCISE This application exercise steps the user through the development of a basic PowerWave/STT welding program using Wave Designer . Your application most likely will vary from this example but the concepts outlined are recommended for all development work. If you would like to follow[...]

2. Pick a wire feed speed from the Wire Feed Speed pulldown menu. We wanted to start with a 130 in/min. WFS. But 130 is not a workpoint in the selected wave shape application. Use the Workpoint Editor window to change the second workpoint (170 in/min.) to 130. 3. Select 130 from the Wire Feed Speed pulldown menu. Also, be sure to set the PowerFeed?[...]

A Adaptive Loop .......................................................................................................... A-4 Adaptive Types ........................................................................................................ A-9 Adaptive and Non-Adaptive Mode ....................................................................[...]

M Making the Waveform Synergic .............................................................................. A-13 O Open Circuit Voltage ................................................................................................ A-10 Operation, Software ..........................................................................................[...]

U Upgrade Firmware .................................................................................................. 2-5 User Responsibility .................................................................................................. 1-1 V Voltage, Arc Reestablish ..............................................................................[...]

INDEX Index-4 WAVEDESIGNER[...]