Operator s Manual PRODUCTION MONITORING 2.2 Save for future reference Date Purchased Code: (ex: 10859) Register your machine: www.lincolnelectric.com/registration Authorized Service and Distributor Locator: www.lincolnelectric.com/locator Need Help? Call 1.888.935.3877 to talk to a Service Representative Hours of Operation: 8:00 AM to 6:00 PM (ET) Mon. thru Fri. After hours? Use Ask the Experts at lincolnelectric.com A Lincoln Service Representative will contact you no later than the following business day. For Service outside the USA: Email: globalservice@lincolnelectric.com Serial: (ex: U1060512345) IM8001 Issue D ate June -13 Lincoln Global, Inc. All Rights Reserved.
THANK YOU FOR SELECTING A QUALITY PRODUCT BY LINCOLN ELEC TRIC. PLEASE EXAMINE CARTON AND EQUIPMENT FOR DAMAGE IMMEDIATELY When this equipment is shipped, title passes to the purchaser upon receipt by the carrier. Consequently, Claims for material damaged in shipment must be made by the purchaser against the transportation company at the time the shipment is received. SAFETY DEPENDS ON YOU Lincoln arc welding and cutting equipment is designed and built with safety in mind. However, your overall safety can be increased by proper installation... and thoughtful operation on your part. DO NOT INSTALL, OPERATE OR REPAIR THIS EQUIPMENT WITHOUT READING THIS MANUAL AND THE SAFETY PRECAUTIONS CONTAINED THROUGHOUT. And, most importantly, think before you act and be careful. WARNING This statement appears where the information must be followed exactly to avoid serious personal injury or loss of life. CAUTION This statement appears where the information must be followed to avoid minor personal injury or damage to this equipment. KEEP YOUR HEAD OUT OF THE FUMES. DON T get too close to the arc. Use corrective lenses if necessary to stay a reasonable distance away from the arc. READ and obey the Material Safety Data Sheet (MSDS) and the warning label that appears on all containers of welding materials. USE ENOUGH VENTILATION or exhaust at the arc, or both, to keep the fumes and gases from your breathing zone and the general area. IN A LARGE ROOM OR OUTDOORS, natural ventilation may be adequate if you keep your head out of the fumes (See below). USE NATURAL DRAFTS or fans to keep the fumes away from your face. If you de velop unusual symptoms, see your supervisor. Perhaps the welding atmosphere and ventilation system should be checked. WEAR CORRECT EYE, EAR & BODY PROTECTION PROTECT your eyes and face with welding helmet properly fitted and with proper grade of filter plate (See ANSI Z49.1). PROTECT your body from welding spatter and arc flash with protective clothing including woolen clothing, flame-proof apron and gloves, leather leggings, and high boots. PROTECT others from splatter, flash, and glare with protective screens or barriers. IN SOME AREAS, protection from noise may be appropriate. BE SURE protective equipment is in good condition. Also, wear safety glasses in work area AT ALL TIMES. SPECI AL SI TUATI ONS DO NOT WELD OR CUT containers or materials which previously had been in contact with hazardous substances unless they are properly cleaned. This is extremely dangerous. DO NOT WELD OR CUT painted or plated parts unless special precautions with ventilation have been taken. They can release highly toxic fumes or gases. Additional precautionary measures PROTECT compressed gas cylinders from excessive heat, mechanical shocks, and arcs; fasten cylinders so they cannot fall. BE SURE cylinders are never grounded or part of an electrical circuit. REMOVE all potential fire hazards from welding area. ALWAYS HAVE FIRE FIGHTING EQUIPMENT READY FOR IMMEDIATE USE AND KNOW HOW TO USE IT.
SAFETY SECTION A: WARNINGS CALIFORNIA PROPOSITION 65 WARNINGS Diesel Engines Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer, birth defects, and other reproductive harm. Gasoline Engines The engine exhaust from this product contains chemicals known to the State of California to cause cancer, birth defects, or other reproductive harm. ARC WELDING CAN BE HAZARDOUS. PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY OR DEATH. KEEP CHILDREN AWAY. PACE- MAKER WEARERS SHOULD CONSULT WITH THEIR DOCTOR BEFORE OPERATING. Read and understand the following safety highlights. For additional safety information, it is strongly recommended that you purchase a copy of Safety in Welding & Cutting - ANSI Standard Z49.1 from the American Welding Society, P.O. Box 351040, Miami, Florida 33135 or CSA Standard W117.2-1974. A Free copy of Arc Welding Safety booklet E205 is available from the Lincoln Electric Company, 22801 St. Clair Avenue, Cleveland, Ohio 44117-1199. BE SURE THAT ALL INSTALLATION, OPERATION, MAINTENANCE AND REPAIR PROCEDURES ARE PERFORMED ONLY BY QUALIFIED INDIVIDUALS. FOR ENGINE POWERED EQUIPMENT. 1.a. Turn the engine off before troubleshooting and maintenance work unless the maintenance work requires it to be running. 1.b. Operate engines in open, well-ventilated areas or vent the engine exhaust fumes outdoors. 1.c. Do not add the fuel near an open flame welding arc or when the engine is running. Stop the engine and allow it to cool before refueling to prevent spilled fuel from vaporizing on contact with hot engine parts and igniting. Do not spill fuel when filling tank. If fuel is spilled, wipe it up and do not start engine until fumes have been eliminated. 1.d. Keep all equipment safety guards, covers and devices in position and in good repair.keep hands, hair, clothing and tools away from V-belts, gears, fans and all other moving parts when starting, operating or repairing equipment. 1.e. In some cases it may be necessary to remove safety guards to perform required maintenance. Remove guards only when necessary and replace them when the maintenance requiring their removal is complete. Always use the greatest care when working near moving parts. 1.f. Do not put your hands near the engine fan. Do not attempt to override the governor or idler by pushing on the throttle control rods while the engine is running. 1.g. To prevent accidentally starting gasoline engines while turning the engine or welding generator during maintenance work, disconnect the spark plug wires, distributor cap or magneto wire as appropriate. 1.h. To avoid scalding, do not remove the radiator pressure cap when the engine is hot. ELECTRIC AND MAGNETIC FIELDS MAY BE DANGEROUS 2.a. Electric current flowing through any conductor causes localized Electric and Magnetic Fields (EMF). Welding current creates EMF fields around welding cables and welding machines 2.b. EMF fields may interfere with some pacemakers, and welders having a pacemaker should consult their physician before welding. 2.c. Exposure to EMF fields in welding may have other health effects which are now not known. 2.d. All welders should use the following procedures in order to minimize exposure to EMF fields from the welding circuit: 2.d.1. Route the electrode and work cables together - Secure them with tape when possible. 2.d.2. Never coil the electrode lead around your body. 2.d.3. Do not place your body between the electrode and work cables. If the electrode cable is on your right side, the work cable should also be on your right side. 2.d.4. Connect the work cable to the workpiece as close as possible to the area being welded. 2.d.5. Do not work next to welding power source. 3
SAFETY ELECTRIC SHOCK CAN KILL. 3.a. The electrode and work (or ground) circuits are electrically hot when the welder is on. Do not touch these hot parts with your bare skin or wet clothing. Wear dry, hole-free gloves to insulate hands. 4.a. ARC RAYS CAN BURN. Use a shield with the proper filter and cover plates to protect your eyes from sparks and the rays of the arc when welding or observing open arc welding. Headshield and filter lens should conform to ANSI Z87. I standards. 3.b. Insulate yourself from work and ground using dry insulation. Make certain the insulation is large enough to cover your full area of physical contact with work and ground. In addition to the normal safety precautions, if welding must be performed under electrically hazardous conditions (in damp locations or while wearing wet clothing; on metal structures such as floors, gratings or scaffolds; when in cramped positions such as sitting, kneeling or lying, if there is a high risk of unavoidable or accidental contact with the workpiece or ground) use the following equipment: Semiautomatic DC Constant Voltage (Wire) Welder. DC Manual (Stick) Welder. AC Welder with Reduced Voltage Control. 3.c. In semiautomatic or automatic wire welding, the electrode, electrode reel, welding head, nozzle or semiautomatic welding gun are also electrically hot. 3.d. Always be sure the work cable makes a good electrical connection with the metal being welded. The connection should be as close as possible to the area being welded. 3.e. Ground the work or metal to be welded to a good electrical (earth) ground. 3.f. Maintain the electrode holder, work clamp, welding cable and welding machine in good, safe operating condition. Replace damaged insulation. 3.g. Never dip the electrode in water for cooling. 3.h. Never simultaneously touch electrically hot parts of electrode holders connected to two welders because voltage between the two can be the total of the open circuit voltage of both welders. 3.i. When working above floor level, use a safety belt to protect yourself from a fall should you get a shock. 3.j. Also see It ems 6.c. and 8. 4.b. 4.c. Use suitable clothing made from durable flame-resistant material to protect your skin and that of your helpers from the arc rays. Protect other nearby personnel with suitable, non-flammable screening and/or warn them not to watch the arc nor expose themselves to the arc rays or to hot spatter or metal. FUMES AND GASES CAN BE DANGEROUS. 5.a. Welding may produce fumes and gases hazardous to health. Avoid breathing these fumes and gases. When welding, keep your head out of the fume. Use enough ventilation and/or exhaust at the arc to keep fumes and gases away from the breathing zone. When welding with electrodes which require special ventilation such as stainless or hard facing (see instructions on container or MSDS) or on lead or cadmium plated steel and other metals or coatings which produce highly toxic fumes, keep exposure as low as possible and within applicable OSHA PEL and ACGIH TLV limits using local exhaust or mechanical ventilation. In confined spaces or in some circumstances, outdoors, a respirator may be required. Additional precautions are also required when welding on galvanized steel. 5. b. The operation of welding fume control equipment is affected by various factors including proper use and positioning of the equipment, maintenance of the equipment and the specific welding procedure and application involved. Worker exposure level should be checked upon installation and periodically thereafter to be certain it is within applicable OSHA PEL and ACGIH TLV limits. 5.c. Do not weld in locations near chlorinated hydrocarbon vapors coming from degreasing, cleaning or spraying operations. The heat and rays of the arc can react with solvent vapors to form phosgene, a highly toxic gas, and other irritating products. 5.d. Shielding gases used for arc welding can displace air and cause injury or death. Always use enough ventilation, especially in confined areas, to insure breathing air is safe. 5.e. Read and understand the manufacturer s instructions for this equipment and the consumables to be used, including the material safety data sheet (MSDS) and follow your employer s safety practices. MSDS forms are available from your welding distributor or from the manufacturer. 5.f. Also see item 1.b. 4
SAFETY WELDING AND CUTTING SPARKS CAN CAUSE FIRE OR EXPLOSION. 6.a. Remove fire hazards from the welding area. If this is not possible, cover them to prevent the welding sparks from starting a fire. Remember that welding sparks and hot materials from welding can easily go through small cracks and openings to adjacent areas. Avoid welding near hydraulic lines. Have a fire extinguisher readily available. 6.b. Where compressed gases are to be used at the job site, special precautions should be used to prevent hazardous situations. Refer to Safety in Welding and Cutting (ANSI Standard Z49.1) and the operating information for the equipment being used. 6.c. When not welding, make certain no part of the electrode circuit is touching the work or ground. Accidental contact can cause overheating and create a fire hazard. 6.d. Do not heat, cut or weld tanks, drums or containers until the proper steps have been taken to insure that such procedures will not cause flammable or toxic vapors from substances inside. They can cause an explosion even though they have been cleaned. For information, purchase Recommended Safe Practices for the Preparation for Welding and Cutting of Containers and Piping That Have Held Hazardous Substances, AWS F4.1 from the American Welding Society (see address above). 6.e. Vent hollow castings or containers before heating, cutting or welding. They may explode. 6.f. Sparks and spatter are thrown from the welding arc. Wear oil free protective garments such as leather gloves, heavy shirt, cuffless trousers, high shoes and a cap over your hair. Wear ear plugs when welding out of position or in confined places. Always wear safety glasses with side shields when in a welding area. 6.g. Connect the work cable to the work as close to the welding area as practical. Work cables connected to the building framework or other locations away from the welding area increase the possibility of the welding current passing through lifting chains, crane cables or other alternate circuits. This can create fire hazards or overheat lifting chains or cables until they fail. 6.h. Also see item 1.c. CYLINDER MAY EXPLODE IF DAMAGED. 7.a. Use only compressed gas cylinders containing the correct shielding gas for the process used and properly operating regulators designed for the gas and pressure used. All hoses, fittings, etc. should be suitable for the application and maintained in good condition. 7.b. Always keep cylinders in an upright position securely chained to an undercarriage or fixed support. 7.c. Cylinders should be located: Away from areas where they may be struck or subjected to physical damage. A safe distance from arc welding or cutting operations and any other source of heat, sparks, or flame. 7.d. Never allow the electrode, electrode holder or any other electrically hot parts to touch a cylinder. 7.e. Keep your head and face away from the cylinder valve outlet when opening the cylinder valve. 7.f. Valve protection caps should always be in place and hand tight except when the cylinder is in use or connected for use. 7.g. Read and follow the instructions on compressed gas cylinders, associated equipment, and CGA publication P-l, Precautions for Safe Handling of Compressed Gases in Cylinders, available from the Compressed Gas Association 1235 Jefferson Davis Highway, Arlington, VA 22202. FOR ELECTRICALLY POWERED EQUIPMENT. 8.a. Turn off input power using the disconnect switch at the fuse box before working on the equipment. 8.b. Install equipment in accordance with the U.S. National Electrical Code, all local codes and the manufacturer s recommendations. 6.I. 6.j. Read and follow NFPA 51B Standard for Fire Prevention During Welding, Cutting and Other Hot Work, available from NFPA, 1 Batterymarch Park, PO box 9101, Quincy, Ma 022690-9101. Do not use a welding power source for pipe thawing. 8.c. Ground the equipment in accordance with the U.S. National Electrical Code and the manufacturer s recommendations. Refer to http://www.lincolnelectric.com/safety for additional safety information. Welding Safety Interactive Web Guide for mobile devices Get t he f r ee mobi l e app a http://gettag.m 5
Table of Contents Preface Typographical Conventions Used... 1 Cross-References... 1 Text You Type Using the Keyboard... 1 Keys You Press and Buttons You Click... 1 Menus You Select... 1 Dialog Box, Application Window Titles, and Field Names... 1 Notes, Warnings, and Tips... 2 Revision History General Information Introduction to Production Monitoring... 1.1 User Roles... 1.1 Weld Profiles... 1.2 Weld Logging... 1.2 E-mail Capability... 1.2 Traceability... 1.3 WeldScore... 1.3 Production Monitoring Architecture... 1.3 Requirements and Limitations... 1.4 Server Computer Requirements... 1.4 User Computer Requirements... 1.5 Power Wave Requirements... 1.5 Network Requirements... 1.6 System Limitations... 1.6 Upgrading from Production Monitoring 2.1 System Requirements... 2.1 Preparing for the Upgrade... 2.1 Running the Production Monitoring 2.2 Patch... 2.2 Installing Production Monitoring Installation Preparation... 3.1 Prerequisites for Installing Production Monitoring 2.2... 3.1 Determining the Production Monitoring Version... 3.2 Uninstalling Production Monitoring 2.0... 3.2 Uninstalling the Production Monitoring 2.0 Application... 3.3 Removing Production Monitoring 2.0 Files... 3.4 Uninstalling SQL Management Studio... 3.4 IM8001 Production Monitoring User Manual TOC.1
Table of Contents Uninstalling the SQL Server Instance... 3.5 Removing the Production Monitoring Web Site... 3.6 Installing Microsoft Internet Information Services (IIS)... 3.7 Windows XP Professional IIS Installation... 3.7 Windows Server 2003 IIS Installation... 3.8 Windows Vista IIS Installation... 3.10 Windows Server 2008 IIS Installation... 3.12 Windows 7 IIS Installation... 3.14 Enabling COM+ (Windows Server 2003)... 3.16 Installing PowerShell for Windows Server 2008... 3.18 Install the Latest Firmware... 3.18 Install the Latest Power Wave Manager... 3.21 Installing Production Monitoring 2.2 Software... 3.23 Production Monitoring Administration Overview... 4.1 Managing the Asset Tree... 4.2 About the Root Asset (or Company Group)... 4.3 Adding Groups... 4.3 Adding a Welding Power Source... 4.5 Displaying Welding Power Sources to Other Users... 4.8 Enabling/Disabling Data Collection from a Welding Power Source... 4.9 Moving Welding Power Sources and Groups... 4.9 Deleting Welding Power Sources and Groups... 4.10 Shift Schedule Configuration... 4.10 Next Production Day... 4.11 General Shift Schedule Information... 4.12 Managing the Shift Schedule... 4.13 Example Shift Setup... 4.16 Example Shift Setup... 4.17 Global Settings... 4.18 Getting the Team Started... 4.19 Restricting Access to Administration... 4.20 Prerequisites... 4.20 IIS 5.1 and IIS 6.0... 4.20 IIS 7.0 and IIS 7.5... 4.23 Using Production Monitoring Launching Production Monitoring... 5.1 Overview of the Application... 5.1 Asset Tree... 5.2 Report Tabs... 5.2 Individual Reports... 5.3 TOC.2 Production Monitoring User Manual IM8001
Table of Contents Panel Resize... 5.3 Overview of Reports... 5.4 Generating Reports... 5.4 Report Criteria... 5.4 Report Links... 5.5 Report Page Numbers... 5.5 Exporting Report Data... 5.6 Refreshing Report Data... 5.6 Current Status Tab... 5.7 Current Status by Time Period... 5.7 System Capacity... 5.9 Production Tab... 5.10 Criteria for the Production Reports... 5.11 Grid Report... 5.12 Weld Profiles Report... 5.13 WeldScore Report... 5.15 Current/Voltage Report... 5.16 Wire Feed Speed (and Deposition) Report... 5.17 True Energy Report... 5.19 Duration/Count Report... 5.20 Weld Listing Tab... 5.21 Criteria for the Weld Listing Reports... 5.21 Grid Report... 5.23 WeldScore... 5.25 Current/Voltage Report... 5.26 Wire Feed Speed Report... 5.27 True Energy (and Duration) Report... 5.28 Wire Deposition Report... 5.29 Weld Detail Tab... 5.30 Weld Detail Criteria... 5.30 Weld Detail Report... 5.30 Traceability Tab... 5.35 Traceability Criteria... 5.36 Traceability Report... 5.37 Downtime Tab... 5.39 Downtime Criteria... 5.39 Grid Report... 5.40 Chart Report... 5.41 Fault Detail Tab... 5.41 Fault Detail Criteria... 5.41 Fault Detail Report... 5.43 Additional Information IM8001 Production Monitoring User Manual TOC.3
Table of Contents Archive of Data from the Database... A.1 Archive Frequency... A.1 Archive File Name Format... A.1 Open an Archive File... A.2 Archive File Format... A.3 Troubleshooting Glossary Cannot Connect to a Power Source...B.1 TOC.4 Production Monitoring User Manual IM8001
Preface Typographical Conventions Used Before using this guide, it is important to understand the typographical conventions used to identify and describe information. Cross-References Cross-references to chapters, sections, page numbers, headings, etc. are shown in an italic typeface. e.g., Refer to Text You Type Using the Keyboard on page 1. Text You Type Using the Keyboard Text that you type using the keyboard is shown in a Courier typeface. e.g., Type John Smith in the Name field. Keys You Press and Buttons You Click Keys that you press on the keyboard and buttons/icons that you click with the mouse are shown in a bold sans-serif typeface. e.g., Press Enter. e.g., Click OK to continue. Menus You Select Menus and the selections you make from the menus are shown in a bold sans-serif typeface. e.g., Select Start > Control Panel from the main computer menu. e.g., Select Tools > Options from the menu. Dialog Box, Application Window Titles, and Field Names The titles of dialog boxes and application windows are shown in italics. Field names and selections made from drop-down menus, etc. are also shown in italics. e.g., The Print Preview window opens. e.g., Select All Shifts from the drop-down list. IM8001 Production Monitoring User Manual 1
Preface Notes, Warnings, and Tips Notes, stops and tips appear throughout the manual. They provide additional information that is important for you to know about the topic. NOTE A note is an important piece of information. STOP You should definitely read the information in a stop table. It could help you prevent a situation from which you cannot recover. TIP A tip table helps you with some interesting or useful information about using the program. 2 Production Monitoring User Manual IM8001
Revision History Date August 2012 May 2013 Change Description Initial release as IM8001 Major revamp and update of manual IM8001 Production Monitoring User Manual REV.1
Revision History THIS PAGE INTENTIONALLY LEFT BLANK. REV.2 Production Monitoring User Manual IM8001
Chapter 1 General Information Introduction to Production Monitoring Production Monitoring is a data collection and reporting technology that is available for the latest models of the Power Wave family of Welding Power Sources. The term Production Monitoring does not refer to any single feature. Instead, it refers to the entire collection of features and functionality included with a Welding Power Source. These features include, but are not limited to: Collecting welding logs complete with statistics for each recorded weld. Setting logical limits on WeldScore, arc current, arc voltage, wire feed speed, and duration; and reporting welds that violate the specified limits. Creating distinct Weld Profiles with separate limit settings for each profile. E-mailing users: Each Welding Power Source has the ability to send e-mails containing reports of weld errors and other information. Tracking wire usage and providing low-package warnings for each Welding Power Source. STOP Production Monitoring does not support consumable tracking for dual wire-feeding systems. NOTE For Production Monitoring support in USA and Canada, dial 1.800.691.5797. The direct dial number is 1.727.786.0121. The e-mail address is support@lincolnproductionmonitoring.com. User Roles For the purposes of this documentation, we use the following terms to help identify the person generally responsible for the task being discussed. These are general terms to help illustrate the use of Production Monitoring in your welding operations. Weld Engineer or Engineer: If you see one of these terms, we generally mean the person in charge of setting up the weld before the weld is made. In some cases, the Weld Engineer and the Weld Operator is the same person. Weld Operator or Operator: This person is the person (or robot) who is actually running the welder and making the weld. Production Monitoring Administrator: This person is responsible for managing the Production Monitoring application. There could be more than one, depending on your company s policies. IM8001 Production Monitoring User Manual 1.1
Chapter 1. General Information Introduction to Production Monitoring Weld Profiles One of the principal goals of Production Monitoring is to report on welds that are outside of user-defined limits with respect to WeldScore, current, voltage, wire feed speed and duration. This goal would be simple to implement if the Welding Power Source were to perform only one type of weld over and over. However, in practical applications, this is not the case. The assembly of many different industrial components requires welds of varying type and length. The concept of Weld Profiles allows the Welding Power Source to apply different limit settings for each weld that is performed on a certain part. Before the Welding Power Source begins a new weld, the wire feeder or system controller selects the corresponding Weld Profile. The Weld Engineer can, therefore, assign one Weld Profile to each weld required for the part assembly. For more in-depth information about Weld Profiles, please refer to the Power Wave Manager User Manual. Weld Logging Production Monitoring records large quantities of weld statistics. Each log entry contains the following welding statistics for each weld: For current, voltage, wire feed speed and duration: - Minimum - Maximum - Average - Percent above limit - Percent below limit - Profile maximum limit - Profile minimum limit True Energy Date and time the weld was made Duration of the weld Weld status after limit checking Part Number, Consumable Lot and Operator ID WeldScore E-mail Capability When a Welding Power Source has access to an e-mail server on your network and you have installed Production Monitoring on the server computer, the power source can send e-mail notifications to multiple addresses. Each e-mail address can be configured to receive messages from the Welding Power Source upon any of several event conditions. 1.2 Production Monitoring User Manual IM8001
WeldScore Chapter 1. General Information Traceability Production Monitoring provides you with the ability to report on all the welds that were made on a specific part number, by a specific operator or using a specific consumable lot code. Before a weld is made, this information is communicated to the Welding Power Source, in a variety of ways. Every weld that is made after this is assigned with these ID numbers until a new number is entered. Production Monitoring users can generate a traceability report that looks for this ID from all the Welding Power Sources in the system. Traceability solutions are typically customized to a customer s specific needs. Please contact Lincoln Electric for a quotation on your needs. WeldScore NOTE Production Monitoring does not support consumable package tracking for dual wire feeding systems. WeldScore, a new feature available in all third-generation Welding Power Source models (including the i400, C300, S350, S500 and AC/DC 1000 SD), can be used to support a weld quality control program. It assigns a score to welds on a 0% to 100% scale that indicates the acceptability of the weld. The score is based on a comparison to previously trained welding conditions. Any weld with a score of 85% to 90% or above can be considered, with a reasonable amount of confidence, to be an acceptable weld. WeldScore can be used independently on the power source or together with Production Monitoring. Please refer to the Power Wave Manager User Manual for more in-depth information on WeldScore. NOTE WeldScore is not a guarantee of quality and is not intended to replace a quality control system. Production Monitoring Architecture The Production Monitoring system uses a web-based front end (the part that you use to run reports and set up the application) with a relational database for storing data (weld statistics sent from the Welding Power Sources). The web-based front end allows users on multiple computers to access the welding data and generate reports using the Production Monitoring application. The main components of the Production Monitoring system are: Microsoft SQL Server Express database for storing data sent from Welding Power Sources Microsoft Internet Information Services (IIS) Web Server IGear Data Transport Utility (DTU): This provides the connectivity from Welding Power Source to the database on the server computer. This piece of software queries the Welding Power Sources for information and stores it in the database. IGear Web Framework: This provides users with a web portal to the database that enables them to generate various reports. You install the Production Monitoring application on a single dedicated server computer. This server computer then communicates with the Welding Power Sources over an Ethernet network. Users can be anywhere and, as long as they have an Ethernet link to the server computer, they can access the Production Monitoring application. IM8001 Production Monitoring User Manual 1.3
Chapter 1. General Information Requirements and Limitations Figure 1.1 Production Monitoring System Requirements and Limitations Server Computer Requirements You install Production Monitoring on a single dedicated computer to which all other computers connect in order to access the application. The following are the requirements for that server computer: Dedicated always on computer: This is a server-type application designed to run on a computer that is on all the time. This application should not be installed on a laptop. CPU: Dual core, 2 GHz RAM: 2 GB An Ethernet (IEEE 802.3 compliant) 10Mbps 10-BaseT or 10/100-BaseT network interface card. Internet browser: Internet Explorer 7 or greater; Firefox; or Chrome Microsoft Internet Information Services (IIS). Refer to page 3.7 for installation instructions. 1.4 Production Monitoring User Manual IM8001
Requirements and Limitations Chapter 1. General Information Operating System: Windows 7, Windows Vista, Windows XP Professional, Windows Server 2003 with Service Pack 1 or greater, and Windows Server 2008. Production Monitoring supports both 32-bit and 64-bit operating systems. NOTE If the system is Windows Server 2003, COM+ must be enabled. Please see page 3.16 for details. If the system is Windows Server 2008, PowerShell must be installed manually. For details on installing PowerShell, refer to page 3.18. Display: Minimum supported resolution is 1024x768 (16-bit color or higher). The Production Monitoring screens should always be expanded to use the full 1024x768 resolution of the monitor. Otherwise, certain necessary sections of the screen may be hidden from view. User Computer Requirements Each user can access Production Monitoring from the computer at their desk or from another computer on the network. The following requirements apply for that computer to view Production Monitoring : Internet Explorer 6 (Service Pack 1) or greater An Ethernet (IEEE 802.3 compliant) 10Mbps 10-BaseT or 10/100-BaseT network interface card Display: Minimum supported resolution is 1024x768 (16-bit color or higher). Connection to the same network as the server computer Power Wave Requirements The Power Wave Welding Power Source that you want to connect to Production Monitoring must meet the following requirements: Ethernet port - The Power Wave 655, AC/DC 1000, and all third-generation Power Waves (i400, S350, S500, etc.) come standard with an Ethernet port, so no additional equipment is needed. - The Power Wave 455M, 455M/STT, 455M Robotic, and 455M/STT Robotic need a K2207-2 Ethernet/DeviceNet Module. - The Power Wave 355M, F355i, and 405M need a K2436-1 Communication Interface. Static IP address set for each Welding Power Source - Each Welding Power Source must have a unique IP address. IP addresses are usually obtained from your local IT department. - Once you retrieve an IP address for each Welding Power Source, you can use the Lincoln Electric Power Wave Manager software to set the IP address in the Welding Power Source. This software utility is available at www.powerwavesoftware.com. The Production Monitoring firmware revision (in the Welding Power Source) must be revision 5 or greater to use Production Monitoring 2.2. You can check the firmware revision using IM8001 Production Monitoring User Manual 1.5
Chapter 1. General Information Requirements and Limitations Power Wave Manager software on the Diagnostics tab under Production Monitoring > Register. If the revision is 4 or lower, see page 3.18 for details on updating the firmware. Network Requirements Production Monitoring uses your computer network to communicate with the Welding Power Sources and the users who want to view data in the application. The following are the network requirements you need to meet in order for Production Monitoring to run properly: Network Type: 10 Base-T or 10/100 Base-T network Cabling: Solid shielded CAT 5 cables or better Connectors: Use RJ-45 environmentally enclosed connectors when connecting the network to the Welding Power Source. Connecting Network Device: The network lines going to the Welding Power Source should go to an industrial switch or a switch with a hardened enclosure. Wireless Network Guidelines: A wireless network requires an 802.11 bridge. Several customers have had success using a NETGEAR wireless adapter (Model: ENCE2001). System Limitations Table 1.1 compares the two recent versions with respect to limitations. While Production Monitoring is a great tool for monitoring your welding operations, please make note of the following limitations: Welds with a total duration less than 0.2 seconds will not be recorded in Production Monitoring 2.2. Welds with a duration less than the sum of the Start Delay time plus the End Delay time will be recorded as a Short Weld. In Production Monitoring 2.2, you have the option to discard Short Welds (i.e., welds with a duration less than the sum of the Start Delay time plus the End Delay time). The maximum number of records the weld table can store is 250,000. The maximum number of records the event table can store is 250,000. The maximum number of weld records stored on the Welding Power Source itself is 1000. The oldest records will be replaced with a new record when a new record is generated. NOTE In the event there is an Ethernet connection issue with the Welding Power Source, the Production Monitoring weld records will be stored in the Welding Power Source up to the maximum number of records. The power source will transfer the data to the Production Monitoring database once the connection has been reestablished. Please keep in mind that if the Welding Power Source is powered down or reset for any reason, these stored weld records will be lost. Non-synergic modes (such as the Power Mode or Non-Synergic CV modes) are not supported when you use the Last Digit of Workpoint method for selecting Weld Profiles. (Please refer to the Power Wave Manager User Manual for more details on this method.) 1.6 Production Monitoring User Manual IM8001
Requirements and Limitations Chapter 1. General Information FANUC ServoTorch Wire Feed Speed (WFS) will not be recorded for older software versions of ArcTool software and older versions of the Welding Power Source s firmware. Starting with the V7.70P/07 release of the ArcTool software, ServoTorch WFS feedback is supported. The robotic analog interface is not recommended when you use the Last Digit of Workpoint method for selecting Weld Profiles. (Please refer to the Power Wave Manager User Manual for more details on this method.) Production Monitoring does not support consumable package tracking or the calculation of Wire Deposition with Dual-Head Wire Feeders. When using the Windows XP Pro operating system for the server computer, only five (5) users at a time can view reports. When you have multiple machines with memory panels connected to your system (e.g., two wire feeders that each have a memory panel of their own), the Weld Operator should not use these buttons to choose the Weld Profile for their weld. You could potentially select the wrong profile for the weld. Table 1.1 Limitation Differences between Version 2.1 and Version 2.2 Item Version 2.1 Version 2.2 Maximum weld duration (seconds) 6,553 429,496,729 Maximum weld records in Welding Power Source memory Shortest weld duration that can be recorded (seconds) Minimum total delay (i.e., Start Delay plus End Delay) (seconds) 5,000 1,000 0.5 0.2 0.7 0.2 Maximum serial number length 16 32 Maximum out-of-limit tolerance time (seconds) 1310.7 85,899,345 TIG and stick welding supported No Yes WeldScore supported No On third-generation Welding Power Sources IM8001 Production Monitoring User Manual 1.7
Chapter 1. General Information Requirements and Limitations THIS PAGE INTENTIONALLY LEFT BLANK. 1.8 Production Monitoring User Manual IM8001
Chapter 2 Upgrading from Production Monitoring 2.1 If you already have Production Monitoring 2.1 installed and simply need to upgrade to version 2.2, this section provides simple information for you to accomplish this as quickly as possible. STOP If you have Production Monitoring 2.0 or lower (or you need to install for the first time), you must refer to Chapter 3 for instructions. Upgrading to the new version requires that you uninstall all older versions and install the new version fresh. System Requirements The system must meet the requirements listed on page 1.4 to install and run the Production Monitoring 2.2 application. If one of these requirements is missing, the installation will fail. For assistance with these requirements, please contact your local IT department or contact support at support@lincolnproductionmonitoring.com. Preparing for the Upgrade To upgrade from Production Monitoring 2.1 to Production Monitoring 2.2, you will need the following: Administrator permissions on your server computer. Production Monitoring 2.2 Patch If you do not have the Production Monitoring 2.2 Patch, contact Production Monitoring support at support@lincolnproductionmonitoring.com for assistance with obtaining the software. A standard installation of Production Monitoring 2.1 running on the server computer. STOP If your Production Monitoring 2.1 installation is nonstandard, you will need to contact support for assistance with the upgrade process. A non-standard installation would include any installation where the Production Monitoring database has been moved to a different server or the password for the Production Monitoring database has been changed within Microsoft SQL Enterprise Manager. IM8001 Production Monitoring User Manual 2.1
Chapter 2. Upgrading from Production Monitoring 2.1 Running the Production Monitoring 2.2 Patch Running the Production Monitoring 2.2 Patch The Production Monitoring 2.2 Patch upgrades Production Monitoring 2.1 software to the latest Production Monitoring 2.2.x release. NOTE If you do not have the patch file and do not know how to obtain it, contact Production Monitoring support at support@lincolnproductionmonitoring.com or your local Lincoln sales representative. NOTE These instructions may vary depending on the operating system installed on the server computer. Procedure 1. Locate the Production Monitoring 2.2 patch file you saved on your computer. 2. Right-click the patch file and select Extract All from the pop-up menu. Details TIP To find the files easily, create an empty folder on your Desktop and extract the files to that folder. 3. Double-click the setup.exe file to begin the installation of the Production Monitoring 2.2 Patch. 4. When the installation process finishes, click OK to close the application. This process is automated and should not require user involvement once the application begins to run. The title bar of the application should now read Production Monitoring 2.2. NOTE If the patch encounters an error during install or the system does not appear to be running version 2.2, you should contact support for assistance. 2.2 Production Monitoring User Manual IM8001
Chapter 3 Installing Production Monitoring If you have a new installation or you need to upgrade from Production Monitoring 2.0 or lower, the information in this chapter provides easy-to-follow instructions. Installation Preparation This section will guide you through the step-by-step process of how to prepare the server computer for the Production Monitoring software install. This installation section also includes how to determine which version is currently running in the event you are performing an upgrade. Prerequisites for Installing Production Monitoring 2.2 Before you can begin installing Production Monitoring, you need to make sure that you have met certain requirements and have certain information available to you. This helps ensure you have as efficient an installation as possible. You must be logged on as an Administrator to the server computer. Determine the current version being used if you are performing a Production Monitoring upgrade. Refer to page 3.2 to determine the version installed on your server computer. STOP If you need to upgrade from Production Monitoring 2.0, you must completely uninstall this version prior to installing Production Monitoring 2.2. Refer to page 3.2 for uninstall instructions. If you need to upgrade from Production Monitoring 2.1, you must run the Production Monitoring 2.2 patch. Refer to Chapter 2 for instructions on running the patch. The computer name must not contain any underscores (_). Example: If the computer name is My_ Computer, it should be changed to something like MyComputer. During installation, it is best to turn off any Firewalls or security software on the server computer. Microsoft Internet Information Server (IIS) must be installed before installing Production Monitoring. Refer to page 3.7 for information on how to install IIS for your operating system. If you are installing the software on a Windows Server 2003 operating system, check to make sure that Service Pack 1 or greater is installed. (Right-click the My Computer or Computer icon on the desktop or Start menu and select Properties.) For the Windows Server 2003 operating system, verify that COM+ is enabled. Refer to page 3.16 for information on how to verify if this is enabled. If your server computer is Windows Server 2008, PowerShell must be installed manually. Refer to page 3.18 to install PowerShell. IM8001 Production Monitoring User Manual 3.1
Chapter 3. Installing Production Monitoring Uninstalling Production Monitoring 2.0 Determining the Production Monitoring Version To determine the version of Production Monitoring installed on your server computer, simply launch Production Monitoring on that computer and look at the Internet browser tab for the application (Figure 3.1). Figure 3.1 Verify Production Monitoring Version Number In the event your browser does not display tabs, the application also displays the version number in the title bar of the window or in the address bar. If the title bar or tab does not show Production Monitoring 2.1, you will then proceed as if your Production Monitoring version is 2.0. Uninstalling Production Monitoring 2.0 This section describes how to uninstall Production Monitoring 2.0. You must do this prior to installing Production Monitoring 2.2. STOP Uninstalling will erase all previous data collected with Production Monitoring 2.0. If you want to save any previously collected data, then do not continue. Contact Production Monitoring support for assistance in saving your data. For Production Monitoring support in the USA or Canada, dial 1.800.691.5797. The direct dial number is 1.727.786.0121. You can also e-mail support at: support@lincolnelectricproductionmonitoring.com Support will need to log in to the server computer remotely in order to back up the previous database from Production Monitoring 2.0. 3.2 Production Monitoring User Manual IM8001
Uninstalling Production Monitoring 2.0 Chapter 3. Installing Production Monitoring Uninstalling the Production Monitoring 2.0 Application As you begin to uninstall Production Monitoring 2.0, you will uninstall various applications that comprise the Production Monitoring system. This section explains how to remove the Production Monitoring 2.0 software application. Keep in mind these steps may vary depending on the computer Operating System. Figure 3.2 Uninstalling Software Procedure 1. Select the Start > Control Panel from the computer s main program menu. Details 2. Double-click the Add or Remove Programs icon. In newer versions of the Windows operating system, the option is called Programs and Features. 3. Locate Lincoln Production Monitoring in the list of software. See Figure 3.2. 4. Click the Remove button. The system prompts you to confirm that you want to uninstall the software. 5. Select the Uninstall button. The system uninstalls the program and will inform you when it is complete. 6. Click the Close button when the system finishes uninstalling Production Monitoring 2.0. IM8001 Production Monitoring User Manual 3.3
Chapter 3. Installing Production Monitoring Uninstalling Production Monitoring 2.0 Removing Production Monitoring 2.0 Files This section describes how to remove any remaining Production Monitoring 2.0 files from the default installation location on the server computer. Keep in mind these instructions may vary depending on the operating system installed on your computer. Procedure Details 1. Open the Start menu and click My Computer. Depending on your operating system, the option could be called Computer. The contents of the computer display. 2. Double-click the Local Disk (C:) icon. The system displays the folders stored on your local drive. 3. Open the Program Files folder. 4. Open the Lincoln Electric folder. TIP If there is no Production Monitoring folder when you open the Lincoln Electric folder, you can move to the next section and skip the remaining steps. 5. Right-click the Production Monitoring folder and select Delete from the pop-up menu. The system prompts you to confirm the deletion of the folder. 6. Click Yes. Uninstalling SQL Management Studio You must uninstall SQL Management Studio if you have it installed on your computer. Procedure 1. Select the Start > Control Panel from the computer s main program menu. 2. Double-click the Add or Remove Programs icon. Details In newer versions of the Windows operating system, the option is called Programs and Features. 3. Locate Microsoft SQL Server Management Studio in the list of software. 4. Click the Remove button. 5. Click Yes if prompted to confirm you want to remove the program. The system proceeds with uninstalling Microsoft SQL Server Management Studio Express. 3.4 Production Monitoring User Manual IM8001
Uninstalling Production Monitoring 2.0 Chapter 3. Installing Production Monitoring Uninstalling the SQL Server Instance After you uninstall Microsoft SQL Server Management Studio Express, you need to remove the SQL database used in version 2.1 so you can start fresh with version 2.2. To remove the SQL Server Instance: Procedure 1. Select the Start > Control Panel from the computer s main program menu. 2. Double-click the Add or Remove Programs icon. Details In newer versions of the Windows operating system, the option is called Programs and Features. 3. Locate Microsoft SQL Server 2005 in the list of software. 4. Click the Remove button. The system proceeds to uninstall the instance. During the process, the system stops and displays the Component Selection window. 5. Choose LINCOLN: Database Engine and click Next. STOP Only remove the LINCOLN: Database Engine entry. DO NOT remove any other databases. The system displays a confirmation message. 6. Click Finish to continue. The system completes the uninstall process. 7. Exit the Add or Remove Programs window when the process is complete. IM8001 Production Monitoring User Manual 3.5
Chapter 3. Installing Production Monitoring Uninstalling Production Monitoring 2.0 Removing the Production Monitoring Web Site This section outlines the steps necessary to completely remove the Production Monitoring 2.0 website from the server computer. Procedure 1. Select the Start > Control Panel from the computer s main program menu. Details The Control Panel opens. 2. Double-click the Administrative Tools icon. The Administrative Tools window opens. 3. Double-click the Internet Information Services shortcut. The system opens the Internet Information Services window. 4. Click the plus sign ( + ) next to Machine Name (local computer) to expand it. Where MachineName is the name of your computer 5. Click the plus sign ( + ) next to the Web Sites folder to expand it. 6. Click the plus sign ( + ) next to Default Web Site folder to expand it. 7. Right-click the LincolnPM option and select Delete from the pop-up menu. The system prompts you to confirm the deletion. 8. Click Yes to delete the item. 9. Right-click the IGear.Lincoln.Configuration option and select Delete from the popup menu. The system prompts you to confirm the deletion. 3.6 Production Monitoring User Manual IM8001
Installing Microsoft Internet Information Services (IIS) Chapter 3. Installing Production Monitoring Procedure Details 10. Click Yes to delete the item. After uninstalling and removing all previous items, you must restart your computer before continuing. 11. Restart your computer. Installing Microsoft Internet Information Services (IIS) Production Monitoring is an internal web-based application that allows you and other users to access data collected from the Welding Power Sources connected to the application. In order for you and others to access this data, you need to set up the server computer to be a web server. You do this by activating or installing Microsoft s Internet Information Services (or IIS) components. TIP When installing IIS on older computers, please be sure you have the Windows installation CD for your operating system. Check with your local IT department for more information. The instructions are slightly different depending on the Operating System (OS) of your Production Monitoring server computer. Click the link below to navigate directly to the section related to your OS. Windows XP Professional Windows Server 2003 Windows Vista Windows Server 2008 Windows 7 Windows XP Professional IIS Installation With Windows XP Professional, IIS is not installed by default. Follow the instructions below to install IIS. Procedure 1. Log in to the server computer as the administrator user. 2. Insert the original Microsoft Operating System disk. 3. Choose the Install Windows XP option under the What do you want to do? question. Details Contact your IT department for appropriate user name and password if necessary. The Welcome to Microsoft Windows XP should appear. The Windows Components Wizard window opens. IM8001 Production Monitoring User Manual 3.7
Chapter 3. Installing Production Monitoring Installing Microsoft Internet Information Services (IIS) Procedure Details 4. Place a check mark next to Internet Information Services (IIS) and click Next. The system installs IIS and completes the process. Congratulations! You have activated IIS for your server computer. Continue to page 3.18 to install or upgrade Power Wave Manager. Windows Server 2003 IIS Installation With Windows Server 2003, IIS is installed by default, but you need to let the system know you want to use it. Follow the instructions below to add the IIS components. Procedure 1. Log in to the server computer as the administrator user. Details Contact your IT department for appropriate user name and password if necessary. 2. Select the Start > Control Panel from the computer s main program menu. 3. Double-click Add or Remove Programs. The Add or Remove Programs List opens. 3.8 Production Monitoring User Manual IM8001
Installing Microsoft Internet Information Services (IIS) Chapter 3. Installing Production Monitoring Procedure 4. Click the Add/Remove Windows Components button. Details The Windows Components Wizard window opens. 5. Place a check mark next to Application Server and click the Details button. The Application Server window opens. 6. Place a check mark next to Internet Information Services (IIS) and click the Details button. The Internet Information Services (IIS) window opens. IM8001 Production Monitoring User Manual 3.9
Chapter 3. Installing Production Monitoring Installing Microsoft Internet Information Services (IIS) Procedure 7. Place a check mark next to World Wide Web Service and click the Details button. Details The World Wide Web Service window opens. 8. Place a check mark next to Server Side Includes and click OK. 9. Click OK on any open windows until you get back to the Windows Component Wizard. 10. Click Finish. The system completes the installation. Windows Vista IIS Installation Congratulations! You have activated IIS for your server computer. If you haven t enabled COM+ on your server or you re not sure, continue to page 3.16. Otherwise, continue to page 3.18 to install or update Power Wave Manager. With Windows Vista, the installation files were saved to the computer when the Operating System was installed on the computer. Since you want to turn the computer into an internal web server, you need to run the IIS installation to enable the appropriate components. Procedure 1. Log in to the server computer as the administrator user. Details Contact your IT department for appropriate user name and password if necessary. 2. Select the Start > Control Panel from the computer s main program menu. 3.10 Production Monitoring User Manual IM8001
Installing Microsoft Internet Information Services (IIS) Chapter 3. Installing Production Monitoring Procedure Details 3. Open Programs and Features. The Programs and Features list opens. 4. Click the Turn Windows features on or off link under Tasks. The Windows Features window opens. 5. Click the plus ( + ) icon next to Internet Information Services to expand the list. 6. Verify there is a check mark next to IIS 6 Management Compatibility and all of the options under it. IIS 6 Management Console IIS 6 Scripting Tools IIS 6 WMI Compatibility IIS Metabase and IIS 6 configuration compatibility 7. Click the plus ( + ) icon next to Application Development Features to expand the list. IM8001 Production Monitoring User Manual 3.11
Chapter 3. Installing Production Monitoring Installing Microsoft Internet Information Services (IIS) Procedure 8. Verify there is a check mark next to the appropriate options. Details ASP ASP.NET Server Side Includes 9. Click the plus ( + ) icon next to Common HTTP Features to expand the list. 10. Verify there is a check mark next to the appropriate options. Static Content 11. Click OK to close the window. Congratulations! You have activated IIS for your server computer. Continue to page 3.18 to install or upgrade Power Wave Manager. Windows Server 2008 IIS Installation The installation files were saved to the computer when the Windows Server 2008 operating system was installed on the computer. Since you want to turn the computer into an internal web server, you need to tell the server that it needs to play the role of a web server (i.e., one that hosts a web site and allows other users to connect). Follow the instructions below to add the IIS components. Procedure 1. Log in to the server computer as the administrator user. Details Contact your IT department for appropriate user name and password if necessary. 2. Select Server Manager from the Start menu. The Server Manager window opens. 3.12 Production Monitoring User Manual IM8001
Installing Microsoft Internet Information Services (IIS) Chapter 3. Installing Production Monitoring Procedure 3. Right-click the Roles option and select Add Roles from the pop-up menu. 4. Click Next on the Before You Begin page if it appears. Details The Add Roles Wizard window opens. The Select Server Roles window appears. 5. Place a check mark in the Web Server (IIS) checkbox and click Next. The system prompts you to add the features required for Web Server (IIS). 6. Click the Add Required Features button. 7. Click Next on the Server Roles screen. The Web Server (IIS) screen appears. 8. Click Next on the Web Server (IIS) screen. The Select Role Services screen displays. 9. Click the plus ( + ) icon next to Web Server to expand the list. 10. Click the plus ( + ) icon next to Application Development to expand the list. IM8001 Production Monitoring User Manual 3.13
Chapter 3. Installing Production Monitoring Installing Microsoft Internet Information Services (IIS) Procedure 11. Verify there is a check mark next to the appropriate options. Details ASP.NET This should produce a dialog requesting the addition of ISAPI Extensions. Add them as well. ASP Server Side Includes 12. Click the plus ( + ) icon next to Management Tools to expand the list. 13. Click the plus ( + ) icon next to IIS 6 Management Compatibility to expand the list. 14. Verify there is a check mark next to IIS 6 Management Compatibility and all of the options under it. IIS Metabase Compatibility IIS 6 WMI Compatibility IIS 6 Scripting Tools IIS 6 Management Console 15. Click Next to continue the installation. The Confirm Installation Selections screen appears. 16. Verify your selections and click Install. The system installs all the components necessary to turn your computer into an internal web server for Production Monitoring. 17. Click the Close button when the installation is complete. Congratulations! You have activated IIS for your server computer. Continue to page 3.18 to install PowerShell on your server computer. Windows 7 IIS Installation With Windows 7, the installation files were saved to the computer when the Operating System was installed on the computer. Since you want to turn the computer into an internal web server, you need to run the IIS installation to enable the appropriate components so users and Welding Power Sources can access Production Monitoring. Procedure 1. Log in to the server computer as the administrator user. Details Contact your IT department for appropriate user name and password if necessary. 2. Select the Start > Control Panel from the computer s main program menu. 3.14 Production Monitoring User Manual IM8001
Installing Microsoft Internet Information Services (IIS) Chapter 3. Installing Production Monitoring Procedure Details 3. Open Programs and Features. The Programs and Features list opens. TIP If you don t see Programs and Features, try changing the View by drop-down from Category to Small icons. 4. Click the Turn Windows features on or off link in the pane on the left. The Windows Features window opens. 5. Click the plus ( + ) icon next to Internet Information Services to expand the list. 6. Click the plus ( + ) icon next to Web Management Tools to expand the list. 7. Verify there is a check mark next to the appropriate options and sub-options. IIS 6 Management Compatibility - IIS 6 Management Console - IIS 6 Scripts - IIS 6 WMI Compatibility - IIS Metabase and IIS 6 configuration compatibility IIS Management Console IIS Management Scripts and Tools IIS Management Service 8. Click the plus ( + ) icon next to World Wide Web Services to expand the list. IM8001 Production Monitoring User Manual 3.15
Chapter 3. Installing Production Monitoring Enabling COM+ (Windows Server 2003) Procedure Details 9. Click the plus ( + ) icon next to Application Development Features to expand the list. 10. Verify there is a check mark next to the appropriate options..net Extensibility ASP ASP.NET ISAPI Extensions ISAPI Filters Server-Side Includes 11. Click the plus ( + ) icon next to Common HTTP Features to expand the list. 12. Verify there is a check mark next to the appropriate options. Default Document Static Content 13. Click the plus ( + ) icon next to Security to expand the list. 14. Verify there is a check mark next to the appropriate options. 15. Once you have the appropriate options checked, click OK to install. Basic Authentication Request Filtering Windows Authentication Windows installs IIS with the options you ve chosen. Once the installation is complete, the system may prompt you to restart your computer. Be sure to do so if prompted. Congratulations! You have activated IIS for your server computer and can close the Programs and Features window. Continue to page 3.18 to install or upgrade Power Wave Manager. Enabling COM+ (Windows Server 2003) Production Monitoring communicates data from the Welding Power Source to the database and then out to the users connected to the web application through the server computer. To allow all components to talk to each other effectively on Windows Server 2003, you need to enable COM+ for Production Monitoring. Procedure 1. Log in to the server computer as the administrator user. Details Contact your IT department for appropriate user name and password if necessary. 2. Select Start > Control Panel from the computer s main menu. 3. Click Add or Remove Programs. 3.16 Production Monitoring User Manual IM8001
Enabling COM+ (Windows Server 2003) Chapter 3. Installing Production Monitoring Procedure Details 4. Click Windows Components. The Windows Components Wizard opens. 5. Place a check mark next to Application Server and click the Details button. The Application Server window opens. 6. Make sure there is a check mark next to Enable network COM+ access. 7. Click OK to close the window. 8. Click Next on the Windows Components Wizard. 9. Click the Finish button once the installation is complete. The system enables the communication components. The system may prompt you to restart the computer. Be sure to do so. Once completed, proceed to page 3.18 to install or update the Power Wave Manager. IM8001 Production Monitoring User Manual 3.17
Chapter 3. Installing Production Monitoring Installing PowerShell for Windows Server 2008 Installing PowerShell for Windows Server 2008 Windows PowerShell provides communication and management components for the Production Monitoring web application, allowing the Welding Power Sources and database to communicate with the web pages. Windows Server 2008 includes PowerShell, but you need to install it manually. The following steps describe how to install PowerShell on Windows Server 2008. Procedure 1. Log in to the server computer as the administrator user. Details Contact your IT department for appropriate user name and password if necessary. 2. Select Start > Server Manager from the computers main menu. 3. Click the Features option in the left pane. 4. Click the Add Features link on the right. 5. Place a check mark in the Windows PowerShell checkbox. 6. Click Next. 7. Click the Install button. 8. Once PowerShell is done installing, click the Close button. Once completed, proceed to page 3.18 to install or update the Power Wave Manager. Install the Latest Firmware Firmware is the memory and programming code within the Welding Power Source that provides the control program for the machine. Making sure you have the latest firmware ensures that you have the latest features available for the power source, including the most recent version of the Production Monitoring software. To install the latest firmware: Procedure 1. Open your browser and go to www.powerwavesoftware.com. 2. Enter your username and password in the Email and Password fields and click Sign In. OR Click the Register Today link to create an account. Details The Login page displays. If you re creating a new account, follow the onscreen instructions and return to this step when finished. Once you log in, the system displays the Power Wave Resource Center. 3.18 Production Monitoring User Manual IM8001
Install the Latest Firmware Chapter 3. Installing Production Monitoring Procedure Details 3. In the Quick Links section, click the Power Wave, Power Feed /MAXsa Software link. The system displays a page containing the Download Power Wave Bundle-FREE button. 4. Click the Download Power Wave Bundle-FREE button to run the update. NOTE Depending on your Windows version, you may have to click Run or Allow to permit your system to launch the file. The system opens the Lincoln Electric System Update Utility window where you tell the utility how to find the Welding Power Source you want to update. 5. Choose the Connect through Ethernet option and enter the IP address of the Welding Power Source you want to update. TIP If there is an IP address already displayed, it is the IP address of the last Welding Power Source that was connected. Be sure you enter the correct address for the current Welding Power Source you want to IM8001 Production Monitoring User Manual 3.19
Chapter 3. Installing Production Monitoring Install the Latest Firmware Procedure Details update. You can enter the IP address for the Welding Power Source in one of two ways: Type the specific IP address into the I know the IP address of the welder field. Choosing the I do not know the IP address of the welder option. The update utility scans your network and displays a list of Welding Power Source IP addresses on the same subnet. NOTE If this Welding Power Source has older firmware, the IP address will not show up using this method. TIP If you run into a problem, please refer to the Troubleshooting section (Appendix B). 6. Click the Connect button once you have entered the IP address for the power source you are updating. The software scans the Welding Power Source to verify if the firmware currently on the machine is up to date. 7. If the firmware is not up to date, you must click Continue to update the Welding Power Source. The system proceeds with the update. If the firmware is already up to date, you will receive the message Update not required and you can click Exit to close the window. 3.20 Production Monitoring User Manual IM8001
Install the Latest Power Wave Manager Chapter 3. Installing Production Monitoring Procedure 8. Exit the program once the firmware has finished updating. 9. Repeat steps 3 through 8 for each power source you need to update. Details Install the Latest Power Wave Manager Once you update the Welding Power Source(s), you need to upgrade to the latest version of Power Wave Manager on the server computer or install the software for the first time. Power Wave Manager is a software application that allows you to manage a multitude of settings and configuration options within the Lincoln Electric Power Wave family of Welding Power Sources. It also provides in-depth diagnostics of the Welding Power Source s hardware and firmware to help identify and eliminate issues with welding or configuration. TIP If you already have Power Wave Manager installed, you can simply open the software. Depending on your version of the software, the system automatically checks for and installs any updates. If it doesn t do this automatically, you can click the Check for Updates button. Procedure 1. Open your browser and go to www.powerwavesoftware.com. 2. Enter your username and password in the Email and Password fields and click Sign In. Details The Login page displays. These are the same credentials you used when updating the Welding Power Source firmware. Once you log in, the system displays the Power Wave Resource Center. 3. In the Quick Links section, click the Power The system displays a page containing the IM8001 Production Monitoring User Manual 3.21
Chapter 3. Installing Production Monitoring Install the Latest Power Wave Manager Procedure Wave Utilities link. Details Download Power Wave Utilities FREE button. 4. Click the Download Power Wave Utilities FREE button to run the update. NOTE Depending on your Windows version, you may have to click Run or Allow to permit your system to launch the file. The system displays the Installer Language dialog. 5. Select your language from the drop-down and click OK. If you are running an older version of Power Wave Manager, the system prompts you to remove the old version. Click OK to allow the installer to remove the old version. If this is a new installation (or once the old version is removed), the system displays the installation welcome window. 6. Click Next on the Welcome screen to move to the License Agreement and continue the installation. 7. You must accept the License Agreement and click Next to continue. 8. Leave the default value in the Destination Folder field and click Install. The system extracts files and installs the Power Wave Utilities on your computer. Once it is complete, the final page of the Setup Wizard opens. 9. Click the Finish button to exit the installer. Congratulations! You have installed Power Wave Manager and can now configure your Welding Power Source. 3.22 Production Monitoring User Manual IM8001
Installing Production Monitoring 2.2 Software Chapter 3. Installing Production Monitoring Installing Production Monitoring 2.2 Software Once you have removed any old versions of Production Monitoring, installed IIS and any other necessary components (depending on your operating system), you are now ready to install Production Monitoring. STOP Be sure that you have completed all the preliminary requirements on the preceding pages before you continue. Your installation could fail if you have not met these requirements. NOTE Installation time is approximately 45 minutes. Procedure 1. Insert the installation CD into the disk drive or locate the downloaded files. 2. Double-click Setup.exe from the installation CD or your downloaded files. Details You either received a CD, or the Lincoln Electric team provided you online access to a ZIP file to download and extract. The Lincoln Production Monitoring welcome window opens. 3. Select your language from the Language drop-down and click Next. 4. Place a check mark in the I accept the terms of the License Agreement checkbox and click Next. The software s License Agreement displays. The system prompts you for the installation path for Production Monitoring. The default location is: C:\Program Files\Lincoln Electric IM8001 Production Monitoring User Manual 3.23
Chapter 3. Installing Production Monitoring Installing Production Monitoring 2.2 Software Procedure Details 5. Leave the default value and click Next. If the directory does not exist, the system prompts you to create it. Click Yes. The installer continues and installs all components. At this point, the installation takes a while to complete. No user interaction is required during this time. TIP You may notice the title bar of the application reads (Not Responding). This is expected during the install and does not indicate a problem. In addition, other windows open and close throughout the installation. This is also expected. Once the installation is complete, the Summary screen displays. 6. Click Finish. Congratulations! You have installed the new Production Monitoring software. Continue to Chapter 4 for details on configuring the system. 3.24 Production Monitoring User Manual IM8001
Production Monitoring Administration Overview Chapter 4 Once you have Production Monitoring installed, you can now configure the system to meet your company s reporting needs. Figure 4.1 There are two web pages for Production Monitoring : Production Monitoring Pages Administration page: You can access this web page only through the server computer. Main application page: With the main page of Production Monitoring, users can view data and reports from the Welding Power Sources. Users can access this through any computer with access to the server. You can also access the main page directly from the server computer. This chapter explains the Administration page and how to use it to configure Production Monitoring. Chapter 5 explains the main application page of Production Monitoring for all users. On the Administration page, you can: add and delete Welding Power Sources establish shift settings set global units of measure IM8001 Production Monitoring User Manual 4.1
Chapter 4. Production Monitoring Administration Managing the Asset Tree Managing the Asset Tree The Asset Tree is where users select the Welding Power Sources or the Group of power sources for which they would like to see data. Based on the choice they make in the Asset Tree on the left of the web page, the report they select on the right side displays the weld data from that power source or group of power sources. Figure 4.2 Asset Tree on the Main Application Page In order for there to be Welding Power Sources and Groups of power sources, you must create the hierarchy of the Asset Tree here on the Administration page of Production Monitoring. Typically, this hierarchy matches the configuration of the welders out on the production floor. The Asset Tree has two types of items: a Group and a single Welding Power Source. A Group entry organizes Welding Power Sources logically. You use these groups to make it easier to review data for Welding Power Sources. Grouping Welding Power Sources together in logical arrangements also makes it much easier to generate reports on power sources that are related (e.g., in the same area on the floor). See page 4.3 for details on the uppermost Group (called the Root Asset ). A Welding Power Source entry simply identifies a Welding Power Source machine for which you would like to collect data. A Welding Power Source entry must always be within a Group entry. If you click on a Group, the system displays the properties of that group (Figure 4.5 on page 4.4). If you click on a Welding Power Source, the system displays the properties and configuration options for that power source (Figure 4.6 on page 4.5). 4.2 Production Monitoring User Manual IM8001
Managing the Asset Tree Chapter 4. Production Monitoring Administration About the Root Asset (or Company Group) When you first install Production Monitoring and access the Administration page, the system displays the empty Root Asset (Figure 4.3). This uppermost Group is the level at which you create your company site. All other Groups and Welding Power Sources for that company appear inside the company group. Figure 4.3 Root Asset on the Asset Tree No other Group or Welding Power Source can be at the same level as the company group. For example, in Figure 4.4, the Groups called Line 1 and Line 2 are organized underneath (or inside) the Advanced Manufacturing Group. If we were to click the minus icon ( ) next to Advanced Manufacturing to collapse the list, both Line 1 and Line 2 would be hidden from view. This is the recommended alignment and allows us to see data for the entire company. The image on the right in Figure 4.4 is not a standard alignment and generally not recommended. Line 1 and Line 2 were saved at the same level as the company Group Advanced Manufacturing. If the users wanted to see data for the entire company, they would be unable to do so. Figure 4.4 Proper Alignment of Groups and Power Sources Adding Groups In general, you create Groups in the Asset Tree to help you organize Welding Power Source entries, giving the Asset Tree a logical structure that reflects your production floor and making it easy to find and view welding data for specific machines. For example, your company has five (5) lines of power sources with IM8001 Production Monitoring User Manual 4.3
Chapter 4. Production Monitoring Administration Managing the Asset Tree three (3) machines on each line. You would create five (5) Group entries in the Asset Tree with three (3) Welding Power Source entries under each one. Figure 4.5 Groups in the Asset Tree In addition, instead of running a report only for a single Welding Power Source or only for all the Welding Power Sources in a company, a Group allows you to limit the report to only those Welding Power Sources that are listed under a particular Group. Please keep this in mind when organizing the Asset Tree. To add a Group to the Asset Tree: Procedure 1. Select the Group entry under which you want to add a new Group. Details 2. Click Add A New Asset at the top of the tree list. The system adds a new entry under the Group you selected. 4.4 Production Monitoring User Manual IM8001
Managing the Asset Tree Chapter 4. Production Monitoring Administration Procedure Details 3. Click the new asset. The system displays the Asset Properties. 4. Edit the Name field to meet your needs. For example, John at Advanced Manufacturing has his machines organized in lines so he types Line 1 for his first group. 5. Make sure you have Group selected in the Tree Node Type drop-down. 6. Click Save Changes. Congratulations! You ve created your Group entry and can now add Welding Power Sources or other Groups to it. Adding a Welding Power Source You can repeat these steps to add all of your groups now or you can create one complete group at a time. Page 4.5 explains adding Welding Power Sources to the Asset Tree. A Welding Power Source entry is a connection to the welder. Once you connect a power source to the Production Monitoring Asset Tree, you will be able to start generating reports on the data collected. Figure 4.6 Welding Power Sources in the Asset Tree IM8001 Production Monitoring User Manual 4.5
Chapter 4. Production Monitoring Administration Managing the Asset Tree In order to connect a Welding Power Source to Production Monitoring, you need to save an installation key file for each power source using the Power Wave Manager. Refer to the Power Wave Manager User Manual for more details. To add a Welding Power Source to Production Monitoring : Procedure 1. Save an installation key file with the Power Wave Manager. 2. Click on the Group to which you want to add the Welding Power Source. Details Refer to the Power Wave Manger User Manual under Saving an Installation Key File. For example, John at Advanced Manufacturing wants to add a welder to Line 1. 3. Click Add A New Asset at the top of the Asset Tree. A New Asset appears under the selected Group and the Asset Properties section displays. 4. Select Welder from the Tree Node Type drop-down. The new Asset Configuration section appears under the Asset Properties. 4.6 Production Monitoring User Manual IM8001
Managing the Asset Tree Chapter 4. Production Monitoring Administration Procedure 5. Click on the Select button next to the Configuration Import field and select the installation key file that you created in step 1. Details The installation key file ends in TOK (e.g., 10.23.10.90.tok). 6. Click Run Import. The system places a check mark in the Enable Data Collection on Welder checkbox for you and displays a list of attributes for the Welding Power Source next to Configuration. You can use information from the Description to name your power source in the Asset Tree if you choose. 7. Enter the name of the Welding Power Source in the Name field under Asset Properties and click Save Changes. Congratulations! You have added a Welding Power Source entry to the Asset Tree in Production Monitoring. 8. Repeat steps 1 through 7 for each power source you want to add to the Asset Tree. IM8001 Production Monitoring User Manual 4.7
Chapter 4. Production Monitoring Administration Managing the Asset Tree Displaying Welding Power Sources to Other Users When you re managing the system for your company, you may need to control which Welding Power Source entries or Group entries other users can see when they access Production Monitoring. There are several reasons you may need to hide a power source or group from other users. The Welding Power Source might not be ready for welding yet, but you want to set it up in the Asset Tree. More often, you have removed a Welding Power Source from the floor, but you still want to retain the data from that power source. If you delete the Welding Power Source entry from Production Monitoring, the system deletes the data as well. Simply removing the item from public view is a safer alternative and allows you to keep the data. Showing an Item To make a Group or Welding Power Source visible to other users in the main web site, click the item in the Asset Tree to select it. Place a check mark in the Show Asset in Tree checkbox and click the Save Changes button. Figure 4.7 Displaying an Asset in Production Monitoring For Welding Power Source entries, you also need to make sure any Group entry that the Welding Power Source is located under also has the Show Asset in Tree checkbox checked. If a Group is hidden then any Welding Power Sources under it also will not display, even if there is a check mark in the Show Asset in Tree checkbox for the Welding Power Source. NOTE If you recheck the Show Asset in Tree checkbox on a Group entry, make sure you verify that all of the Welding Power Source entries under it are also checked. Hiding an Item To prevent other users from seeing a Group or Welding Power Source in their Asset Tree, click the item in the Asset Tree to select it. Remove the check mark from the Show Asset in Tree checkbox and click the Save Changes button. NOTE If you remove the check mark on a Group entry, the system removes the check mark for all entries under the Group automatically. 4.8 Production Monitoring User Manual IM8001
Managing the Asset Tree Chapter 4. Production Monitoring Administration Enabling/Disabling Data Collection from a Welding Power Source At times, you might want to disable collecting data from a Welding Power Source. For example, if you are doing testing or maintenance with the Welding Power Source and do not want the data from this activity to be included in the Production Monitoring data. You can disable Production Monitoring for that power source for the duration. Figure 4.8 Enable Data Collection Enabling Data Collection When you add a new Welding Power Source to the Asset Tree, the system automatically enables data collection for you. If you have disabled the data collection and need to turn it back on, simply click the Welding Power Source in the Asset Tree to select it and place a check mark in the Enable Data Collection on Welder checkbox under Asset Configuration (Figure 4.8). Click the Save Changes button at the top. Disabling Data Collection To turn off data collection for the Welding Power Source, simply click the Welding Power Source in the Asset Tree to select it and remove the check mark from the Enable Data Collection on Welder checkbox under Asset Configuration (Figure 4.8). Click the Save Changes button at the top. Moving Welding Power Sources and Groups You can easily move a Welding Power Source entry or a Group entry to another location in the Asset Tree. This can happen for any number of reasons, including adding the Welding Power Source to the wrong Group, moving the power source on the production floor or changing Groups around. To move a Welding Power Source or a Group of power sources, simply drag-and-drop the entries wherever you need them to be. IM8001 Production Monitoring User Manual 4.9
Chapter 4. Production Monitoring Administration Shift Schedule Configuration Deleting Welding Power Sources and Groups You can delete either a Welding Power Source entry or a Group entry if necessary. Simply select the Group or Welding Power Source and click Delete Asset under Asset Properties on the right. STOP Deleting a Welding Power Source or a Group also deletes all data collected for those welders. You cannot undo this action. If you want to keep the data, choose to hide the entries instead. See page 4.8 for more information. STOP If you delete a Group, you also delete all Welding Power Sources that are under that Group. You cannot undo this action. Figure 4.9 Delete an Asset The system prompts you to confirm that you want to delete the asset. Click Yes if you are sure you want to permanently remove the Group or Welding Power Source. Shift Schedule Configuration When a Welding Power Source records that a weld was made, it only knows the date and time and the statistics of the weld. It doesn t know that the weld occurred during what you consider Second Shift unless you tell the system what time range during the day Second Shift occurs. The Shift Schedule is where you communicate this to Production Monitoring. NOTE A Shift is a block of time for identifying data to a team. Shifts must be greater than 0 seconds long and less than 24 hours long. 4.10 Production Monitoring User Manual IM8001
Shift Schedule Configuration Chapter 4. Production Monitoring Administration Figure 4.10 Configuring Shift Schedules To access the Shift Schedule for Production Monitoring, select System > Shift Schedule on the Administration page. The Production Monitoring Shift Schedule is designed to accommodate both simple and complex Shift Schedules, providing the flexibility to match your company s schedule. TIP You will either edit the Default Shift Schedule or create additional Shift Schedules, depending on your needs. For example: Advanced Manufacturing has a simple daily Shift Schedule with three shifts. However, United Engineering down the street has a complex weekly Shift Schedule with three shifts Monday through Friday, two shifts on Saturday, and one shift on Sunday. Next Production Day The concept of Next Production Day in Production Monitoring relates to a shift that crosses the midnight threshold of a calendar day and the data generated during that time period. For the welds that were performed during this type of shift, the system needs to know how you want to include that data on reports in relation to dates. When you set up the shift schedule, there is a checkbox called Next Production Day that appears when the shift time crosses that midnight threshold. This checkbox controls how the weld data appears on the reports. For example, the first shift of the production day at United Engineering actually begins at 11:00 PM the previous calendar day. Any welds that were performed during the part of the shift before midnight on February 1 need to be included with the data collected after midnight on February 2 (i.e., the next production day). With a check mark in the Next Production Day checkbox on that first shift, if any users generate a report for February 2, those welds performed from 11:00 PM to midnight on February 1 will also be included. Alternatively, the third shift of the production day at Advanced Manufacturing actually ends at 7:00 AM the next calendar day. Any welds that were performed during the part of the shift after midnight on February 2 need to be included with the data collected before midnight on February 1 (i.e., the same production day). With NO check mark in the Next Production Day checkbox on that third shift, if any users generate a report for February 1, those welds performed from midnight to 7:00 AM on February 2 will also be included. IM8001 Production Monitoring User Manual 4.11
Chapter 4. Production Monitoring Administration Shift Schedule Configuration General Shift Schedule Information When you click the Edit icon ( ) next to a shift on the Shift Schedule screen (Figure 4.10 on page 4.11), the system displays the basic information for the Shift Schedule and allows you to access the Details (or list of shifts) for that Shift Schedule. The General section of the Shift Schedule establishes the basis for creating individual shifts for this schedule (Figure 4.11). Table 4.1 explains the fields in more detail. Table 4.1 Field Description Base Date Period Days Figure 4.11 General Information about the Shift Schedule Fields on the Shift Schedule General Screen Description The Description field is text that helps you identify this Shift Schedule if you have multiple schedules in the list. For complex Shift Schedules, the Base Date defines what date and day of the week the system should use as the starting date for the schedule. This field is not necessary for simple schedules where every day has the same setup. The Period Days define how many days are in the Shift Schedule before the schedule repeats. For example, Advanced Manufacturing has a simple Shift Schedule where every day is the same, every week. They would set the Period Days on their Shift Schedule to 1. United Engineering, on the other hand, has a more complex setup with two shift alternating each weekend. They would set the Period Days for their Shift Schedule to 14, since the pattern repeats every 14 days. See schedule examples starting on page 4.16. 4.12 Production Monitoring User Manual IM8001
Shift Schedule Configuration Chapter 4. Production Monitoring Administration Managing the Shift Schedule Each Shift Schedule contains a number of unique shifts that detail what time the shift begins, when it ends and how often it repeats within the Shift Schedule. Click the Details link to view the list of shifts that exist in the schedule (Figure 4.12). Figure 4.12 Shift Schedule Details From the Shift Schedule window, you can add a new shift, edit the settings for an existing shift or remove shifts that are no longer active. STOP Be careful when editing or removing shifts that have data associated with them. You will lose that data. See pages 4.15 and 4.15 for details on editing and deleting shifts, respectively. IM8001 Production Monitoring User Manual 4.13
Chapter 4. Production Monitoring Administration Shift Schedule Configuration Adding a New Shift Adding a shift is simple. Simply click the New Shift link at the top of the Shift Schedule list. The system displays the Shift Details window (Figure 4.13). Complete the information on the window and click Save. Table 4.2 explains the fields in detail. Table 4.2 Fields on the Shift Details Window Field Name Description Figure 4.13 Shift Details Enter the title of the shift you want to create. This text appears in the list of shifts and in the Shift drop-downs in the main Production Monitoring web site. Period Day The Period Day for a shift is the specific day within the shift schedule that this shift occurs. For example, if the shift schedule has seven period days, and this individual shift occurs on period day five, then it will only occur on the fifth day of the shift schedule. You would enter 5 in this Period Day field. This allows you to have a shift occur on Day One, Day Three and Day Five of a shift schedule, without happening on any other day. TIP When defining a shift schedule, you want to determine the shortest repeating shift possible. For example, Advanced Manufacturing uses the exact same shift every day. Their Shift Schedule has 1 in the Period Days field and each of the defined shifts has 1 in the Period Day field. United Manufacturing, on the other hand, has a weekly repeating Shift Schedule. The Period Days field on the Shift Schedule has a 7. Each shift within that Shift Schedule must be defined for each of those seven days with a Period Day of 1 to 7. They would have 21 individual shift entries 4.14 Production Monitoring User Manual IM8001
Shift Schedule Configuration Chapter 4. Production Monitoring Administration Field Start Time Next Production Day Order in Production Day Description within this Shift Schedule (i.e., 7 days times 3 shifts). So there would be a Morning Shift entry with a 1 in the Period Day field. A Morning Shift entry with a 2 in the Period Day field. A Morning Shift entry with a 3 in the Period Day field and so on for each of the seven days. The Afternoon Shift and the Night Shift entries would follow the same pattern. Enter the time of day that this shift begins. The Next Production Day checkbox defines if this shift should count for the next calendar day, even though the shift started before midnight. See page 4.11 for more details on the Next Production Day concept. Enter where this shift appears in the shift line up. Editing a Current Shift The only time you should be editing a shift is when you first set up Production Monitoring for your team and/or when there is no data associated with that shift. STOP Data associated with a shift will be unavailable in reports if you change the name of the shift. If you have lost data for this reason and need to view it, please contact support for Production Monitoring assistance. For support in the USA and Canada, dial 1.800.691.5797. The direct dial number is 1.727.786.0121. The e-mail address is support@lincolnproductionmonitoring.com. Simply click the Edit icon ( button when you re done. ) next to the shift and make your changes. Remember to click the Save Deleting a Shift If you have entered a shift by mistake when you re setting up the system, or you no longer need the data associated with the shift, you can remove it from your system, which removes it from the Shift drop-down on reports. Simply click the Delete icon ( ) next to the shift and confirm you want to delete it. IM8001 Production Monitoring User Manual 4.15
Chapter 4. Production Monitoring Administration Shift Schedule Configuration Example Shift Setup Advanced Manufacturing has a daily Shift Schedule with three shifts. Their Production Day begins with the morning shift, and their shift times are: Morning Shift: 7:00 AM to 3:00 PM Day Shift: 3:00 PM to 11:00 PM Evening Shift: 11:00 PM to 7:00 AM When John (the Production Monitoring administrator) creates the Shift Schedule, the final list looks like Figure 4.14. General Details Figure 4.14 Simple Shift Schedule Example When John edited the Default Shift Schedule in order to create his company s schedule, he entered the following information on the General window: Name: Default (He left the system s default name.) Base Date: 1/1/2000 (He left the system s default date. There is no reason to change this date if all shifts are the same every day.) Period Days: 1 (He left the system s default entry since his shifts are the same every day.) Individual Shift Details When John clicked New Shift to create the Morning Shift entry, he entered the following details: Name: Morning Shift Period Day: 1 Start Time: 7:00 AM Next Production Day: Unchecked Order in Production Day: 1 When John clicked New Shift to create the Day Shift entry, he entered the following details: 4.16 Production Monitoring User Manual IM8001
Shift Schedule Configuration Chapter 4. Production Monitoring Administration Name: Day Shift Period Day: 1 Start Time: 3:00 PM Next Production Day: Unchecked Order in Production Day: 2 And finally, when he clicked New Shift to create the Night Shift entry, he entered the following details: Name: Night Shift Period Day: 1 Start Time: 11:00 PM Next Production Day: Unchecked Order in Production Day: 3 Example Shift Setup Worldwide Industrial has a daily Shift Schedule with three shifts. Their Production Day begins with the evening shift, and their shift times are: Night Shift: 11:00 PM to 7:00 AM Day Shift: 7:00 AM to 3:00 PM Evening Shift: 3:00 PM to 11:00 PM The difference between this shift setup and the shift setup on page 4.16 is the Night Shift. Any data collected at Worldwide Industrial during the Night Shift needs to be included with the data collected on the Next Production Day (the same day as the rest of the shifts in this setup). See page 4.11 for more in-depth information about the concept of Next Production Day. When Mark (the Production Monitoring administrator) creates the Shift Schedule, the final list looks like Figure 4.15. Figure 4.15 Simple Shift Schedule Example IM8001 Production Monitoring User Manual 4.17
Chapter 4. Production Monitoring Administration Global Settings General Details When Mark edited the Default Shift Schedule in order to create his company s schedule, he entered the following information on the General window: Name: Default (He left the system s default name.) Base Date: 1/1/2000 (He left the system s default date. There is no reason to change this date if all shifts are the same every day.) Period Days: 1 (He left the system s default entry since his shifts are the same every day.) Individual Shift Details When Mark clicked New Shift to create the Night Shift entry, he entered the following details: Name: Night Shift Period Day: 1 Start Time: 11:00 PM Next Production Day: Checked (See page 4.11 for details on Next Production Day.) Order in Production Day: 1 When Mark clicked New Shift to create the Day Shift entry, he entered the following details: Name: Day Shift Period Day: 1 Start Time: 7:00 AM Next Production Day: Unchecked Order in Production Day: 2 And finally, when he clicked New Shift to create the Evening Shift entry, he entered the following details: Name: Evening Shift Period Day: 1 Start Time: 3:00 PM Next Production Day: Unchecked Order in Production Day: 3 Global Settings The Global Settings on the Production Monitoring Administration page (Figure 4.16) set the options for all users who access the main web site. At this point in time, there is a single setting: Unit of Measure. You can select either Imperial (inches/minute and pounds) or Metric (meters/minute and kilograms). This setting defines the units that the system uses to report the Wire Feed Speed and Wire Deposition when it displays data on reports. 4.18 Production Monitoring User Manual IM8001
Getting the Team Started Chapter 4. Production Monitoring Administration Getting the Team Started Figure 4.16 Global Unit of Measure Congratulations! You have completed all the setup necessary to get your team using Production Monitoring. Now it s time to share the link to the Production Monitoring web site. The system makes this simple for you. Figure 4.17 Provide Access to Production Monitoring To generate a link to the main page of the Production Monitoring application: Procedure 1. Launch Production Monitoring on the server computer. 2. At the bottom of the screen, click the E-mail a Link to this Site link. Details See Figure 4.17. This should open the default e-mail client program on the server computer. 3. In the To field, enter the e-mail address(es) of the person (or people) who will be monitoring and running reports from Production Monitoring. 4. Send the e-mail. IM8001 Production Monitoring User Manual 4.19
Chapter 4. Production Monitoring Administration Restricting Access to Administration Restricting Access to Administration In Production Monitoring 2.0, the configuration section of the software was password-protected and required a user to log in to make changes to the configuration of the Welding Power Sources. Starting with Production Monitoring 2.2, users no longer have to log in to the Administration page. If you still want to restrict access to the configuration of the Welding Power Sources in Production Monitoring, you must enable Integrated Windows Authentication. STOP This section is highly technical. Please read through the section before attempting any changes to your server. Contact your local IT department or Lincoln Electric Production Monitoring support for assistance. For support in USA and Canada, dial 1.800.691.5797. The direct dial number is 1.727.786.0121. The e-mail address is support@lincolnproductionmonitoring.com. Prerequisites In order to use Windows Authentication, you must first enable the component in the Internet Information Services (IIS) installation. You have already installed IIS on the Production Monitoring server. You simply need to enable another component that restricts access and then provide permissions for the appropriate user(s). The following sections walk you through enabling the necessary components for your version of IIS: IIS 5.1 and IIS 6.0 IIS 7.0 and IIS 7.5 IIS 5.1 and IIS 6.0 If your server has the Windows XP or Windows Server 2003 operating system, you typically have Internet Information Services (IIS) version 5.1 or 6.0 installed. The following sections are for you. Enabling Windows Authentication This section explains how to enable the Windows Authentication components in IIS 5.1 and 6.0. Procedure 1. Select Start > Control Panel from the computer s main menu. 2. Double-click the Administrative Tools icon. Details 4.20 Production Monitoring User Manual IM8001
Restricting Access to Administration Chapter 4. Production Monitoring Administration Procedure 3. Double-click the Internet Information Services icon. Details The Internet Information Services window opens. 4. Right-click the IGear.Lincoln.Configuration virtual directory and select Properties from the pop-up menu. The IGear.Lincoln.Configuration Properties window opens. 5. Click on the Directory Security tab. 6. Click the Edit button in the Anonymous access and authentication control section. The Authentication Methods window opens. 7. Verify that there is no check mark in the Anonymous access checkbox. IM8001 Production Monitoring User Manual 4.21
Chapter 4. Production Monitoring Administration Restricting Access to Administration Procedure 8. Place a check mark in the Integrated Windows authentication checkbox and click OK. Details The system takes you back to the IGear.Lincoln. Configuration Properties window. 9. Click OK. Congratulations! You have restricted all other users from the Administration page of Production Monitoring. You can now enable just those accounts you want to have access. Continue to page 4.22. Enabling Windows Account Permissions Your Windows accounts may not be enabled correctly to access the virtual directory. This section explains how to enable permissions for a Windows account. Procedure 1. Navigate to the physical location where the virtual directory resides and select it. 2. Select Tools > Folder Options from the main menu. Details Typically, this directory is C:\Program Files\Lincoln Electric\Production Monitoring on the server computer. The Folder Options window opens. 3. Click the View tab. 4. Remove the check mark from the Use simple file sharing checkbox. 5. Click OK. 6. Open the Production Monitoring folder. 7. Right-click the Admin folder and select Properties from the pop-up menu. The Virtual Directory Properties window opens. 8. Click the Security tab. 4.22 Production Monitoring User Manual IM8001
Restricting Access to Administration Chapter 4. Production Monitoring Administration Procedure 9. Select the igear (IGEAR-XP-EN\igear) user in the Group or user names list. Details If the user does not exist, click the Add button to add it to the list. 10. In the Permissions list, place a check mark next to all permissions that the account should have. 11. Click OK. 12. Repeat steps 7 through 11 for the Website folder. IIS 7.0 and IIS 7.5 If your server has the Windows Vista, Windows Server 2008 or Windows 7 operating system, it typically has Internet Information Services (IIS) version 7.0 or later. The following sections are for you. Enabling Windows Authentication This section explains how to enable the Windows Authentication components in IIS 7.0 and later. Figure 4.18 Computer Management Window Procedure 1. Click the Start menu button. Details 2. Right-click Computer and select Manage. The Computer Management window opens (Figure 4.18). IM8001 Production Monitoring User Manual 4.23
Chapter 4. Production Monitoring Administration Restricting Access to Administration Procedure 3. Navigate to Computer Manager (Local) > Services and Applications > Internet Information Services (IIS) Manager. 4. In the Connections pane, navigate to the IGear.Lincoln.Configuration virtual directory. 5. Click the Features View button. Details 6. Double-click the Authentication icon. The icons go away and the Authentication page opens in their place. 7. If Anonymous Authentication is Enabled, rightclick the item and select Disable from the popup menu. 8. If Windows Authentication is Disabled, rightclick the item and select Enable from the popup menu. Congratulations! You have restricted all other users from the Administration page of Production Monitoring. You can now enable just those accounts you want to have access. Continue to Enabling Windows Account Permissions. Enabling Windows Account Permissions Windows accounts may not be enabled correctly to access the virtual directory. This section explains how to enable permissions for a Windows account. Procedure 1. Navigate to the physical location where the virtual directory resides. Details Typically, this directory is C:\Program Files\Lincoln Electric\Production Monitoring on the server computer. 2. Open the Production Monitoring folder. 4.24 Production Monitoring User Manual IM8001
Restricting Access to Administration Chapter 4. Production Monitoring Administration Procedure 3. Right-click the Admin folder and select Properties from the pop-up menu. Details The Admin Properties window opens. 4. On the Security tab, click the Edit button. The Permissions for Admin window opens. 5. Select the user account in the Group or user names list. If the user does not exist, click the Add button to add it to the list. 6. In the Permissions list, place a check mark next to all permissions that the account should have. 7. Click OK. 8. Repeat steps 3 through 7 for the Website folder. IM8001 Production Monitoring User Manual 4.25
Chapter 4. Production Monitoring Administration Restricting Access to Administration THIS PAGE INTENTIONALLY LEFT BLANK. 4.26 Production Monitoring User Manual IM8001
Chapter 5 Using Production Monitoring Welcome to Production Monitoring. Production Monitoring is an internal web-based application that the administrator configured to connect to the Welding Power Sources in your company. You can generate a number of reports on the welding data collected. Launching Production Monitoring To open the Production Monitoring application, you simply visit a web site address. Your Production Monitoring administrator most likely sent you an e-mail containing the link to the application. Open that e-mail and click the link. (If the link doesn t work, copy and paste the address into the address bar of your browser.) TIP To make it easy to launch Production Monitoring, create a shortcut on your computer Desktop or a bookmark in your Internet browser. Overview of the Application The Production Monitoring application has several active areas where you can click the mouse. This section explains how to use each one in detail. On the left is the Asset Tree (page 5.2) where you select the individual Welding Power Source or the Group of power sources on which you want to report. Across the top of the right side are the Report Tabs (page 5.2). Each tab contains several individual reports or graphs. Directly below each Report Tab are the Individual Reports (page 5.3). To the right of the Asset Tree and under the Reports are the Panel Resize bars (page 5.3). Most reports allow you to filter the data by certain Report Criteria. This criteria appears under the Individual Reports. The way you select criteria is the same for each report (page 5.4). However, each report contains different criteria. Figure 5.1 Production Monitoring IM8001 Production Monitoring User Manual 5.1
Chapter 5. Using Production Monitoring Overview of the Application Asset Tree The Asset Tree displays all of the Welding Power Sources and Groups of power sources that your Production Monitoring administrator has created and made visible to you in the application. An asset is a Welding Power Source or Group of power sources. Figure 5.2 Asset Tree To navigate through the Asset Tree, simply expand and collapse Groups as needed. Use the plus and minus icons ( and ) to expand and collapse the list. The reports on the right of the web page reflect information for the currently selected asset, whether it is a single Welding Power Source or a Group. TIP You can tell if you have selected a Welding Power Source or Group if the text has a colored background. In Figure 5.2, we have the Group called Advanced Manufacturing selected. NOTE When you switch between a single Welding Power Source and a Group of power sources in the Asset Tree, Production Monitoring automatically changes your report view back to the Current Status tab. Report Tabs The Report Tabs represent categories of reports. The individual reports appear within the tab once you click the tab. When you first click the tab, the system defaults to the first individual report. Figure 5.3 Report Tabs 5.2 Production Monitoring User Manual IM8001
Overview of the Application Chapter 5. Using Production Monitoring If the system can t display all of the tabs on the screen, you will see left and right arrow buttons ( ) to the very right of the last visible tab. Simply click the correct navigation button until you see the tab you want to access. There are several different types of reports available in Production Monitoring : Current Status (page 5.7) Production (page 5.10) Weld Listing (page 5.21) Weld Detail (page 5.30) Traceability (page 5.35) Downtime (page 5.39) Fault Detail (page 5.41) Individual Reports The heart of Production Monitoring is the individual reports you have available under each Report tab. Production Monitoring collects welding data from each weld produced by each Welding Power Source that your administrator connected to the system. Depending if you have a single Welding Power Source selected or a Group of power sources selected, the individual reports available to you varies. Figure 5.4 Example Production Reports For example, if you select a single Welding Power Source, the reports available on the Production tab are: Grid, Weld Profiles, WeldScore, Current/Voltage, Wire Feed Speed, True Energy, and Duration/Count. However, if you select a Group of power sources, the only reports available on the Production tab are: Grid, True Energy and Duration/Count. TIP In-depth information about each report begins on page 5.7. Panel Resize To the right of the Asset Tree and under the Individual Reports are the Panel Resize bars. When you click and drag the bar with your mouse, you can increase or decrease the size of the areas on either side of the bar. IM8001 Production Monitoring User Manual 5.3
Chapter 5. Using Production Monitoring Overview of Reports Overview of Reports The heart of Production Monitoring is the ability to generate reports on the wealth of data provided by your Welding Power Sources. To help you get the most of the reports, several features and functionalities apply to all or most reports. Generating Reports Production Monitoring stores the data generated by your Welding Power Sources in a database on the server. When you generate a report, Production Monitoring goes to that database and submits a query. The data comes back, and the system displays the report for you. To generate a report: TIP In-depth information about each report begins on page 5.7. Procedure 1. From the Asset Tree, select the Welding Power Source or Group for which you want to generate the report. 2. Click the appropriate report tab. Details For more details on navigating the Asset Tree, please see page 5.2. 3. Click the appropriate individual report. The report automatically displays for you. Use the Criteria to customize the data to your needs. Report Criteria The Criteria section on an individual report displays the options used for generating the report you currently see on the screen. If you want to display the data on the report for a specific date or shift (or a variety of other filters), you can click the Criteria link (Figure 5.4 on page 5.3). The Criteria window (Figure 5.5) displays the filters available for the individual report. Not all the Criteria windows are the same, and some reports do not need to be filtered so have no criteria available. Figure 5.5 Criteria Edit Screen 5.4 Production Monitoring User Manual IM8001
Overview of Reports Chapter 5. Using Production Monitoring Simply make your selections and click Save. The report automatically regenerates and displays the data based on your selections. As long as you have cookies enabled on your browser, the system saves your criteria until you enter new selections, you clear the cookies or the cookies expire. Report Links Some reports have links built into the data that, when you click the link, take you to another report. The other report usually provides you with more in-depth information about the data point. You can tell an item has more information if the text appears as a hyperlink (Figure 5.6). Figure 5.6 Report Links For example, in Figure 5.6, the Grid report on the Production tab shows the data in the Period column underlined. This means that there is a link to another report. Click this link to generate a Grid report on the Weld Listing tab for that specific period (page 5.21). Report Page Numbers When all the data for a report cannot fit on a single page, Production Monitoring displays a page navigator at the bottom of the report (Figure 5.7). Figure 5.7 Report Page Numbers Click the page number to move to that page of data on the report. To navigate to the next set of pages, click the ellipsis (... ) after the last page number. Production Monitoring also tells you how many pages are in the report, as well as how many records. IM8001 Production Monitoring User Manual 5.5
Chapter 5. Using Production Monitoring Overview of Reports Exporting Report Data You have the ability with some reports to export the data to a Microsoft Excel file or to a commaseparated text file (CSV). If the report has this option available, you will see export icons ( and ) either at the top of the report or at the bottom of the report (Figure 5.8). Simply click the appropriate icon and save the file to your computer. Figure 5.8 Exporting Data from a Report STOP Depending on the amount of data in your report and the speed of your connection, the report file may take a little time to generate. Your Internet browser displays a save prompt when it is ready for you to save the file. Wait for that prompt after you click the export icon. Refreshing Report Data Production Monitoring refreshes the data for the reports on the Current Status tab automatically every 15 to 20 seconds. For all other reports, you need to click the Refresh icon ( ) to retrieve the data that was collected from the Welding Power Sources since the time you displayed the report on your screen. 5.6 Production Monitoring User Manual IM8001
Current Status Tab Chapter 5. Using Production Monitoring Current Status Tab The Current Status tab is mainly used to display near real-time data for each Welding Power Source or Group of power sources. The system updates the data displayed on your computer screen automatically every 15 to 20 seconds. Figure 5.9 Current Status Report Current Status by Time Period There are several reports that display the status of the Welding Power Source or Group currently selected by time period. The reports are identical except for the time period they cover. The following time periods are available with a single click of your mouse: This Production Hour This Production Shift This Production Day This Week This Month See Table 5.1for details on the columns available on these reports. Table 5.2 on page 5.8 explains the meanings of the indicators you see next to each Welding Power Source in the report. Table 5.1 Column Welder Welds Columns on the Current Status Reports Description This item displays the name of the Welding Power Source (as entered by the Administrator) and an icon with the status of the power source. See Table 5.2 for the meaning of each icon. This column represents the number of completed welds that were made in the selected time period. IM8001 Production Monitoring User Manual 5.7
Chapter 5. Using Production Monitoring Current Status Tab Column Welds Out of Limit Arc Time Time of Last Weld Wire Remaining Description Weld Engineers can set each Weld Profile with a set of acceptable values for WeldScore, current, voltage, wire feed speed and duration. The Welds Out of Limit column displays the actual number of welds where at least one of the parameters was out of limits (and the percentage of total welds this number represents). Refer to the Power Wave Manager User Manual for more information on Weld Profiles. This displays the total number of hours that the Welding Power Source has been welding in the selected time period (e.g., This Production Hour, This Production Shift). This is the start time and date of the most recent weld performed by the Welding Power Source during the selected time period (e.g., This Production Hour, This Production Shift). This column displays the amount of wire (in pounds or kilograms) remaining in the current wire package. Refer to the Power Wave Manager User Manual for setting up wire package information. Table 5.2 Icons and Their Meanings Icon Description No Communications: The Production Monitoring software could not communicate with the Welding Power Source. Check that the Welding Power Source is turned on and that there are no problems with the Ethernet network. Incompatible Firmware: This means that the Production Monitoring firmware is not correct. The software in the Welding Power Source needs to be updated to the latest version. Refer to the Power Wave Manager User Manual under Update the Welding Power Source Firmware for more information. Faulted: This indicates that the Welding Power Source has recently experienced an event that may prevent it from welding. Refer to the Power Wave Manager User Manual under System Status for information on diagnosing the fault. Latched Fault: This indicates that the Welding Power Source stopped welding due to a fault caused by a limit set within the Weld Profile being used. This latched fault must be reset before the Welding Power Source will weld again. Refer to the Power Wave Manager User Manual under Alarm Latch for more information on how to reset this. Not Ready: This indicates that the Welding Power Source is either currently being reprogrammed or has experienced an event that may prevent it from welding. Refer to the Power Wave Manager User Manual under System Status for information on diagnosing the fault. 5.8 Production Monitoring User Manual IM8001
Current Status Tab Chapter 5. Using Production Monitoring Icon Description Off Line: This means that Production Monitoring is not collecting data from the Welding Power Source. There must be a check mark in the Enable Data Collection checkbox for the power source on the Administration page of Production Monitoring. See page 4.9 for details on enabling data collection for the power source or contact your Production Monitoring administrator. There may be a reason the power source was set to not collect data. Ready: This indicates that the Welding Power Source is active and in an idle state (not welding). Welding: The addition of the lightning bolt to the Ready icon indicates that the Welding Power Source is currently welding. Downloading Data: The three small circles on the Ready icon mean that the Welding Power Source has a large amount of data that still needs to be read from the Welding Power Source. NOTE While this icon displays, new welds do not show up in Production Monitoring until the power source finishes downloading the oldest welds first. System Capacity The final report on the Current Status tab is called System Capacity. This report displays information on your database. Your system stores information in two tables within the database: one for weld data and one for event data. Each table can retain data for up to 250,000 records. Once you reach 250,000 records, the system automatically archives off the oldest records in groups of 60,000 records. Table 5.3 explains the data available in this report. See page A.1 for more details on the archive file. Figure 5.10 System Capacity Report TIP You may see the Weld Capacity field or the Event Capacity field show higher than 250,000. There is a built-in buffer that continues to store records until the archive occurs. IM8001 Production Monitoring User Manual 5.9
Chapter 5. Using Production Monitoring Production Tab Table 5.3 Field Oldest Weld Data on the System Capacity Report Description This field displays the date and time of the oldest weld record in the weld history table. Weld Capacity Weld Capacity Usage Oldest Event Event Capacity Event Capacity Usage This field displays how many weld records currently exist in your weld history table. This field displays the percent of the weld history table currently in use by the number of records displayed in the Weld Capacity field. This field displays the date and time of the oldest event record in the event history table. This field displays how many event records currently exist in your event history table. This field displays the percent of the event history table currently in use by the number of records displayed in the Event Capacity field. Production Tab People such as a production foreman will find the Production Reports useful as they monitor the work that occurs on their production floor. The available reports on the Production tab depend on whether you have a single Welding Power Source selected in the Asset Tree or a Group of power sources selected (Figure 5.11). Figure 5.11 Production Reports The Production reports allow you to display data about welds performed over a range of dates, during a specific shift, using a certain Weld Profile and more. Use the fields under the Criteria link to customize your report display. 5.10 Production Monitoring User Manual IM8001
Production Tab Chapter 5. Using Production Monitoring Criteria for the Production Reports The criteria available for each of the Production reports are the same, including whether you have selected a single Welding Power Source or a Group of power sources. The only difference is the Weld Profiles report on page 5.13. That report has a limited set of criteria available. Table 5.4 explains the fields in more detail. For more in-depth information on report criteria in general, please see page 5.4. Figure 5.12 Criteria Available for Production Reports Table 5.4 Field Criteria Fields Available on the Production Reports Description Start Date and End Date Select a date range in which the weld(s) were performed for the production data you want to review. Welds completed within this date range (that also meet all other criteria you select) appear in the resulting report. TIP You can type the date into the field, or you can click the calendar icon ( ) next to the field to display an interactive calendar where you can click on the date you want. Use the arrow icons ( and ) to navigate to previous or future months. The double arrow icons ( and ) move forward and backward by three-month intervals. Shift Group Welds If you want to see weld data for a specific shift during the date range you chose, select that shift from the Shift drop-down. Production Monitoring narrows the data to include only welds performed during that shift. The Production Monitoring administrator configured the shifts on the Administration page of the application. The Group Welds drop-down allows you to break down the data into useful chunks for ease of review. The system totals or averages the column based on how you want to group the data. For example, if you select By Hour from the Group Welds drop-down and the Shift you select is for a single eight-hour shift, the report will have eight items in it. Each of these items is the combined average of the weld information for each hour of the shift. Weld Profile You can generate the report for a specific Weld Profile used for the welds performed during the date range selected. Remember, the Weld Profile must have been selected for the weld in order for Production Monitoring to display any data. IM8001 Production Monitoring User Manual 5.11
Chapter 5. Using Production Monitoring Production Tab Grid Report The Grid report provides you with a list that summarizes the weld data from the production floor based on the criteria you have selected for the report (Figure 5.13). You can see a Grid report for either a single Welding Power Source or a Group of power sources. Table 5.5 explains the columns of the report in more detail. TIP Use the Criteria link to customize the data to meet your needs. See Table 5.4 on page 5.11 for details on the criteria available. Figure 5.13 Production Report: Grid Table 5.5 Column Period Welds Columns on the Production Grid Report Description The Period column reflects the choice made in the Group Welds drop-down on the Criteria window, as well as the Start Date/End Date range and Shift selected. To generate a report for a specific Period in the report, click the link. The system automatically generates a Grid report on the Weld Listing tab based on just the period you clicked. The Welds column reflects the total number of welds performed during the time period represented by the Period column. Welds Out of Limit Total Arc Time WeldScore This column lists the number of welds listed in the Welds column that were out of limit and what percentage of total welds that number represents. The Total Arc Time is the total number of hours that the Welding Power Source or Group of power sources you selected in the Asset Tree were spent in the Welding state during the time period listed in the Period column. The WeldScore column represents the average score of the welds performed during the time period displayed in the Period column for the Welding Power Source or Group of power sources you have selected in the Asset Tree. See page 1.3 for more details on WeldScore. 5.12 Production Monitoring User Manual IM8001
Production Tab Chapter 5. Using Production Monitoring Column Avg. Current Avg. Voltage Avg. WFS Avg. True Energy Description Every weld has an average current value that was measured throughout the duration of the weld. The system takes that averaged value for each weld that was performed during the time period displayed in the Period column, totals them and displays that average in the Avg. Current column. Every weld has an average voltage value that was measured throughout the duration of the weld. The system takes that averaged value for each weld that was performed during the time period displayed in the Period column, totals them and displays that average in the Avg. Voltage column. Every weld has an average wire feed speed value that was measured throughout the duration of the weld. The system takes that averaged value for each weld that was performed during the time period displayed in the Period column, totals them and displays that average in the Avg. WFS column. For each weld in the time period displayed in the Period column, there is a True Energy value. The Avg. True Energy displays the average of those values. Weld Profiles Report The Weld Profiles report is useful when monitoring the performance of the Weld Profiles in use on the selected power source. Within these profiles, Weld Engineers set various limits for the weld. If the weld goes above or below those limits, the system records that information as out of limits. (For more details on managing Weld Profiles, please see the Power Wave Manager User Manual.) NOTE If a Weld Operator did not choose a Weld Profile for a weld, the Welding Power Source automatically assigns the weld to the last profile. For those power sources utilizing 32 profiles, this is Profile 32. For those utilizing 200 profiles, the weld is assigned to Profile 200. The Weld Profiles report is the only Production report that has a limited set of criteria available to you. All others have the full set of criteria. NOTE This report is only available for a single Welding Power Source. IM8001 Production Monitoring User Manual 5.13
Chapter 5. Using Production Monitoring Production Tab Figure 5.14 Production Report: Weld Profiles The top half of the report is a graph that displays the number of welds that were made using each Weld Profile and the number of those welds that were out of limit for that profile. The bottom half of the report is a list that summarizes the weld data for each Weld Profile and further breaks down the welds that were out of limit into what caused it to be out of limit. Table 5.6 explains the columns on the list in more detail. Table 5.6 Column Profile Welds Columns on the Weld Profiles Report Description This column simply lists the Weld Profile number. The Welds column displays the total number of welds performed using this Weld Profile during the date range and shift selected for the report. Current Limit Events Voltage Limit Events WFS Limit Events The Current Limit Events column displays the number of welds that were outside of the minimum and maximum acceptable arc current values set in the profile. The Voltage Limit Events column displays the number of welds that were outside of the minimum and maximum acceptable arc voltage values set in the profile. The WFS Limit Events column displays the number of welds that were outside of the minimum and maximum acceptable wire feed speed values set in the profile. 5.14 Production Monitoring User Manual IM8001
Production Tab Chapter 5. Using Production Monitoring Column WeldScore Events Duration Limit Events Description The WeldScore Events column displays the number of welds that were below the minimum acceptable WeldScore set in the profile. The Duration Limit Events column displays the number of welds that were outside of the minimum and maximum acceptable time values set in the profile. WeldScore Report The WeldScore report is another useful performance monitor. It allows you to view the WeldScore values across all Weld Profiles (or a specific profile) for the single Welding Power Source you have selected in the Asset Tree or across all the power sources in the Group you have selected. Figure 5.15 Production Report: WeldScore The top half of the report is a graph that shows you the average WeldScore for the welds made during each Period in the list below the graph. The Period depends on the selections made on the Criteria window. See page 5.11 for details on the fields of the Criteria window. The bottom half of the report is a list that summarizes the weld data, providing you with an average WeldScore for each time period. On the right, the system also displays the criteria used to generate the data. Table 5.7 explains the columns on this report in more detail. IM8001 Production Monitoring User Manual 5.15
Chapter 5. Using Production Monitoring Production Tab Table 5.7 Column Period Columns on the WeldScore Report Description The Period column reflects the choice made in the Group Welds drop-down on the Criteria window, as well as the Start Date/End Date range and Shift selected. To generate a new, more detailed report for a specific Period in the report, click the link. The system automatically generates the WeldScore report on the Welding Listing tab for you (page 5.25). WeldScore (%) The system averages all WeldScore data for the Welding Power Source or Group of power sources you have selected in the Asset Tree and displays that average score in this column. Current/Voltage Report If you need to review the electrical output of a specific Welding Power Source on the production floor, the Current/Voltage report provides you with a graph that displays both the current and the voltage in the same graph. This allows you make see any adjustments you might need to make. NOTE This report is only available for a single Welding Power Source. Figure 5.16 Production Report: Current/Voltage 5.16 Production Monitoring User Manual IM8001
Production Tab Chapter 5. Using Production Monitoring The top half of the report is a graph that shows you the average current and average voltage used for the welds made during each Period in the list below the graph. The Period depends on the selections made on the Criteria window. See page 5.11 for details on the fields of the Criteria window. The bottom half of the report is a tabular list of the averages for each time period. On the right, the system also displays the criteria used to generate the data. Table 5.8 explains the columns on this report in more detail. Table 5.8 Column Period Avg. Current Avg. Voltage Columns on the Current/Voltage Report Description The Period column reflects the choice made in the Group Welds drop-down on the Criteria window, as well as the Start Date/End Date range and Shift selected. To generate a new, more detailed report for a specific Period in the report, click the link. The system automatically generates the Current/Voltage report on the Welding Listing tab for you (page 5.26). Every weld has an average current value that was measured throughout the duration of the weld. The system takes that averaged value for each weld that was performed during the time period displayed in the Period column, totals them and displays that average in the Avg. Current column. Every weld has an average voltage value that was measured throughout the duration of the weld. The system takes that averaged value for each weld that was performed during the time period displayed in the Period column, totals them and displays that average in the Avg. Voltage column. Wire Feed Speed (and Deposition) Report The Wire Feed Speed report helps you review the performance of a Welding Power Source and provides you with a look at the speed of the wire through the feeder, as well as the amount of material deposited during the welds for this Welding Power Source. NOTE This report is only available for a single Welding Power Source. IM8001 Production Monitoring User Manual 5.17
Chapter 5. Using Production Monitoring Production Tab Figure 5.17 Production Report: Wire Feed Speed The top half of the report is a graph that shows you the average wire feed speed and the wire deposition for the welds made during each Period in the list below the graph. The Period depends on the selections made on the Criteria window. See page 5.11 for details on the fields of the Criteria window. The bottom half of the report is a tabular list of the data. On the right, the system also displays the criteria used to generate the data. Table 5.9 explains the columns on this report in more detail. Table 5.9 Column Period Columns on the Wire Feed Speed Report Description The Period column reflects the choice made in the Group Welds drop-down on the Criteria window, as well as the Start Date/End Date range and Shift selected. To generate a new, more detailed report for a specific Period in the report, click the link. The system automatically generates the Wire Feed Speed report on the Welding Listing tab for you (page 5.27). Avg. WFS Wire Deposition Every weld has an average wire feed speed value that was measured throughout the duration of the weld. The system takes that averaged value for each weld that was performed during the time period displayed in the Period column, totals them and displays that average in the Avg. WFS column. This column displays the amount of wire (in pounds or kilograms) that was deposited for the welds made during the time period displayed in the Period column by the Welding Power Source you have selected in the Asset Tree. 5.18 Production Monitoring User Manual IM8001
Production Tab Chapter 5. Using Production Monitoring True Energy Report The True Energy report shows both the True Energy and the total arc time for the welds made by the power source(s) you have selected in the Asset Tree. True Energy is a Lincoln Electric technology that uses the digital control system embedded in each Power Wave power source to measure and calculate the instantaneous amount of energy put into a weld. The energy is defined as: [ ] = 1 ( ) You can find more information about True Energy at www.lincolnelectric.com. NOTE The True Energy report is available for both a single Welding Power Source and a Container of power sources. Figure 5.18 Production Report: True Energy The top half of the report is a graph that displays the average True Energy put into the welds made during each Period in the list below the graph. It also overlays the total arc time used to calculate the True Energy for those welds. The Period depends on the selections made on the Criteria window. See page 5.11 for details on the fields of the Criteria window. The bottom half of the report is a tabular list of the data. On the right, the system also displays the criteria used to generate the data. Table 5.10 explains the columns on this report in more detail. IM8001 Production Monitoring User Manual 5.19
Chapter 5. Using Production Monitoring Production Tab Table 5.10 Column Period Columns on the True Energy Report Description The Period column reflects the choice made in the Group Welds drop-down on the Criteria window, as well as the Start Date/End Date range and Shift selected. To generate a new, more detailed report for a specific Period in the report, click the link. The system automatically generates the True Energy report on the Welding Listing tab for you (page 5.28). True Energy (kj) Total Arc Time This column displays the average True Energy put into the welds made during the time period displayed in the Period column by the Welding Power Source or Group of power sources you have selected in the Asset Tree. The Total Arc Time is the total number of hours that the Welding Power Source or Group of power sources you selected in the Asset Tree were spent in the Welding state during the time period listed in the Period column. Duration/Count Report The Duration/Count report is a great resource for reviewing how long your Welding Power Sources are actually welding and how many welds they perform over specific time periods. You can generate this report based on a single Welding Power Source or a Group of power sources, depending on what you have selected in the Asset Tree. Figure 5.19 Production Report: Duration/Count The top half of the report is a graph that displays the total amount of time the power source spent in the Welding state during the time period represented by the Period column below the graph. The report also 5.20 Production Monitoring User Manual IM8001
Weld Listing Tab Chapter 5. Using Production Monitoring overlays the number of welds performed during that period. The Period depends on the selections made on the Criteria window. See page 5.11 for details on the fields of the Criteria window. The bottom half of the report is a tabular list of the data. On the right, the system also displays the criteria used to generate the data. Table 5.11 explains the columns on this report in more detail. Table 5.11 Column Period Columns on Duration/Count Report Description The Period column reflects the choice made in the Group Welds drop-down on the Criteria window, as well as the Start Date/End Date range and Shift selected. To generate a new, more detailed report for a specific Period in the report, click the link. The system automatically generates the Grid report on the Welding Listing tab for you (page 5.23). Total Arc Time Welds Out of Limits The Total Arc Time is the total number of hours that the Welding Power Source or Group of power sources you selected in the Asset Tree were spent in the Welding state during the time period listed in the Period column. The Welds column displays the total number of welds performed during the time period listed in the Period column. The number in the Out of Limits column reflects the number of welds performed that went outside of the limits set for the Weld Profile used for the weld. If no Weld Profile limits were enabled, this column displays a zero. If a Weld Profile with limits enabled was selected for only some of the welds, this column may be skewed accordingly. Weld Listing Tab The Weld Listing reports display detailed information about each individual weld, both for a single Welding Power Source and a Group of power sources. People such as Weld Engineers will find these reports especially useful for reviewing all the attributes of the welds performed on the production floor. With the Weld Listing reports, the same reports are available whether you have selected a single Welding Power Source or a Group of power sources in the Asset Tree. Criteria for the Weld Listing Reports The criteria available for each of the Weld Listing reports are the same, including whether you have selected a single Welding Power Source or a Group of power sources. Table 5.12 explains all the fields in more detail. For more in-depth information on report criteria in general, please see page 5.11. IM8001 Production Monitoring User Manual 5.21
Chapter 5. Using Production Monitoring Weld Listing Tab Table 5.12 Field Production Date Figure 5.20 Welding List Criteria Criteria Fields Available on the Welding List Reports Description Select the date on which the weld(s) were performed for the data you want to review. Welds completed on this date (that also meet all other criteria you select) appear in the resulting report. Remember that you may have welds included in the report from the day before the date you selected. This occurs when the weld was performed during a shift that crosses the midnight threshold and where your Production Monitoring administrator indicated that this data should be included in the next production day s reports. See page 4.11 for more information on Next Production Day. TIP You can type the date into the field, or you can click the calendar icon ( ) next to the field to display an interactive calendar where you can click on the date you want. Use the arrow icons ( and ) to navigate to previous or future months. The double arrow icons ( and ) move forward and backward by three-month intervals. Shift Hour in Shift Weld Profile If you want to see weld data for welds made during a specific shift on the production date you chose, select that shift from the Shift drop-down. Production Monitoring narrows the data to include only welds performed during that shift on that day. The Production Monitoring administrator configured the shifts on the Administration page of the application. If you want to narrow the weld data to pinpoint those welds made during a specific time in a shift, select a number from the Hour in Shift drop-down. For example, if you select 3 from the Hour in Shift drop-down and Any from the Shift drop-down, the report displays all welds made during the third hour of every shift for the production date you selected. You can generate the report for a specific Weld Profile used for the welds performed during the date range selected. Remember, if the Weld Operator did not select a Weld Profile for the weld, the Welding Power Source automatically selected either Profile 32 (for machines that support only 32 Weld Profiles) or Profile 200 (for those machines that support 200 profiles) to the weld. 5.22 Production Monitoring User Manual IM8001
Weld Listing Tab Chapter 5. Using Production Monitoring Grid Report The Grid report on the Weld Listing tab provides you with a detailed list of each weld performed on your production floor. You can see individual values for each attribute of the weld, as well as the ability to click any linked data (displayed with an underline) to get into even more details. You can generate the report for a single Welding Power Source you have selected in the Asset Tree or in the Group of power sources you have selected (Figure 5.21). Table 5.13 explains the columns of the report in more detail. TIP Use the Criteria link to customize the data you see to meet your needs. See Table 5.12 on page 5.22 for details on the criteria available. Figure 5.21 Weld Listing Report: Grid Table 5.13 Field Weld ID Columns on the Weld Listing Grid Report Description This is the database record number for the weld. When a Welding Power Source sends weld records to the Production Monitoring database, the database assigns an identification number to each weld. This column represents that number. If you want to see additional information about that individual weld, simply click the underlined Weld ID. The system automatically generates a Weld Detail report for that weld (page 5.30). Start of Weld Welder The Start of Weld column displays the date and specific time the Welding Power Source began performing the weld. This column displays the name of the Welding Power Source that was used to make this weld. The Production Monitoring administrator entered this text when creating the Asset Tree (page 4.2). IM8001 Production Monitoring User Manual 5.23
Chapter 5. Using Production Monitoring Weld Listing Tab Field Part Serial Number Arc Time Profile Status WeldScore Avg. Current Avg. Voltage Avg. WFS True Energy Description The Part Serial Number is the number assigned to this weld. The serial number comes from a variety of sources, depending if a person enters the number in the Power Wave Manager manually or if the information is transmitted automatically. If you click on the serial number, the system automatically generates a new Traceability report (page 5.35) for the part number and displays details for all welds associated with the same Part Serial Number (limited by the Record Count criteria on that report). TIP The information generated by reports in Production Monitoring display based on the individual Welding Power Source or the Group of power sources you have selected in the Asset Tree. If you would like to see all welds with this part number that were made across several Welding Power Sources, be sure to select a Group and not just a single power source. The time displayed in the Arc Time column is the duration of the weld (or the time it took to create the individual weld). This column displays the number of the Weld Profile used during the weld. Based on the Weld Profile used for the weld, the system displays whether the weld fell within the limits set for the Weld Profile or if it was out of limits. The system displays the average WeldScore value for the individual weld. See page 1.3 for more details on WeldScore. Hundreds of times per second, the Welding Power Source takes a measurement of the arc current while the welder is active for this weld. When the weld is complete, the power source averages those measurements together. The Avg. Current column displays that average arc current value for this weld. Hundreds of times per second, the Welding Power Source takes a measurement of the arc voltage while the welder is active for this weld. When the weld is complete, the power source averages those measurements together. The Avg. Voltage column displays that average arc voltage value for this weld. Hundreds of times per second, the Welding Power Source takes a measurement of the speed at which the wire is put into the weld. When the weld is complete, the power source averages those measurements together. The Avg. WFS column displays that average wire feed speed value for this weld. This column displays the actual True Energy put into the individual weld. See page 5.28 for more details on True Energy. 5.24 Production Monitoring User Manual IM8001
Weld Listing Tab Chapter 5. Using Production Monitoring WeldScore A WeldScore is the average WeldScore value taken throughout the duration of the weld. The WeldScore report on the Weld Listing tab provides Weld Engineers with a visual look at the consistency of the welds using a specific Weld Profile. Table 5.14 explains the columns on this report in more detail. Figure 5.22 Weld Listing Report: WeldScore The top half of the report displays a graph of the WeldScore for each individual weld in the report. The bottom half of the report is a tabular list of the data. On the right, the system also displays the criteria used to generate the data. Table 5.14 Field Start of Weld Columns on the Weld Listing WeldScore Report Description The Start of Weld column displays the date and specific time the Welding Power Source began performing the weld. If you want to see additional information about the individual weld, simply click the underlined date and time. The system automatically generates a Weld Detail report for that weld (page 5.30). WeldScore (%) The system displays the average WeldScore value for the individual weld. See page 1.3 for more details on WeldScore. IM8001 Production Monitoring User Manual 5.25
Chapter 5. Using Production Monitoring Weld Listing Tab Current/Voltage Report The Current/Voltage report on the Weld Listing tab is useful for people such as Weld Engineers to analyze the arc current and voltage going into welds for the various Weld Profiles they have created for the Welding Power Source. You can generate the report for a single Welding Power Source or a Group of power sources. Figure 5.23 Weld Listing Report: Current/Voltage The top half of the report is a graph of the average current and average voltage used for each individual weld in the report. The bottom half of the report is a tabular list of the data. On the right, the system also displays the criteria used to generate the data. Table 5.15 explains the columns on the report in more detail. Table 5.15 Field Start of Weld Avg. Current Avg. Voltage Columns on the Weld Listing Current/Voltage Report Description The Start of Weld column displays the date and specific time the Welding Power Source began performing the weld. If you want to see additional information about the individual weld, simply click the underlined date and time. The system automatically generates a Weld Detail report for that weld (page 5.30). Hundreds of times per second, the Welding Power Source takes a measurement of the arc current being used while the welder is active for this weld. When the weld is complete, the power source averages those measurements together. The Avg. Current column displays that average arc current value for this weld. Hundreds of times per second, the Welding Power Source takes a measurement of the arc voltage while the welder is active for this weld. When the weld is complete, the power source averages those measurements together. The Avg. Voltage column displays that average arc voltage value for this weld. 5.26 Production Monitoring User Manual IM8001
Weld Listing Tab Chapter 5. Using Production Monitoring Wire Feed Speed Report Knowing the Wire Feed Speed and deposition of material is important for those who need to analyze how fast the material was put into a weld and how much material was used per weld. This can help identify any adjustments that need to be made at the Welding Power Source. You can generate this report for a single Welding Power Source or a Group of power sources. Figure 5.24 Weld Listing Report: Wire Feed Speed The top half of the report is a graph that shows you the average wire feed speed and the wire deposition for each individual weld in the list below the graph. The bottom half of the report is a tabular list of the data. On the right, the system also displays the criteria used to generate the data. Table 5.16 explains the columns on this report in more detail. Table 5.16 Field Start of Weld Columns on the Wire Feed Speed Report Description The Start of Weld column displays the date and specific time the Welding Power Source began performing the weld. If you want to see additional information about the individual weld, simply click the underlined date and time. The system automatically generates a Weld Detail report for that weld (page 5.30). Avg. WFS Wire Deposition Hundreds of times per second, the Welding Power Source takes a measurement of the speed at which the wire is put into the weld. When the weld is complete, the power source averages those measurements together. The Avg. WFS column displays that average wire feed speed value for this weld. This column displays the amount of wire (in pounds or kilograms) that was deposited for the individual weld. IM8001 Production Monitoring User Manual 5.27
Chapter 5. Using Production Monitoring Weld Listing Tab True Energy (and Duration) Report If you are someone like a weld engineer analyzing welds made on power sources on your production floor, you will find the True Energy report on the Weld Listing tab quite useful. True Energy is a Lincoln Electric technology that uses the digital control system embedded in each Power Wave power source to measure and calculate the instantaneous amount of energy put into a weld. The energy is defined as: [ ] = 1 ( ) The True Energy report shows both the True Energy and the total arc time for the welds made by the power source(s) you have selected in the Asset Tree. Figure 5.25 Weld Listing Report: True Energy The top half of the report is a graph that displays the True Energy put into each individual weld made by the power source(s) selected in the Asset Tree. It also overlays the total arc time used to calculate the True Energy for those welds. The bottom half of the report is a tabular list of the data. On the right, the system also displays the criteria used to generate the data. Table 5.17 explains the columns on this report in more detail. Table 5.17 Field Start of Weld Columns on the Weld Listing True Energy Report Description The Start of Weld column displays the date and specific time the Welding Power Source began performing the weld. If you want to see additional information about the individual weld, simply click the underlined date and time. The system automatically generates a Weld Detail report for that weld (page 5.30). 5.28 Production Monitoring User Manual IM8001
Weld Listing Tab Chapter 5. Using Production Monitoring Field True Energy Arc Time (s) Description This column displays the True Energy calculated for the individual weld. If the Welding Power Source that made the weld has older firmware, it does not support the True Energy calculation, and Production Monitoring displays a 0 for the True Energy column. The time displayed in the Arc Time column is the duration of the weld (or the time it took to create the individual weld). Wire Deposition Report The Wire Deposition Report allows you to analyze how much material was used for each weld made by the Welding Power Source or Group of power sources you have selected in the Asset Tree. Production Monitoring displays this measurement in pounds or kilograms. Figure 5.26 Weld Listing Report: Wire Deposition The top half of the report is a graph that displays the amount of material used to make each individual weld in the list below the graph. The bottom half of the report is a tabular list of the data. On the right, the system also displays the criteria used to generate the data. Table 5.18 explains the columns on this report in more detail. Table 5.18 Field Start of Weld Columns on the Weld Listing Wire Deposition Report Description The Start of Weld column displays the date and specific time the Welding Power Source began performing the weld. If you want to see additional information about the individual weld, simply click the underlined date and time. The system automatically generates a Weld Detail report for that weld (page 5.30). IM8001 Production Monitoring User Manual 5.29
Chapter 5. Using Production Monitoring Weld Detail Tab Field Wire Deposition Description This column displays the amount of wire (in pounds or kilograms) that was deposited for the individual weld. If you want to see which power source made the weld, you can click the link in the Start of Weld column to generate a Weld Detail report. Weld Detail Tab The Weld Detail tab (Figure 5.28 on page 5.31) displays detailed information for an individual weld and provides a wealth of information that was collected for that weld. There are any number of reasons you would need to analyze an individual weld, and the Weld Detail tab allows you to do this. TIP Other reports may contain a link on an individual weld listed in that report. You can click that link, and the system automatically generates the Weld Detail report for you. Weld Detail Criteria When a Welding Power Source creates a weld, it assigns an identification number to that weld and sends it to Production Monitoring. The Weld ID is that number. In general, you access the Weld Detail report by clicking a link in another report. The system automatically enters the Weld ID for the weld and displays the report. Figure 5.27 Weld Detail Criteria If you happen to know the Weld ID of a weld whose data you want to view, you can enter that number in the Criteria window and click Save to generate a report manually. Weld Detail Report Production Monitoring records a great deal of information about each individual weld. The Attribute column displays the name of the piece of data collected, and the Value column displays the actual data. Table 5.19 explains each piece of data in more detail. 5.30 Production Monitoring User Manual IM8001
Weld Detail Tab Chapter 5. Using Production Monitoring Figure 5.28 Weld Detail Report Table 5.19 Attribute Welder Data Displayed on the Weld Detail Report Description This column displays the name of the Welding Power Source. The Production Monitoring administrator entered this text when creating the Asset Tree (page 4.2). Part Serial Number Consumable Serial Number The Part Serial Number is the number assigned to this weld. The part number comes from a variety of sources, depending if a person enters the number in the Power Wave Manager manually or if the information is transmitted automatically. If you click on the part number, the system automatically generates a new Traceability report (page 5.35) and displays all the welds associated with the same part number, based on the Welding Power Source(s) you have selected in the Asset Tree. TIP The information generated by reports in Production Monitoring display based on the individual Welding Power Source or the Group of power sources you have selected in the Asset Tree. If you would like to see all welds with this part number that were made across several Welding Power Sources, be sure to select a Group and not just a single power source. The Consumable Serial Number is the consumable lot code that was entered into the Welding Power Source when the wire was replaced in the Welding Power Source. If you click on the lot code, the system automatically generates a Traceability report (page 5.35) and displays all welds made that used the same consumable, based on the Welding Power Source(s) you have selected in the Asset Tree. TIP The information generated by reports in Production Monitoring display based on the individual Welding Power Source or the Group of power sources you have selected in the Asset Tree. If you would like to see all welds across several Welding Power Sources that could have used this consumable, be sure to select a Group and not just a single power source. IM8001 Production Monitoring User Manual 5.31
Chapter 5. Using Production Monitoring Weld Detail Tab Attribute Operator Serial Number Profile Start of Weld Weld Duration Start Delay End Delay Wire Density Description This is the operator s ID number. When an operator begins welding, his or her ID or badge number is entered through Power Wave Manager or another method. Production Monitoring collects this data and displays the ID in the Operator Serial Number field. If you click on the ID, the system automatically generates a Traceability report (page 5.35) and displays all welds made by that operator on the Welding Power Source(s) you have selected in the Asset Tree. TIP The information generated by reports in Production Monitoring display based on the individual Welding Power Source or the Group of power sources you have selected in the Asset Tree. If you would like to see all welds across several Welding Power Sources that were made by the individual operator, be sure to select a Group and not just a single power source. This is simply the Weld Profile used for this individual weld. The Start of Weld column displays the date and specific time the Welding Power Source began performing the weld. The Weld Duration displays the length of time (in seconds) from the time listed in the Start of Weld field to the time the Welding Power Source stopped welding. This is the amount of delay that was used for the beginning of this weld. The Start Delay is an option set in the Weld Profile and is the amount of time (in seconds) that Production Monitoring will wait, directly after the start of a weld, until the limits entered for the Weld Profile begin to be applied. This option is necessary because the start of a weld is often unpredictable and may fall out of limits easily. For more in-depth details on Start Delay, please refer to the Power Wave Manager User Manual. This is the amount of delay used at the end of this weld. The End Delay is an option set in the Weld Profile and is the amount of time (in seconds) directly before the end of a weld that Production Monitoring stops applying the limits entered for the Weld Profile. This option is necessary because, at the end of a weld, the set points for the Welding Power Source are often different than the rest of the weld (e.g., if the power source is in a burn-back state). For more indepth details on End Delay, please refer to the Power Wave Manager User Manual. The Wire Density field in Production Monitoring displays the density of the metal used for this individual weld. The person who adds the consumable to the Welding Power Source uses the Power Wave Manager software to tell the Welding Power Source how much and what type of wire was loaded. They select the density here as well. The system uses the wire density in its calculation of how much material was deposited for this weld. 5.32 Production Monitoring User Manual IM8001
Weld Detail Tab Chapter 5. Using Production Monitoring Attribute Wire Diameter Deposited Weight Deposition Rate WeldScore Status WeldScore Current Status Current Minimum Current Average Current Maximum Current Minimum Limit Description The Wire Diameter field in Production Monitoring displays the diameter of the wire used for this individual weld. The person who adds the consumable to the Welding Power Source uses the Power Wave Manager software to tell the Welding Power Source how much and what type of wire was loaded. They enter the wire s diameter here as well. The system uses the wire diameter in its calculation of how much material was deposited for this weld. The Deposited Weight is a calculation Production Monitoring performs for the individual weld. Based on the metal density and diameter of the wire in the Welding Power Source at the time of the weld, the system calculates the amount of wire (pounds or kilograms) that was deposited during this weld. The Deposition Rate shows how much material was deposited during the weld, normalized to pounds per hour. Weld Engineers can set each Weld Profile with a minimum WeldScore value considered acceptable. The WeldScore Status field displays whether this weld was above that score (within limits) or below that score (out of limits). The WeldScore column displays the average score for this weld. Every quarter of a second, the Welding Power Source compares the performance of the weld against the trained weld for the Weld Profile being used. When the weld is complete, the power source averages those measurements together for an average WeldScore value. For more details on WeldScore, please see page 1.3. Weld Engineers can set each Weld Profile with a minimum and a maximum arc current value that is considered acceptable. The Current Status field displays whether this weld was within those limits or out of limits. The Current Minimum field displays the lowest arc current measurement taken by the Welding Power Source throughout the duration of this weld (minus the Start and End delays). Hundreds of times per second, the Welding Power Source takes a measurement of the arc current while the welder is active for this weld (minus the Start and End delays). When the weld is complete, the power source averages those measurements together. The Current Average column displays that average arc current value for this weld. The Current Maximum field displays the highest arc current measurement taken by the Welding Power Source throughout the duration of this weld (minus the Start and End delays). This column simply displays the low end of the arc current limit that was set in the Weld Profile used to make the weld. IM8001 Production Monitoring User Manual 5.33
Chapter 5. Using Production Monitoring Weld Detail Tab Attribute Current Maximum Limit Current Percent Low Current Percent High Voltage Status Voltage Minimum Voltage Average Voltage Maximum Voltage Minimum Limit Voltage Maximum Limit Voltage Percent Low Voltage Percent High Wire Feed Speed Status Wire Feed Speed Minimum Description This column simply displays the high end of the arc current limit that was set in the Weld Profile used to make the weld. This value is the percentage of measurements taken during the weld (minus the Start and End delays) that were below the low end of the arc current limit set in the Weld Profile that was used to make this weld. This value is the percentage of measurements taken during the weld (minus the Start and End delays) that were above the high end of the arc current limit set in the Weld Profile that was used to make this weld. Weld Engineers can set each Weld Profile with a minimum and a maximum voltage value that is considered acceptable. The Voltage Status field displays whether this weld was within those limits or out of limits. The Voltage Minimum field displays the lowest arc voltage measurement taken by the Welding Power Source throughout the duration of this weld (minus the Start and End delays). Hundreds of times per second, the Welding Power Source takes a measurement of the arc voltage while the welder is active for this weld (minus the Start and End delays). When the weld is complete, the power source averages those measurements together. The Voltage Average column displays that average arc voltage value for this weld. The Voltage Maximum field displays the highest arc voltage measurement taken by the Welding Power Source throughout the duration of this weld (minus the Start and End delays). This column simply displays the low end of the arc voltage limit that was set in the Weld Profile used to make the weld. This column simply displays the high end of the arc voltage limit that was set in the Weld Profile used to make the weld. This value is the percentage of measurements taken during the weld (minus the Start and End delays) that were below the low end of the arc voltage limit set in the Weld Profile that was used to make this weld. This value is the percentage of measurements taken during the weld (minus the Start and End delays) that were above the high end of the arc voltage limit set in the Weld Profile that was used to make this weld. Weld Engineers can set each Weld Profile with a minimum and a maximum wire feed speed that is considered acceptable. The Wire Feed Speed Status field displays whether this weld was within those limits or out of limits. The Wire Feed Speed Minimum field displays the lowest wire feed speed measurement taken by the Welding Power Source throughout the duration of this weld (minus the Start and End delays). 5.34 Production Monitoring User Manual IM8001
Traceability Tab Chapter 5. Using Production Monitoring Attribute Wire Feed Speed Average Wire Feed Speed Maximum Wire Feed Speed Minimum Limit Wire Feed Speed Maximum Limit Wire Feed Speed Percent Low Wire Feed Speed Percent High True Energy Average Description Hundreds of times per second, the Welding Power Source takes a measurement of the speed at which the wire is put into the weld (minus the Start and End delays). When the weld is complete, the power source averages those measurements together. The Wire Feed Speed Average column displays that average wire feed speed value for this weld. The Wire Feed Speed Maximum column is the highest wire feed speed measurement taken by the Welding Power Source throughout the duration of this weld (minus the Start and End delays). The Wire Feed Speed Minimum Limit column simply displays the low end of the wire feed speed limit that was set in the Weld Profile used for the weld. The Wire Feed Speed Maximum Limit column simply displays the high end of the wire feed speed limit that was set in the Weld Profile used for the weld. This value is the percentage of measurements taken during the weld (minus the Start and End delays) that were below the wire feed speed limit set in the Weld Profile that was used to make this weld. This value is the percentage of measurements taken during the weld (minus the Start and End delays) that were above the wire feed speed limit set in the Weld Profile that was used to make this weld. This column displays the True Energy calculated for this weld using the following equation: [ ] = 1 ( ) If the Welding Power Source that made the weld had older firmware and did not support the True Energy calculation, this column displays a 0. Traceability Tab The Traceability tab displays a list of welds made for a single part number, a single operator ID, or a single consumable lot code. This is extremely useful if you need to research the details of a specific weld. Generally, you come to the Traceability report from elsewhere in Production Monitoring. TIP Other reports may contain a link on the part number, operator or consumable. You can click that link, and the system automatically generates the Traceability report for you based on that criteria. If you know the part, operator or consumable lot you want to research, you can simply enter the ID number in the Criteria and generate a report on your own. Remember: Production Monitoring displays data based on the Welding Power Source or Group of power sources you have selected in the Asset Tree. If you have a single Welding Power Source selected, for IM8001 Production Monitoring User Manual 5.35
Chapter 5. Using Production Monitoring Traceability Tab example, and you want to find all welds associated with a specific part number, only those welds made on that Welding Power Source will display in the report, even if there are other welds on other Welding Power Sources associated with that part number. Traceability Criteria The criteria available for the Traceability report allow you to customize the report to meet your needs. Table 5.20 explains the fields in more detail. For more in-depth information on report criteria in general, please see page 5.4. Figure 5.29 Traceability Report Criteria Table 5.20 Field Criteria Available on the Traceability Report Description Part Serial Number To generate a Traceability report for all the welds associated with a specific part number, enter that number in the Part Serial Number field. TIP The information generated by reports in Production Monitoring display based on the individual Welding Power Source or the Group of power sources you have selected in the Asset Tree. If you would like to see all welds with this part number that were made across several Welding Power Sources, be sure to select a Group and not just a single power source. Record Count Consumable Serial Number Operator Serial Number Enter the maximum number of weld records you want to see in the report. Be sure that you set this number high enough to display all the welds for your needs. If you want to see a list of all the welds that were made using a specific lot of wire, you can enter the lot code or serial number for that consumable in this field. This is the operator s ID number. When an operator begins welding on a Welding Power Source, his or her ID or badge number is entered through Power Wave Manager or another method. If you want to generate a list of welds performed by a specific operator, you can enter their ID in this field. 5.36 Production Monitoring User Manual IM8001
Traceability Tab Chapter 5. Using Production Monitoring Traceability Report The Traceability report lists all the welds that went into making a specific part, based on several bits of information. Table 5.21 explains the columns on the report in more detail. See page 5.36 for details on the criteria available for the report. Figure 5.30 Traceability Report Table 5.21 Field Weld ID Columns on the Traceability Report Description When a Welding Power Source creates a weld, it assigns an identification number to that weld and sends it to Production Monitoring. The Weld ID is that number. If you want to see additional information about that individual weld, simply click the underlined Weld ID. The system automatically generates a Weld Detail report for that weld (page 5.30). Start of Weld The Start of Weld column displays the date and specific time the Welding Power Source began performing the weld. If you want to see additional information about the individual weld, simply click the underlined date and time. The system automatically generates a Weld Detail report for that weld (page 5.30). Welder Part Serial Number Operator Serial Number This column displays the name of the Welding Power Source used to make the weld. The Production Monitoring administrator entered this text when creating the Asset Tree (page 4.2). The Part Serial Number is the number assigned to this weld. The part number comes from a variety of sources, depending if a person enters the number in the Power Wave Manager manually or if the information is transmitted automatically. This is the operator s ID number. When an operator begins welding on a Welding Power Source, his or her ID or badge number is entered through Power Wave Manager or another method. Production Monitoring collects the ID that is active at the time of the weld and displays the ID in this column. IM8001 Production Monitoring User Manual 5.37
Chapter 5. Using Production Monitoring Traceability Tab Field Consumable Serial Number Duration WeldScore Current Voltage Wire Feed True Energy Status Description The Consumable Serial Number is the consumable lot code that comes from a variety of sources, depending if a person enters the number in Power Wave Manager manually or if the information is transmitted automatically. The time displayed in the Duration column is the length of time it took to create the individual weld. The WeldScore column displays the average score for this weld. Every quarter of a second, the Welding Power Source compares the performance of the weld against the trained weld for the Weld Profile being used. When the weld is complete, the power source averages those measurements together for an average WeldScore value. For more details on WeldScore, please see page 1.3. Hundreds of times per second, the Welding Power Source takes a measurement of the arc current while the welder is active for this weld. When the weld is complete, the power source averages those measurements together. The Current column displays that average arc current value for this individual weld. Hundreds of times per second, the Welding Power Source takes a measurement of the arc voltage while the welder is active for this weld. When the weld is complete, the power source averages those measurements together. The Voltage column displays that average arc voltage value for this weld. Hundreds of times per second, the Welding Power Source takes a measurement of the speed at which the wire is put into the weld. When the weld is complete, the power source averages those measurements together. The Wire Feed column displays that average wire feed speed value for this weld. This column displays the True Energy calculated for this weld using the following equation: [ ] = 1 ( ) If the Welding Power Source that made the weld had older software and did not support the True Energy calculation, this column displays a 0. See page 5.28 for more details on True Energy. Based on the Weld Profile used for the weld, the system displays whether the weld fell within the limits set for the Weld Profile or if the weld was out of limits (and for which limit). 5.38 Production Monitoring User Manual IM8001
Downtime Tab Chapter 5. Using Production Monitoring Downtime Tab The Downtime tab summarizes any faults that occur in the system and how much downtime has accumulated due to each type of fault and displays this data in either a graph or chart format. This is a great tool if you need to figure out why your welders aren t welding. For example, if a Thermostat fault occurred at 11:01:05 AM and cleared at 11:06:30 AM, this counts as a single fault with a duration of five (5) minutes and 25 seconds. NOTE Only the primary event that caused a Welding Power Source to fault will be displayed and counted. While the primary event is active, no other events that happen will be displayed or counted. Downtime Criteria The criteria available for the Downtime reports allow you to customize the reports to meet your needs. Table 5.22 explains the fields in more detail. The criteria for both reports are the same, with the exception of one additional field that is available for the Chart report (i.e., Top Quantity). For more in-depth information on report criteria in general, please see page 5.4. Table 5.22 Field Figure 5.31 Downtime Report Criteria Criteria Available on the Downtime Report Description Start Date and End Date Select a date range in which the fault(s) occurred to display the data you want to review. Fault(s) that occurred within this date range (that also meet all other criteria you select) appear in the resulting report. TIP You can type the date into the field, or you can click the calendar icon ( ) next to the field to display an interactive calendar where you can click on the date you want. Use the arrow icons ( and ) to navigate to previous or future months. The double arrow icons ( and ) move forward and backward by three-month intervals. IM8001 Production Monitoring User Manual 5.39
Chapter 5. Using Production Monitoring Downtime Tab Field Shift Top Quantity Description If you want to see fault data for a specific shift during the date range you chose, select that shift from the Shift drop-down. Production Monitoring narrows the data to include only those faults that occurred during that shift. The Production Monitoring administrator configured the shifts on the Administration page of the application. The Top Quantity field is only available for the Chart report. Enter the maximum number of different faults you want to include in the report. For example, if you wanted to see a maximum of five (5) kinds of faults on the report, you would enter 5 in the Top Quantity field. Grid Report The Grid report provides you with a list of faults that occurred for the single Welding Power Source or Group of power sources you have selected in the Asset Tree. Table 5.23 explains the columns of the report in more detail. Figure 5.32 Downtime Grid Report Table 5.23 Field Fault Columns on the Downtime Grid Report Description The Fault column displays the description of the fault that occurred on the Welding Power Source or Group of power sources you have selected in the Asset Tree. If you want to see additional information about that individual fault, simply click the underlined description. The system automatically generates a Fault Detail report for you (page 5.41). Duration Count Each occurrence of the fault lasts for a period of time, whether a few seconds or a few hours. The Duration column is the total accumulated time for each type of fault, adding together the duration of every occurrence of that fault in the date range and shift selected in the report s criteria on the Welding Power Source or Group of power sources you have selected in the Asset Tree. The Count column displays the number of times this fault occurred during the date range and shift selected in the report s criteria on the Welding Power Source or Group of power sources you have selected in the Asset Tree. 5.40 Production Monitoring User Manual IM8001
Fault Detail Tab Chapter 5. Using Production Monitoring Chart Report The Chart report provides you with a graph of the fault data, as well as the list of faults, that occurred for the single Welding Power Source or Group of power sources you have selected in the Asset Tree. Figure 5.33 Downtime Chart Report The top half of the report is a graph that displays how long the fault(s) was active and how many times the fault(s) occurred. The bottom half of the report is a list that summarizes the data for each fault. On the right, the system also displays the criteria used to generate the data. Table 5.23 on page 5.40 explains the columns of the report in more detail. Fault Detail Tab The Fault Detail tab (Figure 5.35 on page 5.43) displays details for each occurrence of a fault and provides specific information that was collected about the occurrence, including the time it happened and what could have caused it. TIP The data in the Fault column of the Downtime report contains a link that will bring you to the Fault Detail report for that specific fault automatically when you click it. Fault Detail Criteria In general, the Downtime report brings you to the Fault Detail report and automatically enters appropriate criteria for you. If you want to generate the report manually, you can customize the data based on several criteria options. Simply click the Criteria link, enter your selections and click Save. IM8001 Production Monitoring User Manual 5.41
Chapter 5. Using Production Monitoring Fault Detail Tab For example, if you want to see every occurrence of a specific fault on a specific power source, this report can do that for you. Table 5.24 explains the fields on the Criteria window in more detail. Figure 5.34 Fault Detail Criteria Table 5.24 Field Criteria Available on the Fault Detail Report Description Start Date and End Date Select a date range in which the fault(s) occurred to display the data you want to review. Fault(s) that occurred within this date range (that also meet all other criteria you select) appear in the resulting report. TIP You can type the date into the field, or you can click the calendar icon ( ) next to the field to display an interactive calendar where you can click on the date you want. Use the arrow icons ( and ) to navigate to previous or future months. The double arrow icons ( and ) move forward and backward by three-month intervals. Shift Fault Code If you want to see fault data for a specific shift during the date range you chose, select that shift from the Shift drop-down. Production Monitoring narrows the data to include only those faults that occurred during that shift. The Production Monitoring administrator configured the shifts on the Administration page of the application. If you want to see a report listing the occurrences of a specific fault for the Welding Power Source or Group of power sources you have selected in the Asset Tree, select the fault from the Fault Code drop-down. As long as the occurrence of the fault meets the other criteria you set on the report, the record displays in the resulting report. 5.42 Production Monitoring User Manual IM8001
Fault Detail Tab Chapter 5. Using Production Monitoring Fault Detail Report The Fault Detail tab provides a list of specific details for each occurrence of a fault. The Welding Power Source collects the details and transfers that information to Production Monitoring, including certain data related to the type of fault that occurred. Table 5.25 explains the columns on this report in more detail. Figure 5.35 Fault Detail Report Table 5.25 Field Welder Log Time Duration Fault Data Columns on the Fault Detail Report Description This column displays the name of the Welding Power Source on which the fault occurred. It was entered by the Production Monitoring administrator when adding the power source to the Asset Tree. The Log Time column displays the date and specific time the fault occurred. The Duration column displays the length of time that the fault lasted. The Fault column displays the description of the actual fault that occurred on the Welding Power Source or Group of power sources you have selected in the Asset Tree. The Data column displays the data associated with the fault and could help troubleshoot the fault. IM8001 Production Monitoring User Manual 5.43
Chapter 5. Using Production Monitoring Fault Detail Tab THIS PAGE INTENTIONALLY LEFT BLANK. 5.44 Production Monitoring User Manual IM8001
Appendix A Additional Information Archive of Data from the Database Production Monitoring uses the Microsoft SQL Server Express database and has a limited storage capacity. There are essentially two tables in Production Monitoring : weld history and event history. The system checks the number of each type of record. When each table reaches 250,000 records, the system automatically removes the oldest data. With the weld history data, the system saves those old records in an archive file. Limiting the number of records in the database maintains the performance of the system, which makes generating reports more efficient. TIP If you find the you ve outgrown the database capacity in Production Monitoring, we encourage you to upgrade to CheckPoint. For more information, please contact Lincoln Electric Production Monitoring support. In the USA and Canada, dial 1.800.691.5797. The direct dial number is 1.727.786.0121. The e-mail address is support@lincolnproductionmonitoring.com. Archive Frequency Once an hour, Production Monitoring checks if the number of weld records in the database has reached the 250,000 limit. If it has, the system creates a Microsoft Excel CSV file containing the oldest 60,000 records. Then it deletes the 60,000 records from the database. When the weld history is archived from the database, the system saves the CSV file in the directory: C:\Program Files\Lincoln Electric\Production Monitoring\Exports. Once a day, the system checks to see if the number of fault records has reached the 250,000 limit. If it has, then the oldest 60,000 records will be deleted from the database. The system does not archive these into a file like the weld history records. Archive File Name Format The file name will be in the format PM-StartTime-EndTime.csv, where StartTime is the date and time of the first weld in the file, and EndTime is the date and time of the last weld in the file. Both times are in the format: YYYYMMDDHHmmss, where: YYYY = Year MM = Month DD = Day HH = Hour (24-hour format) mm = Minute ss = Second IM8001 Production Monitoring User Manual A.1
Appendix A. Additional Information Archive of Data from the Database For example, Advanced Manufacturing has an archived file where the first weld in the file was started on January 8, 2013, at 3:41:39 PM, and the last weld in the file ended January 9, 2013, at 9:43:41 AM. The file name for that archive file is: PM-20130108154139-20130109094341.csv Open an Archive File If you need to review the data in the exported archive file (e.g., you have a part number and need to research a part that failed), you can open the file in Microsoft Excel. Since the file is in the CSV format, it opens differently from a regular Excel file that you may be used to using. If you double-click the file, your system may inform you that it can t open the file. You simply need to open Excel first and tell the software that you re opening a CSV file and how to display it for you. To open this file in Microsoft Excel: NOTE These instructions may vary depending on your version of Microsoft Excel. Procedure 1. Launch Microsoft Excel. 2. Select File > Open from the main menu. OR Click the Office button and select Open from the menu. 3. Navigate to the folder containing the archive file you would like to open. 4. From the File of type drop-down, select Text Files (*.prn; *.txt; *.csv). Details The system displays the Open window. Typically, this path on the server is: C:\Program Files\Lincoln Electric\Production Monitoring\Exports This filters the window to display only those files with the PRN, TXT or CSV file extension. 5. Select the archive file and click Open. The system displays the Text Import Wizard. This wizard helps you tell Microsoft Excel how to display the data in the file. NOTE Depending on your version of Microsoft Excel, the system may prompt you that it can t A.2 Production Monitoring User Manual IM8001
Archive of Data from the Database Appendix A. Additional Information Procedure 6. Choose the Delimited option under Original data type and click Next. Details recognize the file and ask if you want to open it anyway, click Yes. Click OK if the system tells you it has detected the file as a SYLK file. The file should open and you can skip the remaining steps. The second page of the Text Import Wizard opens. 7. Make sure there is only a check mark in the Comma checkbox and click Finish. The file should now open up in Excel in a readable format for you. Archive File Format Once you have the file open in Excel, you can scroll through all the weld records contained within the archive file (Figure 5.1). The top row of the file is the heading of the column and tells you what data appears in that column for each weld. Each row in the file represents a single weld. Table 5.1 explains each column in more detail. Figure 5.1 Sample Archive File IM8001 Production Monitoring User Manual A.3
Appendix A. Additional Information Archive of Data from the Database Table 5.1 Columns in the Weld Archive File Column Heading Description ID WelderName Model ProfileNumber MachineCounter SerialNumber StartDateTime Duration EndDateTime Status This is the database record number for the weld. When a Welding Power Source sends weld records to the Production Monitoring database, the database assigns an identification number to each weld. This column represents that number, also known as the Weld ID in the main application. This column displays the name of the Welding Power Source used to make this weld. This is the name of the power source at the time the weld was made. It was entered by the Production Monitoring administrator when adding the power source to the Asset Tree. This is the model of the Welding Power Source that made this weld. The model information comes from the TOK file uploaded when adding the Welding Power Source to the Asset Tree. This column displays the number of the Weld Profile used at the time of the weld. If a Weld Operator did not choose a Weld Profile for the weld, the Welding Power Source automatically selected the last profile. For those power sources utilizing 32 profiles, this is Profile 32. For those utilizing 200 profiles, the weld is assigned to Profile 200. When a Welding Power Source creates a weld, it assigns an identification number to that weld for debugging purposes. The MachineCounter column represents that number. The SerialNumber is the number that was assigned to this weld. The StartDateTime column displays the date and specific time the Welding Power Source began performing the weld. The Duration column displays the time it took to make the weld. This is the length of time (in seconds) from the time listed in the StartDateTime column to the time the Welding Power Source stopped welding. The EndDateTime column is a calculated value. The system added the Duration column to the StartDateTime column to calculate the date and time the Welding Power Source stopped welding. If any limit errors occurred during the weld, the Status column displays the code of the error. If no error occurred during the weld, the value in this column is 0. The following codes could appear in the Status column: 0x8000 0x4000 0x2000 0x1000 0x0800 0x0400 Fault Latch Fault Alarm Latch Alarm Unused Bit Unused Bit A.4 Production Monitoring User Manual IM8001
Archive of Data from the Database Appendix A. Additional Information Column Heading Description 0x0200 0x0100 0x0080 0x0040 0x0020 0x0010 0x0008 0x0004 0x0002 0x0001 Low-Time Limit Time Limit Power High (Not Used) Power Low (Not Used) Wire Feed Speed High Wire Feed Speed Low Volts High Volts Low Amps High Amps Low StartDelay This is the amount of delay that was used for the beginning of this weld. The Start Delay is an option set in the Weld Profile and is the amount of time (in seconds) that Production Monitoring will wait, directly after the start of a weld, until the limits entered for the Weld Profile begin to be applied. This option is necessary because the start of a weld is often unpredictable and may fall out of limits easily. For more in-depth details on Start Delay, please refer to the Power Wave Manager User Manual. EndDelay ConsumeDensity WireDiameter This is the amount of delay used at the end of this weld. The End Delay is an option set in the Weld Profile and is the amount of time (in seconds) directly before the end of a weld that Production Monitoring stops applying the limits entered for the Weld Profile. This option is necessary because, at the end of a weld, the set points for the Welding Power Source are often different than the rest of the weld (e.g., if the Welding Power Source is in a burn-back state). This column represents the density of the consumable in the Welding Power Source at the time of this weld. The person who adds the consumable to the Welding Power Source uses the Power Wave Manager software to tell the Welding Power Source how much and what type of wire was loaded. They select the density here as well. The system uses the wire density in its calculation of the how much material was deposited to make this weld. The WireDiameter column displays the diameter of the wire used for this individual weld. The person who adds the consumable to the Welding Power Source uses the Power Wave Manager software to tell the Welding Power Source how much and what type of wire was loaded. They enter the wire s diameter here as well. The system uses the wire diameter in its calculation of how much material was deposited to make this weld. IM8001 Production Monitoring User Manual A.5
Appendix A. Additional Information Archive of Data from the Database Column Heading Voltage VAvgValue VMinValue VMaxValue VLowPercent VHighPercent VLowLimit VHighLimit VIsLow VIsHigh VBaseUnits Current CAvgValue CMinValue Description Hundreds of times per second, the Welding Power Source takes a measurement of the arc voltage while the welder is active for this weld. When the weld is complete, the power source averages those measurements together. The VAvgValue column displays that average arc voltage value for this weld. The VMinValue column is the lowest arc voltage measurement taken by the Welding Power Source throughout the duration of this weld. The VMaxValue column is the highest arc voltage measurement taken by the Welding Power Source throughout the duration of this weld. This value is the percentage of measurements taken during the weld that were below the arc voltage limit set in the Weld Profile used to make this weld. This value is the percentage of measurements taken during the weld that were above the arc voltage limit set in the Weld Profile that was used to make this weld. This column simply displays the low end of the voltage limit that was set in the Weld Profile used to make the weld. The value in this column is the high end of the voltage limit that was set in the Weld Profile used to make the weld. If the average voltage used to make the weld fell below the low end of the limit set for the Weld Profile that was used, the value in the VIsLow column will be 1. Otherwise, the value will be 0. If the average voltage used to make the weld was above the high end of the limit set for the Weld Profile that was used, the value in the VIsHigh column will be 1. Otherwise, the value will be 0. The VBaseUnits column simply displays the voltage units used in this weld record. Typically, this is set to V for volts. Hundreds of times per second, the Welding Power Source takes a measurement of the arc current while the welder is active for this weld. When the weld is complete, the power source averages those measurements together. The CAvgValue column displays that average arc current value for this weld. The CMinValue column is the lowest arc current measurement taken by the Welding Power Source throughout the duration of this weld. A.6 Production Monitoring User Manual IM8001
Archive of Data from the Database Appendix A. Additional Information Column Heading CMaxValue CLowPercent CHighPercent CLowLimit CHighLimit CIsLow CIsHigh CBaseUnits Wire Feed Speed WFSAvgValue WFSMinValue WFSMaxValue WFSLowPercent WFSHighPercent Description The CMaxValue column is the highest arc current measurement taken by the Welding Power Source throughout the duration of this weld. This value is the percentage of measurements taken during the weld that were below the low end of the arc current limit set in the Weld Profile that was used to make this weld. This value is the percentage of measurements taken during the weld that were above the high end of the arc current limit set in the Weld Profile that was used to make this weld. This column simply displays the low end of the arc current limit that was set in the Weld Profile used to make the weld. This column simply displays the high end of the arc current limit that was set in the Weld Profile used to make the weld. If the average current used to make the weld fell below the low end of the limit set for the Weld Profile that was used, the value in the CIsLow column will be 1. Otherwise, the value will be 0. If the average current used to make the weld was above the high end of the limit set for the Weld Profile that was used, the value in the CIsHigh column will be 1. Otherwise, the value will be 0. The CBaseUnits column simply displays the arc current units used in this weld record. Typically, this is set to A for amps. Hundreds of times per second, the Welding Power Source takes a measurement of the speed at which the wire is put into the weld. When the weld is complete, the power source averages those measurements together. The WFSAvgValue column displays that average wire feed speed value for this weld. The WFSMinValue column is the lowest wire feed speed measurement taken by the Welding Power Source throughout the duration of this weld. The WFSMaxValue column is the highest wire feed speed measurement taken by the Welding Power Source throughout the duration of this weld. This value is the percentage of measurements taken during the weld that were below the wire feed speed limit set in the Weld Profile that was used to make this weld. This value is the percentage of measurements taken during the weld that were above the wire feed speed limit set in the Weld Profile that was used to make this weld. IM8001 Production Monitoring User Manual A.7
Appendix A. Additional Information Archive of Data from the Database Column Heading WFSLowLimit WFSHighLimit WFSIsLow WFSIsHigh WFSBaseUnits Description This column simply displays the low end of the wire feed speed limit that was set in the Weld Profile used to make the weld. This column simply displays the high end of the wire feed speed limit that was set in the Weld Profile used to make the weld. If the average wire feed speed during the weld fell below the low end of the limit set for the Weld Profile that was used, the value in the WFSIsLow column will be 1. Otherwise, the value will be 0. If the average wire feed speed during the weld was above the high end of the limit set for the Weld Profile that was used, the value in the WFSIsHigh column will be 1. Otherwise, the value will be 0. The WFSBaseUnits column simply displays the speed units used in this weld record. The unit selection is based on the global settings at the time of the weld. The value of this column could be in/min or m/min. True Energy TrueEnergy TEBaseUnits This column displays the True Energy calculated for this weld using the following equation: [ ] = 1 ( ) If the Welding Power Source that made the weld had older firmware and did not support the True Energy calculation, this column displays a 0. The TEBaseUnits column simply displays the units for the True Energy value in this weld record. The value of this column is typically kj for kilojoules. WeldScore WeldScore WeldScoreIsLow WeldScoreLowLimit The WeldScore column displays the average score for this weld. Every quarter of a second, the Welding Power Source compares the performance of the weld against the trained weld for the Weld Profile being used. When the weld is complete, the power source averages those measurements together for an average WeldScore value. For more details on WeldScore, please see page 1.3. If the average WeldScore calculated for the weld fell below the minimum WeldScore set for the Weld Profile that was used, the value in the WeldScoreIsLow column will be 1. Otherwise, the value will be 0. This column simply displays the minimum WeldScore value that was set in the Weld Profile used to make the weld. A.8 Production Monitoring User Manual IM8001
Archive of Data from the Database Appendix A. Additional Information Column Heading Serial Numbers OperatorSerialNumber ConsumableSerialNumber Weld Duration DurationHighLimit DurationLowLimit IsOutOfLimits Description This is the operator s ID number. When an operator begins welding on a Welding Power Source, his or her ID number or badge number is entered into the Welding Power Source, either through Power Wave Manager or another method. This column displays that ID or badge number of the person operating the Welding Power Source during the weld. The ConsumableSerialNumber column displays the lot code of the wire or other consumable entered in the Welding Power Source at the time the weld was made. The lot code comes from a variety of sources, depending if a person enters the number in the Power Wave Manager manually or if the information is transmitted automatically. This column simply displays the high end of the time limit for the weld that was set in the Weld Profile used to make the weld. This column simply displays the low end of the time limit for the weld that was set in the Weld Profile used to make the weld. Based on the minimum and maximum time limits set for the Weld Profile used on this weld, if the weld didn t take long enough, or it took too long, the IsOutOfLimits column will be 1. Otherwise, the value will be 0. IM8001 Production Monitoring User Manual A.9
Appendix A. Additional Information Archive of Data from the Database THIS PAGE INTENTIONALLY LEFT BLANK. A.10 Production Monitoring User Manual IM8001
Appendix B Troubleshooting Inevitably, there will be an issue when working with a software program or installing software that you need a little extra information to help troubleshoot and solve the problem. There are some common minor issues you might be able to fix without a call to support. NOTE If you continue to have trouble, please contact your local IT department or Production Monitoring support. For Production Monitoring support in the USA or Canada, dial 1.800.691.5797. The direct dial number is 1.727.786.0121. You can also e-mail support at: support@lincolnelectricproductionmonitoring.com. Cannot Connect to a Power Source There are multiple reasons you may not be able to connect to the IP address of a power source or why the IP address may not show up in the list of addresses. Check out the following: If the computer is running some type of security software or firewall, this may block the IP from showing up. Do you have multiple Ethernet adapters enabled? This could cause issues. Disable any wireless communication on the computer. This is helpful to allow a computer to directly connect to a Welding Power Source through the hardline. IM8001 Production Monitoring User Manual B.1
Appendix B. Troubleshooting Cannot Connect to a Power Source THIS PAGE INTENTIONALLY LEFT BLANK. B.2 Production Monitoring User Manual IM8001
Glossary ArcLink : This is a communications protocol developed by Lincoln Electric for use in a welding system. This protocol takes into account specific needs of a welding system and the interaction of the multiple components that make up the network. Asset: An asset is entry in the Asset Tree on the left side of the Production Monitoring screen. An asset can be either a single Welding Power Source or a Group of power sources. In a manufacturing facility, the asset in Production Monitoring could represent a single power source, station or line within the plant. Bandwidth: The amount of information that wires and cables can handle, just like a pipe full of water and materials. The pipe can only hold so much before the flow slows down and eventually clogs. Board Serial Number: Each component in an ArcLink system has a unique number that allows it to be identified from the other components. In Lincoln Electric systems, this is used to verify what component is being referenced in software. Criteria: A user-supplied piece of information used to sort or filter the data in a report. DeviceNet: A standard industrial networking protocol usually used by a PLC to control networked devices in a Master/Slave relationship. DNS: Domain Name Service used for translating host names to an IP address so that networked equipment can be given an alphanumeric name instead of a number. See Host Name for an example of what a DNS server does. E-mail: Electronic Mail, an electronic message that is transferred over a communications network, or the Internet. Ethernet: A telecommunications networking protocol used to connect computers to each other. Firmware: The memory and programming code within the Welding Power Source that provides the control program for the Welding Power Source. Front End: The front end to a software program is the part of the application with which you, as the user, interact (e.g., buttons you click, windows that display). Host Name: Alphanumeric name that is used to represent networked equipment at a specific IP address. An example would be www.google.com instead of 216.239.37.99. HTML: Hyper Text Markup Language, the document format used for web pages on the Internet. Intranet: An internal website to your company that no one on the outside can access unless given user names and passwords to do so. IP Address: A number that identifies a device on the network. This number is a 32-bit numeric address written as four octets separated by periods also referred to as dots. The numbers range from zero to 255. An example would be 192.168.1.45. Latched Alarm: Prevents the Welding Power Source from making another weld until the alarm has been acknowledged. This setting can be utilized for verifying a welding setup before making another weld. Module Number: The Welding Power Source consists of modules that communicate with each other to create a welding system. The module number is the name given to each one of these devices. IM8001 Production Monitoring User Manual GLS.1
Glossary Octet through Welding Set Point Octet: A number ranging from zero to 255 used in IP addresses. PLC: Programmable Logic Controller, a specialized device used in the control of industrial processes. Port: In a specific network such as a TCP or a UDP network, a port is an endpoint to a logical connection. The port number defines what type of information will be transmitted. An example would be port 80 for HTML data or port 25 for e- mail data. Proxy Server: A proxy is a server that stands between an external network (such as the Internet) and an organization s internal (private) networks. It serves as a firewall and prevents external users from directly accessing the internal information resources, or even knowing the location of those resources. All external requests for information are intercepted by the proxy server and checked for their validity. Only authorized requests are passed on to the internal server. This security, however, comes at the cost of inconvenience to genuine users and slower performance. Rejected Weld: A weld that was either not consistent enough or long enough to apply statistical equations to generate reasonable limit information. Robotic Feeder I/O: The PF10R feed head comes with an External I/O Connector that can be reconfigured through Power Wave Manager to reroute the I/O from its normal operation to be utilized as a Weld Profile selection. Shift Times: A Production Monitoring feature used to trigger events at a specific time of day that will allow the tracking of usage and clearing out of Weld Totals and Weld History. There are a total of 6 shift times that can be utilized on a daily basis. Short Weld: Welds with a duration that is less than the sum of the Start Delay time plus the End Delay time. SMTP: Simple Mail Transfer Protocol, the standard protocol used for sending e-mail through an e-mail server. Spreadsheet Application: A computer tool such as Microsoft Excel that arranges values into rows and columns. Subnet: A section of a network. Subnets are used to divide up large networks into small sections for ease of management, increased performance and increased security. Tab-Delimited Text File: Generic text file format that is used for arranging data in a spreadsheet. Most spreadsheet applications can import this file format with little or no conversion by the user. TCP: Transmission Control Protocol, used in the transmission of data between two devices. It is a more reliable protocol than UDP since it controls the delivery of data and verifies the order in which the data is sent. UDP: User Datagram Protocol, used in the transmission of data between two or more devices. It is a faster protocol than TCP, but it does not guarantee data delivery or the order in which the data is sent. Weld History: Data on welds that the Welding Power Source has made. This statistical data includes information on current, voltage, wire feed speed, duration and weld status. Weld Mode: A particular process that is selected in the Welding Power Source. The Welding Power Source has a weld table that contains a large variety of processes that the system can use to define welding procedures. Each process is listed as a Weld Mode. Weld Profile: A configurable set of limit settings that Welding Power Source compares to welding data it collects as it welds. Weld Totals: A cumulative count of welds performed in each Weld Profile. Each total count includes the number of welds, and a count of each variable that was out of limits per Weld Profile. Welding Set Point: A value that the Welding Power Source utilizes to regulate its output levels. GLS.2 Production Monitoring User Manual IM8001
NOTES
NOTES
PRODUCT MODEL WARNING Do not touch electrically live parts or electrode with skin or wet clothing. Insulate yourself from work and ground. Keep flammable materials away. Wear eye, ear and body protection. Spanish AVISO DE PRECAUCION No toque las partes o los electrodos bajo carga con la piel o ropa mojada. Aislese del trabajo y de la tierra. Mantenga el material combustible fuera del área de trabajo. Protéjase los ojos, los oídos y el cuerpo. French ATTENTION Ne laissez ni la peau ni des vêtements mouillés entrer en contact avec des pièces sous tension. Isolez-vous du travail et de la terre. Gardez à l écart de tout matériel inflammable. Protégez vos yeux, vos oreilles et votre corps. German WARNUNG Portuguese ATENÇÃO Berühren Sie keine stromführenden Teile oder Elektroden mit Ihrem Körper oder feuchter Kleidung! Isolieren Sie sich von den Elektroden und dem Erdboden! Não toque partes elétricas e electrodos com a pele ou roupa molhada. Isole-se da peça e terra. Entfernen Sie brennbarres Material! Mantenha inflamáveis bem guardados. Tragen Sie Augen-, Ohren- und Körperschutz! Use proteção para a vista, ouvido e corpo. Japanese Chinese Korean Arabic READ AND UNDERSTAND THE MANUFACTURER S INSTRUCTION FOR THIS EQUIPMENT AND THE CONSUMABLES TO BE USED AND FOLLOW YOUR EMPLOYER S SAFETY PRACTICES. SE RECOMIENDA LEER Y ENTENDER LAS INSTRUCCIONES DEL FABRICANTE PARA EL USO DE ESTE EQUIPO Y LOS CONSUMIBLES QUE VA A UTILIZAR, SIGA LAS MEDIDAS DE SEGURIDAD DE SU SUPERVISOR. LISEZ ET COMPRENEZ LES INSTRUCTIONS DU FABRICANT EN CE QUI REGARDE CET EQUIPMENT ET LES PRODUITS A ETRE EMPLOYES ET SUIVEZ LES PROCEDURES DE SECURITE DE VOTRE EMPLOYEUR. LESEN SIE UND BEFOLGEN SIE DIE BETRIEBSANLEITUNG DER ANLAGE UND DEN ELEKTRODENEINSATZ DES HER- STELLERS. DIE UNFALLVERHÜTUNGSVORSCHRIFTEN DES ARBEITGEBERS SIND EBENFALLS ZU BEACHTEN. F-5
PRODUCT MODEL Keep your head out of fumes. Use ventilation or exhaust to remove fumes from breathing zone. Turn power off before servicing. Do not operate with panel open or guards off. WARNING Los humos fuera de la zona de respiración. Mantenga la cabeza fuera de los humos. Utilice ventilación o aspiración para gases. Desconectar el cable de alimentación de poder de la máquina antes de iniciar cualquier servicio. No operar con panel abierto o guardas quitadas. Spanish AVISO DE PRECAUCION Gardez la tête à l écart des fumées. Utilisez un ventilateur ou un aspirateur pour ôter les fumées des zones de travail. Débranchez le courant avant l entretien. N opérez pas avec les panneaux ouverts ou avec les dispositifs de protection enlevés. French ATTENTION Vermeiden Sie das Einatmen von Schweibrauch! Sorgen Sie für gute Be- und Entlüftung des Arbeitsplatzes! Strom vor Wartungsarbeiten abschalten! (Netzstrom völlig öffnen; Maschine anhalten!) Anlage nie ohne Schutzgehäuse oder Innenschutzverkleidung in Betrieb setzen! German WARNUNG Mantenha seu rosto da fumaça. Use ventilação e exhaustão para remover fumo da zona respiratória. Não opere com as tampas removidas. Desligue a corrente antes de fazer serviço. Não toque as partes elétricas nuas. Mantenha-se afastado das partes moventes. Não opere com os paineis abertos ou guardas removidas. Portuguese ATENÇÃO Japanese Chinese Korean Arabic LEIA E COMPREENDA AS INSTRUÇÕES DO FABRICANTE PARA ESTE EQUIPAMENTO E AS PARTES DE USO, E SIGA AS PRÁTICAS DE SEGURANÇA DO EMPREGADOR. F-6
CUSTOMER ASSISTANCE POLICY The business of The Lincoln Electric Company is manufacturing and selling high quality welding equipment, consumables, and cutting equipment. Our challenge is to meet the needs of our customers and to exceed their expectations. On occasion, purchasers may ask Lincoln Electric for advice or information about their use of our products. We respond to our customers based on the best information in our possession at that time. Lincoln Electric is not in a position to warrant or guarantee such advice, and assumes no liability, with respect to such information or advice. We expressly disclaim any warranty of any kind, including any warranty of fitness for any customer s particular purpose, with respect to such information or advice. As a matter of practical consideration, we also cannot assume any responsibility for updating or correcting any such information or advice once it has been given, nor does the provision of information or advice create, expand or alter any warranty with respect to the sale of our products. Lincoln Electric is a responsive manufacturer, but the selection and use of specific products sold by Lincoln Electric is solely within the control of, and remains the sole responsibility of the customer. Many variables beyond the control of Lincoln Electric affect the results obtained in applying these types of fabrication methods and service requirements. Subject to Change This information is accurate to the best of our knowledge at the time of printing. Please refer to www.lincolnelectric.com for any updated information.