Y50056-2

Production Monitoring™ 2.1 User Manual

FOR ENGINEpowered equipment.

1.a. Turn the engine off before troubleshooting and maintenancework unless the maintenance work requires it to be running.

____________________________________________________1.b. Operate engines in open, well-ventilated

areas or vent the engine exhaust fumesoutdoors.

____________________________________________________1.c. Do not add the fuel near an open flame

welding arc or when the engine is running.Stop the engine and allow it to cool beforerefueling to prevent spilled fuel from vaporiz-ing on contact with hot engine parts andigniting. Do not spill fuel when filling tank. Iffuel is spilled, wipe it up and do not startengine until fumes have been eliminated.

____________________________________________________1.d. Keep all equipment safety guards, covers and devices in

position and in good repair.Keep hands, hair, clothing andtools away from V-belts, gears, fans and all other movingparts when starting, operating or repairing equipment.

____________________________________________________

1.e. In some cases it may be necessary to remove safetyguards to perform required maintenance. Removeguards only when necessary and replace them when themaintenance requiring their removal is complete.Always use the greatest care when working near movingparts.

___________________________________________________1.f. Do not put your hands near the engine fan.

Do not attempt to override the governor oridler by pushing on the throttle control rodswhile the engine is running.

___________________________________________________1.g. To prevent accidentally starting gasoline engines while

turning the engine or welding generator during maintenancework, disconnect the spark plug wires, distributor cap ormagneto wire as appropriate.

iSAFETYi

ARC WELDING CAN BE HAZARDOUS. PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY OR DEATH.KEEP CHILDREN AWAY. PACEMAKER WEARERS SHOULD CONSULT WITH THEIR DOCTOR BEFORE OPERATING.

Read and understand the following safety highlights. For additional safety information, it is strongly recommended that youpurchase a copy of “Safety in Welding & Cutting - ANSI Standard Z49.1” from the American Welding Society, P.O. Box351040, Miami, Florida 33135 or CSA Standard W117.2-1974. A Free copy of “Arc Welding Safety” booklet E205 is availablefrom the Lincoln Electric Company, 22801 St. Clair Avenue, Cleveland, Ohio 44117-1199.

BE SURE THAT ALL INSTALLATION, OPERATION, MAINTENANCE AND REPAIR PROCEDURES AREPERFORMED ONLY BY QUALIFIED INDIVIDUALS.

WARNING

Mar ʻ95

ELECTRIC ANDMAGNETIC FIELDSmay be dangerous

2.a. Electric current flowing through any conductor causeslocalized Electric and Magnetic Fields (EMF). Weldingcurrent creates EMF fields around welding cables andwelding machines

2.b. EMF fields may interfere with some pacemakers, andwelders having a pacemaker should consult their physicianbefore welding.

2.c. Exposure to EMF fields in welding may have other healtheffects which are now not known.

2.d. All welders should use the following procedures in order tominimize exposure to EMF fields from the welding circuit:

2.d.1. Route the electrode and work cables together - Securethem with tape when possible.

2.d.2. Never coil the electrode lead around your body.

2.d.3. Do not place your body between the electrode andwork cables. If the electrode cable is on your rightside, the work cable should also be on your right side.

2.d.4. Connect the work cable to the workpiece as close aspossible to the area being welded.

2.d.5. Do not work next to welding power source.

1.h. To avoid scalding, do not remove theradiator pressure cap when the engine ishot.

CALIFORNIA PROPOSITION 65 WARNINGSDiesel engine exhaust and some of its constituentsare known to the State of California to cause can-cer, birth defects, and other reproductive harm.

The engine exhaust from this product containschemicals known to the State of California to causecancer, birth defects, or other reproductive harm.

The Above For Diesel Engines The Above For Gasoline Engines

ARC RAYS can burn.4.a. Use a shield with the proper filter and cover

plates to protect your eyes from sparks andthe rays of the arc when welding or observingopen arc welding. Headshield and filter lensshould conform to ANSI Z87. I standards.

4.b. Use suitable clothing made from durable flame-resistantmaterial to protect your skin and that of your helpers fromthe arc rays.

4.c. Protect other nearby personnel with suitable, non-flammablescreening and/or warn them not to watch the arc nor exposethemselves to the arc rays or to hot spatter or metal.

ELECTRIC SHOCK cankill.3.a. The electrode and work (or ground) circuits

are electrically “hot” when the welder is on.Do not touch these “hot” parts with your bareskin or wet clothing. Wear dry, hole-free

gloves to insulate hands.

3.b. Insulate yourself from work and ground using dry insulation.Make certain the insulation is large enough to cover your fullarea of physical contact with work and ground.

In addition to the normal safety precautions, if weldingmust be performed under electrically hazardousconditions (in damp locations or while wearing wetclothing; on metal structures such as floors, gratings orscaffolds; when in cramped positions such as sitting,kneeling or lying, if there is a high risk of unavoidable oraccidental contact with the workpiece or ground) usethe following equipment:

• Semiautomatic DC Constant Voltage (Wire) Welder.• DC Manual (Stick) Welder.• AC Welder with Reduced Voltage Control.

3.c. In semiautomatic or automatic wire welding, the electrode,electrode reel, welding head, nozzle or semiautomaticwelding gun are also electrically “hot”.

3.d. Always be sure the work cable makes a good electricalconnection with the metal being welded. The connectionshould be as close as possible to the area being welded.

3.e. Ground the work or metal to be welded to a good electrical(earth) ground.

3.f. Maintain the electrode holder, work clamp, welding cable andwelding machine in good, safe operating condition. Replacedamaged insulation.

3.g. Never dip the electrode in water for cooling.

3.h. Never simultaneously touch electrically “hot” parts ofelectrode holders connected to two welders because voltagebetween the two can be the total of the open circuit voltageof both welders.

3.i. When working above floor level, use a safety belt to protectyourself from a fall should you get a shock.

3.j. Also see Items 6.c. and 8.

FUMES AND GASEScan be dangerous.5.a. Welding may produce fumes and gases

hazardous to health. Avoid breathing thesefumes and gases. When welding, keepyour head out of the fume. Use enoughventilation and/or exhaust at the arc to keep

fumes and gases away from the breathing zone. Whenwelding with electrodes which require specialventilation such as stainless or hard facing (seeinstructions on container or MSDS) or on lead orcadmium plated steel and other metals or coatingswhich produce highly toxic fumes, keep exposure aslow as possible and below Threshold Limit Values (TLV)using local exhaust or mechanical ventilation. Inconfined spaces or in some circumstances, outdoors, arespirator may be required. Additional precautions arealso required when welding on galvanized steel.

5. b. The operation of welding fume control equipment is affectedby various factors including proper use and positioning ofthe equipment, maintenance of the equipment and the spe-cific welding procedure and application involved. Workerexposure level should be checked upon installation andperiodically thereafter to be certain it is within applicableOSHA PEL and ACGIH TLV limits.

5.c. Do not weld in locations near chlorinated hydrocarbon vaporscoming from degreasing, cleaning or spraying operations.The heat and rays of the arc can react with solvent vapors toform phosgene, a highly toxic gas, and other irritating prod-ucts.

5.d. Shielding gases used for arc welding can displace air andcause injury or death. Always use enough ventilation,especially in confined areas, to insure breathing air is safe.

5.e. Read and understand the manufacturerʼs instructions for thisequipment and the consumables to be used, including thematerial safety data sheet (MSDS) and follow youremployerʼs safety practices. MSDS forms are available fromyour welding distributor or from the manufacturer.

5.f. Also see item 1.b.

AUG 06

iiSAFETYii

FOR ELECTRICALLYpowered equipment.

8.a. Turn off input power using the disconnectswitch at the fuse box before working onthe equipment.

8.b. Install equipment in accordance with the U.S. NationalElectrical Code, all local codes and the manufacturerʼsrecommendations.

8.c. Ground the equipment in accordance with the U.S. NationalElectrical Code and the manufacturerʼs recommendations.

CYLINDER may explodeif damaged.7.a. Use only compressed gas cylinders

containing the correct shielding gas for theprocess used and properly operatingregulators designed for the gas and

pressure used. All hoses, fittings, etc. should be suitable forthe application and maintained in good condition.

7.b. Always keep cylinders in an upright position securelychained to an undercarriage or fixed support.

7.c. Cylinders should be located:• Away from areas where they may be struck or subjected tophysical damage.

• A safe distance from arc welding or cutting operations andany other source of heat, sparks, or flame.

7.d. Never allow the electrode, electrode holder or any otherelectrically “hot” parts to touch a cylinder.

7.e. Keep your head and face away from the cylinder valve outletwhen opening the cylinder valve.

7.f. Valve protection caps should always be in place and handtight except when the cylinder is in use or connected foruse.

7.g. Read and follow the instructions on compressed gascylinders, associated equipment, and CGA publication P-l,“Precautions for Safe Handling of Compressed Gases inCylinders,” available from the Compressed Gas Association1235 Jefferson Davis Highway, Arlington, VA 22202.

Jan, 07

WELDING and CUTTINGSPARKS cancause fire or explosion.6.a. Remove fire hazards from the welding area.

If this is not possible, cover them to preventthe welding sparks from starting a fire.

Remember that welding sparks and hotmaterials from welding can easily go through small cracksand openings to adjacent areas. Avoid welding nearhydraulic lines. Have a fire extinguisher readily available.

6.b. Where compressed gases are to be used at the job site,special precautions should be used to prevent hazardoussituations. Refer to “Safety in Welding and Cutting” (ANSIStandard Z49.1) and the operating information for theequipment being used.

6.c. When not welding, make certain no part of the electrodecircuit is touching the work or ground. Accidental contactcan cause overheating and create a fire hazard.

6.d. Do not heat, cut or weld tanks, drums or containers until theproper steps have been taken to insure that such procedureswill not cause flammable or toxic vapors from substancesinside. They can cause an explosion even though they havebeen “cleaned”. For information, purchase “RecommendedSafe Practices for the Preparation for Welding and Cutting ofContainers and Piping That Have Held HazardousSubstances”, AWS F4.1 from the American Welding Society(see address above).

6.e. Vent hollow castings or containers before heating, cutting orwelding. They may explode.

6.f. Sparks and spatter are thrown from the welding arc. Wear oilfree protective garments such as leather gloves, heavy shirt,cuffless trousers, high shoes and a cap over your hair. Wearear plugs when welding out of position or in confined places.Always wear safety glasses with side shields when in awelding area.

6.g. Connect the work cable to the work as close to the weldingarea as practical. Work cables connected to the buildingframework or other locations away from the welding areaincrease the possibility of the welding current passingthrough lifting chains, crane cables or other alternate cir-cuits. This can create fire hazards or overheat lifting chainsor cables until they fail.

6.h. Also see item 1.c.

6.I. Read and follow NFPA 51B “ Standard for Fire PreventionDuring Welding, Cutting and Other Hot Work”, availablefrom NFPA, 1 Batterymarch Park,PO box 9101, Quincy, Ma022690-9101.

6.j. Do not use a welding power source for pipe thawing.

iiiSAFETYiii

PRÉCAUTIONS DE SÛRETÉPour votre propre protection lire et observer toutes les instructionset les précautions de sûreté specifiques qui parraissent dans cemanuel aussi bien que les précautions de sûreté générales suiv-antes:

Sûreté Pour Soudage A LʼArc1. Protegez-vous contre la secousse électrique:

a. Les circuits à lʼélectrode et à la piéce sont sous tensionquand la machine à souder est en marche. Eviter toujourstout contact entre les parties sous tension et la peau nueou les vétements mouillés. Porter des gants secs et sanstrous pour isoler les mains.

b. Faire trés attention de bien sʼisoler de la masse quand onsoude dans des endroits humides, ou sur un planchermetallique ou des grilles metalliques, principalement dansles positions assis ou couché pour lesquelles une grandepartie du corps peut être en contact avec la masse.

c. Maintenir le porte-électrode, la pince de masse, le câblede soudage et la machine à souder en bon et sûr étatdefonctionnement.

d.Ne jamais plonger le porte-électrode dans lʼeau pour lerefroidir.

e. Ne jamais toucher simultanément les parties sous tensiondes porte-électrodes connectés à deux machines à souderparce que la tension entre les deux pinces peut être letotal de la tension à vide des deux machines.

f. Si on utilise la machine à souder comme une source decourant pour soudage semi-automatique, ces precautionspour le porte-électrode sʼapplicuent aussi au pistolet desoudage.

2. Dans le cas de travail au dessus du niveau du sol, se protégercontre les chutes dans le cas ou on recoit un choc. Ne jamaisenrouler le câble-électrode autour de nʼimporte quelle partiedu corps.

3. Un coup dʼarc peut être plus sévère quʼun coup de soliel,donc:

a. Utiliser un bon masque avec un verre filtrant appropriéainsi quʼun verre blanc afin de se protéger les yeux du ray-onnement de lʼarc et des projections quand on soude ouquand on regarde lʼarc.

b. Porter des vêtements convenables afin de protéger lapeau de soudeur et des aides contre le rayonnement delʻarc.

c. Protéger lʼautre personnel travaillant à proximité ausoudage à lʼaide dʼécrans appropriés et non-inflammables.

4. Des gouttes de laitier en fusion sont émises de lʼarc desoudage. Se protéger avec des vêtements de protection libresde lʼhuile, tels que les gants en cuir, chemise épaisse, pan-talons sans revers, et chaussures montantes.

5. Toujours porter des lunettes de sécurité dans la zone desoudage. Utiliser des lunettes avec écrans lateraux dans leszones où lʼon pique le laitier.

6. Eloigner les matériaux inflammables ou les recouvrir afin deprévenir tout risque dʼincendie dû aux étincelles.

7. Quand on ne soude pas, poser la pince à une endroit isolé dela masse. Un court-circuit accidental peut provoquer unéchauffement et un risque dʼincendie.

8. Sʼassurer que la masse est connectée le plus prés possiblede la zone de travail quʼil est pratique de le faire. Si on placela masse sur la charpente de la construction ou dʼautresendroits éloignés de la zone de travail, on augmente le risquede voir passer le courant de soudage par les chaines de lev-age, câbles de grue, ou autres circuits. Cela peut provoquerdes risques dʼincendie ou dʼechauffement des chaines et descâbles jusquʼà ce quʼils se rompent.

9. Assurer une ventilation suffisante dans la zone de soudage.Ceci est particuliérement important pour le soudage de tôlesgalvanisées plombées, ou cadmiées ou tout autre métal quiproduit des fumeés toxiques.

10. Ne pas souder en présence de vapeurs de chlore provenantdʼopérations de dégraissage, nettoyage ou pistolage. Lachaleur ou les rayons de lʼarc peuvent réagir avec les vapeursdu solvant pour produire du phosgéne (gas fortement toxique)ou autres produits irritants.

11. Pour obtenir de plus amples renseignements sur la sûreté,voir le code “Code for safety in welding and cutting” CSAStandard W 117.2-1974.

PRÉCAUTIONS DE SÛRETÉ POURLES MACHINES À SOUDER ÀTRANSFORMATEUR ET ÀREDRESSEUR

1. Relier à la terre le chassis du poste conformement au code delʼélectricité et aux recommendations du fabricant. Le dispositifde montage ou la piece à souder doit être branché à unebonne mise à la terre.

2. Autant que possible, Iʼinstallation et lʼentretien du poste seronteffectués par un électricien qualifié.

3. Avant de faires des travaux à lʼinterieur de poste, la debranch-er à lʼinterrupteur à la boite de fusibles.

4. Garder tous les couvercles et dispositifs de sûreté à leurplace.

Mar. ʻ93

ivSAFETYiv

viivii SAFETY

Electromagnetic Compatibility (EMC)

ConformanceProducts displaying the CE mark are in conformity with European Community Council Directive of 3 May1989 on the approximation of the laws of the Member States relating to electromagnetic compatibility(89/336/EEC). It was manufactured in conformity with a national standard that implements a harmonizedstandard: EN 60974-10 Electromagnetic Compatibility (EMC) Product Standard for Arc Welding Equipment.It is for use with other Lincoln Electric equipment. It is designed for industrial and professional use.

IntroductionAll electrical equipment generates small amounts of electromagnetic emission. Electrical emission may betransmitted through power lines or radiated through space, similar to a radio transmitter. When emissionsare received by other equipment, electrical interference may result. Electrical emissions may affect manykinds of electrical equipment; other nearby welding equipment, radio and TV reception, numerical controlledmachines, telephone systems, computers, etc. Be aware that interference may result and extra precautionsmay be required when a welding power source is used in a domestic establishment.

Installation and UseThe user is responsible for installing and using the welding equipment according to the manufacturerʼsinstructions. If electromagnetic disturbances are detected then it shall be the responsibility of the user of thewelding equipment to resolve the situation with the technical assistance of the manufacturer. In some casesthis remedial action may be as simple as earthing (grounding) the welding circuit, see Note. In other cases itcould involve construction of an electromagnetic screen enclosing the power source and the work completewith associated input filters. In all cases electromagnetic disturbances must be reduced to the point wherethey are no longer troublesome.

Note: The welding circuit may or may not be earthed for safety reasons according to national codes.Changing the earthing arrangements should only be authorized by a person who is compe-tent to access whether the changes will increase the risk of injury, e.g., by allowing parallelwelding current return paths which may damage the earth circuits of other equipment.

Assessment of AreaBefore installing welding equipment the user shall make an assessment of potential electromagnetic prob-lems in the surrounding area. The following shall be taken into account:

a) other supply cables, control cables, signaling and telephone cables; above, below and adjacent to thewelding equipment;

b) radio and television transmitters and receivers;

c) computer and other control equipment;

d) safety critical equipment, e.g., guarding of industrial equipment;

e) the health of the people around, e.g., the use of pacemakers and hearing aids;

f) equipment used for calibration or measurement

g) the immunity of other equipment in the environment. The user shall ensure that other equipment beingused in the environment is compatible. This may require additional protection measures;

h) the time of day that welding or other activities are to be carried out.

L10093 3-1-96H

viiiviii SAFETY

Electromagnetic Compatibility (EMC)

The size of the surrounding area to be considered will depend on the structure of the building and otheractivities that are taking place. The surrounding area may extend beyond the boundaries of the premises.

Methods of Reducing Emissions

Mains SupplyWelding equipment should be connected to the mains supply according to the manufacturerʼs recommenda-tions. If interference occurs, it may be necessary to take additional precautions such as filtering of the mainssupply. Consideration should be given to shielding the supply cable of permanently installed welding equip-ment, in metallic conduit or equivalent. Shielding should be electrically continuous throughout its length. Theshielding should be connected to the welding power source so that good electrical contact is maintainedbetween the conduit and the welding power source enclosure.

Maintenance of the Welding EquipmentThe welding equipment should be routinely maintained according to the manufacturerʼs recommendations.All access and service doors and covers should be closed and properly fastened when the welding equip-ment is in operation. The welding equipment should not be modified in any way except for those changesand adjustments covered in the manufacturers instructions. In particular, the spark gaps of arc striking andstabilizing devices should be adjusted and maintained according to the manufacturerʼs recommendations.

Welding CablesThe welding cables should be kept as short as possible and should be positioned close together, running ator close to floor level.

Equipotential BondingBonding of all metallic components in the welding installation and adjacent to it should be considered.However, metallic components bonded to the work piece will increase the risk that the operator couldreceive a shock by touching these metallic components and the electrode at the same time. The operatorshould be insulated from all such bonded metallic components.

Earthing of the WorkpieceWhere the workpiece is not bonded to earth for electrical safety, not connected to earth because of its sizeand position, e.g., ships hull or building steelwork, a connection bonding the workpiece to earth may reduceemissions in some, but not all instances. Care should be taken to prevent the earthing of the workpieceincreasing the risk of injury to users, or damage to other electrical equipment. Where necessary, the connec-tion of the workpiece to earth should be made by a direct connection to the workpiece, but in some countrieswhere direct connection is not permitted, the bonding should be achieved by suitable capacitance, selectedaccording to national regulations.

Screening and ShieldingSelective screening and shielding of other cables and equipment in the surrounding area may alleviate prob-lems of interference. Screening of the entire welding installation may be considered for special applications.1

_________________________

1 Portions of the preceding text are contained in EN 60974-10: “Electromagnetic Compatibility (EMC) prod-uct standard for arc welding equipment.”

L10093 3-1-96H

WARNING

AVISO DEPRECAUCION

ATTENTION

WARNUNG

ATENÇÃO

Spanish

French

German

Portuguese

Japanese

Chinese

Korean

Arabic

READ AND UNDERSTAND THE MANUFACTURER’S INSTRUCTION FOR THIS EQUIPMENT AND THE CONSUMABLES TO BEUSED AND FOLLOW YOUR EMPLOYER’S SAFETY PRACTICES.

SE RECOMIENDA LEER Y ENTENDER LAS INSTRUCCIONES DEL FABRICANTE PARA EL USO DE ESTE EQUIPO Y LOSCONSUMIBLES QUE VA A UTILIZAR, SIGA LAS MEDIDAS DE SEGURIDAD DE SU SUPERVISOR.

LISEZ ET COMPRENEZ LES INSTRUCTIONS DU FABRICANT EN CE QUI REGARDE CET EQUIPMENT ET LES PRODUITS AETRE EMPLOYES ET SUIVEZ LES PROCEDURES DE SECURITE DE VOTRE EMPLOYEUR.

LESEN SIE UND BEFOLGEN SIE DIE BETRIEBSANLEITUNG DER ANLAGE UND DEN ELEKTRODENEINSATZ DES HER-STELLERS. DIE UNFALLVERHÜTUNGSVORSCHRIFTEN DES ARBEITGEBERS SIND EBENFALLS ZU BEACHTEN.

� Do not touch electrically live parts orelectrode with skin or wet clothing.

� Insulate yourself from work andground.

� No toque las partes o los electrodosbajo carga con la piel o ropa moja-da.

� Aislese del trabajo y de la tierra.

� Ne laissez ni la peau ni des vête-ments mouillés entrer en contactavec des pièces sous tension.

� Isolez-vous du travail et de la terre.

� Berühren Sie keine stromführendenTeile oder Elektroden mit IhremKörper oder feuchter Kleidung!

� Isolieren Sie sich von denElektroden und dem Erdboden!

� Não toque partes elétricas e elec-trodos com a pele ou roupa molha-da.

� Isole-se da peça e terra.

� Keep flammable materials away.

� Mantenga el material combustiblefuera del área de trabajo.

� Gardez à l’écart de tout matérielinflammable.

� Entfernen Sie brennbarres Material!

� Mantenha inflamáveis bem guarda-dos.

� Wear eye, ear and body protection.

� Protéjase los ojos, los oídos y elcuerpo.

� Protégez vos yeux, vos oreilles etvotre corps.

� Tragen Sie Augen-, Ohren- und Kör-perschutz!

� Use proteção para a vista, ouvido ecorpo.

WARNING

AVISO DEPRECAUCION

ATTENTION

WARNUNG

ATENÇÃO

Spanish

French

German

Portuguese

Japanese

Chinese

Korean

Arabic

LEIA E COMPREENDA AS INSTRUÇÕES DO FABRICANTE PARA ESTE EQUIPAMENTO E AS PARTES DE USO, E SIGA ASPRÁTICAS DE SEGURANÇA DO EMPREGADOR.

� Keep your head out of fumes.� Use ventilation or exhaust to

remove fumes from breathing zone.

� Los humos fuera de la zona de res-piración.

� Mantenga la cabeza fuera de loshumos. Utilice ventilación oaspiración para gases.

� Gardez la tête à l’écart des fumées.� Utilisez un ventilateur ou un aspira-

teur pour ôter les fumées des zonesde travail.

� Vermeiden Sie das Einatmen vonSchweibrauch!

� Sorgen Sie für gute Be- undEntlüftung des Arbeitsplatzes!

� Mantenha seu rosto da fumaça.� Use ventilação e exhaustão para

remover fumo da zona respiratória.

� Turn power off before servicing.

� Desconectar el cable de ali-mentación de poder de la máquinaantes de iniciar cualquier servicio.

� Débranchez le courant avant l’entre-tien.

� Strom vor Wartungsarbeitenabschalten! (Netzstrom völlig öff-nen; Maschine anhalten!)

� Não opere com as tampas removidas.� Desligue a corrente antes de fazer

serviço.� Não toque as partes elétricas nuas.

� Do not operate with panel open orguards off.

� No operar con panel abierto oguardas quitadas.

� N’opérez pas avec les panneauxouverts ou avec les dispositifs deprotection enlevés.

� Anlage nie ohne Schutzgehäuseoder Innenschutzverkleidung inBetrieb setzen!

� Mantenha-se afastado das partesmoventes.

� Não opere com os paineis abertosou guardas removidas.

02-28-11 1

Table of Contents

1 GENERAL INFORMATION ............................................................................................................................. 4

1.1 INTRODUCTION TO PRODUCTION MONITORING™ ............................................................................................ 4

1.1.1 Weld Profiles ......................................................................................................................................... 4 1.1.2 Weld Logging ......................................................................................................................................... 4 1.1.3 Email Capability .................................................................................................................................... 5 1.1.4 Part Traceability .................................................................................................................................... 5 1.1.5 WeldScore™ .......................................................................................................................................... 5

1.1.5.1 How WeldScore™ works ................................................................................................................................... 5 1.1.5.2 Where to Use WeldScore™ ............................................................................................................................... 6 1.1.5.3 What the Score Means ....................................................................................................................................... 6

1.2 PRODUCTION MONITORING™

2 ARCHITECTURE ............................................................................................. 6 1.3 REQUIREMENTS AND LIMITATIONS ................................................................................................................. 7

1.3.1 PC “Server” Requirements ................................................................................................................... 7 1.3.2 PC “Viewer” Requirements ................................................................................................................... 7 1.3.3 Power Wave® Requirements .................................................................................................................. 8 1.3.4 Network Requirements ........................................................................................................................... 8 1.3.5 System Limitations ................................................................................................................................. 8 1.3.6 Differences between Production Monitoring Version 2.0 and 2.1 ......................................................... 9

1.3.6.1 Production Monitoring PC software changes. .................................................................................................... 9 1.3.6.2 Production Monitoring Power Wave changes. ................................................................................................... 9

2 GETTING STARTED ....................................................................................................................................... 10

2.1 INSTALLING PRODUCTION MONITORING™

2.1 .............................................................................................. 10 2.1.1 Prerequisites before Installing Production Monitoring™ 2.1 .............................................................. 10 2.1.2 Install PM 2.1 Software ....................................................................................................................... 10

2.2 LAUNCHING PRODUCTION MONITORING™.................................................................................................... 13

2.2.1 To Start Production Monitoring on the PC it was installed on ........................................................... 13 2.2.2 To Start Production Monitoring from an External PC ........................................................................ 13

2.2.2.1 To get the Computer Name of the PM Sever PC or Link to the PM Server PC. .............................................. 14

3 ADMINISTRATIVE SECTION ...................................................................................................................... 15

3.1 SELECTING THE LANGUAGE FOR PRODUCTION MONITORING ....................................................................... 15 3.2 MANAGING PRODUCTION MONITORING WELDERS ....................................................................................... 16

3.2.1 The Asset Tree. ..................................................................................................................................... 16 3.2.1.1 Adding Group Nodes ....................................................................................................................................... 17 3.2.1.2 Moving Nodes to a Different Location in the Asset Tree ................................................................................. 18 3.2.1.3 Deleting Nodes (Welders) from the Asset Tree ............................................................................................... 18

3.2.2 Viewing/Hiding Welders in the Main Production Monitoring Screen. ................................................ 18 3.2.2.1 Viewing an Item ............................................................................................................................................... 18 3.2.2.2 Hiding an Item ................................................................................................................................................. 19

3.2.3 Enabling/Disabling Collecting Data from a Welder. .......................................................................... 19 3.2.3.1 Enabling Collecting Data ................................................................................................................................. 19 3.2.3.2 Disabling Collecting Data ................................................................................................................................ 19

3.2.4 Adding a new Welder ........................................................................................................................... 19 3.2.4.1 Example of Adding a Welder to Production Monitoring. ................................................................................ 20

3.3 SHIFT CONFIGURATION ................................................................................................................................ 23 3.3.1 Shift Terminology and Definitions ....................................................................................................... 23 3.3.2 Example Shift Setups ............................................................................................................................ 24

3.3.2.1 Example 1 - A daily shift schedule with three shifts and the production day begins with the 3rd shift. .......... 24 3.3.2.2 Example 2 - A daily shift schedule with 3 shifts and the production day begins with the 1st shift. ................. 24 3.3.2.3 Example 3 - A weekly shift schedule of 3 shifts M-F, a A/B shift on Saturday, and a A shift on Sunday. ...... 24

3.3.3 Shift Configuration Screens ................................................................................................................. 25 3.3.3.1 General Screen ................................................................................................................................................. 26 3.3.3.2 Shift Screen ...................................................................................................................................................... 26

02-28-11 2

3.4 GLOBAL SETTINGS ....................................................................................................................................... 29

4 POWER WAVE MANAGER ........................................................................................................................... 29

4.1 CREATING AN INSTALL KEY FOR ADDING A NEW WELDER TO PRODUCTION MONITORING. ........................ 29 4.2 EDITING PRODUCTION MONITORING CONFIGURATION DATA ....................................................................... 31

4.2.1 Weld Profile Selection Tab .................................................................................................................. 31 4.2.2 Out of Limit Actions Tab ...................................................................................................................... 32

4.2.2.1 Out of Limit Actions ........................................................................................................................................ 32 4.2.2.2 Out of Limit Tolerance..................................................................................................................................... 33

4.2.3 Profile Limits Tab ................................................................................................................................ 33 4.2.4 Wire Package Tab ................................................................................................................................ 34

4.2.4.1 Replenish Current Package .............................................................................................................................. 35 4.2.5 Email Setup Tab ................................................................................................................................... 35

4.2.5.1 Email General Settings ..................................................................................................................................... 36 4.2.5.2 Power Wave® Address Book ........................................................................................................................... 37 4.2.5.3 Sending a Test Email. ...................................................................................................................................... 37

4.2.6 Miscellaneous Tab ............................................................................................................................... 38 4.3 WELD PROFILE TRAINING ............................................................................................................................ 38

4.3.1 What Welds to Train ............................................................................................................................ 39 4.3.2 Starting Training Mode ....................................................................................................................... 39 4.3.3 Viewing the Calculated Limits for a Weld. .......................................................................................... 40 4.3.4 Deleting a Weld from Training ............................................................................................................ 41 4.3.5 Applying Weld Profile Calculated Limits ............................................................................................ 41 4.3.6 Clearing WeldScore Training Data. .................................................................................................... 41

5 MAIN REPORT SECTION .............................................................................................................................. 42

5.1 GETTING STARTED ........................................................................................................................................ 42 5.1.1 Basic Terminology ............................................................................................................................... 42 5.1.2 Selecting the Language for Production Monitoring ............................................................................ 42 5.1.3 Screen Layout ...................................................................................................................................... 43

5.1.3.1 Asset Tree ........................................................................................................................................................ 44 5.1.3.2 Topic Area ....................................................................................................................................................... 44 5.1.3.3 Action Area ...................................................................................................................................................... 44 5.1.3.4 Criteria Area..................................................................................................................................................... 45 5.1.3.5 Panel Area ........................................................................................................................................................ 46

5.2 RUNNING REPORTS ....................................................................................................................................... 47 5.2.1 Report Links ......................................................................................................................................... 47 5.2.2 Exporting Data from a Report ............................................................................................................. 47 5.2.3 Refreshing a Report data ..................................................................................................................... 47 5.2.4 Report Page Numbers .......................................................................................................................... 47

5.3 TOPICS .......................................................................................................................................................... 48 5.3.1 Current Status Tab ............................................................................................................................... 48

5.3.1.1 System Capacity ............................................................................................................................................... 50 5.3.2 Production Tab .................................................................................................................................... 50

5.3.2.1 Grid Report ...................................................................................................................................................... 50 5.3.2.2 Weld Profiles Report ........................................................................................................................................ 51 5.3.2.3 WeldScore Report ............................................................................................................................................ 52 5.3.2.4 Current/Voltage Report .................................................................................................................................... 53 5.3.2.5 Wire Feed Speed/Deposition Report ................................................................................................................ 53 5.3.2.6 True Energy/Duration Report........................................................................................................................... 54 5.3.2.7 Duration/Count Report ..................................................................................................................................... 55

5.3.3 Weld Listing Tab .................................................................................................................................. 55 5.3.3.1 Grid Report ...................................................................................................................................................... 56 5.3.3.2 WeldScore ........................................................................................................................................................ 57 5.3.3.3 Current/Voltage Report .................................................................................................................................... 57 5.3.3.4 Wire Feed Speed/Deposition Report ................................................................................................................ 58 5.3.3.5 True Energy/Duration Report........................................................................................................................... 58 5.3.3.6 Wire Deposition Report ................................................................................................................................... 59

02-28-11 3

5.3.4 Weld Detail Tab ................................................................................................................................... 60 5.3.5 Traceability Tab ................................................................................................................................... 61 5.3.6 Downtime Tab ...................................................................................................................................... 62

5.3.6.1 Grid Report ...................................................................................................................................................... 62 5.3.6.2 Chart Report ..................................................................................................................................................... 62

5.3.7 Fault Detail Tab .................................................................................................................................. 63

6 ADDITIONAL INFORMATION ..................................................................................................................... 64

6.1 EXPORT OF DATA FROM THE DATABASE ...................................................................................................... 64 6.1.1 Export File Name Format .................................................................................................................... 64 6.1.2 Open an Export file in Excel ................................................................................................................ 64 6.1.3 Export File Format .............................................................................................................................. 66

6.2 DEVICENET™ I/O FOR PRODUCTION MONITORING™ ................................................................................... 68

6.3 USING PRODUCTION MONITORING™

IN A FANUC® ROBOTIC APPLICATION ................................................ 70

6.3.1 Overview .............................................................................................................................................. 70 6.3.2 Requirements ....................................................................................................................................... 70 6.3.3 Setting Limits ....................................................................................................................................... 70 6.3.4 Adding Production Monitoring™ To Welding Programs ..................................................................... 71 6.3.5 Alarm/Alert Programs ......................................................................................................................... 71 6.3.6 Erroneous Low Time Limit Alarms ...................................................................................................... 72 6.3.7 Reference ............................................................................................................................................. 72

6.4 NEWER SUPPORT FOR PRODUCTION MONITORING™

IN A FANUC® ROBOTIC APPLICATION ........................ 74

6.4.1 System Variables .................................................................................................................................. 74 6.4.2 Weld Profile Selection ......................................................................................................................... 75 6.4.3 Serial Number Setting .......................................................................................................................... 75 6.4.4 WeldScore and True Energy ................................................................................................................ 75 6.4.5 Error Reporting ................................................................................................................................... 75 6.4.6 ServoTorch Wire Feed Speed Feedback .............................................................................................. 76

6.5 INSTALLING MICROSOFT INTERNET INFORMATION SERVER (IIS) ................................................................. 77 6.5.1 XP Professional ISS Installation .......................................................................................................... 77 6.5.2 Windows 2003 IIS Installation ............................................................................................................. 78 6.5.3 Windows Vista IIS Installation ............................................................................................................. 80 6.5.4 Windows 2008 IIS Installation ............................................................................................................. 81 6.5.5 Windows 7 IIS Installation ................................................................................................................... 84

6.6 VERIFYING THAT COM+ IS ENABLED FOR WINDOWS 2003 ......................................................................... 89 6.7 RESTRICTING ACCESS TO THE ADMINISTRATIVE SECTION ........................................................................... 90

6.7.1 Prerequisites ........................................................................................................................................ 90 6.7.2 Enabling Integrated Windows Authentication ..................................................................................... 90

6.7.2.1 IIS 5.1 and IIS 6.0 ............................................................................................................................................ 90 6.7.2.2 IIS 7.0 and IIS 7.5 ............................................................................................................................................ 94

6.8 UNINSTALLING LINCOLN PM 2.0 .................................................................................................................. 98 6.8.1 Uninstalling Lincoln PM 2.0 ............................................................................................................... 98 6.8.2 Uninstalling SQL Management Studio .............................................................................................. 101 6.8.3 Uninstalling SQL Server Instance ..................................................................................................... 101 6.8.4 Removing Lincoln Virtual IIS Directory ............................................................................................ 103 6.8.5 Removing Lincoln PM 2.0 Files ......................................................................................................... 107

7 GLOSSARY ..................................................................................................................................................... 110

02-28-11 4

1 General Information

1.1 Introduction to Production Monitoring™

Production Monitoring™ is a technology that is available for the latest models of the Lincoln Electric’s Power Wave® 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 up to thirty-two (32) distinct “weld profiles,” with separate limit settings for each profile. 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 limits with respect to voltage, current, wire feed speed, and duration. This goal would be fairly simple to implement if the Power Wave® were to perform only one type of weld over and over. However, in practical applications, this is not the case. The assembly of many different industrial components requires welds of varying type and length. The concept of Weld Profiles allows the Power Wave® to apply different limit settings for each weld that is performed on a certain part. Before the Power Wave® begins a new weld, it switches to the corresponding Weld Profile. The user can, 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 by configuring 10 of the 32 programmable Weld Profiles, with proper limit settings for each of the different welds. The user 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 an ArcLink® compatible controller, and through User Interface memory buttons.

1.1.2 Weld Logging

Production Monitoring™ also has the ability to record large quantities of weld statistics. The Power Wave® has enough memory to store summary data on approximately 2,000 welds, referred to as “Weld History”. Each log entry contains the following welding statistics:

For current, voltage and wire feed speed: o minimum o maximum o average o percent above limit o percent below limit o profile high limit o profile low limit

True Energy™ of the weld Date and time the weld was made

02-28-11 5

Duration of the weld Weld status after limit checking Part serial number, Consumable serial number, and Operator serial Number WeldScore of the weld

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 messages from the Power Wave® upon any of several event conditions.

1.1.4 Part Traceability

Production Monitoring™ 2 provides the capability to produce a report that lists all the welds that were made on a part for a given serial number. Before a weld is made, a serial number is entered in the welder. Then every weld that is made after this is assigned with this serial number until a new serial number is inputted. Then a traceability report can be run that will look for this serial number from all the welders in the system. Traceability solutions are typically customized to a customer’s specific needs, so please contact Lincoln Electric for a quotation on your needs.

1.1.5 WeldScore™

WeldScore, a new feature available in all third generation Power Wave® models including the i400, C300, S350, and AC/DC 1000 SD, can be used to assist a weld quality control program. It assigns a score to welds on a 0-100% scale that indicates the quality of the weld. The score is based on a comparison to previously trained welds. Any weld with a score of 90 or above can be considered with a reasonable amount of confidence to be a good weld. This is not a guarantee of quality and is not intended to replace a quality control system. WeldScore can be used independent of or together with Production Monitoring™ 2.1 or newer

1.1.5.1 How WeldScore™ works

Traditional weld monitoring systems measure voltage and current and must then guess what the power supply is trying to do before attempting to determine how well it is actually doing it. WeldScore is built right into the power supply controller which gives it a significant advantage in that it removes the guesswork involved with how the supply should be functioning. In addition to traditional voltage and current measurements, WeldScore also looks at 40-50 additional variables which help to make it more reliable and accurate than any previous weld monitoring system. In order to assign a score, the Power Wave must first be taught what is considered to be a good weld. This is done through the training section of Power Wave Manager. When a score is assigned to a future weld, it is done by comparing it to the taught weld. Therefore, it is necessary to teach the Power Wave every weld that a WeldScore is desired for. Some examples of when new training is required include changes in wire feed speed, voltage, joint type, or position. WeldScore is able to accommodate both welds with very tight tolerances and welds that have some acceptable process variation. If the welds taught to the Power Wave all have very little variation, then the only welds that will receive a passing WeldScore are ones that meet that very tight tolerance. Likewise, if there is room for some variation (ex. Changes in electrical stickout or work angle) and the acceptable variations are used in the teaching process, then WeldScore will assign passing scores to welds that fall within those variations.

02-28-11 6

1.1.5.2 Where to Use WeldScore™

WeldScore, like any statistical analysis, requires a controlled process. It will produce the most accurate results with single pass welds or welds with a small number of passes because as more passes are used, the process inherently becomes less repeatable. If there are a large number of variables that are allowed a significant amount of variation, the criteria may be too broad for the WeldScore to be a meaningful value.

1.1.5.3 What the Score Means

An instantaneous WeldScore value is calculated every 0.25 seconds. The average of these scores over the entire weld is reported as an overall score in Production Monitoring. A weld may receive a passing overall score if there is only a problem for a short portion of the weld time. For example, if a 50 inch weld has a score of 95 for 49 inches, but a score of 45 for the last inch, the overall score will be a 94. Out of limit error reporting is calculated over a user-defined moving window of time. This means that even a weld with a good overall score will cause an error to be reported if the WeldScore falls out of bounds for this defined amount of time.

1.2 Production Monitoring™ 2 Architecture

Production Monitoring™ 2 uses a web-based front-end with a relational database for data storage. The web-based front end provides the capability of having multiple users who are using Microsoft’s Internet Explorer, on multiple PCs, to be able to access the data and run reports. The main components of the Production Monitoring™ 2 system are:

Microsoft SQL Server Express database for storage of data. Microsoft Internet Information Server (IIS) Web Server. I/Gear Data Transport Utility (DTU) - This provides the welder to database connectivity. This piece of

software will query the welders for information and store it the database. I/Gear Web Framework - This provides users with a web portal to the database which enables them to run

various reports. The above components are installed on a single “server” PC. This server PC then communicates with the Welders over an Ethernet network. The users can be located anywhere. As long as they have an Ethernet link to the server PC they should be able to run Production Monitoring™ 2. Shown below is a conceptual overview of the Production Monitoring™ 2 system.

02-28-11 7

1.3 Requirements and Limitations

1.3.1 PC “Server” Requirements

Internet Explorer Web Brower, Version 6, SP1 or greater. CD-ROM Reader. An Ethernet (IEEE 802.3) compliant (TCPI/IP) 10Mbps 10BaseT or 10/100-BaseT network Interface card. Display - Minimum supported resolution is 1024x768 (16 bit color or higher). The Production Monitoring

screens should always be expanded to use the full 1024X768 resolution of the monitor. If not, certain sections of the screen can get condensed which can problems with clicking on items.

Operating System - Windows 7, Windows Vista, XP Professional , Windows Server 2003 with Service Pack 1 or greater, and Windows Server 2008. Both 32 bit and 64 bit OS systems are supported.

CPU - Dual core, 2 Ghz RAM - 2 GB This is a server type of application that is designed to run on a PC that is on all the time. This application

should not be installed on a laptop.

1.3.2 PC “Viewer” Requirements

Internet Explorer Web Browser, Version 6, SP1 or greater An Ethernet (IEEE 802.3) compliant (TCPI/IP) 10Mbps 10BaseT or 10/100-BaseT network Interface card. Display - Minimum supported resolution is 1024x768 (16 bit color or higher) Connection to the same network as the “server” PC

02-28-11 8

1.3.3 Power Wave® Requirements

Must have an Ethernet port available. .

o The Power Wave® 655, AC/DC 1000, and i400 come standard with an Ethernet Port, so no additional equipment is needed.

o The Power Wave® 455M, 455M/STT, 455M Robotic, and 455M/STT Robotic need a K2207-2 Ethernet /DeviceNet Module.

o The Power Wave® 355M, F355i, and 405M need a K2436-1 Communication Interface. Have a static IP set in each Power Wave®.

o Each Power Wave® must have a unique IP address. IP addresses are usually obtained from the

local IT department. o Once an IP address is obtained for the Power Wave®, Lincoln Electric’s PC Weld Manager

Application then can be used to set the IP in the Power Wave®. This software utility is available at www.powerwavesoftware.com.

The Production Monitoring Revision, found in the Power Wave, must be 5 or greater to support features

found in the 2.1 version of Production Monitoring. If the Production Monitoring firmware revision is only 4, then only Production Monitoring 2.0 is support. Connect with Power Wave Manager and then go to the Install section of the Production Monitoring item on the left to see the current version of the Production Monitoring firmware.

1.3.4 Network Requirements

Network Type - 10Base-T or 10/100 Base-T Ethernet Network. Cabling - Solid Shielded CAT 5 cables or better. Connectors - Use RJ-45 Environmentally Enclosed Connectors when connecting the network to the Power

Wave® Connecting Network Device - The network lines going to the Power Wave® should go to an Industrial

switch or a switch with a Hardened enclosure. Wireless Network Guidelines - Wireless network requires a 802.11 bridge

1.3.5 System Limitations

Item PM 2.0 PM 2.1 Maximum weld duration in seconds 6,553 429,496,729 Maximum stored welds in memory 5,000 2,000 Shortest weld duration that can be record in seconds.

0.5 0.4

Minimum Start plus End Delay Times in seconds 0.7 0.4 Shortest weld duration before a determination can be made on if the weld is with in limits or not.

Duration > (Start + End) Delay Times

Duration > (Start + End) Delay Times + 1 second

Maximum Serial Number length 16 32 Maximum Out of Limit Tolerance Time in seconds

1310.7 85,899,345

TIG and Stick welding supported. No Yes Weld Score supported. No For some Power Wave

models

02-28-11 9

Welds with duration of less than 0.4 seconds will not be recorded for PM 2.1. For welders with support only PM 2.0, welds with a duration of less than 0.5 seconds will not be supported.

Welds with duration of less then the Start + End Delay times will be recorded as a Short Weld. Starting with PM 2.1, the user also has the option of discarding these welds.

Note for the maximum stored welds in memory, after reaching this limit, the oldest weld record will be replaced with a new weld record whenever a weld is generated. This data will be erased if the Power Wave® is reset or powered down for any reason. If the Production Monitoring™ system can not collect this data before the Power Wave® is reset or powered down, this data will be lost.

The longest training weld that can be taken is 21 minutes. The maximum recommended number of welds to have the database store is 250,000. When using the Last Digit of Workpoint method to select the Weld profile, non-synergic modes, such as

the Power Mode or Non-Synergic CV, are not supported. Servo-Torch Wire Feed Speed will not be recorded for older software versions of the Robot’s Arctool

software and for older versions of the welder’s firmware. Starting with theV7.70P/07 release of the Arctool software version, Servo-Torch WFS feedback is supported in Arctool.

The Analog Interface is not deterministic when selecting the weld profile. It is not possible to calculate the Wire Deposition with Dual Head Wire Feeders. When using Windows XP Pro operating system for the “server” function, only five users at a time can view

the reports. With Windows 2003 operating system, there are no limits as to the number of user that can view the reports at once.

When multiple UIs are in the system, selecting weld profiles from the UI memory panels should not be used. Welds could go under the wrong weld profile.

1.3.6 Differences between Production Monitoring Version 2.0 and 2.1

1.3.6.1 Production Monitoring PC software changes.

Power Wave Manager is now needed to train and setup Weld Profiles. Added the ability of reading the WeldScore value and generating WeldScore reports. Added the ability of reading and running traceability reports on an Operator and Consumable serial

number. Added many smaller functional changes to help in the viewing of data, such as: When viewing large

amounts of data pages numbers at the bottom of a report can be clicked on, data can be sorted by clicking on a reports heading, and the panel area size for reports can be increased by hiding the Asset tree and the Topic/Action area.

Multiple language support was added. Added support for newer versions of Windows. Replaced the Configuration section with a simpler Admin section which no longer requires the user to log

in.

1.3.6.2 Production Monitoring Power Wave changes.

Longer weld times; the old limit was 6553 seconds, now welds up to 429,496,729 second are supported. WeldScore is now supported in many Power Wave models. The serial number length can now be up to 32 characters, the old limit was 16 characters. An operator and consumable serial number, both being 32 characters in length is now supported. Now a weld stops recording when there is no current present, before it stopped when there was no current

and voltage present. The maximum Out of Tolerance time was increased from 1310.7 seconds to 85,899,345 seconds. Maximum stored welds in memory are now 2,000 instead of 5,000 as in PM 2.1.

02-28-11 10

Minimum Start plus the End Delay Times must be equal to greater than 0.4 seconds. For PM 2.0, the Start + End Delays must be at least 0.7 seconds.

Shortest weld duration before a determination can be made on if a weld is within limits or not is the Start + End Delay Times + 1 second. For PM 2.0, the weld duration just had to be greater than the Start + End Delay Times.

Changed the way for determining whether a weld is out of limit or not.

For PM 2.0, when a item when above it’s high limit a counter was incremented and if the item went below its low limit, another counter was incremented. If either counter was greater than the Out of Tolerance time for that item, the item would be considered out of limit.

For PM 2.1, when an item goes above its high limit a counter is incremented and when an item goes below its low limit another counter will be incremented just as before. But now, if an item goes back within limits, the high or low counters will be decremented if they were non-zero. Also now if the High out of limit counter plus the Low out of limit counter is greater than then “Out of Limit Tolerance” time, a fault will be signaled. When a fault is signaled, if the low out of limit counter is greater than the high out of limit counter, a low limit fault will be generated; else a high limit fault is generated.

2 Getting Started

2.1 Installing Production Monitoring™ 2.1

2.1.1 Prerequisites before Installing Production Monitoring™ 2.1

Must be logged on as an Administrator to the PC. Any previous install of Production Monitoring must be removed from the system; see section 6.8 for

uninstalling Production Monitoring 2.0. The computer name must not contain any underscores ( _ ). For example, if the computer name is “My_ Computer”, it should be changed to something like “My-Computer”. During installation, it is best to turn off any Firewalls or security software on the PC. Microsoft Internet Information Server (IIS) must be installed before Production Monitoring™ 2. See the

Additional Information section for more information on how to install IIS. For the Windows 2003 operating system, make sure that Service Pack 1 or greater is installed. For the Windows 2003 operating system, verify that COM+ is enabled. See the Additional Information

section for more information on how to verify this is enabled.

2.1.2 Install PM 2.1 Software

Run Setup.exe from the installation CD/package. The first screen will be the Introduction Screen.

02-28-11 11

Select the desired language for the installation program, and then click on the Next button. The screen that will appear will be the license agreement screen. Click the check box if you agree to the terms and click next.

The installer will then prompt for the installation path for Production Monitoring™. The default is the computer’s “c:\Program Files\Lincoln Electric” folder.

02-28-11 12

If the directory does not exist it will prompt to create it.

The Installer will now install all components.

02-28-11 13

After the installation finishes, the below summary screen is shown. Click on the Finish button to exit the install program.

2.2 Launching Production Monitoring™

Once Production Monitoring™ is installed, it can be accessed by the PC it was installed on and by one or more computers that are on the same network as the Production Monitoring™ server PC. The install for Production Monitoring 2 actually has two web interfaces associated with it. The first interface is an Administrative interface that is used to configure the Production Monitoring PC software. This is where Welders are added and deleted to Production Monitoring. Most users do not need to access this interface to Production Monitoring. The second web interface is the main section where users can view data and reports from the welders.

2.2.1 To Start Production Monitoring on the PC it was installed on

A) Click on the Windows Start button or icon. B) Select the Programs/All Programs menu item. C) In the Programs menu list, then select the Lincoln Electric menu item. D) In the Lincoln Electric item, then select the Production Monitoring item. E) Now from here, either select the “Production Monitor Admin” item to configure the system or the

“Production Monitoring” item to launch the main web interface to view data and reports.

2.2.2 To Start Production Monitoring from an External PC

A) Open Internet Explorer. B) In the Address bar, type in the link to the Production Monitoring PC using the PC’s name followed by

/LincolnPM. The link will look like the following - http://type the computer name here/LincolnPM/ C) After the link is typed in, press <Enter>. See below for getting the computer name to use.

For example, to launch Production Monitoring from a PC, open Internet Explorer, in the address bar type in a link to the PM Server name, followed by /lincolnPM, then press <Enter>.

02-28-11 14

The above example shows how to open the report section of Production Monitoring. To open the Administration section of Production Monitoring from an external PC, use the following link - http://Server Name/igear.lincoln.configuration/siteadmin/siteadmin.aspx, where the Server Name is the computer name of the PC where Production Monitor is installed on.

2.2.2.1 To get the Computer Name of the PM Sever PC or Link to the PM Server PC.

To get the PM Server computer name, go to the PM Server Computer and right click on the “My Computer” or “Computer” icon. From the pop-up menu that should appear, select the “Properties” item. In here it shows the computer’s name. To get/generate a link to the PM server PC, open Production Monitoring on the Server PM. Then near the bottom of the screen, click on the “E-mail a Link to this Site”. This should open the default mail server program on the PC and copy the link to use to access Production Monitoring from another PC.

Type “http://Server Name/LincolnPM” here and then press

02-28-11 15

3 Administrative Section

The Administrative Section for Production Monitoring 2.1 is where welders can be added/deleted from the system , where shift settings are setup, and where Production Monitoring Global setting are set. This section is similar to the Configuration section in Production Monitoring 2.0. In this section, welders can be added and deleted to Production Monitoring and some system items can be configured here as well. One major difference between PM 2.0 and 2.1, is that the configuration of the profiles are now done using Lincoln’s Power Wave Manager PC application. See section 4 for more information on using Power Wave Manager. When the Administrative Section is accessed, a web page like below will appear. The page has two main sections: The System selection section on the upper left side of the page and the display area for the selected System item to the right of the System selection area. Note that depending on the selected System item, what is displayed in the middle and right side of the page will vary.

3.1 Selecting the Language for Production Monitoring

At the bottom right corner of the Production Monitoring screens, there is a drop down list that can be used to select what language the report is displayed in. Hovering over the Language area with the mouse will bring up a small gray window like -

When the white area contain the current language that is being used is clicked, a list of the available language will appear. See below.

Click here in here to bring up a list of available

02-28-11 16

3.2 Managing Production Monitoring Welders

To add, delete, name, or organize how the welders are displayed in Production Monitoring, go to the Administrative page of Production Monitoring and select the Asset Tree item under the System item on the upper left side of the page. When this is selected, the display area will display the “Asset Tree” and an Asset Properties area. The Asset Tree area shows the current welders in the Production Monitoring, which are usually organized into logical groups.

3.2.1 The Asset Tree.

The asset tree has two types of nodes; it can be either a Group node or a Welder node. A group node is used to organize welders into logical groups. These groups are used to make it easier to view and find welders, and to specify a group of welders to use for certain Production Monitoring reports. A welder node is used to specify a welder to collect data from. The top most node is called the Root node, in the screen shot below, this is the “Lincoln Electric” item. The other group nodes shown below are the Line 1, Line 2, and Line 3 items. Group nodes have a box to the left of them that enables you to show or hide the items under the group item for easier viewing of the tree. Just click on the box to the left of the group item to either expand or collapse that group’s items.

Once the list of languages is shown, now select the desired language by clicking on it. When the desired language is clicked, the list will disappear and the gray window will now list the new language, like below -

Now click on the button in order for the new language to take effect.

02-28-11 17

The root node must always be a Group node. Also all the rest of the nodes must be placed “under” this root node, no other node can be at the same “level” as the root node. From the example above, notice that the “Line” items are placed under and to the right of the Lincoln Electric group item, this is the correct alignment. If the items are placed at the same level, as shown below, this is an invalid alignment which can cause problems organizing the Asset Tree.

If a group node is clicked on, its asset properties will be displayed. If a welder node is clicked on, its asset properties and an asset configuration section will be displayed. Note that no changes can be made to a Welders configuration section. To change a setting, the old node must be deleted and a new one added in.

3.2.1.1 Adding Group Nodes

Group nodes are usually added to help you organize the welders. Besides just to make it easier to find and view the welders in the asset tree, groups are used to specify what welders to use for certain Production Monitoring reports. So besides just running a report for a single welder, or all the welders, a group can be used to limit the report to just those welders that are listed under a particular group node. Please keep this in mind when organizing the Asset Tree. Follow the below steps to add a group node to the asset tree.

A) First select the group node to add the new group node under by clicking on it in the Asset tree with the mouse.

B) Then click on the “Add A New Asset” item shown at the top of the Asset Tree. C) Now a “New Asset” should appear under the first group node. D) Click on this “New Asset” item in the tree.

The example to the left shows an invalid alignment of the Asset Tree nodes. The Line nodes are placed directly under the main Root node, “Lincoln Electric”, which is not correct. All nodes must be place under and to the right of the root node.

02-28-11 18

E) Now change the name of the New Asset item in the Asset Properties section. F) Now click on the Save Changes item in the Asset Properties section.

3.2.1.2 Moving Nodes to a Different Location in the Asset Tree

A node can be moved to a different level by first clicking and holding down the mouse button on a desired node in the Asset Tree. Then drag the node with the mouse to its new location, and then release the mouse button.

3.2.1.3 Deleting Nodes (Welders) from the Asset Tree

A node can be deleted by first clicking on the desired node to delete in the Asset Tree. Then click on the Delete Asset item in the Asset Properties area to the right of the Asset tree. When this is clicked on, a couple of warning messages will appear, like below. If you are sure you want to delete the node, and then click on the OK buttons for these messages. Note that if this is a group node that you are deleting, then any welder nodes under this will be deleted as well.

3.2.2 Viewing/Hiding Welders in the Main Production Monitoring Screen.

3.2.2.1 Viewing an Item

To view an item in the main report section, first select the item in the asset tree by clicking on it. Then check the “Show Asset in Tree” checkbox as shown to the left by clicking on it with the mouse. After checking this, make sure you click on the “Save Changes” item. For welder nodes, also make sure any group nodes checkboxes that the welder is located under, are also checked. If a group node is selected not to be shown, then any welders under it will not be displayed, even if their box is checked. If you recheck a group node, must sure you also recheck all the welders nodes under it.

02-28-11 19

3.2.2.2 Hiding an Item

3.2.3 Enabling/Disabling Collecting Data from a Welder.

At times it might be desirable to disable collecting data from a welder. For example, if you are doing testing or maintenance with the welder and don’t want the data from this to be included in the Production Monitoring data, you can disable Production Monitoring from collect data during these periods.

3.2.3.1 Enabling Collecting Data

3.2.3.2 Disabling Collecting Data

3.2.4 Adding a new Welder

To add a welder to Production Monitoring, do the following steps -

A) Create an Install Key with Power Wave Manager. See section 4.1, “Creating an Install Key for Adding a New Welder to Production Monitoring”.

B) Click on the Group Asset node to add the welder under. C) Click on the “Add a New Asset” item located at the top of the Asset Tree.

To hide an item in the main report section, first select the item in the asset tree. Then uncheck the “Show Asset in Tree” checkbox as shown to the left by clicking on it with the mouse. After the box is unchecked, make sure you click on the “Save Changes” item. Also note that if you uncheck a group nodes checkbox, all the nodes under it will automatically also get unchecked as well.

To enable collecting data from a welder, first click on the desired welder in the asset tree. Then in the welder’s Asset configuration section, check the “Enable Data Collection on Welder” checkbox item by clicking on it with the mouse, as shown to the left.

To disable collecting data from a welder, first click on the desired welder in the asset tree. Then in the welder’s Asset configuration section, uncheck the “Enable Data Collection on Welder” checkbox item by clicking on it with the mouse, as shown to the left.

02-28-11 20

D) Now a “New Asset” item should appear under the first selected Group node. Click on this “New Asset” node.

E) In the Asset Properties area to the right, change the “Tree Node Type” to welder. F) Now a new section should appear in the Asset configuration area. Click on the “Select” button in this area

and select the .tok file that was created in step A. G) Now click on the “Run Import” item in the Asset Configuration section. G) A list of welder attributes should now appear in the Asset Configuration section. Now change the “Name”

to the desired name in the Asset Properties section. H) Now click on the “Save Changes” item in the Asset Properties area.

3.2.4.1 Example of Adding a Welder to Production Monitoring.

In this example, a welder will be added to the Line 3 Group. 1. First create a Install Key with Power Wave Manager. See the section “Creating an Install Key for Adding a New Welder to Production Monitoring”. 2. Click on the Group Asset node to add the welder under. In this example, this is the Line 3 item in the Asset Tree. The item should now show a gray background. See below.

3. Click on the “Add a New Asset” item located at the top of the Asset Tree.

02-28-11 21

Now a “New Asset” item should appear under the Line 3 group, see above. 4. Click on this “New Asset” node. 5. In the Asset Properties area to the right, change the “Tree Node Type” to welder. When the type is changed to a welder, a new section should appear, this is the Asset configuration area. See below.

Click here to Add a new asset

Change node type to Welder

02-28-11 22

6. Now click on the “Select” button in the Asset Configuration area and select the .tok file that was created in step 1. 7. Now click on the “Run Import” item in the Asset Configuration section. A list of welder attributes should now appear in the Asset Configuration section. See below.

8. Now change the “Name” in the Asset Properties section. 9. Now click on the “Save Changes” item in the Asset Properties area. If everything was successful, the new asset item under the Line 3 group will now show the name of your welder and the Tree Node Type will be listed as a Welder. See below.

Welder attributes should appear here if the import was successful.

02-28-11 23

3.3 Shift Configuration

To access the Shift Schedule for Production Monitoring 2.1, go to the Administrative page of Production Monitoring and select the Shift Schedule item under the System item on the upper left side of the page. The Production Monitoring™ shift schedule is designed to accommodate simple and complex shift schedules. For example, it can be setup for a daily shift schedule with three shifts or for a complex schedule where the production day begins with 3rd shift or a weekly shift schedule with three shifts M-F and only an A / B shift on Sat and an A shift on Sunday. Before the shift schedule information can be entered, an understanding of how it works and its terminology is required.

3.3.1 Shift Terminology and Definitions

Shift – a block of time for identifying data to a team. Shifts must be greater than 0 seconds long and less than 24 hours long. Production Day – starts with the first shift of the day and ends with the last shift for the day. A production day does not have to align exactly with the calendar days unless the first shift starts at midnight. Next Production Day – This checkbox indicates whether or not the calendar day of the start of a given shift matches the current production day or the next production day. This allows for a production day to begin at the start of a shift that actually begins on the previous calendar day. Period Days – A block of production days having a unique schedule that is repeated over and over again. Base Date – A calendar date that indicates when a period begins. This is used to phase the period blocks on top of the calendar.

02-28-11 24

3.3.2 Example Shift Setups

3.3.2.1 Example 1 - A daily shift schedule with three shifts and the production day begins with

the 3rd shift.

Number of Shifts Names to Input = 3 Period Base Date: 1/1/2000 (doesn’t really matter) Period Days: 1 For the Shift Details: 3rd Shift – 11PM to 7AM, Next Production Day: Yes 1st Shift – 7AM to 3PM, Next Production Day: No 2nd Shift – 3PM to 11PM, Next Production Day: No

3.3.2.2 Example 2 - A daily shift schedule with 3 shifts and the production day begins with the 1st shift.

Number of Shifts Names to Input = 3 Period Base Date: 1/1/2000 (doesn’t really matter) Period Days: 1 For the Shift Details: 1st Shift – 7AM to 3PM, Next Production Day: No 2nd Shift – 3PM to 11PM, Next Production Day: No 3rd Shift – 11PM to 7AM, Next Production Day: No

3.3.2.3 Example 3 - A weekly shift schedule of 3 shifts M-F, a A/B shift on Saturday, and a A shift on Sunday.

Number of Shifts Names to Input = The choice is yours. You can reuse shift names, so you might only need to enter 3 names (1st, 2nd, and 3rd). Or you can do something like to identify the shifts on the weekend differently, then you might need 6 names like (1st, 2nd, 3rd, Sat 1st, Sat 2nd, Sunday). Even another possibility would be to enter in 18 shift names, one for each unique shift of the week. Period Base Date: 10/15/2007 (any Monday) Period Days: 7 For the Shift Details (There needs to be 18 shift items in total): Period Day: 1 (Monday) C – 11PM to 7AM, Next Production Day: Yes A – 7AM to 3PM, Next Production Day: No B – 3PM to 11PM, Next Production Day: No Period Day: 2 (Tuesday) C – 11PM to 7AM, Next Production Day: Yes A – 7AM to 3PM, Next Production Day: No B – 3PM to 11PM, Next Production Day: No Period Day: 3 (Wednesday) C – 11PM to 7AM, Next Production Day: Yes A – 7AM to 3PM, Next Production Day: No B – 3PM to 11PM, Next Production Day: No Period Day: 4 (Thursday)

02-28-11 25

C – 11PM to 7AM, Next Production Day: Yes A – 7AM to 3PM, Next Production Day: No B – 3PM to 11PM, Next Production Day: No Period Day: 5 (Friday) C – 11PM to 7AM, Next Production Day: Yes A – 7AM to 3PM, Next Production Day: No B – 3PM to 11PM, Next Production Day: No Period Day: 6 (Saturday) A – 7AM to 3PM, Next Production Day: No B – 3PM to 11PM, Next Production Day: No Period Day: 7 (Sunday) A – 7AM to 3PM, Next Production Day: No

3.3.3 Shift Configuration Screens

When the Shift Schedule item is selected, the display area will show a page like below -

The display area for the Shift Schedule is used to show the general information for how the shifts are setup. To change this information, click on the icon next to the shift description. When the icon is clicked on, a new page will appear (see below) which allows you to change the General information and access the Details section of the Shift Schedule information.

Click here to change the shift setup information and go to the General Settings Screen.

02-28-11 26

3.3.3.1 General Screen

This is a general setup screen for the shifts. The “Description” field is just a text item that is used to name your shift setup. The ”Base Date” defines what day of the week the shifts are to begin on. For more simple schedules with everyday having the same setup, this is not used. The “Period Days” are used to define how many days are in the shift schedule before the schedule repeats. For simple schedules with everyday having the same shift setup, set this to a 1. For more complex setups with perhaps different schedules on the weekend, this might be set to something like 7. See sections 3.3.1 and 3.3.2 for more information and examples on how to set these items. After any changes are made to these fields, click on the item located on the top of the page in order for the change to be saved.

3.3.3.2 Shift Screen

The Shift screen is where information is displayed for each unique shift in the system. See sections 3.3.1 and 3.3.2 for more information and examples on how to set these items. To access this page, click on the item on the General Settings Screen, see the above section, section 3.3.3.1. The Shift Screen will look something like the below.

02-28-11 27

From this page, settings for a particular shift can be changed, a new shift can be added, or a shift can be deleted. To added a new shift, click on the item, see section 3.3.3.2.1 To change a shift setting, click on the icon next the shift you want to change, see section 3.3.3.2.2. To delete a shift, click on the icon the shift you want to delete, see section 3.3.3.2.3.

3.3.3.2.1 Adding a new shift. When the is clicked on in the Shift Screen, a screen like below will appear.

02-28-11 28

Enter in a new Shift name or select a shift name from one that has previous been entered. A shift name can be reused across multiple shifts. Select the Period Day. The number of periods is defined on the “General Settings” tab. Then select the “Start Time” of the shift. The “Next Production Day” checkbox defines if this shift should count for the next day, even though the shift might have started on the previous day. Finally click on the text to save the information that was entered.

3.3.3.2.2 Editing a current shift When the icon is clicked on in the Shift Screen, a screen like the one above (see Adding a new shift) will appear. This screen allows you to edit existing shift information. When done, click on the text to save the information that was entered.

3.3.3.2.3 Deleting a shift When the icon is clicked on in the Shift Screen, a message box will appear like below.

Click on the OK button to delete the shift.

02-28-11 29

3.4 Global Settings

To access the Global Settings for Production Monitoring 2.1, go to the Administrative page of Production Monitoring and select the Global Settings item under the System item on the upper left side of the page. When this is selected, the display area will display the follow -

Right now there is only 1 Global Setting for Production Monitoring 2.1, and that is the “Unit of Measure”. This item defines what units that Wire Feed Speed and Wire Deposition is reported in, the choices are either Imperial (inches/minute and pounds) or Metric (meters/minute and kilograms).

4 Power Wave Manager

Power Wave Manager is a Windows PC utility program provided by Lincoln Electric. This program is needed to configure Production Monitoring 2.1 related items and train profiles limits in the Power Wave. To obtain the Power Wave Manager software, go to http://www.powerwavesoftware.com/. From here download and install the Power Wave Utilities package. Once the Power Wave Utilities are installed, then to start Power Wave Manager, click on the Windows Start icon, then the windows menu item “Programs\Lincoln Electric\Power Wave Utilities\Power Wave Manager”. This section of the Production Monitoring manual only deals with configuring Production Monitoring related items in a Power Wave. See the Power Wave Manager manual and “Help Me Connect Guide” for more information on how to use the Power Wave Manager software and how to connect to a machine with it.

4.1 Creating an Install Key for Adding a New Welder to Production Monitoring.

To create an Install Key that is used to install a welder in to Production Monitoring 2.1, follow the below steps - A) Open Power Wave Manager B) Create a connection to the machine that you wish to install

02-28-11 30

C) Click on the Install item under the Production Monitor menu item on the left, see below.

Note, if you don’t see the Production Monitoring item list on the left side of the program, then this is probably an older version of Power Wave Manager and it needs to be updated. Also note, that the settings on this page are not being used as of now, so it does not matter what they are set to. D) Now click on the “Save Production Monitoring Install Key” panel. A standard windows “Save file…” window will now open, like below -

Navigate to the location you wish to save the key on the computer using the “Save in” item on top of the screen and then by select the desired folder in the window. After this, enter in the File name you wish to save the install key under. You do not have to enter in the file extension; an extension of .tok will automatically be added to the name. E) Now just click on the “Save” button. A file with your filename with the .tok extension should now be created in the location you specified. This file now can be imported in to the Admin section of Production Monitoring to add the welder to the system.

Click here to create an Install Key for Production Monitoring 2.1.

02-28-11 31

4.2 Editing Production Monitoring Configuration data

To edit Production Monitoring data for a welder, first connect to the machine with Power Wave Manager. Then click on the “Configuration” item found under the Production Monitoring item located on the left side of the program. Note, if you don’t see the Production Monitoring item list on the left side of the program, then this is probably an older version of Power Wave Manager and it needs to be updated. After clicking on this, Power Wave Manager will now display a series of tabs. Click on the desired tab to find and change the item you want. Note, that when any changes are made to any of the items on any of the tabs in the “Configuration” section (besides

the Miscellaneous tab), the button must be clicked before moving off the “Configuration” item or closing Power Wave Manager in order for the changes to be saved and take effect in the welder.

4.2.1 Weld Profile Selection Tab

This page is used to setup how the Production Monitoring profiles are selected. When this tab is selected, a page like the following will be displayed -

There are three options to choose from. Note that an option might not be displayed if the Power Source does not support that particular option.

Select Weld Profile automatically based on the last digit of Workpoint - The last digit of the welding set point becomes the Weld Profile number currently in use. For example, if the welding 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 user can access only 10 of the 32 possible Profiles and procedure adjustment is constricted. Despite these limitations, this method is simple and effective, and may be the preferred choice for many applications.

Allow an external controller to select the Weld Profile - The Weld Profile number will be selected by an

external controller that can communicate with the Power Wave® over a DeviceNet or ArcLink® network. The controller has direct access to the Weld Profile number. Consequently, an external DeviceNet controller (such as a PLC) or an ArcLink® controller such as a FANUC® RJ3iB (V6.4) would be able to

02-28-11 32

access all of the 32 Weld Profile numbers, unlike the method of selection based on welding set point. Refer to 6.2 for information on Production Monitoring™ features configurable over DeviceNet. Refer to 6.3 for reference on programming the RJ3iB for use with Production Monitoring™.

Select Weld Profile based on User Interface memory selection - The Weld Profile used will be selected

by pressing the memory buttons found on the Power Feed user interfaces (PF10M, PF25M, and PF-10A). This method offers ease of use and straightforwardness in selecting the Profile, but, since there are six memory buttons on the user interface, it limits the selection to six Profiles. If no UI memory is selected, the Weld Profile 32 will be selected. When no User Interfaces are found in the system, this selection method is grayed out and can not be selected.

4.2.2 Out of Limit Actions Tab

This screen is used to setup what action that the Power Wave® will take when a weld exceeds the Production Monitoring™ limits for weld duration, WeldScore, arc current, arc voltage, or wire feed speed. When this tab is selected, a page like the follow will be displayed -

4.2.2.1 Out of Limit Actions

For Duration (the length of time the Power Source welded for), WeldScore, Current, Voltage, and WFS, this item sets the action taken when one of these items is out of limit for a given weld profile. The possible actions for an out-of-limit weld are:

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”). A latched fault can be reset either through a UI such as a PF10M, through a DeviceNet polled IO connection, or through an Arclink

02-28-11 33

compatible controller that supports this feature. Note, resetting or cycling the power to the Power Wave® will also reset a latched fault.

Note that if the Action on WeldScore Limit value is grayed out, this could be due to either the machine does not support WeldScore or perhaps the machine has older software in it that needs to be updated.

4.2.2.2 Out of Limit Tolerance

Production Monitoring™ can allow WeldScore, arc current, arc voltage, and wire feed speed to go outside of limits for a short duration before any of the above actions are performed. This time represents the total amount of time the item can be out of limit for the duration of the whole weld. This value is represented in seconds and has a 100 millisecond resolution.

4.2.3 Profile Limits Tab

This tab is used to select a weld profile and display the limits associated with it. When this tab is selected, a page like the follow will be displayed -

In the Profile limits view, the green circles next to the Profile number item are used to specify that the WeldScore

, Time , Amperage , Voltage , and WFS items are Enabled and have non-zero limits. If that item is not enabled or the limits are at 0, then no green icon will appear for that item. If an item is changed for a profile,

the icon will change to a icon for that profile.

To change settings to a particular weld profile, first select the Profile number to use from the list box. Click on the Profile number in the list box that is shows the “Profile 1” to “Profile 32”. Once the profile is selected, then on the right side of the screen it will show the limits associated with that profile.

Start Delay: This is the Amount of time (seconds) that Production Monitoring™ will wait, directly after the

start of a weld, until the limits for this Profile begin to be applied. This option is necessary because the start of a weld is often unpredictable and may fall out of limits easily.

02-28-11 34

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

If the welder software only supports Production Monitoring 2.0, it has a Production Monitoring firmware revision of a 4, the combined Start Delay and End Delay times must be 0.7 seconds or greater. If the entered times are not, the Start Delay will automatically be adjusted so that the both times will equal a total of 0.7 seconds. If a weld is less than 0.7 seconds, it will be considered a short weld. If a weld is less than 0.5 seconds, no weld log will be generated at all. If the PM firmware revision is a 5, then it supports PM 2.1. With this version, the Start Delay plus End Delay time must be 0.4 seconds or greater.

Discard welds shorter than “n” seconds: If this option is checked, than welds shorter than the Start pulse

End Delay times will be discarded. Else welds greater than 0.4 seconds but less than the Start pulse End Delay time will be recorded in Production Monitoring but will be marked as a short weld.

For welder software that supports only Production Monitoring 2.0, the Profile can be disabled or enabled by clicking on the “Enable limit checking for this profile” on the top of this section. The Enables next to each item will automatically be disabled and grayed out. For welder software that supports Production Monitoring 2.1 or greater, the Profile is automatically enabled. The “Enable limit checking for this profile” on the top of this section is automatically checked and grayed out. To enable limit checking for an item, click on the check box to the right of the item. Note that when WeldScore is selected, the only other item that you can check is the Weld Duration limits.

Minimum WeldScore: Specifies the minimum WeldScore for this Profile. If this item is grayed out, this

could be due to either the machine does not support WeldScore or perhaps the machine has older software in it that needs to be updated.

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.

4.2.4 Wire Package Tab

Production Monitoring™ allows the configuration of the Wire Package used for welding, so that its usage can be tracked by the Power Wave®, and the user notified when the package begins to run low. When this tab is selected, a page like the follow will be displayed -

02-28-11 35

Package Weight: This is the original weight of the wire package, as indicated on the container. Current Weight of Package: If the package has already been used, the current weight of the package can

be entered. However, if the package is new, this weight should be the same as the initial weight. Warning Package Weight: Production Monitoring™ will issue a “wire package low” warning when the

wire reaches this amount 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 “Steel” o “Stainless Steel” o “Aluminum 4043” o “Aluminum 5356” o “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 be enabled in which the actual density can be entered.

4.2.4.1 Replenish Current Package

To set the current package weight back to the initial package weight, click on the button on the Wire Package tab. Note, that after you replenish the Current weight, you still have to click on the

button in order for this new value to be sent to the welder.

4.2.5 Email Setup Tab

The Email screen provides access to all of the configuration options for the email feature of Production Monitoring™. From this window, email recipients can be added or removed from the Power Wave®’s address book, and email settings can be configured. Contact a network administrator for assistance on obtaining information about the email server and other settings included in this section. When this tab is selected, a page like the follow will be displayed -

02-28-11 36

Before setting up the Power Wave®’s email system, 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.

4.2.5.1 Email General Settings

Enable Email Notifications: This will enable or disable the email system in the Power Wave®. Outgoing Mail Sever: This is the IP address of the email server on the network. Outgoing Mail Port: This is the port number of the SMTP service on the email server. The standard port

number for SMTP servers is 25. This number should only be changed if recommended by a network administrator.

DNS server: This is the IP address of the DNS server on the network. Machine name: Is the name of the machine that will be displayed in emails from the Power Source. Company name: Is the company name that will be used in emails from the Power Source.

02-28-11 37

4.2.5.2 Power Wave® Address Book

4.2.5.2.1 Email Triggers

The Possible email triggers are:

System Event: The Power Wave® will send an email message when a System Event occurs within the Power Wave® (e.g. a thermostat fault) or when it is reprogrammed with new software, or when one of its hardware components is replaced, removed, or added.

Service Event: The Power Wave® will send an email message when some type of Service event occurs within the Power Wave®. These events are used for specific troubleshooting and are reported during general operation.

Profile 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.

Wire Package Warning: The Power Wave® will send an email message when the consumable package begins to run low.

Power On: This causes the Power Wave® to send out an email when the Power Wave® is turned on or reset.

4.2.5.3 Sending a Test Email.

To test the email settings, a test email can be sent to a E-mail address in the address book. First select the address to

send the email to by clicking on it in the Address book. Then click on the button. Note,

The Power Wave contains an internal address book, capable of storing up to twelve different email recipients. Each recipient can choose to receive an email notification when one or more events occurs within the Power Wave. An email must be 62 characters in length or less. The valid characters that can be used are: Uppercase and lower case letters, the digits 0 through 9, the characters ! # $ % * / ? | ^ { } ` ~ & ' + - = _ and the character . provided that it is not the first nor last character in the local-part, nor may it appear two or more times consecutively. To add a user to the address book, click on an “empty” address, type the name in the “Address” field. To edit an address, just click on the address to edit. To delete an address, click on the address to delete. Highlight the address in the “Address” field by holding the mouse right button down will “dragging” the mouse cursor over the name. Then press the “Del” key on the keyboard.

After selecting an address in the Email Addresses list, the email triggers can be assigned to the address recipient. To assign an email trigger to a

recipient, simply click on the checkbox next to the trigger.

02-28-11 38

that the Power Wave will attempt to send out an email immediately after the Send button is pressed, but depending on the email server that is processing the email, it take awhile of time for the recipient to receive the email.

4.2.6 Miscellaneous Tab

This tab is used to set a Part, Operator, or Consumable serial number in the Power Source. When this tab is selected, a page like the following will be displayed -

4.3 Weld Profile Training

Weld Profile Training is another unique feature of Production Monitoring™. Essentially, this feature removes the necessity 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 in normal production. Then, based on the training welds, Production Monitoring™ automatically generates limits for arc current, voltage, wire feed speed, and time. The operator can remove any welds made during the training that are considered “bad” welds. When training is being done to calculate the limits for Voltage, Current, or WFS, the longest training weld that can be taken is 1,260 seconds (21.0 minutes). If an actual weld is longer than this time, it is usually acceptable just to weld a shorter portion of the weld, then manually adjust the calculated time limits to extend them to match the true weld time. To manually adjust the limits, go to the Configuration section of Production Monitoring. When training is being done to calculate WeldScore data, the maximum length of any training weld must be less than 1 minute in duration. Note, that during training, data for WeldScore will be generated. But when the calculated limits are generated for the profile, the minimum limit for WeldScore is not calculated. To change this number from the default value of 80, the user must manually change this in the Configuration section for each profile.

02-28-11 39

4.3.1 What Welds to Train

Each profile that is being used should be trained. In order for accurate limits to be calculated, it is recommended to train at least 5 welds at each allowable production extreme for each profile. For example, if the electrical stickout is allowed to vary from 8

5 ”to ¾”, then train 5 welds at each of these stickouts. Only train the allowable extremes; if

the stickout may be able increase to 1” but this causes a bad quality weld, do not include this in training. The purpose of training is to show the Power Wave the types of welds considered acceptable.

4.3.2 Starting Training Mode

To start the training mode, first connect to the machine with Power Wave Manager. Then click on the “Training” item found under the Production Monitoring item located on the left side of the program. Note, if you don’t see the Production Monitoring item list on the left side of the program, then this is probably an older version of Power Wave Manager and it needs to be updated. After clicking on this, Power Wave Manager will now display a screen like the one shown below.

In the Training view, the green circles next to the Profile number for Time , Amperage , Voltage , and WFS

, show the items that have non-zero limits sets for it. For WeldScore , the icon means that it has valid WeldScore training data for that profile.

Once the “Training” item is selected on the left, then click on the item. This will bring up the following message -

02-28-11 40

Click on the “Yes” button to continue with Weld Profile training. Note that any weld history data that has yet to be collected by the Production Monitoring™ server will be lost. After the “Start training” item is clicked on, the status item located on the top of the window should change to - . Before any welds are taken, all the icons next the “Profile #” item in the profile list box will be a round gray circle, like . Now begin to make “training” welds, switching between different Weld Profiles as necessary. As a new weld starts, the Status line will change to - . When the weld is finished, the Status line will change back to . Also, when a weld is taken for a profile, the

icon next to the Profile number will change to a . Note, that after a training weld is complete, the computer must read the data from the welder. If a new weld is started before this data can be read, the new weld might not be recorded. The length of time to wait for the computer to read this data mainly depends on the length of the previous weld and the network speed. It takes about 1 second to read in data from every 63 seconds worth of welding. This means a very long training weld lasting 21 minutes can take up to 20 seconds to be read in by the PC.

4.3.3 Viewing the Calculated Limits for a Weld.

Once a weld has been taken for a profile, a box will appear next to the Profiles checkbox. Click on this to expand the profile item. When a Profile is expanded, it will list the number of welds that have been taken using that profile number. For example the below section shows that three welds have been take with Profile 11.

Click the “Profile” item in this column to see the calculated limits for that

The calculated limits are shown in this section.

02-28-11 41

Instead of viewing the calculated limits for a weld, you can click on an individual weld item and view the data just from that weld. This will be displayed in the same area as the calculated limits are shown. For example, if you

wanted to see the data from Weld 2, click on the item.

4.3.4 Deleting a Weld from Training

If for some reason there was a problem with a weld, it can be deleted from the profile. To delete a weld, expanded the Profile, see above. Then right click on the desired weld to delete. Now a popup item will appear, like the follow

Just click on this now to delete the weld from the training data.

4.3.5 Applying Weld Profile Calculated Limits

When all of the training welds have been completed, click on the item. The status should now change to . To save and use the calculated limits for those profile that you took training welds for, click on and check the checkboxes for the profiles that you want to save. Not all the profiles that had training

welds taken need to be clicked on. After the checkboxes are checked, now click on the item.

4.3.6 Clearing WeldScore Training Data.

To clear WeldScore training data for a profile, select the profile and click on the “Clear WeldScore data” button.

The icon next to the profile number will disappear.

Clicking this button tells Power Wave manager that WeldScore data is going to be cleared, but does not send the command to the Power Wave to erase it. To do that, the profile must be saved by checking the box next to the

profile and clicking on the button. If training data is not applied, WeldScore data will not be

cleared and the icon will reappear next time the profile screen is loaded in Power Wave Manager.

The example to the left shows that training welds were taken for Profiles 7,

11 and 12, since the icon to the left of their Profile item is now a . But

only Profiles 11 and 12 limits will be saved when the item is clicked on.

Check the boxes in this column for a profile to have its calculated limits saved after it was trained.

02-28-11 42

5 Main Report Section

See section 2.2 for launching the Main Report section. Note that before any reports can be run, welders must be added to the Production Monitoring system, see section 3 for how to add welders to the system. When launched, a screen like below should be displayed.

5.1 Getting started

5.1.1 Basic Terminology

Asset: A physical or logical grouping of items. In a manufacturing facility, this could be a single welder, station, or line within the plant. Topic: This is a categorization of information that may contain one or more actions. The topics are selected using different tabs. The Topics basically divide and organize the main sections of the program’s interface. Action: Actions are intended to describe and/or filter data related to the selected Topic. For Production Monitoring™ 2, actions will usually select some type of report. Criteria: A user supplied piece of information used to sort or filter the data returned to an Action or Panel.

5.1.2 Selecting the Language for Production Monitoring

See section 3.1 for selecting the language for Production Monitoring. The language can be selected in the Admin section or the report section of Production Monitoring; both sections use the same procedure.

02-28-11 43

5.1.3 Screen Layout

Asset Tree

Criteria Area

Action Area Topic Area

Panel Area

Hover the mouse over this to select the language

02-28-11 44

5.1.3.1 Asset Tree

A single welder can be selected for a report just by click on the desired welder. In the example shown to the left, welder WC#164 S350 will be used for any generated reports. Also a group item can be selected for a report. For example if the Line 1 group item is selected, then the welders WC#14 ACDC1000, WC#18 ACDC1000, and WC#69 i400 will be used for any generated reports. If the top most item is selected, in the example to the left this would be the “Lincoln Electric” item, then all the welders will be included in the report. Note that when selecting between a single welder and a group of welders, the Current Status tab will be switched back to automatically.

5.1.3.2 Topic Area

The topic area lists the main sections for Production Monitor 2.

There are seven different topics, Current Status, Production, Weld Listing, Weld Detail, Traceability, Downtime, and Fault Detail. To select a topic, simply click on the “tab” with the mouse. If all the topics items are not displayed, then two buttons will be displayed to the very right of the last topic that is showing. The buttons will look like . Click these buttons to have the rotate until the desired topic is shown.

5.1.3.3 Action Area

For Production Monitoring™ 2, the Action Area is used to run various reports for the selected Topic. Example Action Area:

To run a report, simply click on report text in the Action Area. Note that the listed reports can vary depending on if a single welder is selected or a group of welders are selected. For example, if a group of welders are selected in the asset tree, the reports under the Production tab will show Grid, True Energy, and Duration/Count. But if only a

This displays all Assets that have been created, and also allows navigation through those Assets. This section is used to select which welders will be used for a report. Assets are added, edited and deleted with the Administrative section of Production Monitoring; see section 3 for more information on configuring the Asset Tree. To navigate through the Asset Tree, simply expand and collapse Assets as needed. If an appears in a box next to an Asset, then there are other Assets (sub-Assets, or child nodes) beneath this one in the hierarchy that are not being shown. Click on the box and the Asset will expand, displaying all of its sub-Assets.

If an is in the box, the Asset has already been expanded and all sub-Assets are currently shown. To hide these Assets, click on the box and the parent Asset will collapse. To select an Asset, simply navigate through the Asset Tree until the desired Asset is found. Select it by clicking on the text portion. A selected Asset will be highlighted.

02-28-11 45

single welder was selected, then the reports will show Grid, Weld Profiles, WeldScore, Current/Voltage, Wire Feed Speed, True Energy, and Duration/Count.

5.1.3.4 Criteria Area

The Criteria area displays the data selection criteria that were used for a given report. Clicking on this area brings up a window that enables the user to set the selection criteria for a report. Example Criteria Area:

Clicking on the item in the Criteria area to bring up a “Criteria Edit Dialog” like the following -

Not all the Criteria Edit Dialogs are the same. What selection filters are displayed depends on the action or report that is selected. Some Topic criteria area might even be empty and not show anything. To change the Criteria data, enter the desired values in the dialog box and then click on the item. The criteria now will be saved until new criteria is reentered or as long as “cookies” on the computer are not cleared and do not expire. The different filters that can be displayed in a Criteria box are:

Start Date - Specifies the beginning date for a report.

End Date - Specifies the ending date for a report. Shift - Specifies which shift to display information for when generating a report. The available choices

depend on how the shifts are configured. All the available shifts should be shown along with the “Any” option.

Group Welds: Specifies the time period of how the data is averaged for the report. For example, if “By Hour” is selected, and the report is for a single eight hour shift, then the report will have eight items in it. Each of these items will be the combined average of the weld information for each hour of the shift. The available selections are: By Shift, By Hour, By Day, By Week, By Month, By Quarter, and By Year.

Weld Profile: This specifies the weld profile will be used for the report. The available selections are: Any and 1 to 32.

Production Date: Specifies the date for a report. See “Start Date” on how to select the date.

To select a different day from what is shown, click on the icon located at end of text box. Clicking on this will bring up a graphical calendar, like what is shown to the left. To select a different month, click either the or icons on the top of the calendar. This will have the calendar go to the either the previous or next month then what is shown. The and icons will have the selected month change by three month intervals.

02-28-11 46

Production Shift: Same as Shift. Production Hour: Sets the hour of the shift to use for the report. The possible values to select from are 0 to

24, where 0 means “any” hour. Record Count: Specifies the number of welds to use for the report. Weld ID: This item is only used for the Weld Detail Topic. This specifies the individual weld ID to use be

used to display information for. Part Serial Number: This item is only used for the Traceability Topic. This specifies the Part Serial

number to use for the report. Consumable Serial Number: This item is only used for the Traceability Topic. This specifies the

Consumable number to use for the report. Operator Serial Number: This item is only used for the Traceability Topic. This specifies the Operator

number to use for the report. Top Quantity: This item is only used for the Downtime Topic, chart report. This specifies the max number

of the different kinds of Faults to be displayed for the report. Fault: This item is only used for the Fault Detail Topic. This specifies the Fault to use for the report. The

user can select an individual fault or “Any” in which case all faults will be displayed.

5.1.3.5 Panel Area

This area displays the contents of the selected reports. If all the reports data can not fit in the panel area, horizontal and vertical scroll bars will be added as needed. Use these to scroll the page from left to right, or up and down. The

panel area size can also be increased by clicking on the and items located above and to the left of the area. Also a report heading text item can be clicked on to sort the report data in ascending or descending order.

Click on this, , to expand the panel area height.

Click on this, , to expand the panel area width.

Click on a report heading text to sort the data.

02-28-11 47

5.2 Running Reports

To run a report, follow the below procedure:

1. Select the welders for the report from the Asset Tree; see section 5.1.3.1. 2. Select the desired Topic tab (Current Status, Production, Weld Listing, etc) 3. Click on the desired report in the Action area. 4. Click on the Criteria area and set the report filters to use.

5.2.1 Report Links

Some reports have links to other reports “built into” the data. When a report data item is underlined, clicking on it will take you to another report. This other report will usually show more detail for the selected item.

5.2.2 Exporting Data from a Report

At the bottom of every report, there should be two items: and . These items can be used to export the data from the selected report to an Excel spreadsheet. Even though only part of the data maybe displayed

on the screen, the export will copy all the data from the report to the file. The will export the data using a standard Excel spreadsheet format. The item will export the data using a Comma Separated format.

5.2.3 Refreshing a Report data

At the bottom of every report, there should be an item. Clicking this will have the Production Monitoring update the data on the page. The reports on the Current Status tab should be refreshed automatically about every 15 to 20 seconds. All other reports must be manually refreshed to show data that was collected since the report was produced.

5.2.4 Report Page Numbers

When all the data can not fit on a single report page, “page numbers” will be shown on the very bottom of the reports data section. Clicking on these page numbers will bring up the next group of data for that report. The number of page numbers will vary depending on the amount of data there is.

For example, for the Production Tab, Grid report, the period field is underlined. This means that this item is a “link” to another report. Clicking on this field will run a Weld Listing Grid report for the selected Period item.

02-28-11 48

5.3 Topics

5.3.1 Current Status Tab

The Current Status Tab is mainly used to display status information for a welder or a group of welders. There are five actions (This Production Hour, This Production Shift, This Production Day, This Week, and This Month) which sets the time period for a report that will display status information for the currently selected welder or welders.

Click on these numbers to select another group of data to view for the report.

Click here to export data to an Excel spreadsheet.

Click here to refresh the Report’s data.

02-28-11 49

There is also a sixth action, System Capacity, which is used to display information on the database current usage.

Status Icon: The status icon is located next to the Welder (Name). See below for the icon definitions.

No Communications - The Production Monitoring™ software could not communicate with the Power Wave®. Check that the Power Wave® is turned on and that there are no problems with the Ethernet network.

Incompatible Firmware - Means that the Production Monitor Revision is not correct. The software in the Power Wave® needs to be updated to the latest version.

Faulted - Indicates that the Power Wave® has recently experienced an event that may prevent it from welding. Run Lincoln Electric’s PC Diagnostic Utility program to diagnose what the fault is.

Latched Fault - Indicates that the Power Wave® has a latched fault caused by Production Monitoring™. This latched fault must be reset before the Power Wave® will weld. See the “Alarm Latch” item in section 4.2.2.1 for more information on how to reset this.

Not Ready - Indicates that the Power Wave® is either currently being reprogrammed, or has experienced an event that may prevent it from welding. Run Lincoln Electric’s PC Diagnostic Utility program to diagnose why the Power Wave® is Not Ready.

Off Line - This means that Production Monitoring™ is not collecting data from the machine. The “Enable Data Collection” checkbox must be checked using the Administrative section, see section 3.2.3Error! Reference source not found.

Ready - Indicates that the Power Wave® is in an idle state (not welding).

Welding - Indicates that the Power Wave® is currently welding.

Download Data - The three small circles mean that the welder has a large amount of data that still needs to be read from the welder. Note, while this is shown, new welds will not show up in Production Monitoring until it is done reading out the oldest welds first.

Welder: This item displays the welders name and an icon with the welder’s status. Note, that since this tab is only updated only about every 20 seconds, the welder’s status can as much as 20 seconds out of date. The item can be clicked to update the information on this tab.

Welds: This is the number of welds that were made in the selected time period. Welds Out of Limit: This list the actual number of welds that were out of limit and what percent of the

total as well. See section 4.2.3 for more information limits and the setting of these. Arc Time: This displays the total number of hours that the Power Wave® has been welding in the selected

time period. Time of Last Weld: This is the time of the last weld that the Power Wave® performed during the selected

time period. Wire Remaining: This displays the amount of wire (in pounds or kilograms) remaining in the current wire

package. See section 4.2.4 for setting up wire package information.

02-28-11 50

5.3.1.1 System Capacity

This action displays information on the database utilization.

Oldest Weld: This displays the date and time of the oldest weld record in the database. Weld Capacity: This displays how much of the weld history database is being utilized. Weld Capacity Usage: This shows the percent of the weld history database that is being utilized Oldest Event: This displays the date and time of the oldest event record in the database. Event Capacity: This displays how much of the event history database is being utilized. Event Capacity Usage: This shows the percent of the event history database that is being utilized

5.3.2 Production Tab

The available reports that are shown on the Production tab depends on whether a single welder is selected in the Asset tree or a group of welders are selected. When a group of welders are selected, the Production tab will show the following reports -

When a single welder is selected, then the Production tab will show -

The Production tab enables the user to select reports which can be run over a range of dates. The data points for the reports in this tab will be groups of data which are averaged out either by hour, shift, day, week, month, quarter, or year. The data can be further filtered by the shift and weld profile number. There are seven different reports that can be run from this Topic: Grid, Weld Profiles, WeldScore, Current/Voltage, Wire Feed Speed/Deposition, True Energy/Duration, and Duration/Count. A report can be run against an individual welder or against one a groups of welders. Use the asset tree to select what welders are include in the report. See section 5.1.3.1 for more information on selecting welders for reports from the asset tree.

5.3.2.1 Grid Report

This produces a tabular text listing that summarizes the data, like what is shown below.

02-28-11 51

Period: This lists the time period that this group of data was averaged out over. Clicking on an item in the period field will cause a Weld Listing, Grid Report, to run for the selected item.

Welds: This is the number of welds that were made in the given time period. Welds Out of Limit: This list the actual number of welds that were out of limit and what percent of the

total as well. Total Arc Time: This displays the total number of hours that was spent in the welding state in the selected

time period. WeldScore: This displays the average WeldScore for the given time period. Avg. Current: This displays the average current for the given time period. Avg. Voltage: This displays the average voltage for the given time period. Avg. WFS: This displays the average Wire Feed Speed for the given time period. Avg. True Energy: This displays the average True Energy for the given time period.

5.3.2.2 Weld Profiles Report

The top half of the report is a graphical display of the number of welds that were made and the number that were out of limit based on the weld profile. The bottom half is a tabular text listing that summarizes the data and further breaks down the welds that were out of limit into what caused it to be out of limit.

02-28-11 52

Profile: This list the profile number. Welds: Total number of welds performed in this Profile. Current Limit Events: Number of welds that were outside of the arc current limits. Voltage Limit Events: Number of welds that were outside of the arc voltage limits. WFS Limit Events: Number of welds that were outside of the wire feed speed limits. WeldScore Events: Number of welds that were outside of the WeldScore limit. Duration Limit Events: Number of welds that were outside of the time limits.

5.3.2.3 WeldScore Report

The top half of the report is a graphical display that shows the average WeldScore data points for each time period of the report. The bottom half is a tabular text listing that summarizes the data and lists the criteria on how the data was selected.

02-28-11 53

Period: This lists the time period that this group of data was averaged out over. Clicking on an item in the period field will cause a Weld Listing, WeldScore Report, to run for the selected item.

WeldScore: This displays the average WeldScore for the given time period.

5.3.2.4 Current/Voltage Report

The top half of the report is a graphical display that shows the average current and average voltage data points for each time period of the report. The bottom half is a tabular text listing that summarizes the data and lists the criteria on how the data was selected.

Period: This lists the time period that this group of data was averaged out over. Clicking on an item in the period field will cause a Weld Listing, Current/Voltage Report, to run for the selected item.

Avg. Current: This displays the average current for the given time period. Avg. Voltage: This displays the average voltage for the given time period.

5.3.2.5 Wire Feed Speed/Deposition Report

The top half of the report is a graphical display that shows the average wire feed speed and wire deposition data points for each time period of the report. The bottom half is a tabular text listing that summarizes the data and lists the criteria on how the data was selected.

02-28-11 54

Period: This lists the time period that this group of data was averaged out over. Clicking on an item in the

period field will cause a Weld Listing, Wire Feed Speed/Deposition Report, to run for the selected item. Avg. WFS: This displays the average wire feed speed for the given time period. Wire Deposition: This displays the amount of wire that was deposited (in pounds or kilograms) for the

given time period.

5.3.2.6 True Energy/Duration Report

The top half of the report is a graphical display that shows the average True Energy and the weld duration data points for each time period of the report. The bottom half is a tabular text listing that summarizes the data and lists the criteria on how the data was selected.

Period: This lists the time period that this group of data was averaged out over. Clicking on an item in the period field will cause a Weld Listing, True Energy/Duration, to run for the selected item.

True Energy: This displays the average True Energy for the given time period.

02-28-11 55

Total Arc Time: This displays the total number of hours that was spent in the welding state in the selected time period.

5.3.2.7 Duration/Count Report

The top half of the report is a graphical display that shows the average wire feed speed and wire deposition data points for each time period of the report. The bottom half is a tabular text listing that summarizes the data and lists the criteria on how the data was selected.

Period: This lists the time period that this group of data was averaged out over. Clicking on an item in the period field will cause a Weld Listing, True Energy/Duration, to run for the selected item.

Total Arc Time: This displays the total number of hours that was spent in the welding state in the selected time period.

Welds: This is the number of welds that were made in the given time period. Welds Out of Limit: This list the actual number of welds that were out of limit and what percent of the

total as well.

5.3.3 Weld Listing Tab

The available reports that are shown on the Weld List tab depends on whether a single welder is selected in the Asset tree or a group of welders are selected. When a group of welders are selected, the Weld Listing tab will show the following reports -

When a single welder is selected, then the Weld Listing tab will show -

02-28-11 56

The Weld Listing tab enables the user to select reports for a particular date. The data points for the reports in this tab will be the individual welds themselves. The data can then be filtered by the shift, the hour of the shift, and the weld profile number. There are six different reports that can be run from this Topic: Grid, WeldScore, Current/Voltage, Wire Feed Speed/Deposition, True Energy/Duration, and Wire Deposition. A report can be run against an individual welder or against one a groups of welders. Use the asset tree to select what welders are include in the report. See section 5.1.3.1 for more information on selecting welders for reports from the asset tree.

5.3.3.1 Grid Report

This produces a tabular text listing that summarizes the data.

Weld ID: This is a record number that is assigned by the database. Clicking on an item in the Weld ID field will cause a Weld Detail report to run for the selected Weld ID.

Start of Weld: This lists the date and time that the weld began at. Welder: This is the name of the welder. Part Serial Number: This lists the part Serial Number that was assigned to this weld. Clicking on an item

in the Serial Number field will cause a Traceability report to run for the selected serial number. Arc Time: This displays the duration of the weld. Profile: This is the Profile that was used during the weld. Status: This displays the status of the weld as to whether it was in limits or not. WeldScore: This displays the average WeldScore for the weld. Avg. Current: This displays the average current for weld. Avg. Voltage: This displays the average voltage weld. Avg. WFS: This displays the average Wire Feed Speed for the weld. True Energy: This displays the True Energy for the weld.

02-28-11 57

5.3.3.2 WeldScore

The top half of the report is a graphical display that shows the WeldScore data points for each weld in the report. The bottom half is a tabular text listing that summarizes the data and lists the criteria on how the data was selected.

Start of Weld: This lists the date and time that the weld began at. Clicking on an item in the Start of Weld field will cause a Weld Detail report to run for the selected weld.

WeldScore: This displays the average WeldScore for the weld.

5.3.3.3 Current/Voltage Report

The top half of the report is a graphical display that shows the current and voltage data points for each weld in the report. The bottom half is a tabular text listing that summarizes the data and lists the criteria on how the data was selected.

02-28-11 58

Start of Weld: This lists the date and time that the weld began at. Clicking on an item in the Start of Weld field will cause a Weld Detail report to run for the selected weld.

Avg. Current: This displays the average current for the weld. Avg. Voltage: This displays the average voltage for the weld.

5.3.3.4 Wire Feed Speed/Deposition Report

The top half of the report is a graphical display that shows the average wire feed speed and wire deposition data points for each weld in the report. The bottom half is a tabular text listing that summarizes the data and lists the criteria on how the data was selected.

Start of Weld: This lists the date and time that the weld began at. Clicking on an item in the Start of Weld field will cause a Weld Detail report to run for the selected weld.

Avg. WFS: This displays the average wire feed speed for the weld. Wire Deposition: This displays the amount of wire that was deposited (in pounds or kilograms) for the

weld.

5.3.3.5 True Energy/Duration Report

The top half of the report is a graphical display that shows the True Energy™ and the weld duration data points for each weld in the report. The bottom half is a tabular text listing that summarizes the data and lists the criteria on how the data was selected. True Energy™ is the amount of energy that was put in the weld as defined by Energy = Current * Volts * Time.

02-28-11 59

Start of Weld: This lists the date and time that the weld began at. Clicking on an item in the Start of Weld field will cause a Weld Detail report to run for the selected weld.

True Energy™: This displays the True Energy™ for the weld. If a welder has older software in it and does not support the True Energy calculation a 0 will be displayed for this item.

Arc Time: This displays duration of the weld.

5.3.3.6 Wire Deposition Report

The top half of the report is a graphical display that shows the amount of wire deposited for each weld of the report. The bottom half is a tabular text listing that summarizes the data and lists the criteria on how the data was selected.

Start of Weld: This lists the date and time that the weld began at. Clicking on an item in the Start of Weld field will cause a Weld Detail report to run for the selected weld.

Wire Deposition: This displays the amount of wire that was deposited (in pounds or kilograms) for the weld.

02-28-11 60

5.3.4 Weld Detail Tab

The Weld Detail Tab is used to display information about a single individual weld. Basically there is only a single report associated with this tab, below is an example of what the panel area will look like for this report.

Welder: This is the name of the welder that was assigned to it. Serial Number: This lists the part Serial Number that was assigned to this weld. Clicking on the Serial

Number field value will cause a Traceability report to run for the selected serial number. Consumable Serial Number: This lists the Consumable Serial Number that was assigned to this weld.

Clicking on this field value will cause a Traceability report to run for the selected serial number. Operator Serial Number: This lists the Operator Serial Number that was assigned to this weld. Clicking

on this field value will cause a Traceability report to run for the selected serial number. Profile: This lists the profile number that was used for this weld. Start of Weld: The date and time on which the weld was started. Weld Duration: The duration of the weld (seconds). Start Delay: This lists the amount of Start Delay that was used for this weld; see section 4.2.3 for

information on this item. End Delay: This lists the amount of End Delay that was used for this weld; see section 4.2.3 for

information on this item. Wire Density: This lists the density of the wire that was set for this weld. Wire Diameter: This lists the diameter of the wire that was set for this weld. Deposited Weight: Amount of wire (pounds or kilograms) that was deposited during this weld. This

amount depends on the density and diameter settings of the Wire Package Deposition Rate: The deposition rate, calculated from the deposited weight and weld duration Status: This lists the status of the weld. If any item was out of limits, it will be listed here. If all the

parameters were in limit, this will show “In Limits”. WeldScore Status: This lists the status of the WeldScore for this weld. WeldScore: This shows the average WeldScore value measured during this weld.

Current Status: This lists the status of the current for this weld. Current Minimum: Minimum arc current measured during this weld. Current Average: Average arc current measured during this weld. Current Maximum: Maximum arc current (Amps) measured during this weld.

02-28-11 61

Current Minimum Limit: This lists the Current low limit for the weld. Current Maximum Limit: This lists the Current high limit for the weld. Current Percent High: Percent of the weld that was above the arc current limit. Current Percent Low: Percent of the weld that was below the arc current limit.

Voltage Status: This lists the status of the voltage for this weld. Voltage Minimum: Minimum arc voltage measured during this weld. Voltage Average: Average arc voltage measured during this weld. Voltage Maximum: Maximum arc voltage (Volts) measured during this weld. Voltage Minimum Limit: This lists the Voltage low limit for the weld. Voltage Maximum Limit: This lists the Voltage high limit for the weld. Voltage Percent High: Percent of the weld that was above the arc voltage limit. Voltage Percent Low: Percent of the weld that was below the arc voltage limit.

WFS Status: This lists the status of the WFS for this weld. WFS Minimum: Minimum wire feed speed measured during this weld. WFS Average: Average wire feed speed measured during this weld. WFS Maximum: Maximum wire feed speed (IPM) measured during this weld. WFS Minimum Limit: This lists the WFS low limit for the weld. WFS Maximum Limit: This lists the WFS high limit for the weld. WFS Percent High: Percent of the weld above the wire feed speed limit. WFS Percent Low: Percent of the weld that was below the wire feed speed limit. True Energy™ Average: This lists the True Energy™ for this weld.

5.3.5 Traceability Tab

The Traceability Tab is used to display information on a “part”. A part’s serial number is entered into the criteria area and then the welds in the database are searched to see if they have this serial number assigned to them. If they do, then they are listed in the report. The system will search all the welds for this serial number or until the required number of “Record Counts” is reached. In order to list all the welds for a part, the Record Count in the criteria area must be greater than the number of welds with the assigned serial number.

02-28-11 62

Weld ID: This is the record number that is assigned by the database. Clicking on an item in the Weld ID

field will cause a Weld Detail report to run for the selected Weld ID Start of Weld: This lists the date and time that the weld began at. Clicking on an item in the Start of Weld

field will cause a Weld Listing, Grid, report to run for the selected weld. Welder: This is the name of the welder. Arc Time: This displays duration of the weld. Current: This displays the average current for weld. Voltage: This displays the average voltage weld. WFS: This displays the average Wire Feed Speed for the weld. True Energy: This list the True Energy for the weld. Status: This displays the status of the weld as to whether it was in limits or not.

5.3.6 Downtime Tab

The Downtime tab is used to summarize faults in the system and how much “downtime” has accumulated due to each type of fault. For example, if a Thermostat fault occurred at 11:01:05 and then cleared at 11:06:30, this will increment the Thermostat fault count by 1 and the duration by 5 minutes and 25 seconds. Note that only the primary event that caused a machine to fault will be displayed and counted. While the primary event is active, no secondary events that happen will be displayed or counted. There are two different reports that can be run from this Topic: Grid and Chart.

5.3.6.1 Grid Report

This produces a tabular text listing that summarizes the fault data.

Fault: Lists the type fault. Clicking on an item in the Fault field will cause a Fault Detail report to run for the selected fault.

Duration: This lists the total time that a particular type fault was active for over the reports selected time period.

Count: This list the number of times this fault occurred over the reports selected time period.

5.3.6.2 Chart Report

The top half of the report is a graphical display that shows the total duration a type of fault was active for and the total number of times this fault occurred. The bottom half is a tabular text listing that summarizes the data and lists the criteria on how the data was selected.

02-28-11 63

Fault: Lists the type fault. Clicking on an item in the Fault field will cause a Fault Detail report to run for the selected fault.

Duration: This lists the total time that a particular type fault was active for over the reports selected time period.

Count: This list the number of times this fault occurred over the reports selected time period.

5.3.7 Fault Detail Tab

The Fault Detail Tab is used to lists individual faults and the time that they occurred. There is only a single report associated with this tab, below is an example of what the panel area will look like for this report.

Welder: This is the name of the welder. Log Time: This lists the date and time the fault occurred at. Duration: This lists how long the fault persisted for. Fault: Lists the actual fault that occurred. Data: List data associated with the fault.

02-28-11 64

6 Additional Information

6.1 Export of Data from the Database

Production Monitoring™ 2 uses the SQL Server Express Database. This has a limited storage capacity so when the database reaches a specified size, 250,000, the oldest data in the database will be exported and then deleted from it. Limiting the number of records in the database will also improve the performance of the system, which will make the generation of reports more efficient. Once an hour, the system will check to see if this number has been reached. If it has, then the oldest 60,000 records will be written out to an Excel CSV file, then these values will be deleted from the database. When the weld history is exported from the database, the CSV file that is created will be placed in the directory C:\Program Files\Lincoln Electric\Production Monitoring\Exports. Once a day, the system will check to see if the maximum number of fault records has been reached. If it has, then the oldest 60,000 records will be deleted from the database. These are not exported like the Weld History Records.

6.1.1 Export File Name Format

The file name will be in the format PM-StartTime-EndTime.csv. Where StartTime is the date and time of the first weld in the file and EndTime is the date and time of the last weld in the file. Both items have the format of - YYYYMMDDHHmmss, where YYYY - Year MM - Month DD - Day HH - Hour mm - Minute ss - Second Example, a file where the first weld in the file was started on 2007, Aug 8th, at 15:41:39 and the last weld in the file ended 2007, Aug 9th, at 09:43:41 will have a file name of “PM-20070808154139-20070809094341.csv”.

6.1.2 Open an Export file in Excel

To open this file in Excel, follow the below steps -

1. Open Microsoft Excel. 2. Click on the File menu item, then the “Open” menu item. 3. This will bring up an Open dialog box. From here select “Text File (*.prn; *.text; *.csv)” on the “Files of

type” drop down box at the bottom of the Open dialog box.

02-28-11 65

4. Now select the file you wish to open. 5. After the file is selected and the “Open” button is clicked, the follow dialog box will open up.

6. From here, click on the “Delimited” item (as shown above), then click the “Next” button. 7. Another dialog box will appear -

Make sure the “Files of type” is set to “Text Files” here.

Set the “Original data type” to Delimited.

02-28-11 66

8. From here, only check on the “Comma” checkbox, as shown above. 9. Now click the “Finish” button. The file should now open up in Excel in a “readable” format.

6.1.3 Export File Format

The top line of the file is a “heading line”, all other lines in the file are data, where each line represents a single weld. Going “across” the Excel spreadsheet is the data for the weld. The below table breaks this out and lists the column letter, the heading for each column, and an explanation what each column represents.

Col. Heading Column Information A ID This was the database ID of the Weld B WelderName This is the name of the welder that was assigned to it C Profile Number This lists the profile number that was used for this weld D MachineCounter This was the weld ID from the welder E SerialNumber This lists the part Serial Number that was assigned to this weld F StartDateTime The date and time on which the weld was started G Duration The duration of the weld (seconds). H EndDateTime This is the Start date and time with the weld duration added to it I Status This is a bit mapped field that specifies what Production Monitoring™ limit

errors occurred (if any). A value of zero means that no errors occurred. If it is non-zero, then see below for what bit means what -

Bit # Fault 0x8000 Fault Latch 0x4000 Fault 0x2000 Alarm Latch 0x1000 Alarm 0x0800 Unused Bit 0x0400 Unused Bit 0x0200 Low Time Limit 0x0100 Time Lim 0x0080 Power Hi (Not Used) 0x0040 Power Low (Not Used) 0x0020 WFS Hi 0x0010 WFS Low

Set the Delimiters to “Comma” only.

02-28-11 67

0x0008 Volts Hi 0x0004 Volts Low 0x0002 Amps Hi 0x0001 Amps Low

J StartDelay This is lists the amount of Start Delay that was used for this weld, K EndDelay This is lists the amount of End Delay that was used for this weld L ConsumeDensity This lists the density of the wire that was set for this weld M WireDiameter This lists the diameter of the wire that was set for this weld N VAvgValue Average arc voltage measured during this weld O VMinValue Minimum arc voltage measured during this weld P VMaxValue Maximum arc voltage (Volts) measured during this weld Q VLowPercent Percent of the weld that was below the arc voltage limit R VHighPercent Percent of the weld that was above the arc voltage limit S VLowLimit This lists the Voltage low limit for the weld T VHighLimit This lists the Voltage high limit for the weld U VIsLow This will be set to 1 if the weld was below the voltage low limit, else it will

be 0. V VIsHigh This will be set to 1 if the weld was above the voltage high limit, else it will

be 0. W VBaseUnits List the units for voltage, should be set to V (for Volts) X CAvgValue Average arc current measured during this weld Y CMinValue Minimum arc current measured during this weld Z CMaxValue Maximum arc current (Amps) measured during this weld

AA CLowPercent Percent of the weld that was below the arc current limit AB CHighPercent Percent of the weld that was above the arc current limit AC CLowLimit This lists the Current low limit for the weld AD CHighLimit This lists the Current high limit for the weld AE CIsLow This will be set to 1 if the weld was below the current low limit, else it will be

0. AF CIsHigh This will be set to 1 if the weld was above the current high limit, else it will

be 0. AG CBaseUnits List the units for current, should be set to A (for Amps). AH WFSAvgValue Average wire feed speed measured during this weld AI WFSMinValue Minimum wire feed speed measured during this weld AJ WFSMaxValue Maximum wire feed speed (IPM) measured during this weld. AK WFSLowPercent Percent of the weld that was below the wire feed speed limit AL WFSHighPercent Percent of the weld above the wire feed speed limit AM WFSLowLimit This lists the WFS low limit for the weld AN WFSHighLimit This lists the WFS high limit for the weld AO WFSIsLow This will be set to 1 if the weld was below the WFS low limit, else it will be

0. AP WFSIsHigh This will be set to 1 if the weld was above the WFS high limit, else it will be

0. AQ WFSBaseUnits Lists the units for WFS (Can be in/min or m/min). AR TrueEnergy The True Energy for the Weld AS TEBaseUnits Lists the units for True Energy AT WeldScore This is the average WeldScore value from the weld. AU WeldScoreISLow This will be set to 1 if the weld was below the WeldScore low limit, else it

will be 0. AV WeldScoreLowLimit This is the WeldScore Low Limit AW OperatorSerialNumber This lists the Operator Serial Number that was assigned to this weld AX ConsumableSerialNumber This lists the Consumable Serial Number that was assigned to this weld

02-28-11 68

AY DurationHighLimit This is the Time High limit from the weld. AZ DurationLowLimit This is the Time Low limit from the weld. BA IsOutOfLimits This will be set to 1 if the weld was out of the time limits, else it will be 0.

Example Excel screen shot from a file import of the weld data that was exported to a file.

6.2 DeviceNet™ I/O for Production Monitoring™

This section outlines the features of Production Monitoring™ that are accessible and controllable using a DeviceNet interface (for a complete description of the Power Wave® DeviceNet interface, refer to the document entitled Y50031-xx_DeviceNetInterfaceSpecification.pdf). The DeviceNet interface allows access to the Production Monitoring™ attributes “WStats Weld Select” and “Select Weld Based on welding set point.” The “Wstats Weld Select” attribute contains the number of the Weld Profile currently in use. 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 setting0. To access these attributes, use the following DeviceNet class/attributes: WStats Weld Select: DN Class 100, Instance 1, Attribute 70

DN Class 15, Instance 165

02-28-11 69

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

The DeviceNet I/O also includes a feedback bit for when there is a Production Monitoring™ Fault, as well as a Production 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 0 0 Fault Reset

(Arc Obj) Weld Output Disable

Cold Inch Rev

Cold Inch Fwd

Touch Sense Cmd

Gas Purge

Trigger

1 Prod. Mon. Fault Reset

Attribute Request

Process Select Ready

Schedule Select (Bit 2)

Schedule Select (Bit 1)

Schedule Select (Bit 0)

Consumed Assembly (Perspective of DeviceNet Master): Byte Bit 7 Bit 6 Bit 5 Bit 4 Bit 3 Bit 2 Bit 1 Bit 0

0 DN Fault (Sys Fault)

Wire Stick

Inverter Fault

Water Fault

Wire Fault

Gas Fault Touch Sensed

Arc Detect

1 Attribute Response

Toggle Bit (Arc Obj)

Active Feed Head

Gas Purge On

Prod. Mon. Fault

Weld Cmplete

Limit Error

Process Select Ack.

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 when the Production Monitoring™ Alarm Reset Attribute is written to, or when the DeviceNet trigger is reasserted. When Alarm Latch is used, asserting the Production Monitoring™ Fault Reset will turn off the Production Monitoring™ Fault bit on the DeviceNet I/O and it will call Alarm Reset for Production Monitoring™. Note: this bit is active even when the DeviceNet interface is in Passive Mode. DeviceNet can also be used to set the part serial number. See section 7.7 of Lincoln Electric’s Y50031 DeviceNet Interface Specifications document for more information on setting this over the polled IO connection. See section 10.1.5.6 for setting the part serial using DeviceNet Explicit messaging.

02-28-11 70

6.3 Using Production Monitoring™ in a FANUC® Robotic Application

Sections 6.3.1 to 6.3.7 which covers supporting Production Monitoring in a Faunc robot prior to the V7.70P/07 release; see section 6.4 for Fanuc support for Production Monitoring starting with the V7.70P/07 release.

6.3.1 Overview

1. Production Monitoring™ is a tool used to send weld process data to a remote computer for monitoring. It can also be used to alert the robot operator if a weld process has exceeded predetermined limits. Limits that can be monitored include voltage, current, wire feed speed, and time. If a limit is exceeded, an alarm can be generated at the robot to alert the operator. Up to 32 different welds can be monitored.

2. The system uses programs already loaded into the robot to monitor and check to see if the weld is within the limits. These programs will then generate an alarm or other desired action to alert the operator.

3. Production Monitoring™ determines if a weld is within specified limits. It does not determine if it is a good or bad weld. It is the end user’s responsibility to make that determination.

6.3.2 Requirements

1. The robot must have Arctool software version 6.40-1M or later installed. This version includes two programs, WR_AL_AT.VR and RD_AL_AT.VR that form the basis of Production Monitoring™ robotic interface. These two program names are seen in the Select key program listing along with the all other programs in the robot’s memory.

2. The Karel software function must be Enabled. Karel is a Fanuc software tool that performs functions behind the scenes, out of view, during normal robot operations. To check to see if it is Enabled, press the Menu key, cursor to line 0-next, Enter, cursor to line System, Enter. Press F1-Type key, cursor to line Variables, Enter. Cursor down to line $KAREL_ENB, approximately line #190, $KAREL_ENB should be set to 1; if it is set to 0, key in a 1, Enter. Then power down the robot and power up to save this setting.

3. Nine Registers need to be set aside and dedicated for Production Monitoring™ use. The robot has 200 Registers available for use to perform math functions. This manual will use Registers 1-9 for example use.

4. The Power Wave® must have the Ethernet Module installed, set up and running on a network. A network connection can also be established to the Power Wave® through the robot, providing it has been setup, configured, and running on a network. Refer to FANUC® CD Manual set, Internet/Ethernet Manual for instructions.

NOTE: Production Monitoring™ email functionally is only available when the Power Wave® is directly connected to the network. NOTE: If the robot is an E-model, an E-Cell for example, the network connection must be directly to the Power Wave® External Ethernet Module.

5. The software from the Production Monitoring™ CD has been installed on a computer connected to the same network as the Power Wave® or the robot.

6.3.3 Setting Limits

1. Before Production Monitoring™ is enabled; limits have to be established ahead of time. Production Monitoring™ has a built in tool to simplify this task called Weld Profile Training. By running a series of test welds, the Production Monitoring™ Training function will collect data and automatically calculate a set of limits that can be used as a starting point and adjusted as needed.

02-28-11 71

6.3.4 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 data titled PM_SEL and one to compare data titled PM_VER. They will be listed in the Select key program listing along with all other programs. Through the use of a CALL instruction, PM_SEL will be taught and run 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 as part of the instruction. A sample weld program is shown below:

1: J P[1] 100% CNT100 2: J P[2] 100% CNT100 3: CALL PM_SEL(1) 4: J P[3] 100% FINE ARC START[1] 5: L P[4] 40 in/min FINE ARC END[1] 6: CALL PM_VER(1) 7: J P[5] 100% CNT100 8: J P[1] 100% CNT100 END

2. To teach the Production Monitoring™ instructions, press F1-INST, cursor to line CALL, Enter. At new

submenu, cursor to line Call Program, Enter. A list of programs will now appear; cursor to PM_SEL or PM_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.

6.3.5 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 programs are installed in the robot for ease of adding additional actions to take place. These programs are titled ALERT_1 through ALERT_5, and ALERT_10. They would be used as follows:

ALERT_1 Weld Profile Runt occurred ALERT_2 Weld Profile Time Limit occurred ALERT_3 Weld Profile I (current) Limit occurred ALERT_4 Weld Profile V (voltage) Limit occurred ALERT_5 Weld Profile WFS (wire feed speed) occurred ALERT_10 Invalid Profile has been selected

The program names will have already been created but it is the end user’s responsibility to set these programs 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 for interfacing instructions. An example program is shown below:

ALERT_4 1: DO[1] = ON 2: WAIT UI[6] = ON 3: DO[1] = OFF END

02-28-11 72

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

6.3.6 Erroneous Low Time Limit Alarms

1. A low time limit can occur if the duration of the weld is 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 the TorchMate and Touch Sensing options are used, the momentary touch the wire makes at the part or the TorchMate block is enough to cause a low time limit to be generated. If these becoming a nuisance, it is possible to turn off Production Monitoring™ prior to running a Touch Sensing routine or running 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.

3. To avoid tampering with the original TorchMate Adjust program, it may be desirable to create a new program titled TorchMate, for example, that begins with a line to turn off Production Monitoring™, followed by 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:

TORCHMATE 1: CALL PM_OFF 2: Torchmate Adjust 3: CALL PM_ON END

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.

6.3.7 Reference

1. Programs Installed To Operate Production Monitoring™

WR_AL_AT.PC RD_AL_AT.PC PM_SEL PM_VER PM_OFF PM_ON ALERT_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]<0 OR R[1]>31, CALL ALERT(10); 3: LBL[1]; 4: ! set profile selection 5: CALL WR_AL_AT(1,17,1008,R[1],3,4); 6: ! verify that the write was ok 7: 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;

02-28-11 73

11: R[1] = R[1] + 2013; 12: ! Get runt counts 13: LBL[3]; 14: CALL RD_AL_AT(1,17,R[1]); 15: IF $ARCLINK_ATR.$STATUS<>0 JMP LBL[3]; 16: R[5] = $ARCLINK_ATR.$INT_VALUE; 17: R[1] = R[1] + 1; 18: ! Get Time Limit counts 19: LBL[4]; 20: CALL RD_AL_AT(1,17,R[1]); 21: IF $ARCLINK_ATR.$STATUS<>0 JMP LBL[4]; 22: R[6] = $ARCLINK_ATR.$INT_VALUE; 23: R[1] = R[1] + 1; 24: ! Get I Limit counts 25: LBL[5]; 26: CALL RD_AL_AT(1,17,R[1]); 27: IF $ARCLINK_ATR.$STATUS<>0 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 $ARCLINK_ATR.$STATUS<>0 JMP LBL[6]; 34: R[8] = $ARCLINK_ATR.$INT_VALUE; 35: R[1] = R[1] + 1; 35: ! Get WFS limit counts 37: LBL[7]; 38: CALL RD_AL_AT(1,17,R[1]); 39: IF $ARCLINK_ATR.$STATUS<>0 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]<0 OR R[1]>31, CALL ALERT(10); 3: R[1] = R[1] * 25; 4: R[1] = R[1] + 2013; 5: ! Get runt counts 6: LBL[3]; 7: CALL RD_AL_AT(1,17,R[1]); 8: IF $ARCLINK_ATR.$STATUS<>0 JMP LBL[3]; 9: IF R[5] <> $ARCLINK_ATR.$INT_VALUE, CALL ALERT(1) 10: R[1] = R[1] + 1; 11: ! Get Time Limit counts 12: LBL[4]; 13: CALL RD_AL_AT(1,17,R[1]); 14: IF $ARCLINK_ATR.$STATUS<>0 JMP LBL[4]; 15: IF R[6] <> $ARCLINK_ATR.$INT_VALUE, CALL ALERT(2) 16: R[1] = R[1] + 1; 17: ! Get I Limit counts 18: LBL[5]; 19: CALL RD_AL_AT(1,17,R[1]); 20: IF $ARCLINK_ATR.$STATUS<>0 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

02-28-11 74

24: LBL[6]; 25: CALL RD_AL_AT(1,17,R[1]); 26: IF $ARCLINK_ATR.$STATUS<>0 JMP LBL[6]; 27: IF R[8] <> $ARCLINK_ATR.$INT_VALUE, CALL ALERT(4) 28: R[1] = R[1] + 1; 29: ! Get WFS limit counts 30: LBL[7]; 31: CALL RD_AL_AT(1,17,R[1]); 32: IF $ARCLINK_ATR.$STATUS<>0 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

6.4 Newer Support for Production Monitoring™ in a FANUC® Robotic Application

Sections 6.3.1 to 6.3.7 cover supporting Production Monitoring in a Faunc robot prior to the V7.70P/07 release. This section is for Fanuc support for Production Monitoring starting with the V7.70P/07 release or later.

6.4.1 System Variables

Below list the System variables were added and an example of how they are set. $AWELEPM[1] 1 $PM_ENABLE FALSE 2 $PM_EXISTS FALSE 3 $WP_NUM 0 4 $I_WELDSCORE 0 5 $A_WELDSCORE 0 6 $PART 'FOO' 7 $OPER '123456789012345678> 8 $CONS '123456789012345678> 9 $PART_CFG 0 10 $OPER_CFG 0 11 $CONS_CFG 0 12 $DEBUG 0 13 $WP_NUM_MAX 32 14 $ALARM 0 15 $LATCH_ALARM 0 16 $FAULT 0 17 $ALARM_PTYP 2 18 $ALARM_PNUM 19 19 $FAULT_PTYP 2 20 $FAULTPNUM 20 21 $TRUE_ENERGY 72412.000

To enable Lincoln Electric Production Monitoring support in the robot, Set the $PM_ENABLE variable to TRUE.

02-28-11 75

6.4.2 Weld Profile Selection

6.4.3 Serial Number Setting

The MACRO “Set_PM_Part” allows you to set the part serial number directly or by reference. The string is copied into the system variable and sent to the Power Wave with the Weld Start (or Arc Start) command. If Multi-Equipment is configured, the MACRO name changes to Set_PM_Part_E1, Set_PM_Part_E2, Set_PM_Part_E3, or Set_PM_Part_E4 for the appropriate weld equipment.

6.4.4 WeldScore and True Energy

During welding the $I_WELDSCORE variable is updated with the most recent value and the average value is held upon weld completion. During welding the $TRUE_ENERGY variable is updated with the most recent value and held upon weld completion

6.4.5 Error Reporting

The Lincoln Production Monitor feature allows the user to define 3 response actions when an out-of-tolerance error is encountered: Lincoln Error Robot Behavior

Log Event Post Warning error and turn on user-defined Digital Output Alarm Latch Post Warning error, turn on user-defined Digital Output, allow current weld to complete

but prohibit starting next weld until user reset. Fault System

Post Pause error, turn on user-defined Digital Output, execute Arc End processing, and stop welding.

To select the Weld Profile, insert the statement, $AWELEPM[1].$WP_NUM=X , ahead of the Arc Start or Weld Start instruction. Where X is a number between 1 and 32. The Weld Profile selected remains in effect until changed so this profile number is used for both welds in the sample program. Note the F4 [CHOICE] key contains the parameter name to use for Equipment 1. Simply edit the index for equipment 2, 3, or 4.

02-28-11 76

6.4.6 ServoTorch Wire Feed Speed Feedback

Added support for reading Wire Feed Speed from the ServoTorch for Production Monitoring. ServoTorch must be enabled and the System variable, $AWELEWC[1].$WIR_MTR_TIM, in the robot that sets the frequency the WFS events come out at must be non-zero.

There are 2 Digital Outputs that can be set by the user: $ALARM_PNUM holds the DO[number] for an Alarm error. $FAULT_PNUM holds the DO[number] for a Fault error.

Note the alarm indicates if the measured value is high or low. The error detail shows the values of voltage, current and the TCP position (weld distance) when the error was reported.

02-28-11 77

6.5 Installing Microsoft Internet Information Server (IIS)

6.5.1 XP Professional ISS Installation

With XP Professional IIS is not installed by default, do the follow to install it. 1. You must be logged in to the PC as an Administrator 2. Put the Microsoft Operating System disk in. A window like below should appear.

3. Click on “Install Optional Windows Components”. A new window should appear like below.

4. Check the Internet Information Services (IIS) box, then click Next to install this item.

02-28-11 78

6.5.2 Windows 2003 IIS Installation

1. You must be logged in to the PC as an Administrator 2. Go to the Control Panel and select the Add or Remove Programs item. 3. From here select the Windows Components item. A window like below should appear.

3. Select the Application Server and then click the “Details” button. A new should appear like below.

4. Make sure Information Services (IIS) is selected. 5. Then click on the “Details” button again. A new window should appear.

02-28-11 79

6. Make sure World Wide Web Service is selected. 7. Then click on the “Details” button again. A new window should appear.

8. From here, make sure that Active Server Pages, Server Side Includes, and World Wide Web Service are selected.

02-28-11 80

6.5.3 Windows Vista IIS Installation 1. Start Control Panel Programs And Features 2. Click on “Turn Windows features on or off”

3. Select the Internet Information Services item and the following features under that item

02-28-11 81

IIS 6 Management Compatibility IIS 6 Management Console IIS 6 Scripting Tools IIS 6 WMI Compatibility IIS Metabase and IIS 6 configuration compatibility Application Development Features ASP ASP.NET Server Side Includes Common Http Features Static Content Press OK

6.5.4 Windows 2008 IIS Installation

1. Start Server Manager

02-28-11 82

2. Click on Roles and then click Add Roles

3. Go through the Wizard. On the Select Server Roles Page select Web Server (IIS) and click Next.

4. If a message box appears click the button that says Add Required Features

02-28-11 83

5. Click Next Again to get to the page that is titled Select Role Services. You will need to select the following in Application Development.

ASP.NET (This should produce a dialog requesting the addition of ISAPI Extensions, add them as well) ASP Server Side Includes

6. Select all items in IIS 6 Management Compatibility

02-28-11 84

7. Click Next and then Click Install.

6.5.5 Windows 7 IIS Installation

1. Open Control Panel. Open the Start Menu. Then select Control Panel.

2. Open Programs and Features. Locate the Programs and Features link in Control Panel and select it.

02-28-11 85

3. Open Windows Features. Select the link: “Turn Windows features on or off”. This link should be located on the left-hand side of the Programs and Features window.

4. Locate Internet Information Services (IIS). When the Windows Features window is done loading, find Internet Information Services.

02-28-11 86

5. Expanding IIS. Expand IIS to look like the image below.

02-28-11 87

6. Checking Correct Components The image below has all the correct components checked. Also below the image is a list of all the components that are needed.

02-28-11 88

Web Management Tools IIS 6 Management Compatibility IIS Management Console IIS Management Scripts and Tools IIS Management Service World Wide Web Services Application Development Features .NET Extensibility ASP ASP.NET ISAPI Extensions ISAPI Filters Server-Side Includes Common HTTP Features

02-28-11 89

Default Document Static Content Security Basic Authentication Request Filtering Windows Authorization 7. Finalizing Once all the components are correctly checked, select the OK button. IIS should now be installed correctly.

6.6 Verifying that COM+ is Enabled for Windows 2003

1. You must be logged in to the PC as an Administrator 2. Go to the Control Panel and select the Add or Remove Programs item. 3. From here select the Windows Components item. A window like below should appear.

3. Select the Application Server and then click the “Details” button. A new should appear like below.

02-28-11 90

On the Application Server details page make sure “Enable network COM+ access “is checked.

6.7 Restricting Access to the Administrative Section

In Production Monitoring 2.0 the configuration section of the software was password protect and required a user to log in to make changes to the configuration of the welders. Starting with Production Monitoring 2.1, users no longer have to log into a configuration section. If you still wish to restrict access to the configuration of the welders, then you must Enable Integrated Windows Authentication. The below section describes this process.

6.7.1 Prerequisites

IIS must be installed. If using IIS 7 or above, the Windows Authentication component must also be installed.

6.7.2 Enabling Integrated Windows Authentication

6.7.2.1 IIS 5.1 and IIS 6.0

6.7.2.1.1 Enabling Windows Authentication 1. Click the Start menu button. 2. Click Control Panel.

02-28-11 91

3. Click the Administrative Tools icon.

4. Double-click the Internet Information Services icon.

5. In the dialog that is displayed, navigate to the IGear.Lincoln.Configuration virtual directory (as shown below).

6. Right-click the virtual directory and select Properties.

7. In the IGear.Lincoln.Configuration Properties dialog, click on the Directory Security Tab.

02-28-11 92

8. Click the Edit… button in the Anonymous access and authentication control group.

9. Ensure that the Anonymous access option is unchecked and that the Integrated Windows authentication is checked. When done, click OK.

10. On the IGear.Lincoln.Configuration Properties dialog, click OK.

6.7.2.1.2 Enabling a Windows Account’s Permissions Windows accounts may not be enabled correctly to access the virtual directory. This section will explain how to enable permissions for a windows account.

1. Navigate to the physical location where the virtual directory resides (i.e. the folder called “Production Monitoring” in the installation directory).

02-28-11 93

2. Click on Tools in the menu bar and then click Folder Options.

3. Under the view tab, uncheck Use simple file sharing and then click OK.

4. Right-click the Admin folder and click on Properties.

02-28-11 94

5. Under the Security tab, locate the account in the Group or user name list (if user does not exist add them to the list by clicking the Add… button).

6. With the account selected, check all permissions that the account should have under the Permissions list.

6.7.2.2 IIS 7.0 and IIS 7.5

6.7.2.2.1 Enabling Windows Authentication 1. Click the Start menu button.

02-28-11 95

2. Right-click Computer and select Manage.

3. In the Computer Management dialog, navigate to Internet Information Services under the Services and Applications group.

4. In the Connections pane, navigate to the IGear.Lincoln.Configuration virtual directory (as shown below).

02-28-11 96

5. Ensure that the Features View button is selected.

6. Double click the Authentication icon.

The following window should be displayed.

7. If Anonymous Authentication is enabled, right-click its icon and select disable.

8. If Windows Authentication is not enabled, right-click its icon and select Enable.

6.7.2.2.2 Enabling a Windows Account’s Permissions Windows accounts may not be enabled correctly to access the virtual directory. This section will explain how to enable permissions for a windows account.

1. Navigate to the physical location where the virtual directory resides (i.e. the folder called “Production Monitoring” in the installation directory).

2. Right-click the Admin folder and click on Properties.

02-28-11 97

3. Under the Security tab, click the Edit… button.

4. In the ensuing dialog, locate the account in the Group or user name list (if user does not exist add them to the list by clicking the Add… button).

02-28-11 98

5. With the account selected, check all permissions that the account should have under the Permissions list.

6.8 Uninstalling Lincoln PM 2.0

This section describes how to uninstall Production Monitoring 2.0 from a PC. This is a required step before install Production Monitoring 2.1. Note that this will erase all previous data collected with Production Monitoring 2.0. If you wish to save any previous collected data, then do not continue. To save any previous collected data, IGear must be contacted and they must perform the update. It will be required to allow them to remotely log into the PC and be allowed to backup and restore the previous database from PM 2.0.

6.8.1 Uninstalling Lincoln PM 2.0

This section will show the user how to completely remove the Lincoln PM 2.0 software.

1. Open Control Panel. Click the Start Menu and then click Control Panel option.

02-28-11 99

2. Open Add or Remove Programs. Double-click on the Add or Remove Programs icon.

3. Locate Lincoln Software to be removed.

02-28-11 100

4. Remove the Lincoln Production Monitoring. While the Lincoln Production Monitoring is selected, click on the Remove button.

5. Uninstall Lincoln Production Monitoring. The following windows should open. Click on the Uninstall button.

6. Uninstall Complete. Once the uninstalling is complete, click on the Close button.

02-28-11 101

6.8.2 Uninstalling SQL Management Studio

After Lincoln PM 2.0 is removed from the Add or Remove Programs list, hit F5 to refresh the list. If Microsoft SQL Server Management Studio Express still exists in the list, it will need to be uninstalled. Otherwise skip this section.

1. Open Add or Remove Programs. If Add or Remove Programs is not open, complete steps 1 and 2 in the Uninstalling Lincoln PM 2.0 section of this document.

2. Locate Microsoft SQL Server Management Studio.

3. Remove Microsoft SQL Server Management Studio. While Microsoft SQL Server Management Studio Express is selected, click on the Remove button.

If the following window opens, click Yes.

6.8.3 Uninstalling SQL Server Instance

This section will explain how to uninstall the SQL Server Lincoln instance. 1. Open Add or Remove Programs

If Add or Remove Programs is not open, complete steps 1 and 2 in the Uninstalling Lincoln PM 2.0 section of this document.

2. Locate Microsoft SQL Server 2005

02-28-11 102

3. Remove Microsoft SQL Server 2005. While Microsoft SQL Server 2005 is selected, click on the Remove button.

4. Uninstall Lincoln Instance. SQL Server 2005 Uninstall window should open. Under Select an instance, select the Lincoln: Database Engine. Then click Next.

02-28-11 103

5. Confirm Uninstall. Verify that the Lincoln Instance has been chosen, and then click Finish.

6.8.4 Removing Lincoln Virtual IIS Directory

This section outlines the steps necessary to completely remove the old PM2 website from the machine. 1. Open Control Panel. If the Control Panel window is not open, complete step 1 from the Uninstalling

Lincoln PM 2.0 section of this document. 2. Open Administrative Tools. Double-click on the Administrative Tools icon.

02-28-11 104

3. Open IIS. Double-click on the Internet Information Services (IIS) icon.

4. Expand the (local computer) node. The following window should open. Expand the (local computer) node.

02-28-11 105

5. Expand Web Sites node.

6. Expand Default Web Site node.

02-28-11 106

7. Remove LincolnPM node. Right-click the LincolnPM node and select Delete.

If the following window opens, click Yes.

02-28-11 107

8. Remove IGear.Lincoln.Configuration node. Right-click the IGear.Lincoln.Configuration node, and select Delete

If the following window opens, click Yes.

9. Restart Computer. Restart the computer before processing to the next section.

6.8.5 Removing Lincoln PM 2.0 Files

This section describes how remove the Lincoln PM 2.0 files from default installation location on the computer. 1. Open My Computer. Click the Start Menu and then click My Computer option.

02-28-11 108

2. Open the C: drive. Double-click on the C: drive.

3. Open Program Files. Double-click on the Program Files folder.

02-28-11 109

4. Delete Lincoln Directory. Right-click on the Lincoln Electric folder and select Delete.

If the following window opens, select Yes.

02-28-11 110

After all sections in this document has been completed, the Lincoln PM 2.1 software can be installed.

7 Glossary

Action Actions are intended to describe and/or filter data related to the selected Topic. For Production Monitoring™ 2, actions will usually select some type of report. ArcLink This is a communications protocol developed by Lincoln Electric for use in a welding system. This protocol takes into account specific needs of a welding system and the interaction of the multiple components that make up the network to greatly improve reliability and robustness. Asset A physical or logical grouping of items. In a manufacturing facility, this could be a single welder, station, or line within the plant. Board Serial Number Each component in an ArcLink system has a unique number that allows it to be identified from the other components. In Lincoln Electric systems, this is used to verify what component is being referenced in software. Criteria: A user supplied piece of information used to sort or filter the data returned to an Action or Panel DeviceNet A standard industrial networking protocol usually used by a PLC to control networked devices in a Master/Slave relationship. DNS Domain Name Service used for translating host names to an IP address so that networked equipment can be given 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. An example 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 as four octets separated by periods also referred to as “dots.” The numbers range from zero to 255. An example would be 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 welding system. 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.

02-28-11 111

Port In a specific network such as a TCP or a UDP network, a port is an endpoint to a logical connection. The port number defines what type of information will be transmitted. An example would be port 80 for HTML data or port 25 for email data. Power Wave® Name A name given to a Power Wave® for easy reference of where the machine is located and/or what the machine welds together. Production Report Summary of Weld History that shows all Weld Profiles and their totals. The report also includes the total time the Power Wave® has welded during the given shift, and the amount of wire left in the wire package. Rejected Weld A weld that was either not consistent enough or long enough to apply statistical equations to generate reasonable limit information. Robotic Feeder I/O The PF10R feed head comes with an External I/O Connector that can be reconfigured through Production Monitoring™ to reroute the I/O from its normal operation to be utilized as a Weld Profile Selection. Shift Times A Production Monitoring™ feature used to trigger events at a specific time of day that will allow the tracking of usage and clearing out of Weld Totals and Weld History. There are a total of 6 shift times that can be utilized on a daily basis. 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 spreadsheet applications 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 reliable protocol than UDP since it controls the delivery of data and verifies the order in which the data is sent. Topic This is a categorization of information that may contain one or more actions. The topics are selected using different tabs. The Topics basically divide and organize the main sections of the program’s interface. UDP User Datagram Protocol, used in the transmission of data between two or more devices. It is a faster protocol than 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, and weld status. Weld Mode A particular process that is selected in the Power Wave®. The Power Wave® has a weld table that contains a large variety of processes that the system can use to define welding procedures. Each process is listed as a Weld Mode. Weld Profile A configurable set of limit setting against which Production Monitoring™ compares welding data as the system welds. Weld Totals A cumulative count of welds performed in each Weld Profile. Each total count includes the number of welds, and a count of each variable that was out of limits per Weld Profile. Welding set point A value which the Power Wave® utilizes to regulate its output levels.