Power Wave Observer

User Manual
Version 3.2f
Y50021-09

July 25, 2004

Power Wave Observer User Manual

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 Power Wave Observer
Power Wave Observer is an application that is used for two main purposes:
• View the current status of the Power Wave
• Configure the non-volatile memory of the Power Wave DeviceNet module.

The application will connect to an ArcLink based Power Wave family machine1
via direct serial cable2 or network connection3.

1 Connection to Power Wave

The connection dialog will automatically open when the application is started and
may also be accessed from the “File | Connect to machine” menu.

Select TCP and enter “localhost” in the IP Address edit box to allow multiple
applications to communicate with the Power Wave4. Set the Communications
Port field to match the computer port in use.

Select Serial when the computer is connected directly to the machine via RS232
serial cable and the serial port is not being shared with other applications.

Select TCP or UDP and enter an IP address if your machine is ethernet

compatible.

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

1
Observer is not compatible with Power Wave 450 or LincNet PW455/STT/PF10 semi-automatic systems.
2
Typical computer to Power Wave serial connection requires a 9 pin female to 25 pin male adapter cable
(Radio Shack cat no. 26-269).
3
Ethernet module (G3894) is required to connect Power Wave to network.
4
The LEAL Server application (LealSrv.exe) is required to share a serial port connection and should be in
the same working directory as Observer.
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2 Basic Screen

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

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

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2.1 Welding Feedback
The Welding feedback section has three major components: Current, Voltage,
and Wire Feed Speed charts. The graph for each feedback is auto scaled5 to fit
the feedback values. This chart automatically pauses when the Weld Sequencer
is not active (IDLE). The three components of the graph are described below.

2.1.1 Current
This chart recorder component displays the Average Welding Current that the
Power Wave ‘sees’.

2.1.2 Voltage
This chart recorder component displays the Average Welding Voltage that the
Power Wave ‘sees’.

2.1.3 Wire Feed Speed (WFS)

This chart recorder component displays the Wire Feed Speed that the PF10/R
Control Board ‘sees’. This value is not the actual Wire Feed Speed, but a Wire
Feed Speed that is calculated from the Actual Motor Speed using known values
such as the gear box ratio and drive roll diameter.

5
Double-clicking on a graph section will bring up a dialog box to set minimum/maximum values displayed
in each graphing window. This allows the user to increase resolution around a particular range of values.
Selecting “Auto-scale” will display the full range of values collected.
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2.2 Graphing Utilities
The graphing utilities include Window Size Control, Start/Stop Graphing, Clear
Graphs, and Save Data from the graph. With the exception of window size
control all utilities are found under the ‘Graphs’ heading at the main menu.

2.2.1 Window Size Control

The graphing area can be enlarged by using the boxes located in the upper
right and lower left of the graphing area. When these boxes are clicked on they
will convert to and hide the components that were on the side or bottom of
the Observer window. To restore the components click on the boxes and
the components will be restored.

2.2.2 Start/Stop Graphing

The Start/Stop Graphing option under the ‘Graphs’ heading of the main menu is
used as a toggle selection to control the logging of all three chart components.
The default causes Observer to start graphing when the weld sequencer
becomes active. Select ‘Stop Graphing’ to prevent Observer form logging data.

2.2.3 Clear Graphs

This selection clears the data on the graphs.

2.2.4 Save Data

This selection saves the data that is stored in the graphs in a comma delimited
text file to allow import into a data analysis or a spreadsheet program. It will
store all data values since the starting of the application or since the previous
time that the graphs were cleared.

2.3 LEAL Connection Status

The upper right side of the Observer window contains the
connection status display. When a serial connection to a
Power Wave is made the name LOCALHOST will appear in
the window. If ‘LOCALHOST’ does not appear, follow the
steps in section 1 Connecting to a Power Wave.

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2.4 System Status
The system status is on the right side of the Observer window. The System
Status section contains the current value of critical system status attributes. The
status of these attributes are portrayed as virtual lights on the user interface. The
convention that is used is as follows:
Light is not illuminated: Condition is not present
Light is blinking RED: Fault Condition is present
Light is illuminated GREEN: Normal or expected Status is present

The following status conditions are reported in the System

Status section: Sequencer State, Arc Detect, DeviceNet
Connection, Sequencer Fault, Power Source Fault, Water
Fault, DeviceNet Fault, and DeviceNet Limit Error.

NOTE: The System Status is not intended as an exhaustive

system diagnostic, but as a general overview of system health.

2.4.1 Sequencer State

This line displays the current state of the Sequencer. Its state is displayed in
blue. The Weld Sequencer Object is a state machine responsible for
synchronizing the actions of the weld cell components. The value of Sequencer
State reflects the current state of the state machine. States names that may be
displayed are: IDLE, PREFLOW, STRIKE, WELD, POSTFLOW, RESTRIKE, and
FAULTED.

2.4.2 Arc Detect Status

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

2.4.3 DeviceNet Connection

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

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2.4.4 Sequencer Fault
Indicates that the Weld Sequencer Object has entered the FAULTED state.
Some reasons the Weld Sequencer Object may enter the FAULTED state are
but are not limited to:
• An unexpected error on the Power Wave’s internal network
• A fault in a device that is under the Weld Sequencer’s control such as the
Wire Drive or Weld Controller Objects
• The trigger was asserted prior to the system being Ready to Weld
• A necessary state machine condition was not met
• The Weld Sequencer Object was forced to the FAULTED state
• An external shutdown such as a Water Fault

2.4.5 Power Source Fault

Indicates that an inverter fault has been detected. Some causes of an inverter
fault are, but are not limited to:
• CAP under/over voltage
• CAP imbalance
• Primary overcurrent
• Failure to complete inverter softstart

If these errors persist or reoccur regularly, please contact Lincoln Electric service
personnel for assistance.

2.4.6 Water Fault

Indicates that the fault line that is typically assigned to the assigned to the water
fault is open. These fault lines are accessed through a green Phoenix Terminal
Connector on the front of the Power Wave. An open fault line indicates a fault.
In the case of water flow, a flow sensor that is normally open will cause a fault
when there is no water flow. If a water cooler is not connected to the Power
Wave, verify that the fault jumper is in place in the Phoenix Terminal Connector.
Consult the Power Wave Instruction Manual for the pinout of the Phoenix
terminal connector.

2.4.7 DeviceNet Fault

Indicates that a fault has occurred in the DeviceNet connection. Some causes of
a DeviceNet fault are, but are not limited to:
• Attempt to select an invalid schedule
• Schedule select timeout

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2.4.8 DeviceNet Limit Error
Indicates that a commanded value that is being passed on at least one of the
three analog DeviceNet channels is out of limit for the schedule that is currently
selected. Verify the values that are being sent to make certain that they are
within the operating limits. The Power Wave rejects any value that is out of limit.
When a limit error is encountered, the Power Wave will continue to use the most
recent value that was within limit.

2.5 Weld Schedule Variables

The Weld Variables Section contains the current value of critical system
attributes. These attributes are: Weld Mode, Set Wire Feed Speed, Workpoint,
Trim, Wave 1, Wave 2, Wave 3, and Wave 4. There is a tab at the bottom to
switch from Schedule 1A to Schedule 1B. To switch from on schedule to
another, select the appropriate tab and if a make active line appears next to the
tabs click on it and that selected schedule will have the active name next to it.
The attributes in these schedules are described below.

2.5.1 Weld Mode

Displays the value of the Weld Schedule’s Weld Mode attribute. The Weld Mode
attribute is used to select one of the possible welding procedure programs that
are stored in the Power Wave. A Weld Mode can be categorized based on
process type, wire type, wire size, and gas type. Weld Modes may be further
sub-categorized based on process variations such as pulse, or STT. A mode
number can be directly entered into this field. It holds the value of the Weld
Mode that will be used when the schedule becomes active.

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

From above it can be seen that Weld Mode 22 is a Pulse-GMAW Procedure for
.045 Steel Wire. The mode is intended to be used with an Ar/CO2 Gas mixture.
There is also a Sort By selection that will arrange the present Weld Modes into
numerical order or grouping by process type.

NOTE: The Weld Mode of an active schedule is not allowed to change. To

prevent this, the Mode Memory field and Weld Table Browser button are disabled
while the Power Wave is active.

2.5.2 Workpoint
Displays the current commanded value of the Workpoint attribute. The
Workpoint attribute is a primary control variable. The properties of the Workpoint
attribute such as units or high/low limits vary with the active Weld Mode.
Typically, in a synergic Weld Mode, Workpoint is the commanded wire feed
speed. The units of Workpoint are shown to the right of the current value. The
name or function assigned to Workpoint is shown to the left. Consult the Power
Wave Instruction Manual for more detailed information concerning the effects of
Workpoint.

2.5.3 Trim
Displays the current commanded value of the Trim attribute. The Trim attribute is
a secondary control variable of the Weld Controller object. The value displayed
will be in engineering units if “Display Scaled Trim/Wave Controls” is checked or
“raw” machine units otherwise.

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2.5.4 Wave Controls 1,2,3,4
Displays the current commanded value of the Wave Control attributes. Wave
Controls are optional secondary control variables of the Weld Controller object.
Only active Wave Controls will be displayed. The value displayed will be in
engineering units if “Display Scaled Trim/Wave Controls” is checked or “raw”
machine units otherwise.

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

NOTE: User may override the current value for Workpoint, Trim, and Wave
Control by typing a new value in the associated edit box and pressing the Enter
key6. This value will remain valid until a new value is received through the
DeviceNet Network or entered into the variable field.

2.5.5 Names/Units
The units for all the Weld Schedule Variables will be displayed to the right of the
entry box for that variable. The name to left of the entry box reflects the function
of the variable in the weld table. The names and units will change depending on
the weld mode selected. If the Weld Schedule Variable does not require units,
no units will be displayed.

NOTE: Trim and Wave Controls are stored in the machine as a signed number
between –32767 and +32767. The Trim and Wave Control attributes of the Weld
Controller do not change their limits or units. However, the user has the option of
providing a Trim or Wave command as an engineering value. When Trim or
Wave Control is commanded as an engineering value, its limits may be
dependent on the value of Workpoint.

2.5.6 Schedule Select

Selects the schedule that will be configured by the Schedule Configuration
parameters. Currently, the Power Wave supports two unique schedules. It is
important to note that although only two preset schedules are available, this does
not restrict the welding parameters that are passed to the system. For example,
a single schedule will support any number of analog commands that are passed
to the system over the polled DeviceNet connection and will alter the machine
output on-the-fly. A schedule selection is not required to alter welding
parameters.

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

6
Workpoint and Trim/Wave Controls are write-enabled based on the settings in the Observer Preferences
dialog box accessible from the File|Preferences menu.
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2.6 Additional Weld Schedule Variables7
The Power Wave has the capability of storing multiple schedule configurations.
This creates a large matrix of sequence steps that the Power Wave goes through
during a weld. Observer provides the ability to modify a minimal subset these
schedule parameters. The Schedule Configuration section includes the following
parameters: Strike Wire Feed Speed, Preflow Time, Burnback Time, and
Postflow Time.

2.6.1 Strike Wire Feed Speed (inches per minute)

Configures the Wire Feed Speed for the STRIKE state. STRIKE is the time
period between the end of the PREFLOW state and the establishment of a
welding arc. This is also known as “run-in WFS”. Configuring a STRIKE Wire
Feed Speed prevents the welding wire from running full-speed into the part
before an arc has been established. This is especially useful for electrode types
that are sensitive to starting- i.e. large gauge Aluminum.

A valid Strike Wire Feed Speed MUST be configured in order for the system to
feed wire to strike an arc.

2.6.2 Preflow Time (milliseconds)8

Sets the time that the Weld Sequencer object will remain in the PREFLOW state.
PREFLOW is the time period between assertion of the trigger and enabling of the
welding output. A value of zero disables the PREFLOW state.

2.6.3 Burnback Time (milliseconds)

Sets the time that the Weld Sequencer object will remain in the BURNBACK
state prior to moving to the POSTFLOW state. BURNBACK is the time following
the de-assertion of the trigger that the welding output will remain on while the
wire feeding is stopped. The configuration of the BURNBACK time is highly
application specific and is dependent on welding wire feed speed and stickout. A
value of zero disables the BURNBACK state.

2.6.4 Postflow time (milliseconds)

Sets the time that the Weld Sequencer object will remain in the POSTFLOW
state. POSTFLOW is the time period between the Welding Output being
disabled by the Weld Sequencer Object and returning to the IDLE state. A value
of zero disables the POSTFLOW state.

7
Strike WFS, Preflow, Postflow and Burnback are hidden/displayed based on the settings in the Observer
Preferences dialog box accessible from the File|Preferences menu.
8
The DeviceNet module will automatically enable sequencer states when non-zero values for preflow,
burnback and postflow times are commanded. Observer will set the appropriate times but will make no
attempt to enable/disable states if a DeviceNet module is not present.
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3 DeviceNet

3.1 DeviceNet Configuration

The DeviceNet Configuration parameters are used to configure the Power
Wave’s critical DeviceNet network parameters and define how it responds to
changes in command values that are passed to it. The DeviceNet Configuration
dialog is accessible from the DeviceNet | Configuration menu and is only
available when a DeviceNet module is detected9.

3.1.1 DeviceNet Communication - MAC ID

This field indicates the current configuration of the Power Wave’s DeviceNet
MAC ID. This value will only change if the DIP switches on the Power Wave’s
DeviceNet interface boards are configured to allow retrieval of the MAC ID from
EEPROM memory. If this value is altered, the Power Wave must be reset (cycle
power) in order for the change to become effective.

9
See Power Wave instruction manual or DeviceNet Interface Specification (Y50031) for configuration
details.
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3.1.2 DeviceNet Communication - Baud Rate
This field indicates the current configuration of the Power Wave’s DeviceNet
Baud Rate. This value will only change if the DIP switches on the Power Wave’s
DeviceNet interface boards are configured to allow retrieval of the Baud Rate
from EEPROM memory. If this value is altered, the Power Wave must be reset
(cycle power) in order for the change to become effective.

3.1.3 Analog Input Channels/Hysteresis

These values indicate the magnitude of change that must occur on the first three
analog DeviceNet channels before the Power Wave will respond to the change.
In the case of a command value that is sourced from an A/D whose output may
dither slightly, this configuration prevents unintended parameter changes. This
attribute is not useful for command values whose source is completely digital and
should be set to 0. One exception is when the Power Wave has an Analog
Interface module, in this case set these values to a 30. Input channels will be
ignored if their Active boxes are unchecked in which case the Power Wave will
assign default values to the associated parameters10.

3.1.4 Analog Output

Configure AN2 output channel to report actual (default) or commanded WFS.
Note: This control is for AC/DC systems only.

3.1.5 System Control – Enable passive mode operation

If checked, then the DeviceNet polled inputs will have no effect on the system
except for the Weld Output disable bit and the Production Monitoring Fault Reset
bit.. Enable this when the DeviceNet connection is used only to monitor system
operation.

3.1.6 System Control – Restore settings from memory on reset

The DeviceNet board will automatically restore weld schedule values on power-
up that are not accessible from a polled connection. These include Weld Mode,
strike, restrike and cold inch wire feed speeds, and times for preflow, postflow
and burnback. If the system contains an UI with memory a memory panel or a
robot/PLC that restore settings on power up, do not check this box.

3.1.7 System Control – Fault if no polled connection detected

Disables welding if a polled DeviceNet connection is not present. Check this
when a DeviceNet master controls machine.

3.1.8 Workpoint Input

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

10
Analog Input Masking and Analog Output configuration are available in DN Vendor Rev 1.008 and later.
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engineering values. Selecting the “Engineering Units” option indicates that
scaled engineering values for Workpoint will be passed across the analog
DeviceNet channel. For example when the workpoint is in Inches/per Minute and
scaled engineering units are used, then a value of 50 to 800 might be expected
to be commanded on the DeviceNet analog input for the workpoint. This would
represent a value of 50 to 800 inches/per minute. When the “Unscaled Values”
option is selected, the commands for Workpoint range from 0 to 32767
corresponding to the minimum and maximum workpoint of the selected weld
mode. For most applications, Engineering Units is normally selected.

3.1.9 Trim/Wave Control Input

This indicates whether the values passed to the system through the analog
DeviceNet channels for the Trim and Wave Control parameters are raw values or
scaled engineering values. Selecting the “Engineering Units” option indicates
that scaled engineering value for Trim or Wave Control 1 will be passed across
the analog DeviceNet channels. For example when the Trim is in volts and
scaled engineering units are used, then a value of 75 to 520 might be expected
to be commanded on the DeviceNet analog input for the trim. This would
represent a value of 7.5 to 52.0 volts. When the “Unscaled Values” option is
selected, the commands range for Trim and Wave Control 1, 2, 3, 4 range from –
32768 to 32767 with 0 representing a nominal value. A great majority of
applications will require Trim and Wave Control command values to be set near
the nominal value.

3.1.10 Report Trim/ Wave Outer Process Limits

When the Trim and Wave are being reported in Engineering Units and these
inputs are depended on the workpoint, then this item is used to determine how to
report back the trim and wave high and low limits. If the above conditions are
meet, then checking this box will have the absolute high and low limit always be
returned, unchecking the box will have the returned limits be based on the
workpoint. As the workpoint changes, the acceptable range that the trim and
waves can be in will change as well, unchecking this box will have the limits
report back what this range is. Normally this item is checked.

3.1.11 TAST Update Frequency

This parameter is used for Through the Arc Seam Tracking. The lower the
number the more often the feedback is updated, but higher the system load on
the boards. If Through the Arc Seam tracking is being used, then this is usually
set to a value of 10 to 20, else a value of 100 is usually acceptable.

3.1.12 Metering Time Constant

This parameter sets the filtering of the feedback data. The default value of 400 is
usually used unless Through the Arc Seam Tracking is being done, then this item
is usually set to a value of around 75.

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3.1.13 Analog Scans Between Updates
This determines how often the analog input channels (workpoint, trim, and wave
control) update the system in terms of Polled I/O scans. For example a value of
50 means that every 50th I/O scan will be accepted. The setting of this item
depends on how often the Power Wave is scanned. For systems with a scan
rate of 200 or more, then the default of 50 is usually acceptable. For systems
with very low scan rates, such as 10hz then the setting as low as 2 might be
needed. Once a DeviceNet connection has been established, see IO Scans/Sec
item in the DeviceNet monitor screen in Observer for the current scan rate. Note
that this setting does not affect the digital I/O bits updating rate.

3.1.14 Cold Inch Wire Feed Speed

This parameter sets the feed speed of the wire while cold inching or jogging the
wire. This value is used for either cold inching forward (Jog +) or cold inching
reverse (Jog -). This value is in units of IPM. A value of 0 will cause the wire to
inch at 0 IPM, or in other words, not at all.

3.1.15 DN Event Logging

The DeviceNet module keeps a running history of system in an on-board event
log. These events may be generated during normal operation when power is
applied to or removed from the system. These boxes should be left unchecked
unless troubleshooting the system.

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3.2 DeviceNet Monitor
The DeviceNet Monitor interprets command input and feedback passing through
the DeviceNet module. This is a troubleshooting tool for those customers
implementing a DeviceNet connection to the Power Wave. This dialog is
accessed from the DeviceNet | Monitor menu and is only available when a
DeviceNet module is detected. Refer to Y50031-xx Device Net Interface
Specification for more information on these items.

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3.3 DeviceNet Trace
The DeviceNet Trace displays low-level communication passing through the
DeviceNet module. This is a troubleshooting tool for those customers
implementing a DeviceNet connection to the Power Wave. This dialog is
accessed from the DeviceNet | Trace menu and is only available when a
DeviceNet module is detected.

4 Observer Preferences
Observer operation is determined by the settings in the Preferences dialog
accessible from the File | Preferences menu. The default settings (shown below)
assume the machine will be controlled via a DeviceNet module. Only those
controls that cannot be set with a polled DeviceNet connection are displayed.

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4.1 Observer Preferences - General

4.1.1 General – Period between attribute updates

Enter the time (in milliseconds) to refresh machine attributes read by Observer.

4.1.2 General – Display Strike/Burnback/Postflow

When checked, the associated controls will be visible on the
main Observer screen. These controls configure sequence
memory not available through a polled DeviceNet
connection. See “Additional Weld Schedule Variables” for
details.

4.1.3 General – Show Trigger Button

When checked, a Trigger control is visible on the main
screen. This button allows triggering the machine through
the Observer program. To turn on welding output, hold the
CTRL key while clicking the button while the output is off. Clicking the button
when output is on will turn the trigger off.

4.1.4 General – Show Weld Statistics

When checked, arc statistics for the last weld become visible
on the main screen. Total Arc Time and the history of welds
since Observer was started is available from the View menu.

NOTE: The heat calculation (Joules) is based on average

current and voltage readings and should be used for
reference only.

4.1.5 General – Enable Workpoint/Trim Controls

When checked, the edit boxes for Workpoint, Trim and Wave Controls become
active so that new values may be entered from the main Observer screen. To
override a value, type a new value in the associated control and press the Enter
key. This value will remain valid until a new value is received through the
DeviceNet Network or entered into the variable field.

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

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4.2 Observer Preferences – Weld Control

4.2.1 Weld Control

This screen determines which sequence

states are updated when a new value is
entered in the associated edit box.
Typically, all states shown in red should
be be set11. Checking “Use Strike WFS
for Restrike WFS” will update the
Restrike state when new values for Strike
WFS are entered.

NOTE: Hovering over each control will

display the associated sequencer state in
a “tool-tip” window.

11
Observer displays the value of the Weld1 state for Workpoint, Trim and Wave Controls. Right-clicking
on the Workpoint, Trim or Wave Control edit box in the main Observer screen will allow you to view all
sequencer state values and the active limits for a control at the selected workpoint.
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4.3 Observer Preferences – Graphs

4.3.1 Observer may connect to several

machines simultaneously. Current from
each machine may be displayed
graphically as individual waveforms
and/or as a composite sum. Volts and
Wire Feed Speed graphs display
waveforms from all machines.

4.3.2 Select whether the AMPS

readout shows the composite current
from all machines or the individual
contribution of the highlighted
connection. Voltage and WFS readouts
always display values from the selected
machine connection.

4.3.3 Click on a color square to

customize graph colors.

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5 Help
Observer includes an “About Box” that lists program revision
particulars. The “System Info” dialog provides details about
the Power Wave hardware and software. If problems arise,
this information will be crucial to help solve them.

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