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Summary of Contents for WELDWISE 2400

Page 1: ...Revision C 001 User s Manual WeldWise 2400 THE WELD MONITORING SPECIALISTS TM...

Page 2: ......

Page 3: ...or incidental consequential damages in connection with the furnishing performance or use of this material Copyright This document contains proprietary information that is protected by copyright All ri...

Page 4: ...A basic how to guide to weld monitoring with Livingston equipment WMS Reference Guide A complete software reference to the Livingston Weld Monitoring Software WMS program Installing the Sensors Descri...

Page 5: ...8 RECOMMENDATIONS FOR PRODUCING QUALITY WELDS 1 9 AVOID THESE POTENTIAL SOURCES OF WELD PROBLEMS 1 10 INTRODUCTION TO RESISTANCE WELD MONITORING 2 INTRODUCTION 2 1 WHY MONITOR 2 1 WELD LOBES AND THE W...

Page 6: ...E GUIDE 6 MAIN PROGRAM SCREEN 6 1 MAIN MENU OPTIONS 6 4 DATA MENU OPTIONS 6 5 HALFCYCLE SUMMARY SCREEN 6 6 WELD SUMMARY SCREEN 6 11 SYSTEM LOG SCREEN 6 12 DATABASE MANAGEMENT 6 13 DATABASE IMPORT SCRE...

Page 7: ...THE INPUT MONITOR 8 2 INSTALLING SWAPPING TOROIDS 8 3 PERCENTAGE ADJUSTMENT 8 4 CALIBRATING DISPLACEMENT 8 5 ZEROING THE DISPLACEMENT 8 5 CALIBRATING FORCE 8 6 CALIBRATING VOLTAGE 8 8 FREQUENTLY ASKE...

Page 8: ...21 WARRANTY REPAIR POLICY 11 23 APPLICATION NOTES 12 APP NOTE 118 Changing WeldWise 2400 Identification and IP address 12 1 APP NOTE 121 Copy weld data and use it to create an MS Excel chart 12 7 APP...

Page 9: ...rent passed through the metals it would create such a high heat that the metals would melt and run together and a weld would be made Many times the welded metal would be even stronger than the origina...

Page 10: ...iness of materials Electrode force Design of the electrode Workpiece material The Weld Cycle A typical resistance weld is broken down into several distinct periods as shown in figure 1 1 below The Squ...

Page 11: ...ans of a welding transformer A transformer consists of two coils of wire called the primary and the secondary wound around an iron core Power is transferred from primary to secondary via the magnetic...

Page 12: ...ying surfaces of the workpieces then that s where the heat will go Likewise if the greatest resistance is at the contact area between the electrode tip and the workpiece the heat generated there will...

Page 13: ...urrent generates heat the workpiece metal begins to melt A good analogy to this process is a child eating a popsicle on a hot summer day When the popsicle melts it doesn t remain on the stick it drips...

Page 14: ...ed by the surface area area of contact between the electrode and the workpiece As a rule the smaller the surface area the denser the current When the current is denser the surface area gets hotter and...

Page 15: ...ter pressure there is in a pipe more voltage the more water can flow through that pipe more current If the size of the pipe decreases more resistance then the water flow will decrease less current but...

Page 16: ...rmine if welds are being made consistently within the lobe If a weld control is programmed to deliver a certain amount of current at a certain amount of force how can you ensure that the right amount...

Page 17: ...r f a c e C r a c k e d o r P o o r W e l d N u g g e t D i s c o l o r e d W e l d N u g g e t N o W e l d Weld Force Too High X X X X Weld Current Too High X X X X X Weld Time Too Long X X X X X Wel...

Page 18: ...ith a standard straight tip 3 Do not use a small tip for welding heavy gauge materials or a large tip on small piece 4 Do not overlook turning on the cooling water to the appropriate force when beginn...

Page 19: ...s during its destruction For all its reliability however destructive testing doesn t tell the whole story While it can easily be determined whether a weld is good or bad uncovering the precise factors...

Page 20: ...s All these different measurements of electrode movement are measures of what s commonly called Electrode Displacement or simply Displacement Measuring displacement provides a good indication of wheth...

Page 21: ...to three separate sections the pre weld weld and post weld segments If the force during each of these sections was 1700 300 and 400 lbs respectively the average would be 800 lbs The end result appears...

Page 22: ...d itself to be weaker than it would be without expulsion Voltage measured in Volts is also a key indicator during the weld process As discussed earlier voltage is a relative measure in that the locati...

Page 23: ...ollected from all or a combination of these sensors and displayed by the halfcycle cycle or average for the entire weld depending on the type of monitor used The more weld parameters monitored the har...

Page 24: ...ty or delta welds can be reduced or even eliminated The ability to quantify what constitutes a known good weld makes it possible to achieve consistent results even in high volume situations Productivi...

Page 25: ...WMS Weld Monitoring Software program is running the monitor continually collects data from the sensors When a weld is made information about that weld is captured analyzed displayed and stored by the...

Page 26: ...shows force and current all weld parameters can be toleranced using a Livingston monitor The locations of the diamonds show exactly how much force was used at a particular current for the displayed w...

Page 27: ...ments A segment is simply a collection of halfcycles before during and after the firing of weld current By default there are three segments created when a master is made the Pre Weld Squeeze Weld and...

Page 28: ...actors that may be critically important to weld integrity and include these factors when accepting or rejecting welds Data Collection Data can be collected for each halfcycle segment and or weld Pleas...

Page 29: ...making selections and performing tasks The touch screen refers to the touch sensitive display The touch screen itself is interactive by pressing an item on the display the user can select or move it a...

Page 30: ...n use the ESCAPE button to return to the Main Menu ESCAPE always takes you back one level at a time towards the Main Menu of the program or cancels your previous action If you press ESCAPE enough time...

Page 31: ...on will return you to navigation mode Note Once you have selected and highlighted a value to be changed you must use the ENTER button to exit the highlighted item even if the value has not changed Oth...

Page 32: ...INS 400 Rev D 4 4 The WeldWise 2400 Back Panel The back panel features connectors for attaching peripherals such as an external keyboard monitor printer UPS or other device Figure 4 3 Back panel of a...

Page 33: ...have frequent power problems For permanent installations the installation of a UPS uninterruptible power supply is recommended to avoid a hard shutdown of the computer due to sudden loss of power Thi...

Page 34: ...4 6...

Page 35: ...te description of all functions in the WMS program refer to Chapter 6 WMS Reference Guide General Setup The first step is to confirm that the general configuration settings are appropriate for this pr...

Page 36: ...he main screen at one time In this example Current RMS Voltage RMS Force and Hcycle On Cnt are shown Your screen may look different if other parameters have been selected There are multiple parameters...

Page 37: ...ore details Smaller arrows are displayed to the right of the bar graphs for each parameter display While the big arrows in the both the Weld Status and Job Status boxes tell you if any of the multiple...

Page 38: ...s on the right You can select either box and scroll through the list to change which two parameters are displayed The parameter in the left box will be displayed as a non bold line The parameter in th...

Page 39: ...sing the arrow keys to scroll through or enter the desired weld number To return to graph format select Graph Highlight any cell in the Accept Status column and press the SELECT key A window will appe...

Page 40: ...ade The most recent weld recorded will always be at the top of the list you can scroll down to see information for each weld Definitions of additional parameter headings in this screen can be found in...

Page 41: ...ettings and standard parts customary for the application 5 Press the Done button to end the data capture The screen will say Updating master weld set The date time stamp of the new master is displayed...

Page 42: ...tus for the weld you just made the most recent weld will be at the top An Accept Status of 0 indicates that the weld was accepted If the weld was rejected highlight the Accept Status number and press...

Page 43: ...ing the new weld schedule and observe the monitor screen You should see a blinking arrow in the Weld Status box as shown in figure 5 16 If one of your displayed parameters is Hcycle On Cnt you ll also...

Page 44: ...ter we just made Press SELECT Your screen should look similar to figure 5 18 2 Touch anywhere in the Weld segment middle of the screen so that the pointer thinnest vertical arrow is in Segment 1 Weld...

Page 45: ...hould display flashing arrows indicating a REJECTED weld as shown in figure 5 21 Go to the Halfcycle Summary screen It should look similar to figure 5 22 Notice that the Current Rms line is below the...

Page 46: ...5 12...

Page 47: ...r for this weld the display will read No Master If the weld data for this weld was used to generate a master then the display will read Master Weld In the figure above the Master ID is 3 13 01 3 50 40...

Page 48: ...heck Mark is displayed Parameter Displays All of the different weld summary parameters are available from the main screen Each parameter display can show data for one of these parameters A parameter d...

Page 49: ...ce but is not shown in one of the parameter displays the Weld Status high low indicators will flash In this situation you can scroll through the parameters or use the Weld Summary to determine why a w...

Page 50: ...nd press D Data This option displays the Data Menu which allows you to review weld data access the system log and perform database backup restore options Mastering This option displays the Mastering s...

Page 51: ...ifferent system events This information is used by Livingston technicians for system diagnostics Database Displays sub menus and commands which backup restore or delete information from the weld datab...

Page 52: ...eft Right axis Parameter Select The left parameter select box corresponds to the left y axis vertical and the brighter trace on the touch screen The right parameter select box corresponds to the y axi...

Page 53: ...the scroll bars or the arrow buttons to move through the table display The Halfcycle Summary Table contains the following parameters Segment A weld is divided into segments The segment field indicate...

Page 54: ...Segment High and Low Tolerance limits for that parameter as shown in figure 6 14 If a master was NOT used to qualify this weld then no limits will be displayed The tolerance limits displayed are taki...

Page 55: ...on is the increase in thickness as a part is welded relative to initial thickness Halfcycle Expansion is the highest thickness during the halfcycle minus from the Initial Thickness value at the beginn...

Page 56: ...d data was recorded MasterID Name of the master used to qualify the weld Bin Select Binary Master Select For each POD ID there are up to 15 masters which are selected using the binary select inputs Th...

Page 57: ...for a specific parameter navigate to the data for that parameter and press the SELECT key A pop up window will display the weld tolerance limits Use ESCAPE to close the pop up window In addition to ma...

Page 58: ...It is an event log with date time stamps intended for diagnostic purposes It is recommend that the system log be deleted periodically as it does add to the size of the livco mdb database It is also re...

Page 59: ...tions all remote user interfaces and applications accessing the database should be closed Database functions should be performed from the WeldWise 2400 weld monitor only Some options will allow you to...

Page 60: ...ve over the network the Compact Database command will reduce the archive space required This compact option is basically the same compact tool that is provided with Microsoft Access WARNING Welds cann...

Page 61: ...n or monitor welds until the repair operation is complete DO NOT shutdown the weld monitor during this operation Delete All Welds This option will delete all weld data records but will not compact the...

Page 62: ...ed DO NOT shutdown the weld monitor during this operation Import Masters This option imports masters previously stored in an archive database by an Export Masters command The masters archive database...

Page 63: ...ill overwrite the existing setup and calibration data WARNING Welds cannot be monitored while the Import Setup option is in use Any remote user interface windows must also be closed If the Cancel butt...

Page 64: ...ton is used the weld monitor must be shut down and restarted DO NOT shutdown the weld monitor during this operation Export Masters This option saves the current masters to an archive database backing...

Page 65: ...nformation to an archive database The setup archive database file name is setup mdb This command will overwrite the existing setup and calibration data WARNING Welds cannot be monitored while the Expo...

Page 66: ...he graph heading shows which weld the waveform is for as well as how many samples there were in the waveform The current sampling rate used by Livingston monitors in Scope Mode is about 104 samples pe...

Page 67: ...be compared to the known good welds in the master Note Using different bin selects multiple masters can be made at the same time For more information about refer to Chapter 9 FAQ The Mastering option...

Page 68: ...a selected master COPY if the Copy Replace button is pressed and then the Done button is pressed without any new welds being made the selected master will be copied and named with the current date an...

Page 69: ...onitor to begin qualifying welds with the new edited master A master must also be updated before using the replace function Delete Master This button deletes the selected master Pod ID The current Pod...

Page 70: ...on to add delete welds to from the master set If a weld is accidentally deleted from the master set it can be re added using the Add button New welds cannot be added to an existing master set Refer to...

Page 71: ...alfcycles in that segment If you want to impose different limits on halfcycles in the same weld you can divide the weld up into more segments and tolerance the halfcycles in each segment differently S...

Page 72: ...aphically along with the master The limit traces are displayed as dimmer lines on the display Low High Limit Boxes The high and low limits for the selected parameter are displayed edited in these boxe...

Page 73: ...ine Move the cursor to a section of the weld other than the pre weld segment and use the Down Arrow Key to add a segment line The new segment line will divide the existing segment into two at the loca...

Page 74: ...ance limits will be those to the left of the cursor Use the Update button to record any segment line or tolerancing changes Figure 6 44 The segment line has been removed and the Update button has not...

Page 75: ...ment Tolerancing Segment Summary Segment Tolerance High Limit RELATIVE Segment Tolerance Low Limit RELATIVE Segment Tolerancing allows each segment summary the average of all halfcycles in a segment t...

Page 76: ...Defaults screen which controls the halfcycle and segment default tolerances used when a master is created Graph Setup This option displays the Graph Setup screen which controls the graph display unit...

Page 77: ...ons in Chapter 6 NOTE Pod Servers and the WeldWise 2400 use the same User Interface software and by default contain the same General Setup parameters in the livco mdb database Not all of these paramet...

Page 78: ...ng 10 see figure 6 50 This setting determines the amount of time in halfcycles that data is recorded before the weld current begins It is recommended that the Pre be set to less than the Squeeze time...

Page 79: ...is accepted or rejected based on this comparison No Masters are disabled and the WeldWise 2400 monitors without comparing welds to masters Note All welds will be rejected for all parameters when mast...

Page 80: ...ed 1 Scope Mode is enabled This function is for diagnostic purposes and should only be used under the direction of a Livingston representative Due to the significant amount of data processed in Scope...

Page 81: ...low Although the weld may be Accepted the rejected halfcycle data is still recorded in the database and displayed in the Halfcycle and Weld Summaries AD Threshold adjustment may be required Recommende...

Page 82: ...D weld BUSY STAT Relay 1 remains in its unenergized state while the 2400 is NOT busy Relay 0 changes to and holds its unenergized state after the completion of an ACCEPTED weld Relay 0 changes to and...

Page 83: ...d Weld Summaries using data only from halfcycles in which there was measurable current within the weld segment Yes The weld monitor calculates average values using data from all of the halfcycles in t...

Page 84: ...should be entered as a whole number in this screen Example CF of 0 354 should be entered as 354 Calibrate Voltage This utility is used to calibrate the voltage sensor input channel The voltage calibra...

Page 85: ...cate saturation or overflow on that channel If all of the A D values appear frozen you may have a problem with your monitor Refer to Chapter 10 Troubleshooting Guide for more information External Mast...

Page 86: ...ton To return to the factory calibration simply enter 100 for a percentage Update Configuration Sends the calibration to the weld monitor This button must be used for any new settings to take effect T...

Page 87: ...If however there is an extenuating circumstance requiring re calibration of the voltage use the following procedure You will need a battery and a multimeter to calibrate voltage Refer to Chapter 8 Cal...

Page 88: ...quired when a new sensor is installed An external hand held force gauge will be required to determine the exact amount of force that is being applied during this calibration Refer to Chapter 8 Calibra...

Page 89: ...procedure is basically the same as the procedure for the voltage and force channels A piece of metal with known thickness less than 0 100 or less than 4 5 of the displacement sensor stroke will be req...

Page 90: ...meter REL Relative Limits All tolerance limits are relative to the master ABS Absolute Limits The master values are ignored and all limits are absolute Unit Some parameters can be measured in differen...

Page 91: ...ct the high and low display limits for the Main Screen bar graphs Trend Graph display and the graphs in the Summary and Tolerancing screens Radio buttons also allow separate settings for Halfcycle Seg...

Page 92: ...nterface Window but don t quit Weld Monitor This option closes the WMS graphical user interface livcoset exe but does not stop the WMS weld monitor service Doit exe The weld monitor will continue to c...

Page 93: ...e shutdown menu will appear slightly different as shown in figure 6 65 Likewise if a database function has been cancelled the shutdown menu will feature only one option as shown in figure 6 66 Figure...

Page 94: ...6 48...

Page 95: ...Voltage Force and Displacement sensors to the weld monitor Each sensor must be attached to the appropriate cable lead as indicated by the color coding It is not necessary to have a sensor attached to...

Page 96: ...incorporate it into the weld loop Pressure Sensors These sensors are typically small transducers that connect to the supply line of a hydraulic or pneumatic cylinder They work by sensing the pressure...

Page 97: ...d is typically used in situations when the space surrounding the weld force cylinder is limited When the potentiometer pot is retracted by the weld head tooling an internal spring allows the pot to ex...

Page 98: ...is at least inch away from the framework of the machine or any ferrous metal Reconnect the clasp on the toroid and route the cable away from current carrying tooling Best results are achieved with th...

Page 99: ...tor you should install a Voltage Lead Noise Suppression Filter Make sure that the contact surfaces on the ring terminals and the electrodes are free of dirt grease or corrosion The cable connector sho...

Page 100: ...on a modified air over oil cylinder General mounting guidelines Be sure to avoid mounting the sensor on or too close to an electrical bus Take precautions to isolate the load cell from the welding gro...

Page 101: ...hs of an inch can result in erratic and inaccurate displacement readings The displacement sensor window is approximately 9 of the range of the stroke of the displacement sensor For example a 4 inch se...

Page 102: ...sensor installation the WeldWise 2400 must be installed and the WMS program running Note Incoming sensor readings will not be accurate if the sensors have not been calibrated Current Toroid Non conduc...

Page 103: ...er parameter box and select VoltageRms The graphic display indicates the levels of the sensor readings for these factors and these values are recorded for the weld Note Readings will be uncalibrated a...

Page 104: ...7 10...

Page 105: ...efaults screen Calibrating and Zeroing the displacement sensor are not the same thing As a rule calibration is done only once while zeroing is done during periodic maintenance whenever tooling tips or...

Page 106: ...dates each channel If the monitor sensor cable is attached to the unit and the A D values appear frozen there may be a problem with the monitor Refer to Chapter 10 Troubleshooting Guide for more infor...

Page 107: ...er the toroid calibration factor 1 From the Utilities Menu select Toroid Settings 2 Enter the number shown on the calibration factor sticker located on the cylindrical housing on the cable Be sure to...

Page 108: ...e current reading from a Livingston monitor absolutely needs to match the current reading from another current measuring device the Livingston monitor can be easily adjusted so that the readings are t...

Page 109: ...weld head electrodes and add a second gauge block of known thickness on top of the first block Close the weld electrodes onto the blocks and enter the known thickness of the gauge block as the Point 2...

Page 110: ...is listed as optional but is highly recommended to reduce error Press ENTER to input the value Or b With the electrodes unclamped enter 0 for Point 1 This value is listed as optional but is highly re...

Page 111: ...the Point 2 value For example an 8 bore cylinder with a 70 psi line pressure Surface area of the bore r2 Radius of an 8 bore 4 42 16 16 3 14 50 24 50 24 70 psi 3516 8 psi electrode force Enter 3516 8...

Page 112: ...ltage 4 Short the voltage leads together and set the value to 0 This reading is listed as optional but is highly recommended Click ENTER to confirm the entry 5 Connect a 1 5V or 9V battery to the lead...

Page 113: ...e stackup height of the parts being welded and c consistency A high cost displacement sensor can measure to four places 0 0001 using the full stroke length A low cost displacement sensor can accomplis...

Page 114: ...e feature will the Master I m copying replacing be deleted No Whether you are copying or replacing the selected Master is always copied first When would I use the Copy Replace feature This feature is...

Page 115: ...delete the other two Masters Why does the weld monitor display a single weld as several welds If you re using a pulsed weld then the post delay may not be set high enough to account for the time betwe...

Page 116: ...9 4...

Page 117: ...READINGS OR CHANNEL 10 14 CALIBRATED FORCE SIGNAL IS READING HIGHER OR LOWER THAN NORMAL CALIBRATED FORCE SIGNAL IS INDICATING A FROZEN STATIC READING WHEN A WELD IS MADE THERE IS LITTLE OR NO FORCE...

Page 118: ...E FAILURE 10 24 7 TROUBLE WITH BIN SELECT OR ACCEPT REJECT 10 25 THE BIN SELECT IS ALWAYS ZERO THE BIN SELECT IS INCORRECT AND IS NOT ZERO THE EXTERNAL BIN SELECT IS NOT WORKING CORRECTLY ACCEPT REJEC...

Page 119: ...e amount supported by cabling shunts etc is not repeatable When troubleshooting displacement be sure to check the rigidity of the displacement bracket While observing the displacement channel on the I...

Page 120: ...ary based on sensor millivolt per volt output and load range verses actual load The point is that if A D readings with sensor loaded are similar to the sensor with no load this generally indicates a f...

Page 121: ...on has been changed Check calibration and recalibrate sensor if necessary Refer to Chapter 8 Calibrating the Sensors Note If an Export Setup was performed the last time this sensor was properly calibr...

Page 122: ...e weld schedule back to what it was when the Master was created create a new Master or adjust the Master Tolerance Limits to accommodate the new schedule Electrodes were changed dressed and the displa...

Page 123: ...er Mechanical binding Check for mechanical binding Process timing has changed Weld head is extending too late or retracting too soon Check for mechanical binding Check for PLC program changes Sensor f...

Page 124: ...ections relating to this sensor Repair or replace cable as necessary Calibration has changed Check calibration and recalibrate sensor if necessary Refer to Chapter 8 Calibrating the Sensors Note If an...

Page 125: ...s EVERY WELD IS REJECTED The Weld Summary screen indicates that Force Parameters are out of tolerance CONT D Sensor cable failure Disconnect the sensor cable from the weld monitor sensor and then usin...

Page 126: ...ors and or cable Using the cable pinout documentation for your system check the continuity of all connections relating to this sensor Repair or replace cable as necessary Sensor cable failure Disconne...

Page 127: ...Timer operation Firings boards and SCRs Call your resident logic programmer and have him her inspect the logic Toroid failure or loose buckle Inspect the Toroid for physical damage or abrasion Replace...

Page 128: ...Master was created or was recalibrated after the master was created Using the Input Monitor check the calibration of the sensors and recalibrate if necessary Create a new Master or set of Master tole...

Page 129: ...ected or damaged Inspect the toroid for poor connections and or physical damage or abrasion Reconnect replace and or relocate toroid if necessary A D Threshold setting is too high incorrect In the Gen...

Page 130: ...erve the force channel readings Apply and remove pressure If the A D value does not change this may indicate a failed sensor sensor cable see below or weld monitor hardware problem Refer to Section 8...

Page 131: ...ton Service Sensor failure A reading of 32767 indicates that the input channel is reading its maximum value and is saturated There may be problem with the sensor sensor cable or weld monitor hardware...

Page 132: ...pare sensor cable and or weld monitor If the readings still appear to be incorrect replace the sensor Sensor cable failure Try using a spare sensor cable Apply and remove force and see if the A D inpu...

Page 133: ...e sensor will not calibrate or A D readings don t look right Test the sensor Independent of the Livingston system Sensor failure Test the sensor independent of the Livingston System by using an Oscill...

Page 134: ...it causes intermittent readings CALIBRATED DISPLACEMENT SIGNAL IS INDICATING A FROZEN static READING CONT D Sensor Cable or weld monitor failure CONT D If the displacement window cannot be found then...

Page 135: ...If the A D reading changes to a value within 100 from 0 the sensor cable should be repaired or replaced If the A D reading remains at maximum value refer to Section 8 Trouble With Hardware Sensor fai...

Page 136: ...monitor If the A D reading changes to a value within 100 from 0 the sensor cable should be repaired or replaced If the A D reading remains at maximum value refer to Section 8 Trouble With Hardware INA...

Page 137: ...ble for physical damage A cable that is deformed severed partially severed shredded abraded and or has bare wires showing may be suspect Disconnect sensor cable from the weld monitor and replace Try t...

Page 138: ...R THAN NORMAL OR CALIBRATED VOLTAGE SIGNAL IS INDICATING A FROZEN static READING Sensor Cable or weld monitor failure Inspect sensor cable for physical damage A cable that is deformed severed partiall...

Page 139: ...ading of 32767 during a weld Weld monitor has a problem with the voltage channel If the A D reading remains at maximum value when not welding zero volts on the secondary refer to Section 8 Trouble Wit...

Page 140: ...hasn t been changed Constant failure on the DISPLACEMENT channel Use the Input Monitor to observe the incoming sensor readings If the A D readings for the FORCE CURRENT or VOLTAGE channels are 32767 t...

Page 141: ...ALWAYS 0 The weld summary screen indicates that weld data is being recorded with the Binary Select of 0 Main screen indicates that the weld was recorded with No Master Weld Monitor Malfunction Shutdo...

Page 142: ...select logic is not working properly Check the programming logic Weld Monitor Malfunction Shutdown and restart the weld monitor If the problem persists contact Livingston Service THE EXTERNAL BIN SEL...

Page 143: ...several minutes THE READY LED IS OFF The weld monitor is not ready to process welds The monitor may be still be initializing If after several minutes the LED is still OFF then shutdown and restart the...

Page 144: ...or If the any or all A D channels are pegged saturated there is a problem with the weld monitor Call Livingston Service THE A D READING ON THE INPUT MONITOR IS FROZEN Both the sensor in question and t...

Page 145: ...s been mechanically disconnected and extended retracted but the readings on the Input Monitor do not make sense Sensor failure Try re zeroing the displacement sensor See the appropriate sensor trouble...

Page 146: ...10 30...

Page 147: ...Delete System Log Entries Import All Import Masters From Floppy Import Setup From Floppy Import Setup Import Masters Export All Export Masters From Floppy Export Setup From Floppy Export Setup Export...

Page 148: ...fferent database operations masters mdb contains a backup of masters with tolerance limits Located on the WeldWise 2400 hard drive livco mdb file in use by the weld monitor contains configurations inc...

Page 149: ...he same in both livcopy mdb and masters mdb It will also ensure that the calibration and setup information is the same in both livcopy mdb and setup mdb Keeping the files in synch will also avoid conf...

Page 150: ...es in size This will make it easier for those who wish to make a copy of the data prior to deleting weld data A file size of 600Mbytes is still manageable when copying data across the company network...

Page 151: ...weld 1 Records per weld weld 2 etc Database size per process cycle bytes Records per process cycle X 280 bytes each Total Database size per day Database size per process cycle X process cycles per day...

Page 152: ...port Masters This makes a backup of each of the masters includes master tolerance limits and stores the information in the masters mdb file 4 Export All This makes a backup all of the system informati...

Page 153: ...ity to recover the known good masters OR If a floppy was created with the Export Masters from Floppy then insert the floppy and use the Import Masters from Floppy option What if at some point a sudden...

Page 154: ...on to exit this window Label this disk LDCT Livco Default Calibration Tables and keep it with the rest of your Livingston files To make a copy of the adjusted calibrations perform the same steps after...

Page 155: ...ld you ever need it for future use Should your calibration settings change you should update the ACT disk Calibration settings weld data and masters can also be imported exported to an archive in the...

Page 156: ...nce Guide the A D reading will saturate at 32767 0 45 volts and 32768 0 45 volts Since the displacement sensor returns a signal from 0 to 10 volts the displacement channel will be saturated over all b...

Page 157: ...and displacement must be calibrated only when a new sensor or slide potentiometer is installed Under normal operating conditions the only continuing procedure that is required is to zero the displacem...

Page 158: ...that signifies the parameters that failed and whether the failure was higher or lower than the tolerance threshold To convert an Accept Status code 1 Enter the value of the code into a calculator that...

Page 159: ...00000000 01000000 00000000 EXPANSION_HI 15 32768 00000000 00000000 10000000 00000000 EXPANSION_LOW 16 65536 00000000 00000001 00000000 00000000 INITTHICK_HI 17 131072 00000000 00000010 00000000 000000...

Page 160: ...o Monitor To attach an external video monitor plug in the monitor connector to the port labeled VIDEO VGA on the back panel of your WeldWise 2400 Attaching an External Printer Your Livingston monitor...

Page 161: ...would like to your WeldWise 2400 to remotely shut down other WeldWise 2400s or devices in the event of a power loss you will need to re configure the UPS settings Note Please be aware that once the U...

Page 162: ...on 1 Power up the WeldWise 2400 and allow to boot If prompted log on as Administrator password 2400 2 If Livco software starts running select MENU Select SHUTDOWN Select Quit Livco program but don t s...

Page 163: ...software starts running select MENU Select SHUTDOWN Select Quit Livco program but don t shutdown Windows NT 3 Click Start on the task bar Select Programs Windows NT Explorer 4 In the root directory c...

Page 164: ...0340 DWG 400 Rev C 11 18...

Page 165: ...0308 DWG 400 Rev D 11 19...

Page 166: ...KEYBOARD Sensor input connector SENSOR CABLE for acquiring current voltage force and displacement data A 9 pin Interlock connector INTERLOCK for Accept Reject signaling and PLC interfacing LED Indica...

Page 167: ...ce Electrodes for the spot and seam welding of high resistance materials such as stainless steel nichrome and monel metal As a casting they are used for flash butt and projection welding electrodes an...

Page 168: ...11 22...

Page 169: ...IN CONNECTION WITH ANY COMPANY PRODUCT EVEN IF THE COMPANY HAS BEEN OR IS ADVISED OF THE POSSIBILITY OF SUCH DAMAGE THIS EXPRESS WARRANTY IS MADE IN LIEU OF ANY AND ALL OTHER WARRANTIES EXPRESS OR IM...

Page 170: ...tomer obtain insurance to cover damage that might occur during shipping Shipment to the Company shall be at the Customer s expense Repaired products shipped ground to the Customer shall be at the Cust...

Page 171: ...on and or IP address of your WeldWise 2400 weld monitor or POD Server using a keyboard with or without a mouse You may want to connect a video monitor to the weld monitor for easier viewing but this i...

Page 172: ...u will not be able to see everything you are doing on the weld monitor screen It is critical that you follow each step exactly so that the settings are properly entered If at any time you need to exit...

Page 173: ...s Alt W then the right arrow key to change the Workgroup Press Alt D then the right arrow key to change the Domain 4 Click OK or press Enter on the keyboard to accept the changes and close the window...

Page 174: ...n then press Alt I to go to the IP Address entry field If you wish to change the Subnet Mask and or Default Gateway press Alt U for Subnet Mask and Alt G for Default Gateway Begin typing the new IP or...

Page 175: ...Windows NT Security window 9 Without a mouse press Alt S to select the Shutdown option or simply click on the Shutdown button 10 The Shutdown Computer window will appear Press Alt S again to shut down...

Page 176: ...0454 APP 118 Rev A 12 6...

Page 177: ...ing has a network connection to the Livingston monitor for further information please refer to the procedure on How to Establish a Network Connection 2 On your computer s desktop or on another drive t...

Page 178: ...ay take a minute or two If you are using Windows NT you may be prompted for a password Type in Administrator in the Connect As box and 2400 in the Password box 5 If the unit is a 2400 open the c folde...

Page 179: ...may not be capitalized and select Copy 8 Go back to the open window containing the new folder that you created named 2400_xxxx MMDDYY Open the folder and paste WeldData mdb 9 Return to the livcosetup...

Page 180: ...EXCEL CHART OR GRAPH FROM THE LIVINGSTON DATABASE 1 Open a new spreadsheet in MS Excel 2 Go to Data Get External Data Create New Query 3 The Choose Data Source window will appear Under the Databases t...

Page 181: ...e New Data Source window will appear The first item will ask for a name Type in whatever name you wish to call your query 5 The second item will ask for a driver Select Microsoft Access Driver mdb fro...

Page 182: ...ed the folder named 2400_xxxx MMDDYY See example below 9 In the window labeled Directories find the 2400_xxxx MMDDYY folder and double click it to open it The file WeldData mdb should appear in the le...

Page 183: ...up window Under Database the file path of WeldData mdb will be displayed Click OK 12 You will now be returned to the Create New Data Source window Leave item 4 blank and click OK 13 The Choose Data So...

Page 184: ...you to filter or sort the weld data in a number of different ways Note In this procedure we ll use the pod recordtype and weld fields as examples Once you are familiar with this process you can filte...

Page 185: ...Column to filter window and click once on weld to highlight it It will appear under the Only include rows where windows Use the first pull down list to select is greater than or equal to In the second...

Page 186: ...the returned information by whichever parameter you want We ll use ID as an example Select ID from the pull down list and Descending most recent welds will appear first 20 Click Next 21 The Query Wiz...

Page 187: ...into the uppermost left hand corner of the spreadsheet 23 You should now have a spreadsheet containing weld data for the 2400 or whichever POD ID you selected of recordtype 2 sorted by ID You should...

Page 188: ...d data while preserving the top headers 25 Let s say for example that you wanted to look at Current Rms plotted against Force On your spreadsheet click once on the column letter in this example it sho...

Page 189: ...lbar Note This screen shot has been cropped to show the selected columns 27 The Chart Wizard Step 1 of 4 Chart Type window will appear Under the Standard Types tab click once on XY Scatter in the Char...

Page 190: ...29 You can now format the chart as you like The x axis represents Current Rms in KA while the y axis represents Force in lbs To change the title of the chart double click on the title box and type in...

Page 191: ...mputer or you can connect the monitor to your existing network using a straight Ethernet cable Livingston monitors currently run Windows NT 4 0 The default network protocols are TCP IP and NetBEUI You...

Page 192: ...last 3 digits of the monitor s serial number If your local IP address does not use these number groupings you may type a to indicate a space You may want to select the Obtain IP address from a DHCP s...

Page 193: ...05068 Telephone 802 763 2934 Fax 802 763 2746 Email info livco com URL www livco com Livingston Company Inc Michigan Office Sales and Service Suite 250 1100 North Opdyke Road Auburn Hills MI 48326 Te...

Page 194: ...13 2...

Page 195: ...April 2005 User Interface livcoset exe 8 008 8 8 0 0 Monitor Version doit exe 8 008 8 8 0 0 Revision C 001 Notable changes to the Pod User s Manual starting with the following software versions User I...

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Livingston & Company WELDWISE 2400, User Manual

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