Lincoln Electric IM8000 User Manual
Operator’s Manual
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IM8000 | Issue D ate Aug-13
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THANK YOU FOR SELECTING
AT ALL
TIMES.
SPECIAL SITUATIONS
Additional precautionary measures
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
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.
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.
SECTION A:
Diesel Engines
Gasoline Engines
WARNINGS
CALIFORNIA PROPOSITION 65 WARNINGS
Diesel engine exhaust and some of its constituents are known
to the State of California to cause cancer, birth defects, and other
reproductive harm.
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. PACEMAKER 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.
SAFETY
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
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.
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.
III
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.
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
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.
between the
ARC RAYS CAN BURN.
4.a. 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.
4.b. Use suitable clothing made from durable flame-resistant material
to protect your skin and that of your helpers from the arc rays.
4.c. 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.
3.j. Also see It ems 6.c. and 8.
5.d. Shielding gases used for arc welding can displace air and
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.
IV
cause
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. 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.
6.j. 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
V
NOTES
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, a nd F ield Name s .......................................................... 1
Notes, Warnings, and Tips ................................................................................................................... 2
Revision History
General Informa t io n
Introduction to CheckPoint™ ............................................................................................................ 1.1
CheckPoint™ Editions.............................................................................................................. 1.1
Weld Profiles ........................................................................................................................... 1.2
Weld Logging .......................................................................................................................... 1.2
Electronic Notificat ion S yste m ................................................................................................ 1.3
Traceability ............................................................................................................................. 1.3
Mobile Devices........................................................................................................................ 1.4
WeldScore™ ..................................................................................................................................... 1.4
CheckPoint™ Cloud-Based Architecture ........................................................................................... 1.4
Security and Da ta Storage ................................................................................................................ 1.5
Requirements and Network Capacity ............................................................................................... 1.5
Access Requirements .............................................................................................................. 1.5
Accessing Data in the CheckPoint ™ Data Center .................................................................... 1.5
Network Capacity .................................................................................................................... 1.6
Preparing for CheckPoint™
Providing Access to the Internet ....................................................................................................... 2.1
Update the Welding Power Source Firmw a re .................................................................................. 2.1
Install the Latest Power Wave® Manager ......................................................................................... 2.4
Enable CheckPoint™ for a Power Source .......................................................................................... 2.6
Establish Connection to the Welding Pow er Source ............................................................... 2.6
Enabling CheckPoint™ ............................................................................................................. 2.8
Save the Production Monitoring Installat ion Key F ile ........................................................... 2.10
Setting up CheckPoint™
Connecting to CheckPoint™ .............................................................................................................. 3.1
Create Administrato r Account .......................................................................................................... 3.2
Validate User Information in Chec kPoint ™ ....................................................................................... 3.3
IM8000 CheckPoint™User Manual TOC.1
Table of Contents
Uploading the Installat ion Key File ................................................................................................... 3.4
Register Your Company .................................................................................................................... 3.5
Creating Multiple Site s ..................................................................................................................... 3.7
Managing CheckPoint™
Tabs in the CheckPoint™ Manager ................................................................................................... 4.1
Filtering Lists in the CheckP oint™ Manager ...................................................................................... 4.2
General Tab ...................................................................................................................................... 4.3
Company Information ............................................................................................................. 4.3
Allowable IP Addresses ........................................................................................................... 4.3
User Management ............................................................................................................................ 4.4
Display Current Users ............................................................................................................. 4.4
Add a User Account ................................................................................................................ 4.5
Edit a User Account ................................................................................................................. 4.6
Delete a User Account ............................................................................................................ 4.7
Shift Schedules ................................................................................................................................. 4.8
Next Production Day ............................................................................................................... 4.8
Add a Shift............................................................................................................................... 4.9
Edit a Shift .................................................................................................................. ........... 4.13
Remove a Shift ...................................................................................................................... 4.13
Shift Schedule Exa mple – Three Basic Shift s ......................................................................... 4.13
Shift Schedule Exa mple – Two Alternating Shifts, No Weekends .......................................... 4.15
Welding Power Sources .................................................................................................................. 4.17
Site Configurat ion and Overall Equipment Efficiency (OEE) .................................................. 4.19
Adding a Container ............................................................................................................... 4.20
Adding a Welding Power Source ........................................................................................... 4.21
Changing the Container for a Welding Power Sourc e ........................................................... 4.23
Alert History ................................................................................................................................... 4.24
Documents ..................................................................................................................................... 4.25
Access and Navigate the Library ........................................................................................... 4.25
Add a Document to the Library ............................................................................................. 4.26
Add a Link to the Document Library ..................................................................................... 4.28
Your CheckPoint™ User Account
Finalize User Registra t ion ................................................................................................................. 5.1
Accept the End-User License Agreeme nt ................................................................................ 5.1
Confirm Security Settings ........................................................................................................ 5.2
Managing Your User Account ........................................................................................................... 5.2
Notifications............................................................................................................................ 5.3
Personal Information .............................................................................................................. 5.3
Password Change .................................................................................................................... 5.4
play Preferenc e s ................................................................................................................ 5.4
Dis
Daily Digest ............................................................................................................................. 5.5
TOC.2 CheckPoint™ User Manual IM8000
Overview
Navigating CheckPoint ™ ................................................................................................................... 6.1
Overview of Reports ......................................................................................................................... 6.4
Table of Contents
Alert Subscriptions .................................................................................................................. 5.6
Site Membership ..................................................................................................................... 5.9
Asset Tree ............................................................................................................................... 6.1
Report Tabs ............................................................................................................................. 6.2
Individual Reports ................................................................................................................... 6.3
Panel Resize ............................................................................................................................ 6.3
Generating Reports ................................................................................................................. 6.4
Report Criteria ........................................................................................................................ 6.4
Report Links ............................................................................................................................ 6.5
Sorting by Columns ................................................................................................................. 6.6
Report Page Numbers ............................................................................................................. 6.6
Exporting Report Data ............................................................................................................ 6.7
Refreshing Report Data ........................................................................................................... 6.7
Summary Tab – Container Level
Equipment Reports ........................................................................................................................... 7.1
Operator Reports .............................................................................................................................. 7.4
Overview Reports ............................................................................................................................. 7.6
Utilization................................................................................................................................ 7.6
Productivity ............................................................................................................................. 7.7
Lowest Consumable Time Remaining ..................................................................................... 7.8
WeldScore™ ............................................................................................................................ 7.8
Avg. WeldScore™ Top 10 and Avg. WeldScore™ Bottom 10 ................................................... 7.9
Summary Tab – Power Source Level
Today ................................................................................................................................................ 8.1
Status ...................................................................................................................................... 8.2
Availability (Last 24 H our s)...................................................................................................... 8.3
Consumable Package .............................................................................................................. 8.5
Serial Numbers........................................................................................................................ 8.6
Utilization (Last 24 H our s) ....................................................................................................... 8.7
WeldScore™ Live Update ........................................................................................................ 8.7
Welder Detail .......................................................................................................................... 8.8
Productivity (Last 24 Hours) .................................................................................................... 8.9
ldScore™ (Last 24 Hours) ................................................................................................. 8.10
We
Last 7 Days ...................................................................................................................................... 8.10
Utilization (Last 7 Da ys)......................................................................................................... 8.10
Productivity (Last 7 Days) ...................................................................................................... 8.11
WeldScore™ (Last 7 Days) ..................................................................................................... 8.12
Avg. True Energy™ in Kilojoules (7 Days) .............................................................................. 8.13
IM8000 CheckPoint™ User Manual TOC.3
Table of Contents
Custom ........................................................................................................................................... 8.14
Overall Equipment Efficiency (OEE)
OEE Tab ............................................................................................................................................ 9.1
Today Reports ......................................................................................................................... 9.2
Last 7 Days .............................................................................................................................. 9.3
Custom .................................................................................................................................... 9.4
Calculations of OEE in CheckP oint ™ ................................................................................................. 9.5
OEE Percentage....................................................................................................................... 9.5
Availability Fac t or ................................................................................................................... 9.5
Performance Factor ................................................................................................................ 9.8
Quality Factor ......................................................................................................................... 9.9
Establishing Planned Downt ime ..................................................................................................... 9.10
Planned Downtime Example ................................................................................................. 9.11
Adding Planned Downtime ................................................................................................... 9.11
Planned Downtime – Company Site ...................................................................................... 9.13
Planned Downtime – Container ............................................................................................ 9.14
Planned Downtime – Welding Power Source ....................................................................... 9.15
Assembly Li sting Tab
Overview Report ............................................................................................................................. 10.1
Main Overview List ............................................................................................................... 10.1
Overview Drilldown .............................................................................................................. 10.3
Weld Sequence Drilldown ..................................................................................................... 10.5
By Assembly.................................................................................................................................... 10.6
Weld Listing Tab
Summary Report............................................................................................................................. 11.1
Summary Criteria .................................................................................................................. 11.1
Data on the Report ............................................................................................................... 11.3
Weld Detail ........................................................................................................................... 11.5
Weld Profiles ................................................................................................................................ 11.10
Profile Reports .............................................................................................................................. 11.11
Criteria on the Profile Report s ............................................................................................ 11.12
WeldScore™ ........................................................................................................................ 11.13
Current/Voltage .................................................................................................................. 11.13
Wire Feed Speed ................................................................................................................. 11.13
Deposition ........................................................................................................................... 11.13
True Energy™ ...................................................................................................................... 11.14
Duration .............................................................................................................................. 11.14
ount .................................................................................................................................. 11.14
C
TOC.4 CheckPoint™ User Manual IM8000
Limit Errors Tab
Overview ........................................................................................................................................ 12.1
Today .............................................................................................................................................. 12.1
Last 7 Days ...................................................................................................................................... 12.2
Custom ........................................................................................................................................... 12.2
Events Tab
Report Criteria ................................................................................................................................ 13.2
Summary ........................................................................................................................................ 13.3
History ............................................................................................................................................ 13.4
Documents Tab
Opening Documents and Links ....................................................................................................... 14.1
Operators Manuals ......................................................................................................................... 14.2
Troubleshooting
Cannot Connect to a Power Source ................................................................................................. A.1
Cannot Apply Settings ..................................................................................................................... A.1
Table of Contents
Overall Equipment Efficiency Examples
Availability Example 1 .......................................................................................................................B.1
Availability for Eac h Hour ........................................................................................................B.2
Availability for the Entir e Shift ................................................................................................B.2
Availability Example 2 .......................................................................................................................B.2
Availability for Eac h Hour ........................................................................................................B.3
Availability for the Entir e Shift ................................................................................................B.3
Availability Example 3 .......................................................................................................................B.4
Availability for Eac h Hour ........................................................................................................B.4
Availability for the Entir e Shift ................................................................................................B.5
Glossary
IM8000 CheckPoint™ User Manual TOC.5
Table of Contents
TOC.6 CheckPoint™ User Manual IM8000
Preface
Typographical Conventions Used
Before using this guide, it is importa nt to understa nd t he typographic al conventions used to identify and
describe information.
Cross-References
Cross-references t o chapter s, sections, page numbers, hea dings, e t c . a re shown in a n italic t yp e fa ce .
e.g., Refer to Text You Type Using the Keybo ard 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 Smi th in t he Name field.
Keys You Press and Buttons You Click
Keys tha t you press on the key board and buttons/icon s that you click with the mouse are shown in a bold
sans-serif t y peface.
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.
IM8000 CheckPoint™User Manual 1
Preface Notes, Warnings, and Tips
Notes, Warnings, and Tips
Notes, stops and tips appear throughout the manual. They provide additiona l informa t ion t hat is important
for you to know about the topic.
NOTE | A note is a n important piece of information.
STOP | You should definitely read the informatio n in a stop table.
It could help y ou prevent a situation from which you cannot
recover.
TIP | A tip table helps you w it h s ome interesting or useful
informatio n about using the program.
2 CheckPoint™ User Manual IM8000
Revision Histor y
Date Change Description
August 2012 Initial release a s IM8000
June 2013 Major revamp and update of manual
August 2013 Made the following updates reflecting t he new ver sion:
Added Overall Equipment Efficiency (OEE)features to setup instructions
Updated description of Daily Digest to reflect check mark behavior
Edited User Time/Company time descriptions for shifts
Edited chapters to reflect Summary tab changes
Added new OEE tab section
Added new Assembly Listing tab section
Updated screenshots to reflect new tabs, features and changes
IM8000 CheckPoint™User Manual REV.1
Revision History
THIS PAGE INTENTIONALLY LEFT BLANK.
REV.2 CheckPoint™ User Manual IM8000
Chapter 1
General Information
Introduction to CheckPoint™
CheckPoint™ is the newest data collection and repo r ting technology available for the latest models of t he
Lincoln Electric P owe r Wave® family of Welding Power Sources.
CheckPoint™ is cloud-based co mput ing ba sed on Production Monit or ing™ but with mor e funct ionalit y a nd
more flexibility. C he ckPoint™ does not require additional har dwa r e or softw are installation, allowing you
to work from you own computer using your Internet browser. CheckPoint™ enables you to measure the
Pulse™ of your Lincoln Electr ic ® welders with critical alerts and unpr ece de nte d pr oduction visibilit y.
CheckPoint™ is available for viewing on your smart phone, tablet and laptop or desktop of any computer or
device with Internet access.
Cloud-based computing refer s to the delive r y of computing a nd storage capacity a s a service to a
community of end users. End users access cloud-based applications through a web br owser or a desktop or
mobile app while the business software a nd data ar e store d on server s at a remote location. Cloud
computing allows compa nie s to get applications up and running faster, with improved manage a bilit y and
less maintenance. It relies on sh a ring of resources t o achieve coherence and economies of sca le similar to a
utility (like th e electricity grid) over a networ k (typ ic ally the Internet).
CheckPoint ™ allow s gr e a ter visibility. You can access your data anytime, anywhere, with any web device
without the need for VPN client software. CheckPoint ™ is ea sy to implem e nt and mainta in. You simply
plug the Welding Power Source into your network. (Refer to the Power Wave® Manager User Manual for
instructions.) There is low ove r hear d a nd no computer hardware required in the field; it is as user-friendly
as going to a website. CheckPoint™ is more dynamic in t ha t any updat e s to the applicat ion’s func t iona lit y
are instant across all users.
CheckPoin t ™ Editions
CheckPoint™ offers two options: Standard E dit ion and Premium Edition. The Standard Edition is available
free of charge w it h eve r y Powe r Wa ve®. Sta ndar d Edition includes a rolling 30 days of data storage after
which point the data is permanent ly de lete d from the system. The Premium Edition is available for an
annual subscription fee , w hich includes a rolling 12 months of data storage with a permanent offline
archive. With CheckPoint™, it is possible to have a combina tion of Standard and Premium Editions based
on your needs. Table 1.1 details the differ ences in features.
NOTE | For details on the Premi um Edition, please send a n e-mail
with your conta c t information to sales@igearonline.com
.
IM8000 CheckPoint™User Manual 1.1
Chapter 1. General Information Introduction to CheckPoint™
Table 1.1 Features in Each Versi on
Field Standard Premium
Mobile Ready, Global Data Access
Cloud Ready, Global Data Access
E-mail Notification System
Reporting
Manual Data Export
Document Library
Extended Document Library
(Upload and store up to 15 GB of custom documents and files)
1 Year of Live Rolling Data Storage
Automated Data Archiving
Share Data wit h Third-P a r ty Applications and Systems
(with ODATA API)
Weld Profiles
One of the principal goals of CheckPoint™ 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 th e Welding P o w e r So ur ce we r e to per for m on ly on e t y pe of we ld ov e r and over. H owe ver, in
practical applicat ions, t his is not the case. The assembly of many different industrial components re quires
welds of varying type and length .
The concept of Weld Pr o file s allows the Welding Power Source to apply differ ent 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 P r o file to each weld required for the part asse m b ly.
For more in-dept h info r ma tion about Weld Profiles, please refer to the Power Wave® Manager User
Manual.
Weld Logging
CheckPo int ™ records large quantities of weld statistics. Each log entry contains th e fo llowing welding
statistics for each weld:
For current, voltage, wire feed speed and duration:
- Minimum
- Maximum
- Average
- Percent above limit
1.2 CheckPoint™User Manual IM8000
Introduction to CheckPoint™ Chapter 1. General Information
- Percent belo w lim it
- Profile ma ximu m limit
- Profile minimum lim it
True Energy™
Date and time the weld was made
Duration of the weld
Weld stat us a f te r limit checking
Part Number, Consumable Lot and Operator ID
WeldScore™
Electronic Notificat ion System
When a Welding Power Source is used with CheckPoint ™, t he data center can send e-mail and text-message
notifications to multiple use r s. Eac h user’s e-mail a ddr e ss and mobile numbe r can be configur e d t o receive
messages from the CheckPoint™ data center upon any of several e ve nt condit ions. See page 5.6 for more
details on the alerts available.
Traceability
CheckPoint ™ pr o vides you with the ability t o repo r t on all the welds that were made on a specific part
number, by a specific o per ator or using a specific consumable lot c ode. Before a w e ld is made , this
information is communic ated to the Welding Power Source, in a variety of ways. Every weld that is ma de
after this is assigned with these ID numbe r s until a ne w number is e ntered. CheckP oint ™ users can
generate a traceability report that looks fo r this ID from a ll t h e W e lding Power Sources in the system.
Traceability solutions are typica lly c u stomized to a customer’s specific needs. Please contact Linco ln
Electric for a quote on your needs.
NOTE | CheckPoint™ does not s upport consumable package
tracking f or dual wire feeding syst ems .
IM8000 CheckPoint™ User Manual 1.3
Chapter 1. General Information WeldScore™
Mobile Devices
With CheckPoint™, you can download native apps for iPhone®, Bla ckbe r r y® and Android t o provide mobile
users access to their welder data anytime from anywhe re. Users can view da shboa rd widget s, history a nd
alarm events, receive real-time text and e-mail messages, download the latest documents, and scan
barcodes a s part o f an ea sy-to-use traceability solution.
Links for downloading m o bile a pplic ations are available at www.lincolncheckpoint.com under the Mobile
Enabled portion of the home page. For more information on using the mobile version, please refer to the
CheckPoint™ Mobile App User Manual.
WeldScore™
WeldScore™, a new fe atur e ava ila ble in all third-generation Welding Power Sour ce mo de ls (including the
i400, C300, S350, S500 and AC/DC 1000 SD), can be used to support a weld qua lity control program. It
assigns a scor e 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 condit ions. Any weld w ith 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 CheckPoint™. 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 t o replace a quality co ntrol system.
CheckPoint™ Cloud-Based Architecture
The CheckPoint™ system uses a cloud-based ar c hit e ctur e . This means that ther e is no dedicate d compute r
required at your company to collect and store the data. Each piece of welding e quipme nt simply require s a
network connection. The Welding P o w e r Source initiates the transfer of information through firewallfriendly communications to the data center. (The data transfer does not initiat e fr om outside the power
source.) At that point, the data is accessible using a w e b brow se r and a secure login.
Figure 1.1 CheckPoint™ Cloud-Based Architecture
1.4 CheckPoint™User Manual IM8000
Security and Data Storage Chapter 1. General Information
Security and Data Storage
Each CheckPoint™ customer’s data is stored in a state-of-the -art data cent e r in dedicate d and par t it ione d
databases, exclusive t o eac h custome r . Additionally, when viewing the CheckPoint™ application, highsecurity, industr y-st andard encryption is utilized.
The hosting cent er is a SAS 70 Ty pe II c om pliant fa c ility. SAS 70 is designated by the U.S. Securities and
Exchange Commission (SEC) as an acceptable method to obtain assurance of a service organization’s
internal controls without c o nducting separ ate assessment s. Suc c essful complet ion of t he SAS 70 Type II
examination indicat es that the processes, procedures, and contro ls have been formally e valuate d and
tested by an independent auditing firm.
A service auditor ’s exa minat ion pe r formed in accordance with SAS No. 70 (SAS 70 audit) is widely
recognized. It represents that a service orga nization ha s bee n thro ugh a n in-depth audit of the ir contr ol
objectives and control act ivit ies, w hic h oft e n include c ontrols over information technology and related
processes. A Type II report not only includes the service organiza t ion’s descr iption of c o nt rols but also
includes detaile d testing of the design and operating effec t iveness.
The hosting center environme nt is built w it h stat e-of-t he-art equipment, technology investments and
operational expert ise . The re is an esta blished disa ster recovery program with redundancy and failover to
protect the information stored in the system.
Requirements and Network Capacity
Access Requ irements
Each computer or mobile device that wants to conne ct t o CheckPoint™ must have access to the Inte r net.
All Welding Power Sources also need to have access to the Internet to report information back to the
CheckPoint™ data center . Every Welding Power Sourc e has a unique 16-charact er serial number.
This identification serial number is save d dur ing the registra t ion pr ocess and sent to the CheckPoint™ data
center with each welding data packet. When data arrives at the CheckPoint™ data center, the identification
serial number is used to save the data into your customer database.
See Chapter 2 for details on preparing for CheckPoint™.
Accessing Dat a in the CheckPoint™ Data Center
Each customer has a separate partition in the database for the ir data . You control acce ss to your data with
usernames and passwords that are created by your CheckPoint™ Administrator. The administrator
provides access to the data, as needed, for those users who need to access the data and generate reports.
See page 4.4 for details on User Management.
IM8000 CheckPoint™ User Manual 1.5
Chapter 1. General Information Requirements and Network Capacity
Network Cap acity
Networks and Internet connections have a limited amount of bandw idt h for sending dat a . Each Welding
Power Source uses a small amount of bandwidth. In order to estimate the total ba ndw idt h on your
network, you can multiply the number of power welding source s by the data qua ntit y of data pack ets
described:
Every 20 seconds, each power source sends a status update to the Chec kP oint ™ data center; th e
data packet is about 1 KB in size.
If a power source has completed a weld, or multiple welds, ever y 92 seconds it will send the new
data; the data packet is about 2 KB per weld.
If there is an oc c urr e nce of a powe r so ur c e e vent o r fault , every 66 seconds it w ill se nd the new
data; the data packet is 0.5 KB in size per event.
In the event the network or Internet connection goes down due to unexpected problems or scheduled
maintenanc e , the Welding Power Sources will continue to c ollect and hold the welding data until the
network connection is reest a blished.
Each power source has enough internal memory to hold welding da t a for 1000 welds. Once t he Interne t
connection is r eest ablished, all welding data will be sent to the CheckPoint™ data center. If more than
1000 welds are made before the Internet connect ions is ree st a blished, only the data from the la st 1000
welds will be saved; data for the oldest welds will be lost.
STOP | If the power source is turned off before the Internet
connecti on is reestablished, al l w e lding data will be lost.
1.6 CheckPoint™ User Manual IM8000
Chapter 2
Preparing for CheckPoint™
It is essential to have at least one Welding Power Source set up in CheckPoint ™ pr ior to creating a n acc ount
for your company. This chapt er walks you through t h e necessary step s to c omplete this task. Af ter
successfully c om pleting these steps, you will becom e the Che ckPoint™ Site Administrator and have the
ability to add Welding P o w e r So ur ces a nd user s through the CheckPoint™ Manager function of the
application.
Providing Access to the Internet
You need to open up the following information on your server in order to grant the Welding P ow er S ources
access to the Internet: http://ws.lincolncheckpoint.com at IP address 216.26.175.3 (subject to change)
using port 80 to send out TCP/IP and HTTP messages.
TIP | Contact y our local IT department for assistance.
Update the Welding Power Source Firmware
“Firmware ” is th e memo r y and programming code within the Welding Power So ur ce t hat is the co nt r o l
program for the machine. Making sure you have the latest firmware ensures that you have the latest
features available for the power source, inc luding th e most rec e nt ver sion of the Production Monitoring™
and CheckPoint™ software .
To install the latest firmware:
Procedure Details
1. Log in to the computer as a user with
administrat ive pr ivileges.
2. Open your browser and go to
www.powerwavesoftware.com.
3. 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.
Contact your IT department if you do not have
administrat o r pr ivile ges.
The Login page displays.
If you’re creating a new account, follow t he
onscreen instructions and return to this st ep
when finished.
Once yo u log in , t h e system displays the Power
Wave Resource Center.
IM8000 CheckPoint™User Manual 2.1
Chapter 2. Preparing for CheckPoint™ Update the Welding Power Source Firmware
Procedure Details
4. In the Quick Li n k s se c tion, click the Power
Wave®, Power Feed®/MAXsa® Software link.
5. Click the Download Power Wave® Bundle-FREE
button to run the update.
The system displays a page co ntaining t he
Download Power Wave® Bundle-FREE button.
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 t he ut ility
how to find the Welding Power Source you want
to update.
6. Choose the Connect through E thernet option
and enter the IP address of the Welding Power
Source you want to update.
2.2 CheckPoint™User Manual IM8000
TIP | If there is an IP address a lready
displaye d, it is the IP address of the las t
Welding Pow er Source that wa s c onnected.
Be sure you enter the correct address f or t he
current We lding Power Source you w a nt t o
Update the Welding Power Source Firmware Chapter 2. Preparing for CheckPoint™
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 t he 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 W e lding P o w er Source
IP addresses on the same subnet.
NOTE | If this Welding P ow er 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 (0).
7. Click the Connect button once you have
entered the IP address for the power source
you are updating.
The soft ware scans the We ld in g Power Source to
verify if the firmware currently on the machine
is up to date.
TIP | You can also see this i nformation under
System Status > Module Information > Software
Version in Power Wave® Manager. See Error!
Reference source not found. on page Error!
Bookmark not defined..
IM8000 CheckPoint™ User Manual 2.3
Chapter 2. Preparing for CheckPoint™ Install the Latest Power Wave® Manager
Procedure Details
8. If the firmware is not up to date, you must click
Continue to update the Welding Power Source.
9. Exit the program once the firmware has
finished updating.
10. Repeat steps 4 through 9 for each power source
you need to update.
The system proceeds with the update.
If the firmware is a lr ea dy up to dat e , yo u will
receive the message Update not required and
you can click Exit to close the window.
Install the Latest Power Wave® Manager
Once you update the Welding Power Source(s), you need t o upgrade to the latest version of Powe r Wave ®
Manager. If installing P ower Wave® Manager for the first time, these instructions are also for you. Power
Wave® Manager is a software application that allows you to manage a mult it ude o f set t ings and
configuration options within the Lincoln Electric Power Wa ve® fam ily of W e lding Power Sources. It also
provides in-depth diagnostics of t he We lding Power Source’s hardware and firmware to help identify and
eliminate issues w it h w e lding o r c o nfigur a tion.
TIP | If you already have P ow e r Wave® Manager installed, you
can simply ope n t he s oftware. Depending o n y our v ersion
of the software, the syst em a ut omatically checks for and
installs any updates. If it doesn’t do t his a utomatically, you
can click the Check for Updates button. If the software
updates, y ou c a n s kip ahead to the next section.
2.4 CheckPoint™ User Manual IM8000
Install the Latest Power Wave® Manager Chapter 2. Preparing for CheckPoint™
Procedure Details
1. Log in to the computer as a user with
administrat ive pr ivileges.
2. Open your browser and go to
www.powerwavesoftware.com
.
3. Enter your username and password in the
Email and Password fields and click Sign In.
Contact your IT department if you do not have
administrat o r pr ivile ges.
The Login page displays.
These are the same credentials you used when
updating the Welding Power Sour ce fir mw are.
Once yo u log in , t h e system displays the Power
Wave Resource Center.
4. In the Quick Li n k s se c tion, click the Power
Wave® Utilit ies link.
5. Click the Download Power Wave® Ut ilities
FREE button to run the update.
6. Select your language from the drop-down
and click OK.
The system displays a page co ntaining t he
Download Power Wave® Utilities FREE button.
NOTE | Depending on your Windows version,
you may have to click Run or Allow to permit your
system to launch the file.
TIP | If you haven’t logged in as a user with
administrative privileges, you may have to
download the f ile, open the location where y ou
downloaded it, right-click the file and select Run
as administrator.
The syste m d isp lays the Installer Langua ge dialog.
If you are running an older version of Power Wave®
Manager, the system pr o m pt s y o u to remove the
old version. Click OK to allow the installer to
remove the old version.
IM8000 CheckPoint™User Manual 2.5
Chapter 2. Preparing for CheckPoint™ Enable CheckPoint™ for a Power Source
Procedure Details
If this is a new inst a llation (or once the old version
is removed), t he system displays the installation
welcome windo w.
7. Click Next on the Welcomescreen to move to
the License Agreement and continue the
installation.
8. You must accept the License Agreement and
click Next to continue.
9. Leave the default value in the Destination
Folder field and click Install.
10. Click the Finish button to exit the installer.
The syste m extracts files and in stalls the Power
Wave® Utilities o n yo ur c o mputer. Once it is
complete, the final page of the Setup Wizard
opens.
Congratulations! You have installed Power Wave®
Manager and can now configure your Welding
Power Source.
Enable CheckPoint™ for a Power Source
Now that you have upgraded the firmwa re on the Welding P ow er Source and installed the latest version of
Power Wave® Manager on your computer, you can now use Power Wave® Manager to enable CheckPoint™
on the Welding Power Source.
Establish Connection to the Welding Power Source
When you updated the firmware on the Welding Power Source (page 2.1), you needed to tell the Update
Utility whe r e to find the Welding Power Source on your network. Now you need to tell P owe r Wave®
Manager where to find the Welding Power Source on your network so you can enable CheckPoint ™ for t hat
power source.
2.6 CheckPoint™User Manual IM8000
Enable CheckPoint™ for a Power Source Chapter 2. Preparing for CheckPoint™
Figure 2.1 Connecting to the Welding Power Source
NOTE | Remember that the IP address displayed is either the last
Welding Pow er Source to which Pow er Wave® Manager
connected o r t hat you recently upda t e d w ith the Update
Utility.
Procedure Details
1. Select Start > Programs > Lincoln Electric >
Power Wave® Utilities from the computer’s
main program menu.
2. Select Power Wave® Manager to launch
the utility.
3. Choose the Connect through E thernet option
and enter the IP address of the Welding
Power Source.
4. Click the Connect button.
The Power Wave® Manager window opens and
defaults to the Connect screen. See Figure 2.1.
For more details or information on finding t he IP
address of the Welding Powe r Sour ce, ple a se refer
to the Power Wave® Manager User Manual.
The system establishes the connection and
automatically displays the Registration page of
Power Wave® Manager so you can enable
CheckPoint™ (Figure 2.2 on page 2.8). Please
continue to Enabling CheckPoint™ on page 2.8.
IM8000 CheckPoint™ User Manual 2.7
Chapter 2. Preparing for CheckPoint™ Enable CheckPoint™ for a Power Source
Enabling CheckPoint™
Once you connect the Welding Power Source to Powe r Wave® Manage r, you can now enable and set up
CheckPoint™ for that power source. Once you enable Chec kPoint ™ for the power source, the CheckPoint™
administrato r w ill be able to begin adding Welding Power Sources to the C hec kPoint™ system for
monitoring and reporting.
Figure 2.2 Registration Section of P ower Wave® Manager
Procedure Details
1. Select Register under Production Monitoring
in Power Wave® Manager.
2. Enter a name for the Welding Power Source
in the Power Source name field.
3. Place a check mark in the Enable
CheckPoint™ over the Internet checkbox
under CheckPo int™ Set u p .
If you do not see this section, the firmware on the
connected Welding Power S ource is not up to date.
Please refer to page 2.1 to update the firmware of
the power source. Return here when complete.
Once you enable CheckPoint™ for the power source,
the Welding Power Source no longer sends e-mail
notifications. With Chec kPoint ™, e-ma il a nd text
message notifications come from the data center.
2.8 CheckPoint™ User Manual IM8000
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