WELD PROCESS SCREEN PRESS MENUS, SETUP, ENTER, F1-TYPE, WELD PROC, ENTER

SETUP\Weld\Proc\\\\\\\\\\\\\\\\\\\\\\\\\\JOINT\\10\% 1/8 Selected Process: 1 [ ] 1 PowerWave+ArcLnk \\\\\\\\\\\\\\\\ 21 2 PowerWave+ArcLnk 0 3 PowerWave+ArcLnk 0 4 PowerWave+ArcLnk 0 5 PowerWave+ArcLnk 0 6 PowerWave+ArcLnk 0 7 PowerWave+ArcLnk 0 8 PowerWave+ArcLnk 0 TYPE SELECT | TYPE | COPY SELECT CLEAR HELP

8 AVAILABLE PROCESSES CAN BE SETUP. PROCESS 1 IS THE CURRENTLY SELECTED PROCESS ( THESE 8 ARE LIKE THE 8 BUTTONS ON THE PW450)

THIS NUMBER REFERS TO A SPECIFIC INTERNAL POWERWAVE MODE (MEMORY LOCATION). PROCESS 1 WILL CALL UP PW MODE 21.

TO SETUP A DESIRED PROCESS, CURSOR TO DESIRED PROCESS LINE AND PRESS F3-SELECT. THEN PRESS F1-TYPE, CURSOR TO WELD EQPT, ENTER

THIS NUMBER IS ALSO TAUGHT INTO THE WELD SCHEDULE DETAIL SCREEN BEING USED BY THE WELDING PROGRAM. AT ARC START, THE ROBOT TELLS THE PW TO ACTIVATE THE DESIRED PROCESS.

F1 F3

7

SETUP\Weld\Equip \\\\\\\\\\\JOINT\\10\% 1/17 Welder:Lincoln Electric PowerWave+ArcLnk 1 Process: 1 Wire diameter: [ ] Gas mixture: [ ] Description: [ ]

2 SEARCH for process = GMAW ? YES 3 SEARCH for pulse = NO ? YES 4 SEARCH for wire = Steel ? YES [ TYPE ] SEARCH HELP

THIS SCREEN DISPLAYS DETAILS OF WELD PROCESS SELECTED IN PRIOR SCREEN(EXAMPLE SHOWS PROCESS 1).IT'S ALSO USED TO SETUP A NEW PROCESS.SELECTED PROCESS DETAILS:

FOR SETTING SEARCH CRITERIA FOR A NEW PROCESS. THE ROBOT SEARCHES THE PW MEMORY FOR PROCESSES WHICH HAVE ALL THE DESIRED ITEMS: 2. PROCESS- GMAW, FCAW: F4-CHOICE 3. PULSE- YES OR NO: F-KEYS YES/NO 4. WIRE- STEEL, ALUM.: F4-CHOICE

A YES HERE LIMITS THE SEARCH TO PROCESSES HAVING THESE ITEMS

AFTER 3 LINES ARE SET, PRESS F3-SEARCH. ROBOT SEARCHES PW MEMORY FOR ALL MATCHES TO CRITERIA, THEN DISPLAYS THE MATCHES

F3

8 WELD EQUIPMENT SCREENPRESS MENU, SETUP, F1-TYPE, WELD EQPT.

SETUP\Eq\Search\\\\\\ JOINT\\10\% 1/17 PROCESS PULSE WIRE MATERIAL GMAW NO Steel # WIRE DIA DESCRIPTION 1 \10 .035 in [GMAW Steel ] [CV CO2 ] [CO2 ] 2 11 .035 in [GMAW Steel ] [CV ArMix ] [Argon Blends ]

[ TYPE ] SELECT HELP

THE SEARCH RESULTS ARE NOW DISPLAYED, AS A RESULT OF PRESSING THE F3-SEARCH KEY IN THE PREVIOUS SCREEN.THE VARIOUS MATCHES ARE NUMBERED

THIS NOTES THAT THE CURSOR IS ON LINE 1 OF 17 TOTAL MATCHES FOUND.

PROCESS DETAILS OF EACH MODE

MATCH NUMBER

PRESS F2-SELECT TO LOCK IN THE DESIRED MATCH.THE PREVIOUS WELD EQPT SCREEN WILL APPEAR NEXT, DISPLAYING THE PROCESS.

PW MODE /MEMORY NUMBER

F2

9SEARCH RESULTS SCREEN

SETUP\Weld\Equip \\\\\\\\\\\JOINT\\10\% 1/17 Welder:Lincoln Electric PowerWave+ArcLnk 1 Process: 1 GMAW Steel # \21 Wire diameter: [ .045 in] Gas mixture: [Ar CO2 ] Description: [CV ArMix ]

2 SEARCH for process = GMAW ? YES 3 SEARCH for pulse = NO ? YES 4 SEARCH for wire = Steel ? YES [ TYPE ] SEARCH HELP

LINE 1 AND ITS BRACKETED AREAS ARE NOW FILLED IN WITH THE PROCESS DETAILS PREVIOUSLY SELECTED.

8 WELD EQUIPMENT SCREENPRESS MENU, SETUP, F1-TYPE, WELD EQPT.

ZERO LINE 0 DATA\Weld\Sched\\\\\\\\\\\\\\JOINT\\10\% 1/64 IPM COMMENT 1 \300.0 23.5 25 2 300.0 23.5 35 3 300.0 1.0 35 4 300.0 1.0 35 5 300.0 1.0 35 6 300.0 1.0 35 7 300.0 1.0 35 8 300.0 1.0 35 9 300.0 1.0 35 [ TYPE ] DETAIL HELP >

F2

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TO SETUP A WELD SCHEDULE, FIRST MAKE SURE THE DESIRED WELD PROCESS HAS BEEN SELECTED IN THE WELD PROCESS SETUP SCREEN. THEN CURSOR TO DESIRED SCHEDULE NUMBER AND PRESS F2-DETAIL. SEE SCREEN BELOW:

SETTING UP A WELD SCHEDULE TO TO USE DESIRED WELD PROCESS

PRESS DATA KEY TO DISPLAY WELD SCHEDULES. FIRST COLUMN INDICATES WIRE FEED SPEED.

SECOND COLUMN INDICATES TRIM/VOLTAGE SETTING.

THIRD COLUMN IS FOR WELDING TRAVEL SPEED.

ZERO LINE 0 DATA\Weld\Sched\\\\\\\\\\\\\\JOINT\\10\% 1/7 1 Weld Schedule: 2 [****************] 2 Process select: 1 [GMAW Steel ] 3 WFS 300.00 ipm 4 VOLTS 23.500 V 5 Pinch 0.00 6 Travel speed 35 IPM 7 Delay Time 0.00 sec Feedback Avg Voltage 0.0 V Feedback Avg Current 0.0 A [ TYPE ]SCHEDULE HELP >

DETAIL VIEW OF WELD SCHEDULE 2

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CURSOR TO LINE 2-PROCESS SELECT, KEY IN WELD PROCESS NUMBER(1-8) THAT WAS JUST SELECTED. CURSOR TO LINE 3- KEY IN DESIRED WIRE FEED SPEED

CURSOR TO LINE 4- FOR POWERWAVE CV PROCESSES, KEY IN DESIRED WELD VOLTAGE(0-50). FOR POWERWAVE PULSE PROCESSES, KEY IN DESIRED TRIM VALUE(.5-1.5)

LINE 5-FOR PINCHING THE ARC; WAVE CONTROL FOR PULSING, ADJUST FREQUENCY

STT ONLY: LINE 4 WILL INDICATE BACKGROUND CURRENT, RANGE IS TYPICALLY FROM 40 TO 80 AMPS LINE 5 WILL INDICATE PEAK CURRENT, RANGE IS TYPICALLY FROM 150 TO 300 AMPS

SETUP\Weld\Equip \\\\\\\\\\\JOINT\\10\% 1/17 Welder:Lincoln Electric PowerWave+ArcLnk 1 Process: 1 GMAW Steel # 112 Wire diameter: [ .035 in] Gas mixture: [Ar CO2 ] Description: [STT ArCO2 ] 2 SEARCH for process = GMAW ? YES 3 SEARCH for pulse = NO ? YES 4 SEARCH for wire = Steel ? YES

[ TYPE ] SEARCH HELP

SETUP\Eq\Search \\\\\\\\\\\JOINT\\10\% 10/17 ] 9 111 .035 in [GMAW Steel ] [STT CO2 ] [100% CO2 ] 10 112 .035 in [GMAW Steel ] [STT ArCO2 ] [Ar/CO2 Blends ] [ TYPE ] SELECT HELP

NOTE STT IS ON DESC.LINE STT HAS IT'S OWN

UNIQUE SET OF MODE/ MEMORY NUMBERS

USE NO FOR PULSE !

EXAMPLE OF SEARCH RESULTS SHOWING MATCHES INVOLVING STT

10WELD EQUIPMENT SCREENS FOR STT SETUP

SETUP\Weld\Equip\\\\\\\\\\\\\JOINT\\10\% 1/17 Welder:Lincoln Electric PowerWave 455 1 Process: 1 GMAW Steel # \21 Wire diameter: [ .045 in] Gas mixture: [Ar CO2 ] Description: [CV ArMix ] 2 SEARCH for process = GMAW ? YES 3 SEARCH for pulse = No ? YES 4 SEARCH for wire = Steel ? YES Feeder: Power Feed 10 5 Wire feed speed units: IPM\\\ 6 WIRE+ WIRE- speed: 50 IPM 7 Feed forward/backward: ENABLED 8 Wire stick reset: ENABLED 9 Wire stick reset tries: 1 Timing: 10 Arc start error time: 2.00 sec 11 Arc detect time: 0.06 sec 12 Arc loss error time: 0.25 sec 13 Gas detect time: 0.05 sec 14 Gas purge time: 0.35 sec 15 Gas preflow time: 0.00 sec 16 Gas postflow time: \0.20 sec 17 Strike wire feed speed 50\ IPM

[ TYPE ] SEARCH HELP

11

COMPLETE WELD EQUIPMENT SCREEN

DATA WELD PROCESS SCREEN

PRIMARILY USED FOR FOR SETTING UP BURNBACK PROCEDURE TO END THE ARC ( RUNIN PROCEDURE IS NORMALLY PREDETERMINED AND CONTROLLED BY THE PW455. THEREFORE, MANUAL SETUP OF RUNIN IS DISABLED IN THE WELD SYSTEM SCREEN, UNDER MENUS-SETUP) PRESS DATA KEY, F1-TYPE, CURSOR TO LINE WELD PROCESS, ENTER. FOLLOWING SCREEN APPEARS:

DATA/WELD PROCESS JOINT 50% 5/32

Process select: 2 [GMAW - STEEL] 21 1 300.0 26.0 Runin 2 300.0 26.0 Burnback 3 300.0 26.0 Wirestick 4 11.5 .5 OnTheFly 5 300.0 1.0 Runin 6 300.0 1.0 Burnback 7 300.0 1.0 Wirestick 8 7.5 .1 OnTheFly 9 300.0 1.0 Runin [ TYPE ] DETAIL HELP >

8 GROUPS OF 4 ITEMS ; 32 TOTAL LINES.EACH GROUP IS FOR EACH OF THE WELD PROCESSES SETUP IN THE WELD EQUIP. SCREEN. ONLY THE FIRST 8 LINES,FOR PROCESSES 1 AND 2, ARE VALID ARCTOOL S/W 5.20 AND BEFORE.

FOR THESE SETTINGS TO TAKE EFFECT, RUNINAND BURNBACK ARE ENABLED IN THE WELD SYSTEM SCREEN, UNDER MENUS-SETUP.

CURSOR TO DESIRED LINE AND PRESS F2-DETAIL TO SETUP SPECIFICS

WHEN YOU CURSOR DOWN TO LINE 5, PROCESS SELECT 2 NOW APPEARS AT TOP OF SCREEN, LINE 9, PROCESS SELECT 3, ETC.

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PW455 MODE/MEMORYNUMBER

DATA\Weld\Process\\\\\\\\\\\\JOINT\\10\% 1/4 Schedule: 6 [ Burnback ] Process select: 2 [GMAW- Steel ] 1 WFS \300.0 ipm 2 VOLTS 25.000 3 Wave Control 1 10.000 4 Delay Time 0.05 sec [ TYPE ]SCHEDULE HELP >

TO SETUP THE BURNBACK FOR PROCESS 2, CURSOR DOWN TO LINE 6 OF THE WELD PROCESS SCREEN AND PRESS F2-DETAIL KEY. THE SCREEN BELOW NOW APPEARS ON THE TEACH PENDANT SCREEN:

LINE 1 WFS- NORMALLY SET TO 300, RANGE IS FROM 75 TO 350, DOES NOT REPRESENT WIRE FEED SPEED; THE LOWER THE VALUE THE BIGGER THE BALL LINE 2 VOLTS - SET TO 1.0 (25 VOLTS FOR CV PROCESS) LINE 3 WAVE- SET TO 10 LINE 4 DELAY- SET TO .05 SEC

14 WELD PROCESS SCREEN (cont.)