Lincoln Electric WAVE DESIGNER Operator'S Manual Download | Manualshive

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Section 5

TROUBLESHOOTING

WAVE DESIGNER

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Summary of Contents for WAVE DESIGNER

Page 1: ...e Waveform Editor Wire Feed Speed Ramp Up Rate Peak Amps Peak Time ms Tailout Time Tailout Speed Stepoff Amps Backgrd Amps Backgrd Time Frequency Ramp Overshoot 26 4 33 4 21 40 100 3 0 1 2 250 20 600...

Page 2: ......

Page 3: ...ve Design Process 3 11 3 4 Downloading Wave Shapes 3 12 3 5 Autosave 3 13 ArcScope Section 4 4 1 Introduction 4 1 Troubleshooting Section 5 5 1 Overview 5 1 5 2 Wave Designer Troubleshooting Procedure...

Page 4: ...that the Software is free of errors or limitations No warranty is made by Lincoln with respect to the Java Runtime software THE ABOVE WARRANTIES ARE THE ONLY WARRANTIES OF ANY KIND EITHER EXPRESSED O...

Page 5: ...rademarks html ii not do anything harmful to or inconsistent with Sun s rights in the Java Marks and iii assist Sun in protecting those rights including assigning to Sun any rights acquired by License...

Page 6: ...iv iv LICENSE INFORMATION WAVE DESIGNER...

Page 7: ...ferent than those expected Some adjustments to procedures may be necessary to compensate for unique individual conditions When possible test all procedures duplicating actual field conditions 1 3 COMP...

Page 8: ...reports to wavedesigner lincolnelectric com Refer to the Wave Designer Welcome screen for the applicable release version of the Wave Designer software package Wave Designer is a JAVA TM application a...

Page 9: ...from your START window to start up the program Refer to Table 2 1 for alternate installation procedures On startup the Wave Designer screens in Figure 2 1 will be displayed NOTE If upgrading a previou...

Page 10: ...s as follows 1 Disconnect the electrical power to the welding machine 2 Remove the control box LED display panel Figure 2 2 Be careful not to pull hard on the panel wiring harness 3 Locate the bottom...

Page 11: ...that it uses alternate resources If you are not using infrared for printing or file sharing it is recommended that it be disabled To disable infrared and enable the serial port on COM 1 do the followi...

Page 12: ...ms Tailout Time Tailout Speed Stepoff Amps Backgrd Amps Backgrd Time Frequency Ramp Overshoot 26 4 33 4 21 40 100 3 0 1 2 250 20 600 Edit Start About Adapt Short End Wave Designer Pro Off Line pulse s...

Page 13: ...e If a selected WFS is between two pre programmed workpoints the Power Wave will interpolate values for each of the welding variables The result is a precise and continuous range of welding control Re...

Page 14: ...w for selecting a workpoint and an edit window for changing the listing of workpoint values For the Pulse Waveform Editor the workpoints are wire feed speeds The workpoint parameter peak voltage curre...

Page 15: ...bar provides a scrolled listing of recent program events error conditions etc Use the arrow keys to scroll through the listings The status bar includes three system status indicators on line off line...

Page 16: ...rms volts ohms amps etc for any stored waveform swf file Save Scope As Wave Designer Pro option only Use this option to save an open Scope Trace file under a different filename Save Scope Wave Designe...

Page 17: ...ploaded Adaptive File Tools Print Help Search for Mode 12 NST3510C SWG Steel Pulse 035 Steel Argon CO2 Blends Mode 20 N45ST00C SWG Mig 3 045 Steel CO2 Mode 21 N45ST10C SWG Mig 3 045 Steel Argon CO2 Bl...

Page 18: ...Amps Backgrd Amps Peak Time ms Backgrd Time Frequency Tailout Speed Ramp Overshoot Peak Voltage Adaptive Type Inductance Short Detect Volt Pinch Current Rise Rate Arc Restablish Volt End Amp End Time...

Page 19: ...ection 3 3 7 SOFTWARE OPERATION WAVE DESIGNER Pulse Waveform Editor Wire Feed Speed Ramp Up Rate Peak Amps Peak Time ms Tailout Time Tailout Speed Stepoff Amps Backgrd Amps Backgrd Time Frequency Ramp...

Page 20: ...ly one workpoint is fixed checked Go Figure copies the workpoint sets the wave shape parameters for all other defined workpoints equal to those of the fixed workpoint This function should be used just...

Page 21: ...hine setting is not equal to the selected workpoint value changes to the wave shape will be applied to the workpoint value nearest the welding machine setting The welding machine Trim encoder must be...

Page 22: ...keyboard arrow keys to move the hot spot Press Ctrl and an arrow key to move the hot spot 10 times faster Use the F1 key to jump to the next hot spot Uncontrolled drag with the mouse can result in la...

Page 23: ...ep can be found in the listed reference paragraphs 27850021 Set NO ADAPT Set ADAPT Save File to Disk Develop Next Workpoint A 4 2 Step 1 A 4 1 A 4 2 Step 2 A 4 2 Steps 3 4 A 4 2 Steps 5 6 7 A 4 2 Step...

Page 24: ...pload from a welding machine If a weld file is corrupted you will not be able to upload the machine s weld mode directory You can download up to ten custom waveforms to the weld mode directory The ass...

Page 25: ...les with factory default files for download b Last uploaded files Merges selected files with weld mode directory last uploaded from a welding machine Overwrites modes 155 through 164 if like mode I D...

Page 26: ...3 14 Section 3 SOFTWARE OPERATION WAVE DESIGNER...

Page 27: ...tout of the active ArcScope graphics 2 Toggle Options Live Update and Condense are toggled on and off with the mouse Additional information about the Live Update and Condense options is provided in pa...

Page 28: ...application is running The Let Go option disables the Pause function Configure Use the Scope Configuration window to select the power source measurements for the graphical display area Centerline Sel...

Page 29: ...application File Open Scope Trace Use the Open Scope Trace option to open a saved scope trace data file Section 4 4 3 ARCSCOPE WAVE DESIGNER File Open Waveform Ctrl O Ctrl S Ctrl Q Save Waveform As S...

Page 30: ...4 4 Section 4 ARCSCOPE WAVE DESIGNER...

Page 31: ...gner program with a DOS console window for diagnostic messages in the background a From your Windows Start screen move the mouse over the Wave Designer icon b Right click the mouse and select Properti...

Page 32: ...5 2 Section 5 TROUBLESHOOTING WAVE DESIGNER...

Page 33: ...ve shape parameters effect Mode welding A 4 Pulse Wave Design Process Flowchart and step by step descriptions of the pulse wave design process A 5 Primary Pulse Waveform How peak current peak time fre...

Page 34: ...Adaptive A 2 GMAW PULSE OVERVIEW Figure A 1 illustrates the variables of the GMAW P welding process Each of these variables can be programmed into a weld table using the Wave Designer software Figure...

Page 35: ...r force are controlled by peak current and peak time From time T4 to T5 Tailout current controls the heat input to and agitation of the weld puddle Shorter tailout contributes less heat to the weld Th...

Page 36: ...paragraph A 4 Note This step must be performed with the Trim set equal to 1 0 on the Power Wave machine A 3 2 NON ADAPTIVE MODE In non adaptive mode the Power Wave does not adapt the pulse variables t...

Page 37: ...ented Where an editing function is described as optional and you choose not to perform the edit function proceed to the next edit function in the design process FIGURE A 4 PROCESS FLOWCHART Appendix A...

Page 38: ...en custom weld modes can be downloaded to the welding machine You cannot upload a custom weld from the welding machine but you can overwrite any or all of your allotted weld file memory locations b In...

Page 39: ...wave shaping Thereafter refer to the following wave shaping procedure 1 Select a Workpoint a Select a workpoint from the Wire Feed Speed pulldown menu The first workpoint selected should be in the mid...

Page 40: ...of the trim adjustment capability The welding machine s trim control allows the welder to adjust the arc length between 0 5 to 1 5 50 to 150 times the established arc length adjustment factor c Mainta...

Page 41: ...Editor screen to view the Adapting Stickout screen Click on the arrow in the adaptive type box to display the adaptive types listing b Select each adaptive type in turn and perform a trial weld After...

Page 42: ...Strike Peak Time Strike Peak Amps Open Circuit Volt 48 0 2 0 28 0 50 50 550 0 150 27850035 STRIKE PEAK AMPS STRIKE PEAK TIME START TIME ARC STRIKE OPEN CIRCUIT VOLTS AVERAGE START AMPS START VOLTS Op...

Page 43: ...ULSE WAVE SHAPING PRINCIPLES WAVE DESIGNER AMPS VOLTS ARC REESTABLISH VOLTS SHORT DETECT VOLTS PINCH CURRENT RISE PLATE 27850036 Shorting Control Shorting Control 5 55 18 15 For Wire Feed Speed Short...

Page 44: ...ollowing parameter descriptions A 12 Appendix A PULSE WAVE SHAPING PRINCIPLES WAVE DESIGNER 27850037 End Conditioning End Conditioning For Wire Feed Speed End Amp End Time Amp Time 50 550 0 2 5 1375 0...

Page 45: ...ER WIRE FEED SPEEDS WORKPOINT VARIABLE WorkPoint Editor WorkPoint Editor 1 0 2 3 4 5 6 7 8 9 10 11 80 700 80 700 110 700 150 700 205 300 400 600 inch min meter min Go Figure FIXED VALUE INTERPOLATED E...

Page 46: ...etach the weld droplet from the electrode and propel it across the arc Transition current is the current level required to achieve weld droplet formation In order to achieve weld droplet transfer the...

Page 47: ...average current levels FIGURE A 7 FREQUENCY Appendix A A 15 PULSE WAVE SHAPING PRINCIPLES WAVE DESIGNER 27850040 AVERAGE CURRENT AVERAGE CURRENT BACKGROUND CURRENT BACKGROUND CURRENT T1 T1 T2 T2 T3 T3...

Page 48: ...ore likely to short circuit the electrode to the work A 6 4 TAILOUT TIME The tailout time is the duration of tailout Longer tailout times maintain the system heat longer Shorter tailout times can forc...

Page 49: ...working properly with the welder We recommend using a standard waveshape such as mode 5 to confirm that the welding system performs under normal conditions before attempting to develop waveshapes 1 Se...

Page 50: ...set the Peak Voltage to obtain the desired arc length at the 1 00 trim setting Adapting Stickout Adapting Stickout For Wire Feed Speed No Adapt Maintain constant wire extension 27850043 Adaptive Maint...

Page 51: ...0 150 1200 205 300 400 600 inch min meter min Go Figure 28750032 6 The Start Short and End windows can be adjusted at this time to optimize the starting shorting and ending routines Start Control Puls...

Page 52: ...ps Backgrd Amps Backgrd Time Ramp Overshoot 8 3 20 25 100 1 5 1 4 250 0 600 Edit 150 27850045 Our Experiment At the higher wire feed speed we needed more heat to melt the added wire We took the backgr...

Page 53: ...e checked its performance across the range of wire feed speeds 13 The specific wire feed speed points of the program are now developed in the range of 150 in min to 300 in min Check the full range of...

Page 54: ...A 22 Appendix A PULSE WAVE SHAPING PRINCIPLES WAVE DESIGNER...

Page 55: ...Transfer How WFS and wave shape parameters effect welding B 4 STT Wave Design Process Flowchart and step by step descriptions of the STT wave design process B 5 Primary STT Waveform How peak current b...

Page 56: ...27850057 500 60 200 AMPERES PINCH START dV dt CALCULATE PEAK TIME PEAK AMPS TAILOUT SPEED BACKGROUND AMPS TIME B 2 STT OVERVIEW Figure B 1 illustrates the variables of the STT welding process Each of...

Page 57: ...ackground Ball Time current is reduced for approximately 0 75 milliseconds From time T2 to T3 High current is applied to speed the transfer of molten metal to the Pinch weld puddle A dV dt calculation...

Page 58: ...6 7 Time 27850063 T T T 1 2 T0 T1 A background current between 50 and 100 Amps is delivered to the arc prior to shorting of the electrode to the weld puddle Background current is a steady state curren...

Page 59: ...separation has occurred but at a very low current T5 T6 Immediately following separation of the electrode from the weld puddle peak current occurs Peak current is a period of high arc current The ele...

Page 60: ...you perform all editing functions in the order presented Where an editing function is described as optional and you choose not to perform the edit function proceed to the next edit function in the des...

Page 61: ...en custom weld modes can be downloaded to the welding machine You cannot upload a custom weld from the welding machine but you can overwrite any or all of your allotted weld file memory locations b In...

Page 62: ...o get thoroughly acquainted with wave shaping Thereafter refer the following wave shaping procedure 1 Select a Workpoint a Select a workpoint from the Wire Feed Speed pulldown menu The first workpoint...

Page 63: ...bout 5 8 in to 3 4 in 16 mm to 19 mm electrical stickout c While welding a trial weld bead adjust the waveform variables peak current background current tailout etc to achieve a desired droplet transf...

Page 64: ...ll Formation Start Volt Start Time 90 42 00 750 1 0 23 00 700 20 0 STRIKE I Open circuit voltage Sets the power source output voltage for the torch idle condition the welding machine is on but not wel...

Page 65: ...op the second workpoint in the same manner as the first Appendix B B 11 STT WAVE SHAPING PRINCIPLES WAVE DESIGNER WorkPoint Editor WorkPoint Editor 1 0 2 3 90 170 200 225 inch min meter min Go Figure...

Page 66: ...ing the arc length If set too high long arc lengths will inhibit travel speed Setting this level too low will cause instability and wire stubbing In practice this current level should be adjusted for...

Page 67: ...5 LONG OPTIMUM CONTACT TIP TO WORK DISTANCE SHORT 24850065 OPTIMUM LOW HIGH ADJUST BEAD SHAPE USING BACKGROUND CURRENT NOTE Applications using 100 CO2 require less background current than similar proc...

Page 68: ...rrent must exceed background current B 6 2 PINCH PEAK Pinch Peak is the ratio of maximum pinch current to peak current This parameter is used to establish the desired maximum pinch current value B 6 3...

Page 69: ...lop more workpoints for practice Before starting the waveshape development process confirm that the consumables are working properly with the welder We recommend using a standard waveshape such as mod...

Page 70: ...HAPING PRINCIPLES WAVE DESIGNER Our Experiment The weld produced by this setting is too hot We burned through the 16 gauge fillet The arc is too long and is producing too much spatter First we reduced...

Page 71: ...puter System Requirements 1 1 Control Board Dip Switch Settings 2 2 Current Background A 15 B 4 B 13 Peak A 14 B 5 B 12 Transition A 14 D Data Table Waveform 3 6 Dip Switch Settings Control Board 2 2...

Page 72: ...n B 6 Process Wave Design 3 11 Product Overview 1 1 Pulse Frequency A 15 Pulse Wave Design Process 3 11 Pulse Wave Shaping Principles A 1 R Ramp Up Rate A 16 S Secondary Waveform Parameters Pulse A 16...

Page 73: ...1 Start A 10 W Wave Design Process Pulse 3 11 Wave Design Process STT B 6 Wave Shaping Pulse A 1 Wave Shaping STT B 1 Wave Designer Operation 3 2 Waveform Data Table 3 6 Waveform Editor Window 3 2 Wel...

Page 74: ...INDEX Index 4 WAVEDESIGNER...

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