Instruction/ maintenance manual of the product WELDWISE 2400 Livingston & Company
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Revision C.001 Use r’ s M a n ual WeldWise 2400 THE WELD MONITORING SPECIALIST S T M.
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0453-INS-400 Rev. F i Disclaimer Livingston & Company makes no warrant y of any kind with regard to this material, including, but not limited to, implied warranties of merchantabil ity and fitness for a particular purpose.
ii 0452-INS-400 Rev. C Product Road Map The Livingston User's Manual in cludes the following sections: • Overview of Resistance Welding : E xplains the fundamentals of resistance welding and fa.
0427-INS-400 Rev. D iii Table of Contents OVERVIEW OF RESISTANCE WELDING 1 I N T R O D U C T I O N 1 - 1 VARIABLES IN THE WELDING PROCESS 1-2 T H E W E L D C Y C L E 1 - 2 C R I T I C A L F A C T O R .
0427-INS-400 Rev. D iv GETTING FAMILIAR WITH THE WELDWISE™ 2400 4 T H E F R O N T P A N E L 4 - 1 WMS NAVIGATION AND EDITING 4-2 N A V I G A T I O N 4 - 2 E D I T I N G 4 - 2 O T H E R B U T T O N S.
0427-INS-400 Rev. D v G R A P H S E T U P 6 - 4 5 S H U T D O W N M E N U 6 - 4 6 I N S T A L L I N G T H E S E N S O R S 7 T Y P E S O F S E N S O R S 7 - 2 C U R R E N T 7 - 2 V O L T A G E 7 - 2 F .
0427-INS-400 Rev. D vi COMMON USES OF RWMA MATERIAL 11-21 WARRANTY & REPAIR POLICY 11-23 A P P L I C A T I O N N O T E S 1 2 APP NOTE 118 – Changing WeldWise™ 2400 Id entification and IP addre.
0428-INS-400 Rev. E 1- 1 Overview of Resistance Welding Introduction In simplest terms, welding is a process by which two or more pieces of me tal are joined by applying heat and pressure. Back in the good old days, blacksm iths and other crafty people would heat metals in a furnace and then weld them by hammering the red-hot m etals together.
0428-INS-400 Rev. E 1-2 Variables in the Welding Process The many variables involved in welding can be broa dly categorized into two basic sections: process variables and m aterial variables.
0428-INS-400 Rev. E 1- 3 During the Hold Time , electrode force is still applied, even after the weld current has ceased. During this period, the weld nugget cools an d the metals are forged under th e force of the electrodes.
0428-INS-400 Rev. E 1-4 Power Power is Voltage multiplied by Current, and is measured in W atts, or KVA (KVA stands for Kilo- Volt-Amperes. Watts and KVA will be used interchangeab ly in this text). This means that the am ount of current flowing times the pressu re that's causing it to flow equals the amount of power generated.
0428-INS-400 Rev. E 1- 5 an acorn to the size of a plum, it is also important to choose electrodes that are able to withstand the force needed to make a good weld. A key point to understand is that force and resist ance have an inverse relationship: m ore force will result in less resistance, and vice-v ersa.
0428-INS-400 Rev. E 1-6 Surface Contact The ultimate goal of the weld proces s is for the weld current to generate suf ficient heat between the workpieces being welded so that the metal will melt, fuse together and form a weld nugget. For this to happen, the surface contact must be maximized.
0428-INS-400 Rev. E 1- 7 size of the loss if they've m ushroomed 2, 3, even 4 millim eters! A constant current control o r a weld stepper may be used to regulate the amount of curre nt used, but a controller or stepper does not track the change in surface area.
0428-INS-400 Rev. E 1-8 Law, Current is not constant either. This means th at the I-squ ared version Joule' s Law will not reveal the amount of heat generated at the workpi ece u nless the resistance at the tips is kno wn.
0428-INS-400 Rev. E 1- 9 Recommendations for Pr oducing Quality Welds To produce high quality welds c onsistently, follow these tips: 1. Be sure that the electrodes you are using are suitable for the job. 2. Use standard electrodes whenever possible. 3.
0428-INS-400 Rev. E 1-10 7. Ensure that the top of the adjustable water-coo ling tube in the holders is the proper height when changing to a different tip length. 8. Coat the tip with a thin film of cup grease before placing it in the holder to simplify removal.
0429-INS-400 Rev. C 2-1 Introduction to Resistance Weld Monitoring Introduction As discussed in the last chapter, what you see is not always what you get.
2 0429-INS-400 Rev. C 2-2 Weld Lobes and the Weld Process Each of the factors involved in th e creation of a weld (C urrent, Voltage, Resistan ce, etc.) h as a specific range in which good welds can be made. This range is commonly known as the weld lobe .
0429-INS-400 Rev. C 2-3 displacement can indicate whether the resulting weld was formed properly. BA monitoring m easures the displacement bef ore the weld is made (Initial Th ickness), and then again after the weld is m ade (Final Thickness). However, if it is d etermined that the displa cement is consistently b elow where it should be (e.
2 0429-INS-400 Rev. C 2-4 Effects of Different Factors Each of the four main parameters— Current, Voltage, Force, and Displacement — affect the properties of a weld.
0429-INS-400 Rev. C 2-5 air over oil cylinders. If the el ectrode force drops too low, resistance can increase betw een the electrodes and the workpiece, result ing in expulsion. If the electrode force becomes too great, the resistance is lowered, resulting in poo rly formed nuggets or even brittle welds, particularly with coated metals.
2 0429-INS-400 Rev. C 2-6 Both quality improvements and efficiency can be gained through weld-process monitoring. For example, by demonstrating and tracking the consiste nt high quality of primary welds, the need for additional "safety" or "de lta" welds can be reduced or even eliminated.
0430-INS-400 Rev. D 3- 1 Tolerancing and Monitoring Introduction This chapter will introduce Livingsto n's concept of dynamic resistance weld monitoring.
0430-INS-400 Rev. D 3-2 remain clamped until the ladder logic has been re set). Parts with r ejected welds can then be immediately identified and isolated from parts with accep ted welds. Selecting a Master A Livingston weld monitor can store a number of masters (contains master tolerance limits) that are selectable using the binary select inputs.
0430-INS-400 Rev. D 3- 3 Every factor involved in making a we ld has its own weld lobe and se t of unique tolerances. There are multiple parameters that can be m easured and toleranced using a Livings ton monitor. The WMS program makes it easy to define, track and record to le rances for each parameter critic al to the weld process.
0430-INS-400 Rev. D 3-4 To resolve this issue, the exact time (in halfcycles) needed for th e weld current to burn through the coating could be determined by ex amining collected weld data. Us ing this information, a segment could then be added that would e ffectively divide the W eld segment into two.
0431-INS-400 Rev. D 4-1 Getting Familiar With The WeldWise™ 2400 This chapter will review the external features of the W eldWise ™ 2400 (hereafter referred to as 2400), as well as the various menus and options of the Weld Monitoring Software (WMS) program , including the proper shutdown procedure for all Livingston equipment.
0431-INS-400 Rev. D 4-2 WMS Navigation and Editing There are two modes in the W MS program: naviga ting m ode and editing mode. Navigating mode simply refers to moving from one portion of the scr een to another or from sc reen to screen. Editing mode refers to selecting an item for change and/or actually changing the value of it.
0431-INS-400 Rev. D 4-3 number, you can increase or decrease it by us ing the arrow buttons, or if you have a keyboard you can simply type in the de sired number. The SELECT button takes you to the next level or the next set of choices . You can also double click the item with a mouse or press Enter on an external keyboard.
0431-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.
0431-INS-400 Rev. D 4-5 Proper Shutdown Procedure The WMS program uses databases to keep track of configuration settings and weld data. Properly shutting down or exiting the software is important since improper shutdown m ay result in a corrupt database.
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0432-INS-400 Rev. E 5-1 WMS Quick Start Guide This chapter is a quick how-to guide to begin us ing a Livingston weld monitor. The provided example describes the necessary steps to collect and v i ew data, create a master and set tolerances.
0432-INS-400 Rev. E 5-2 Gathering Data 1. Make one weld and then look at the main screen of the monitor. It should appear similar to the figure below (Please refer to Main Program Screen in Section 6, W MS Reference Guide, for main screen specifics): • Weld Master ID Indicates which master the displayed weld data wa s com pared to.
0432-INS-400 Rev. E 5-3 • POD / ID Select Pod / ID indicates which WeldWise™ 2400 ID is cu rrently selected. The factory setting is 60. • Weld Status Indicators Indicates the status of the displaye d weld. If a check mark is displayed then the weld was accepted.
0432-INS-400 Rev. E 5-4 Figure 5-6 By changing the Low/High values for a displayed parameter in the Graph Setup… 2. Make a few welds using weld settings and parts customary for the application. After each weld is made, notice the weld number increase by one.
0432-INS-400 Rev. E 5-5 At the bottom of the Halfcycle Summary screen are two buttons: Zoom and T able . In between them is a box labeled " Weld :" that is fo llowed by the number of the weld being displayed.
0432-INS-400 Rev. E 5-6 • The screen will look similar to figure 5-11 below. Unlike the Halfcycle Summary screen, the Weld Summary screen displays recorded weld summa ry information for each weld m 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.
0432-INS-400 Rev. E 5-7 Creating a Master Now that you have observed recorded weld data, we will make a master which will pro vide known good values to compare subsequent welds against. Note: An appropriate weld schedule should be established before creating a master.
0432-INS-400 Rev. E 5-8 Accepting / Rejecting Welds Once a master has been created a nd updated, the monitor has a basis on which to compare subsequent welds. If all parameters fall within th e master tolerance lim its, the weld is accepted by the m onitor.
0432-INS-400 Rev. E 5-9 5. If for some reason your weld rejected, try maki ng more welds to see if any accept. If the welds continue to reject, review the f ailed parameters and skip ahead to the tolerancing section of the WMS quick start guide.
0432-INS-400 Rev. E 5-10 Tolerancing In the WMS program, welds are accepted or rejected based on specific tolerances assigned for individual parameters within an ac tive master. Tolerances can be define d as relative or absolute values. Refer to the Tolerancing in section 6, WMS Reference Guide, for a definition of relative and absolute tolerances.
0432-INS-400 Rev E. 5- 11 Figure 5-20 Halfcycle Summary for ACCEPTED weld Figure 5-21 Main program screen displaying a REJECTED weld ( Current Rms , etc. too low) Figure 5-22 Halfcycle Summary for REJECTED weld 7. Decrease the heat on yo ur weld schedule by 20.
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0433-INS-400 Rev. E 6-1 WMS Reference Guide This chapter reviews every screen in the WMS progr am. There is an organ izational chart (WMS Road Map) for the all screens in Chapter 11, Appendices . Main Program Screen The main program screen of the W eldWise™ 2400 is shown in figure 6-1 below.
0433-INS-400 Rev. E 6-2 • Weld Status High/Low Limit Indicators One or both of the indicators will be displayed if the most recent weld was rejected. The top arrow will flash if a parameter exceeded high lim its; the bottom arrow will flash if a parameter exceeded low limits.
0433-INS-400 Rev. E 6-3 • Parameter Value The most recent weld summary data for the selected param eter is displayed. The units displayed may be changed in the Tolerance Defaults screen. In figure 6-3, the weld summary data for Current Rms is displayed in KA .
0433-INS-400 Rev. E 6-4 Main Menu Options Selecting the MENU button on the touch-pad displays the Main Menu , as shown in figure 6-6. You can return to the Main Menu from sub-menus by using the MENU or ESCAPE buttons.
0433-INS-400 Rev. E 6-5 Data Menu Options • Halfcycle Summary This option displays Halfcycle , Segment and Weld Summary data in a graphical or tabular format. • Weld Summary This option displays Weld Summary data in a tabular format. • System Log This option displays System Log information for different system events.
0433-INS-400 Rev. E 6-6 Halfcycle Summary Screen The WMS software displays weld da ta on a halfcycle, segment and weld basis. If the system is set up to record halfcycle information, data records are stor ed in a database for each halfcycle of the weld.
0433-INS-400 Rev. E 6-7 • Zoom Button Expands the graph in the horizontal direction. When the graph is se lected in zoom view, it can be scrolled left or right us ing the arrow buttons. The Beginning Segment ( Beg Sg ) defines which segment the cursor (arr ow) is in.
0433-INS-400 Rev. E 6-8 • Accept Status The Accept Status field will be z ero if the weld was within all specified toleran ces in the master. If the Accept Status field is not zero, then at least one parameter of the weld was outside of the master tolerance limits.
0433-INS-400 Rev. E 6-9 • VoltageRms The RMS voltage in a halfcycle, or average RMS voltage for a segm ent or weld. • VoltagePeak The peak (positive or negative ) voltage in a halfcy cle, or the peak voltage in a segment or weld.
0433-INS-400 Rev. E 6-10 • Energy The calculated energy during the halfcycle, equal to Curren t RMS multiplied by Voltage RMS. The average energy for a segment or weld. • Power Factor Power Factor is not yet implemented and will d isplay zero. • Cyc Len Cyc Len shows the number of samples per halfcy cle in the A-D conversion.
0433-INS-400 Rev. E 6-11 Weld Summary Screen The Weld Summary displays a table of stored weld summary data records (Rtype 2), with the most current record at the top. Use the arrow keys to scroll through the rows (data records) and columns (data param e ters).
0433-INS-400 Rev. E 6-12 System Log Screen • System Log This screen displays a ta ble of recorded system information. 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.
0433-INS-400 Rev. E 6-13 Figure 6-18 Database Management options Database Management The WMS software running on the WeldWise™ 2400 uses Microsoft Access database files fo r storing configuration, calibratio n, masters, master tolerance lim its, and we ld data.
0433-INS-400 Rev. E 6-14 • Compact Database System data records are constantly added to and deleted from the database during normal operation. When certain data records are deleted from the database (e.g., Delete System Log or Delete Master is performed), space for these records is not automatically reclaimed.
0433-INS-400 Rev. E 6-15 • Repair Database If a database file is open by the weld monitor software (or an external application such as Microsoft Access) and an improper shutdown occurs, the database may become damaged. This repair option is basically the s ame repair tool that is provided w ith Microsoft Access.
0433-INS-400 Rev. E 6-16 Database Import Screen • Import All This option deletes the current databases, and reverts to archive databases that have been saved by a previous Export All command. The current and archive database file names are: Current Database Archive Database Livco.
0433-INS-400 Rev. E 6-17 • Import Masters From Floppy This option is the same as the Import Masters command above, except that the archive database has been compressed and stored to a floppy disk previously by an Export Masters To Floppy command. WARNING : Welds cannot be monitored while the Import Masters From Floppy option is in use .
0433-INS-400 Rev. E 6-18 Database Export Screen • Export All This option saves the current databas es to archive databases, back ing up all system and weld data. An Export All command should be executed periodically as system settings are changed and masters are developed.
0433-INS-400 Rev. E 6-19 • Export Masters To Floppy This option is the same as the Export Masters command above, except that the archive database is compressed and stored to a floppy disk. This command will overwrite any m asters written by a previous Export Masters To Floppy command.
0433-INS-400 Rev. E 6-20 Scope Data Screen NOTE: The scope data feature is intended for use as a diagnostic tool by Livi ngston. Please contact Livingston if you need the abi lity to record scope data. • Scope Data This option displays the raw and fi ltered data from the external sens ors.
0433-INS-400 Rev. E 6-21 Mastering Screen In order to be sure that production welds are good, it must be verified that the parameters of each weld match the parameters of a known good weld. A master is made from a weld or welds which are proven to be good through destructive testing.
0433-INS-400 Rev. E 6-22 Each segment will have the toler ances specified in the Tolerance Defaults Screen. (The weld can be divided up into more segments in the Toleran cing Screen ). The binary selec t value when the master was made is indicated at the end of th e m aster name by “Mxx”, where xx is the binary select number.
0433-INS-400 Rev. E 6-23 • Update When a master is created, edited or selected, it must be updated in order for the weld monitor to begin qualifying welds with the new/edited master. A master m ust also be updated before using the replace function. • Delete Master This button deletes the selected master.
0433-INS-400 Rev. E 6-24 Edit Master Screen The Edit Master screen is shown below in figure 6-39. The graph line represents the data for the displayed parameter and weld number. The shaded area represents the av erage of all the welds included in the master set.
0433-INS-400 Rev. E 6-25 Tolerancing Screen When new welds are compared to the master, they ar e given a certain amount of “forgiveness” relative to the values in the master.
0433-INS-400 Rev. E 6-26 • Master ID When a master is selected, the Master ID is di splayed at the top of the screen. The tolerancing screen adjusts the limits for this m aster. • Select Master Button This option displays a list of st ored masters and allows one to be picked for tolerance editing.
0433-INS-400 Rev. E 6-27 • Segment Line When a master is origina lly created, a weld is di vided into three segments. More segm ents can be added if desired in the Tolerancing Master screen. Segment lines ar e placed at the b eginning of each segment, with the exception of segm ent 0.
0433-INS-400 Rev. E 6-28 • Delete Segment Line Move the cursor to a segment line other than the first segm ent line, and use the Up Arrow button to delete the line. Once the se gment has been deleted, the tolerance lim its will be those to the left of the cursor.
0433-INS-400 Rev. E 6-29 Figure 6-46 Segment Tolerancing Se g ment Summar y Segment Tolerance High Limit (RELATIVE) Segment Tolerance Low Limit (RELATIVE) Segment Tolerancing allows each segment summary (the average of all halfcycles in a segment) to be toleranced, as shown in figure 6-46.
0433-INS-400 Rev. E 6-30 Setup Menu • General Setup This option displays the General Setup screen, which controls setup parameters for a POD / ID. • Setup Utilities This option displays the Utilities Menu , which provides diagnostic and calibration utilities.
0433-INS-400 Rev. E 6-31 General Setup The General Setup is used to change the g eneral configuration of a WeldWise™ 2400. The Current ID at the bottom of th e screen is the ID to which the configuration settings apply. Separate configuration se ttings for each ID are maintained in the database.
0433-INS-400 Rev. E 6-32 GENERAL SETUP - Parameter Descriptions • Binary Select Mode (Default Setting: Internal) Binary Select inputs are to select different masters fo r a single weld head. For each ID there are up to 15 masters which can be on line, and immediately av ailable for use.
0433-INS-400 Rev. E 6-33 • Post Delay (Default Setting: 0) Once weld current has ended, the weld monitor waits for a period of tim e to see if weld current begins again. This amount of 'waiting' tim e can be specified in halfcycles using the Post Delay setting.
0433-INS-400 Rev. E 6-34 • Segment Data Mode (Default Setting: None) All: All segment summary data records will be record ed and stored in the data base. If a segment summary is stored in the database, the n the associated weld record must be stored also.
0433-INS-400 Rev. E 6-35 • Trigger Hcycle (Applies only when Scope Mode is Enabled) Trigger Hcycle determines the ha lfcycle within th e Trigger Segm ent that will be the start of data gathering in Scope Mode. This halfcycl e is the 'trigger point' for Scope Mode.
0433-INS-400 Rev. E 6-36 • AD Hysteresis (Adjustment may be required) Recommended initial setting: 250 AD Hysteresis is used in conjunction with AD Th reshold and should generally be set to 25% to 40% of the AD Threshold value. Higher AD Hyst eresis settings may be required in noisy environments.
0433-INS-400 Rev. E 6-37 • Displacement Polarity (Default Setting: Positive) Positive: Displacement data is recorded and di splayed indicating “positive” displacem ent changes for positive voltage changes at the displacem ent sensor.
0433-INS-400 Rev. E 6-38 Setup Utilities • Input Monitor This option displays the input monitor screen, which shows the data values from external sensors and inputs. A Zero Displacement utility is also provided. • Toroid Settings This utility is used adjust the toro id calibration.
0433-INS-400 Rev. E 6-39 Input Monitor The Input Monitor display allows you to see the raw data readings from th e sensor input channels (A/D values) as well as the calibr ated readings for Voltage, Force, and Displacem ent are also shown (Value). Calculated Cu rrent values are not displayed.
0433-INS-400 Rev. E 6-40 Toroid Settings Utility The screen is used to cali brate the current reported by the weld monitor. This calibration will af fect the data reported for Current RMS, Current Peak, Energy, and Resistance. Note: WeldWise 2400 s and Toroids are calibrated at the factory.
0433-INS-400 Rev. E 6-41 Voltage Calibration Utility Voltage is calibrated at the factory and does not need to be re-calibrated . If, however, there is an extenuating circumstance re quiring re-calibration of the voltage, use the following procedure. You will need a battery and a multim eter to calibrate voltage.
0433-INS-400 Rev. E 6-42 Force Calibration Utility Force sensor calibration is required 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.
0433-INS-400 Rev. E 6-43 Displacement Calibration Utility Displacement sensor calibration is required when a new sensor is installed. The displacement channel calibration procedure is basically the same as the procedure for the voltage and force channels.
0433-INS-400 Rev. E 6-44 Tolerance Defaults Setup These tolerance defaults sett ings are ‘global’ and used for all IDs. When a master is f irst created, the default measurement m ode, units and High/Low limits for both Halfcycle and Segment displays are specified by this table.
0433-INS-400 Rev. E 6-45 Graph Setup This option allows you to custom ize the graph scale settings for each param eter. These settings affect the high and low display limits for the Ma in Screen bar graphs, Tre nd Graph display and the graphs in the Summary a nd Tolerancing screens.
0433-INS-400 Rev. E 6-46 Shutdown Menu The Shutdown Menu gives you 4 different exit options. Figure 6-64 shows the typical options. • No, I didn’t really mean to come here, please take me back Use this button or ESCAPE to leave the Shutdown Menu. • Yes, I’m sure.
0433-INS-400 Rev. E 6-47 If a database operation has failed, the shutdown menu will appear slig htly different, as shown in figure 6-65. Likewise, if a database function ha s been cancelled, the shutdown menu will f eature only one option, as shown in figure 6-66.
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0434-INS-400 Rev. C 7-1 Red: Current sensor Green: Voltage sensor Yellow: Force sensor Blue: Displacement sens or Figure 7-1 Color-coding on the Monitor-Sensor cable Installing the Sensors The Monitor.
0434-INS-400 Rev. C 7-2 Types of Sensors Current: A Livingston-supplied toroid must be used with a Livingston weld monitor. No substitutions can be made . Voltage: Livingston uses voltage leads to read incoming volta ge signals and to calib rate the weld monitor.
0434-INS-400 Rev. C 7-3 Displacement: • Double Rod End: This type of sensor is an industrial li near potentiometer, utilizing rod ends to connect it to weld head tooling. The rod end’s sp herical bearings take up any minor misalignment in tooling or brackets, making inst allation a little more forgiving than a spring return type.
0434-INS-400 Rev. C 7-4 Installing the Current Toroid Before installing the toroid, make a note of the three-digit calibration factor that appears on a Livingston sticker on the toroid (for e xample, .388); this va lue will be used late r to enter the toroid calibration factor.
0434-INS-400 Rev. C 7-5 Installing the Voltage Leads Voltage leads should be as short as possible; do not be afraid to cut them. They should be connected as close as possible to the electrodes, ideally on a permanent fixture so th at the leads will not have to be re-attached during electrode mainte nance.
0434-INS-400 Rev. C 7-6 Installing the Force Sensor The mounting of the force transducer is completely dependent on the configur ation of the equipm ent and the type of sensor in use. In the case of a load cell, an equi pm ent integrator may have already installed the transducer or special tooling may be needed to acco mmodate it.
0434-INS-400 Rev. C 7-7 Installing the Displacement Sensor Livingston recommends the use of a double rod end displacem ent sensor . The size of this sensor will depend on the stroke of weld cylinder: the sensor's stroke must always be greater than the full stroke of the cylinder to prevent ov er-travel of the sensor.
0434-INS-400 Rev. C 7-8 Testing Sensor Installation This quick test will verify if all sensors have been properly inst alled by confirming that the weld monitor is receiving incoming sensor readings. To test the sensor installation, the WeldWise™ 2400 must be installed and the WMS program running.
0434-INS-400 Rev. C 7-9 Figure 7-6 Weld Summary screen To perform a quick test of the sensor installation: 1. With the sensors connected and the WeldWise™ 2400 turned on, set up the welder as usual to perform a weld.
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0435-INS-400 Rev. D 8-1 Calibrating the Sensors All sensors must be properly ca librated to obtain maximum accuracy fro m the weld monitor. The WMS program includes calibration sc reens that simplify this proce ss by guiding the user through the necessary steps.
0435-INS-400 Rev. D 8-2 The Input Monitor Sensor calibration is managed through the Utilities Menu , under the Setup Utilities option of the Setup Menu . The Input Monitor display shows the real-time readi ngs on all sensor input channels. Use this display after calibrating a s ensor to check the validity of the calibration adjustment.
0435-INS-400 Rev. D 8-3 Installing/Swapping Toroids Each toroid has its own propertie s. The Toroid Calibration Fa ctor, established when the toroid was manufactured, is clearly labeled on a sticker located on a cylindrical hous ing on the cable. This value is entered directly into the monitoring program .
0435-INS-400 Rev. D 8-4 Fi g ure 8-4 Percent chan g e After Enterin g Percentage Adjustment The current reading from a Livingston toroid may not match the local factory weld current standard. There are three reasons for this: 1. The way a toroid is mounted on the welding bus can affect the accuracy o f the reading; 2.
0435-INS-400 Rev. D 8-5 Calibrating Displacement Livingston strongly recommends fabr icating two different gauge bloc ks that fit into the welding electrodes for displacement calibration. Typically, thes e blocks are made of hardened steel. The first block should be equal to the stack -up thickness of the parts to be welded.
0435-INS-400 Rev. D 8-6 Calibrating Force An external handheld force gauge is required to determine the exact amount of force that is being applied during this calibration.
0435-INS-400 Rev. D 8-7 Air Cylinder: Multiply the surface area of the bor e of the cylinder by the airline pr es sure. Input this n umber as the Point 2 value. For example, an 8" bore cylinde r with a 70 psi line pressure: Surface area of the bore = π r 2 Radius of an 8" bore = 4" 4 2 = 16 16*3.
0435-INS-400 Rev. D 8-8 Calibrating Voltage Voltage is calibrated at the factory and does not need to be re-calibrated. If there is an extenuating circumstance requiring re-ca libration of the voltage , use the f ollowing procedure. You will need a set of Livingston voltage leads, a battery and a m ultim eter to calibrate voltag e.
0443-INS-400 Rev. C 9-1 Frequently Asked Questions When I change my electrodes, why do I have to zero displacement? D o I have to re-calibrate? Any time minor changes to the too ling are made, electrodes w are or mushroom beyond tolerance limits or when work piece material thickness changes (e .
0443-INS-400 Rev. C 9-2 Livingston strongly recommends fabric ating a calibration block as well— typically sized 3-4% of the stroke length. Such a block provides a known thickne ss for sensor calibration. By using both a zeroing gauge block and calibration gauge block, you can be assured of a consistent zero and a proper calibration.
0443-INS-400 Rev. C 9-3 Can I make more than one Master at a time? Yes, if multiple bina ry selects are u sed. For example, if the New button is pressed in the Mastering screen, then three different welds on three different bin selects are made with the welder in auto mode, as the welds are made the binary selects are sen t by the PLC.
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INDEX TROUBLESHOOTING GUIDE ___ INTRODUCTION 10-3 1. SOME OR ALL WELDS ARE REJE CTED, NOT CATCHING FAULTY WELDS, 10-6 WELD COUNT IS NOT INCREASING EVERY WELD IS REJECTED FOR ALMOST EVERY PARAMETER EVE.
5. TROUBLE WITH VOLTA GE LEADS, READINGS OR CHANNEL 10-22 CALIBRATED VOLTAGE SIG NAL IS READING HIGHER OR LOWER TH AN NORMAL CALIBRATED VOLTAGE SIGNAL IS IN DICATING A FROZEN (ST ATIC) READING A/D REA.
Troubleshooting Guide Before You Begin A little common sense will go a long way in tro ubleshooting a Livingston system. Check for obvious problems first, such as loose sens ors or cables and/or physically dama ged components. Pay attention to the system settings, especially ca librations and zeroing.
cable are shorted or open, an inaccu rate calibra tion will result. Check for “frozen” or “pegged” A/D readings. Plug in a known good sensor and cable check th e A/D values and compare them with the suspect sensor and cable. As an example a properly sized force sensor with no load on it will have an A/D reading of approximately 0 to 40.
1. SOME OR ALL WELDS ARE REJECTED, NOT CATCHING FAULTY WELDS, WELD COUNT NOT INCREASING PROBLEM POSSIBLE CAUSE OR SYMPTOM POSSIBLE FIX No Master or Master tolerance limits have been created. It is possibl e that they were made, but not updated. Check to see if "No Master" is displayed on the Main Program screen.
PROBLEM POSSIBLE CAUSE OR SYMPTOM POSSIBLE FIX Inspect sensor cable for physic al damage. A cable that is deformed, severed, partially severed, shredded, abraded and/or has bare wires showing may be suspect. Disconnect sensor cable from weld monitor and replace.
PROBLEM POSSIBLE CAUSE OR SYMPTOM POSSIBLE FIX Sensor is reading outside of usable range (window). Zero the displacement. (Refer to Chapter 8, Calib rating the Sensors or Supplementary Procedure, if applicable). If monitoring more than 1 specific weld with the weld monitor (e.
PROBLEM POSSIBLE CAUSE OR SYMPTOM POSSIBLE FIX Use the Input Monitor to observe the displacement channel readings. Mechanically disconne ct one end of the sensor and extend/retract until you are readi ng within the window of the displacement channel.
PROBLEM POSSIBLE CAUSE OR SYMPTOM POSSIBLE FIX Inspect sensor cable for physic al 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.
PROBLEM POSSIBLE CAUSE OR SYMPTOM POSSIBLE FIX Inspect sensor cable for physic al 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.
PROBLEM POSSIBLE CAUSE OR SYMPTOM POSSIBLE FIX External Bin Select is working intermittently. Refer to Section 7, Trouble With Bin Select o r Accept /Reject. Internal Bin Select is working intermittently. Refer to Section 7, Trouble With Bin Select o r Accept /Reject.
PROBLEM POSSIBLE CAUSE OR SYMPTOM POSSIBLE FIX Tolerances are improperly adjusted. Analyze th e weld data and process to determine which parameters need tighter tolerances to REJECT defective welds. Displacement sensor was not zeroed before a new Master was created.
PROBLEM POSSIBLE CAUSE OR SYMPTOM POSSIBLE FIX Sensor cable disconnected. Check to see if th e sensor cable is properly connected to the weld monitor. Toroid disconnected or damaged. Inspect the toroid for poor connections and/or physical damage or abrasion.
2. TROUBLE WITH FORCE SENS OR, READINGS OR CHANNEL PROBLEM POSSIBLE CAUSE OR SYMPTOM POSSIBLE FIX CALIBRATED FORCE SIGNAL IS READINGS HIGHER OR LOWER THAN NORMAL Calibration has changed or is incorrec t. Inspect and recalibrate sensor if necessary (Refer to Chapter 8, Calibrating the Sensors ).
PROBLEM POSSIBLE CAUSE OR SYMPTOM POSSIBLE FIX The air pressure was adjusted or system pressure has changed. Check air pressure setting. Check the force at th e electrodes. Process timing has changed. Weld head is extending later or retr acting sooner than it was when Master or tolerance limits were set.
PROBLEM POSSIBLE CAUSE OR SYMPTOM POSSIBLE FIX Sensor failure. A damaged force sensor ma y result in an offset or inaccurate readings. Use the Input Monitor to observe the force channel readings, then refer to the force sensor m anufacturer specifications and determine what the mV output of the sensor should be at a given force.
3. TROUBLE WITH DISPLACEMENT SENSOR, READINGS OR CHANNEL PROBLEM POSSIBLE CAUSE OR SYMPTOM POSSIBLE FIX CALIBRATED DISPLACEMENT SIGNAL IS READING HIGHER OR LOWER THAN NORMAL The sensor was not zeroed. Zero the displacement sensor. Calibration has changed.
PROBLEM POSSIBLE CAUSE OR SYMPTOM POSSIBLE FIX Inspect electrical connections for damage, poor connections and/or corrosion. Replace c onnectors and/or cable.
PROBLEM POSSIBLE CAUSE OR SYMPTOM POSSIBLE FIX The sensor was not zeroed (displacement only). Zero the displacement sensor. If the sensor will n ot zero, the sensor, sensor cable or weld monitor may be m alfunctioning. Sensor failure. A reading of +/-32767 in dicates that the input channel is saturated and readi ng its maxim um value.
PROBLEM POSSIBLE CAUSE OR SYMPTOM POSSIBLE FIX Sensor failure. A reading of +/-32767 in dicates that the input channel is saturated and readi ng its maxim um value. There may be a problem with the sensor, sensor cable, or weld monitor. Disconnect the sensor from the sens or cable.
4. TROUBLE WITH TOROID PROBLEM POSSIBLE CAUSE OR SYMPTOM POSSIBLE FIX Weld control failure. Check the weld controller. Toroid settings not prop erly adjusted. In the General Setup menu, check the A/D Threshold settings. Set the A/D Threshold to 750 and A/D Hysteresis to 250 .
5. TROUBLE WITH VOLTAGE LEADS, READINGS OR CHANNEL PROBLEM SYMPTOM OR POSSIBLE CAUSE POSSIBLE FIX Voltage leads are broken. Inspect for da mage, use an ohmmeter to check for high resistance, flex and manipulate le ads to see if readings change, indicating an intermittent connection.
PROBLEM POSSIBLE CAUSE OR SYMPTOM POSSIBLE FIX Voltage applied to leads is above 9.9 volts. A reading of +/-32767 indi cates that the input channel is saturated and reading its maximum value. It is possible that the voltage leads were connected t oo close to the transformer.
6. POSSIBLE SENSOR CABLE FAILURE PROBLEM POSSIBLE CAUSE OR SYMPTOM POSSIBLE FIX Inspect sensor cable for physic al 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.
7. TROUBLE WITH BIN SELECTS OR ACCEPT/REJECT PROBLEM POSSIBLE CAUSE OR SYMPTOM POSSIBLE FIX No Master has been created for the requested Binary Select. The value will default to 0 . If a Master does not already exis t for this Bin Select, create a new Master for this Binary Sele ct value.
PROBLEM POSSIBLE CAUSE OR SYMPTOM POSSIBLE FIX Binary Select Mode is not set to External . Go to the General Setup m enu and set Binary Select Mode to External . Device controlling the Binary Select signals is not working correctly. Typically the Binary Select is controlled by a PLC and/or switches on a panel.
8. TROUBLE WITH HARDWARE PROBLEM SYMPTOM OR POSSIBLE CAUSE POSSIBLE FIX THE TRIGGER LED IS YELLOW The weld monitor in the middle of processing a weld. Wait for the monitor to finish processing. If scope mode is enabled the processing may take several minutes.
PROBLEM POSSIBLE CAUSE OR SYMPTOM POSSIBLE FIX THE A/D READING ON THE INPUT MONITOR REMAINS AT MAXIMUM VALUE : Both the sensor in question and the sensor cable have been examined, repaired and/or replaced but the A/D reading for the FORCE, CURRENT or VOLTAGE channel remains at +/- 32767.
PROBLEM POSSIBLE CAUSE OR SYMPTOM POSSIBLE FIX THE DISPLACEMENT WINDOW CANNOT BE FOUND : The displacement sensor has been mechanically disconnected and extended/retracted, but the readings on the Input Monitor do not make sense. Sensor failure. Try re-zeroing the disp lacement sensor.
10-30.
0436-INS-763 Rev. D Main Me nu Data Masteri ng (P3 Pod or 2400) Tolerancing Setup Shutdown Halfc ycle Summ ary Main Screen Weld Su mmary System Log Database Management Scope Data (2400 only) Impo rt U.
11-2 0614-INS-400 Rev. D Recommended Database Management This section discusses recommendations for mainta ining W eldWise™ 2400 databases to get the best system performance, calculate database size, and backup the WeldW ise 2400 configuration to prepare for a quick and easy recovery if the configuration needs to be restored.
0614-INS-400 Rev. D 11-3 Probably the most difficult concept for users to un derstand is that each Import/Export operation, imports/exports data to /from a different f ile or files. For example, the “ Export All ” writes to livcopy.mdb and welddata.
11-4 0614-INS-400 Rev. D Recommended maintenance Refer to Database Management section in Chapter 6, the WMS reference Guide , for more information about the database operations referenced in this document.
0614-INS-400 Rev. D 11-5 Determining the file size of the stored weld data The following can be used as an aide to determ ine how quickly the welddata.mdb database will f ill up with weld data. This database can hold up to 1 gigabyte (minus some overhead) of weld data.
11-6 0614-INS-400 Rev. D Backup of WeldWise 2400 Settings One feature with a WeldWise 2400 is that the entire configuration can be quickly restored provided the proper steps have been taken ahead of time. The export database utilities provide a great way to back up all of the settings.
0614-INS-400 Rev. D 11-7 What If? What if someone made changes to some settings a nd then forgot the known-good settings, or changed sensor calibration and then realized that they had made a m istake .
11-8 0437-INS-400 Rev. D Importing / Exporting Tables This procedure describes how to import and/or export default calibrati on tables to a floppy disk. It is recommended that you make copy of the default calibra tion settings in your Li vingston m onitor before performing sensor calibration.
0437-INS-400 Rev. D 1 1 - 9 You will want to keep the LDCT disk in a safe place, should 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 im ported/exporte d to an archive in the monitor itself.
11-10 0442-INS-400 Rev. C Displacement Channel Overview The displacement channel is used to measure the th ickness of a part before, during, and after the weld process.
0445-INS-400 Rev. D 11-11 Sensor Calibration Utilities Overview Sensors such as toroids, slide-potentiometers, and force gauges are used by Livingston weld monitors to get information about the weld process as we lds are taking place.
11-12 0459-IN S-400 Rev. D Identifying and Interpreting Accept Status Codes The main operating display for the weld monitor pr ovides a quick view of the ongoing status of the welding operation.
0459-INS-400 Rev. D 11-13 Table 11-5: Accept Status Code Values Bit Decimal Binary Values Fault 0 1 00000000 00000000 00000000 0000000 1 CURRE NTRMS_HI 1 2 00000000 00000000 00000000 000000 1 0 CURRE .
0438-INS-4 00 Rev. C 11-14 Attaching Peripherals The WeldWise 2400™ includes ports on the back pane l for connecting an external keyboard, video monitor and mouse. There is also a port for connec ting a UPS. All peripheral s should be connected to your Livingston monitor before the monitor is powered on.
0438-INS-400 Rev. C 11-15 power loss. An APC manufactured Back-UPS Pr o 280 (Model BP280S) or a Back-UPS 650 (Model BK650M) are two recommended and approved models which may be used with the WeldW ise™ 2400. If your WeldWise™ 2400 has been shipped with an op tional UPS, the necessary UPS software is pre- installed.
0438-INS-4 00 Rev. C 11-16 Calibrating the UPS The following prerequisites must be met before in itiating runtim e calibration: An approved UPS must be connected to the WeldWise™ 2400 via the C OM 2 por t using the gray serial cable included in the UPS package.
0438-INS-400 Rev. C 11-17 Configuration for Remote Shutdown In the event of a power outage, you may wish to have your WeldWi se™ 2400 act as a 'm aster' and remotely shutdown any number of ' slave' devices also connected to the UPS.
0340-DWG-400 Rev. C 11-18.
0308-DWG-400 Rev. D. 11-19.
0439-INS-400 Rev. C 11-20 WeldWise ™ 2400 Specifications External Controls and Connectors The WeldWise ™ 2400 features: • Video connector (VIDEO/VGA) for c onnecting an external monitor; • Par.
0447-INS-400 Rev. C 11-21 Common Uses of RWMA Material Electrode Material Properties Material To Be Welded Class 1 High Conductivity Soft High current and heat conduction Electrodes for welding alum inum alloys, magnesium alloys, coated m aterials, brass and bronzes.
11 -22.
0079-PRD-ADM Rev D 11-23 Warranty & Repair Policy Livingston & Company, Inc. shall herein be referred to as the “Company” and any customer Purchasing goods or services from the Company shall herein be referred to as Purchaser.
11-24 0079-PRD-ADM Rev D O BTAINING N ON -W ARRANTY S ERVICE Advance authorization is required prior to all returns to the Company. Before returning any product, the Customer must first contact the Customer Service Depa rtment at (802) 763-2934.
0454-APP-118 Rev. A 12-1 Document #: 0454-APP-118 Author: E. Barbiero Date: 04-26-01 Revision: A APPLICATION NOTE Category: Procedure Applies to: WeldWise 2400 or POD Server Subject: Change IP Address.
0454-APP-118 Rev. A 12-2 2. A) If a video monitor an d m ouse are connected, go to Ö Start Ö Settings Ö Control Panel Ö Network; B) If there is no video mon itor and/or mouse, press the Wind ows f.
0454-APP-118 Rev. A 12-3 3. The Network window will appear, with the Identification tab in the foreground. If you do not wish to change the Identifi cation, skip to the step 5 . Otherwise, click the C hange button, or press Alt-C to bring up the Identification Changes window.
0454-APP-118 Rev. A 12-4 7. If you are using a mouse, click on the radio button next to S pecify an IP Address and enter the desired IP address. You may also enter a diffe rent Subnet Mask and/or Default Gateway.
0454-APP-118 Rev. A 12-5 8. If you are using a mouse, close all open windows and then press the key com bination Ctrl-Alt-Del . This will bring up the Windows NT Security window. 9. Without a mouse, press Alt-S to select the S hutdown option, or simply click on the S hutdown button.
0454-APP-118 Rev. A 12-6.
0454-APP-121 Rev. A 12-7 Document #: 0454-APP-121 Author: E. Barbiero Date: 04-26-01 Revision: A APPLICATION NOTE Category: Procedure Applies to: 2400 or POD Server Subject: Copy weld data & creat.
0454-APP-121 Rev. A 12-8 4. Once the unit is found, double-click on it to open it (this may take a m inute or two). If you are using Windows NT, you may be prom pted for a password. Type in Adminis trator in the 'C onnect As:' box and 2400 in the 'P assword:' box.
0454-APP-121 Rev. A 12-9 7. Right click on the file named WeldData.mdb ('WeldData' m ay or ma y not be capitalized) and select C opy. 8. Go back to the open window containing the new folder that you created named '2400_xxxx MMDDYY'.
0454-APP-121 Rev. A 12-10 T O CREATE A SIMPLE MS E XCEL C HART O R G RAPH FROM THE L IVINGSTON D ATABASE : 1. Open a new spreadsheet in MS Excel. 2. Go to D ata Ö Get External D ata Ö Create N ew Query . 3. The 'Choose Data Source' window will appear.
0454-APP-121 Rev. A 12-11 4. The 'Create 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 (*.
0454-APP-121 Rev. A 12-12 7. The 'ODBC Microsoft Access Setup' wi ndow will appear. Under Database, click S elect... 8. The 'Select Database' window will appear. On the bottom right is a window labeled Driv es. Select from the pull-down list the drive on which you created the folder named '2400_xxxx MMDDYY'.
0454-APP-121 Rev. A 12-13 11. You will be returned to the 'ODBC Microsoft Access Setup' wi ndow. Under Database, the file path of WeldData.mdb will be d isplayed. Click OK . 12. You will now be returned to the 'C reate New Data Source' window.
0454-APP-121 Rev. A 12-14 14. The 'Query Wizard – Choose Column s' window will appear. Under the 'A vailable tables and columns:' should be posteddata , with a sm all checkbox next to it. Click the ' > ' button between the two windows.
0454-APP-121 Rev. A 12-15 16. Go back to the 'Colum n to filter:' window and click once on recordtype to highlight it. (Once you have clicked another field, the 'pod' field will appear in bold). It will appe ar in the first of the 'Only include rows where:' windows.
0454-APP-121 Rev. A 12-16 18. Click N ext > . 19. The 'Query Wizard – Sort Order' window will a ppear. This allows you to sort 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 appe ar first).
0454-APP-121 Rev. A 12-17 22. The 'Returning Data To Microsoft E xcel' window will appear, asking where you wan t to put the data. Click OK .
0454-APP-121 Rev. A 12-18 24. To keep the headers on top, click once on the 2 at the beginning of row two to highlight the entire row. On the top toolbar, under W indow , select F reeze Panes . You will now be able to scroll down through the weld data whil e preserving the top headers.
0454-APP-121 Rev. A 12-19 26. Go to the top toolbar under I nsert and select Ch art (or you can click on the chart icon in the standard toolbar). Note: This screen shot has been cr opped to show the selected columns. 27. The 'Chart Wizard – Step 1 of 4 – Chart Type' window will appear.
0454-APP-121 Rev. A 12-20 28. You will now have a chart that appears over the spreadsheet. For easier viewing, right-click on the white border of the chart and select Cut . Go to Sheet2 of the workbook and paste the chart anywhere in the sheet. 29. You can now format the chart as you like.
454-APP-299 Rev. B 12-21 Document #: 0454-APP-299 Author: E. Barbiero Date: 11-27-01 Revision: B Location: LivcolivcoDocApp. Notes APPLICATION NOTE Category: 2400 / Pod Server / Ethernet Applies to: 2.
454-APP- 299 Rev. B 12-22 unique. For example, if the IP addres s of your computer was 10.43.5.23, a sim ilar address would be 10.43.5.67. − The Subnet Mask should be identi cal to other local Subnet Masks.
0450-INS-400 Rev. E 13-1 Contact Information Livingston & Company, Inc. (Administr ation, Engineering, and Manufacturing) 415 Waterman Road South Royalton, VT 05068 Telephone: (802) 763-2934 Fax: (802) 763-2746 Email: info @livco.com URL: www.livco.
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0446-INS-400 Rev. C.001 14-1 UPDATES – THE WELDWISE™USER’S MANUAL Revision C: The WeldWise™ 2400 User’s Manual Re vision C is intended for use with Version 8 software starting with the follow ing versions released April 2005: User Interface: livcoset.
An important point after buying a device Livingston & Company WELDWISE 2400 (or even before the purchase) is to read its user manual. We should do this for several simple reasons:
If you have not bought Livingston & Company WELDWISE 2400 yet, this is a good time to familiarize yourself with the basic data on the product. First of all view first pages of the manual, you can find above. You should find there the most important technical data Livingston & Company WELDWISE 2400 - thus you can check whether the hardware meets your expectations. When delving into next pages of the user manual, Livingston & Company WELDWISE 2400 you will learn all the available features of the product, as well as information on its operation. The information that you get Livingston & Company WELDWISE 2400 will certainly help you make a decision on the purchase.
If you already are a holder of Livingston & Company WELDWISE 2400, but have not read the manual yet, you should do it for the reasons described above. You will learn then if you properly used the available features, and whether you have not made any mistakes, which can shorten the lifetime Livingston & Company WELDWISE 2400.
However, one of the most important roles played by the user manual is to help in solving problems with Livingston & Company WELDWISE 2400. Almost always you will find there Troubleshooting, which are the most frequently occurring failures and malfunctions of the device Livingston & Company WELDWISE 2400 along with tips on how to solve them. Even if you fail to solve the problem, the manual will show you a further procedure – contact to the customer service center or the nearest service center
