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
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.
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. 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.
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.
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.
4
cause
SAFETY
a
m
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
Get t he f ree mobi l e app
http://gettag.
5
Table of Contents
Preface
Typographical Conventions Used ........................................................................................................ 1
port ........................................................................................................................... 5.40
Additional Information
IM8001 Production Monitoring™ User Manua l 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
Cannot Connect to a Power Source ..................................................................................................B.1
Glossary
TOC.4 Production Monitoring™ User Manual IM8001
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 Keyboard on pa ge 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 keyb o ar d and buttons/icons that you click with t hemouse 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.
IM8001Production Monitoring™User Manual1
Preface
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 an important piece of informatio n.
STOP |You should definitely rea d t he information in a st op t a ble.
It could help y ou prevent a situation f rom 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 Production Monitoring™ User Manua l IM8001
Revision Histor y
DateChange Description
August 2012 Initial release a s IM8001
May 2013 Major revamp and update of manual
IM8001Production Monitoring™User ManualREV.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 colle c tion and reporting technology that is available fo r the la test models
of the Power Wave® fam ily of Welding Power Sources.
The term “Production Monitoring” does not refer to any single featur e . Instead, it refers to the ent ire
collection of feature s an d functionality included with a Welding Power Source. These features include, but
are not limite d to:
Collecting w elding logs complete with statist ic s for each recorded weld.
Setting logical limits on WeldScore™, arc current , a rc vo ltage, wire feed speed, and duration; and
reporting welds t h a t viola te the specified limits.
Creating d istinct Weld Profiles with separate limit se ttings for each pro file.
E-mailing users: Ea c h Welding Power Source has the ability to send e-mails co nt a ining r eports of
weld errors and other information.
Tracking wire usage and providing low-pac k age w arnings for ea c h Welding P ow e r Sour ce.
STOP | Production Monito ring™ does not support consumable
tracking f or dual wire-feeding syst ems.
NOTE | For Production Mo nit oring™ support in U S A and C a nada,
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 follow ing t erms to help ident ify t he person gener a lly
responsible for the task being discussed. These ar e general terms to help illustrat e the use of Pro duct io n
Monitoring™ in your welding o pe r a tions.
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. Ther e could be more t han one, depending on your company’s policies.
IM8001Production Monitoring™User Manual1.1
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 impleme n t if the Welding Power Source were to perform on ly o ne t ype of we ld over a nd o ver.
However, in practica l a pplic ations, this is not the case. The assembly of many different industrial
components requires 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 bly .
For more in-dept h info r ma tion about Weld Profiles, please refe r to the Power Wave® Manager User Manual.
Weld Logging
Production Monitoring™ records lar ge quantities of we ld st atistic s. Eac h log ent ry cont a ins the following
welding stat istics for each weld:
For current, voltage, wire feed speed and duration:
- Minimum
- Maximum
- Average
- Percent above limit
- Perce n t below limit
- Profile m aximum limit
- Profile m inim um limit
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™
E-mail Capability
When a Welding Powe r So ur ce ha s ac c e ss to an e-mail server on your net work and you have installed
Production Monitoring™ on the server compute r, the power source can send e-mail notifications to
multiple addre sse s. Each e-mail address can be configured to receive messages fr o m t h e Welding P o w e r
Source upon any of several event conditions.
1.2 P ro d uction Monitoring™ User Manual IM8001
WeldScore™ Chapter 1. Gene ra l Information
Traceability
Production M onitoring™ provides you with the ability to re po rt on all th e we lds that were made on a
specific part numbe r , by a spe c ific o per ator or using a specific consumable lot co de. Before a weld is ma de,
this informatio n is c o mm unic a ted to the Welding Power Source, in a variety of wa ys. Every we ld that is
made after this is assigned with these ID numbers unt il a new numbe r is ente red. Production Monitoring™
users can gener ate a traceability report th at looks for this ID from all the Welding Power Sources in the
system. Trac eability solutions are typic a lly customized t o a c ustomer’s specific needs. Please contact
Lincoln Electric for a quotation on your needs.
NOTE | Production Monitoring™ does not support consumable
package t ra c king for dual wire feeding sy stems.
WeldScore™
WeldScore™, a new fe atur e ava ila ble 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 qua lit y c o ntrol program. It
assigns a scor e to welds on a 0% to 100% scale that indic a te s 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 c onfidence, 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 infor ma tion on WeldScore™.
NOTE | WeldScore™ is not a guarantee of quality and is not
intended t o replace a quality co nt rol 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 c o mput e r s to access the welding data
and generate reports using the Production Monitoring™ applic a tion. The main components of the
Production Monitoring™ system are:
Microsoft SQL Server Expr ess database for stor in g d ata sent from Welding Power Sources
Microsoft Internet Information Services (IIS) Web Server
IGear Data Transpor t Utility (DTU): This provides the connec tivity 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 t he databa se.
IGear Web Framework: This provides users with a web portal to the database that enables them
to generate various reports.
You install the Production Monito ring™ a pplic a t ion on a single dedica te d ser ve r 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 compute r , they can access the Production
Monitoring™ application.
IM8001 Production Monitoring™ User Manua l 1.3
Chapter 1. General Information Requirements and Limitations
Figure 1.1 Production Monitoring™ System
Requirements and Limitations
Server Compu t er Requiremen t s
You install Production Monitor ing™ on a single de dic ate d computer to which all other computers conne ct in
order to access the application. The following ar e th e requir e ments for tha t serve r computer :
Dedicated “alway s on” compute r : This is a server-t ype applica tion designed to run on a
computer tha t is on a ll 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-Ba seT or 10/ 100-Ba seT ne twork interface card.
Internet browser: Internet Explorer 7 or greater; Firefox; or Chrome
Microsoft Internet Information Services (IIS). Refer to page 3.7 for installa t io n inst r u c tions.
1.4 P ro d uction Monitoring™ User Manual IM8001
Requirements and Limitations Chapter 1. General Information
Operating System: Window s 7, Window s Vista , Windows XP P r ofe ssional, Windows Ser ve r 2003
with Service Pack 1 or greater, and Windows Serve r 2008. Production Monit or ing™ support s
both 32-bit and 64-bit operating syste m s.
NOTE | If the system is Windows Server 2003, COM+ must be
enabled. Please see pa ge 3.16 for details.
If the system is Windows Server 2008, PowerShell must be
installe d ma nually. For details on ins t alling PowerShell,
refer to page 3.1 8.
Display: Minimum supported re solut ion is 10 24x768 (16-b it c olor or highe r ).
The Production Monitoring™ screens should alwa ys be expanded to use the full 1024x768
resolution of the monitor. Otherwise, certa in nec e ssary sections of the scre e n may be hidden
from view.
User Computer R equirements
Each user can access Production Monitoring™ from the computer at their desk or from another computer
on the network. The following requirement s apply for that c omputer to view Pr oduction Monitoring™:
Internet Explorer 6 (Service Pack 1) or greater
An Ethernet (IEEE 802.3–compliant ) 10Mbps 10-Ba seT or 10/ 100-Ba seT ne twork 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 connec t to Production Monit or ing™ must meet
the following requireme nt s:
Ethernet port
- The Power Wa ve® 655, AC/ DC 1000, and a ll third-ge ne r a t ion P owe r Waves (i400, S 350, S 500,
etc.) come standard wit h an Ethernet port, so no a ddit iona l equipme nt is nee de d.
- The Power Wave® 455M, 455M/S TT, 455M Robotic, and 455M/ S TT Robot ic need a K2207-2
Ethernet/DeviceNet Module.
- The Power Wave® 355M, F355i, a nd 405M need a K2436-1 Co mmunic a t ion Interfa ce.
Static IP addre ss se t for each Welding Power Source
- Each Welding Po wer S o urce must have a unique IP address. IP addre sses ar e usually
obtained from your loc a l IT de partment.
- Once you retrieve an IP addre ss 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 ut ility is available at www.powerwavesoftware.com
The Production Monitoring™ firmwa re revision (in the We lding 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 Manua l 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 firmwa re.
Network Req uirements
Production Monitoring™ uses your computer networ k to communicate with the Welding Power Sources
and the users who want to view data in the application. The following a r e the net work requirement s 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 C AT 5 c a bles or better
Connectors: Use RJ-45 environmentally enclosed connectors when connecting the network to
the Welding Power Sourc e .
Connecting Ne tw o r k De vice : The ne twork lines going to the Welding Power Source should go t o
an industrial switch or a switc h with a har dened e nc losure .
Wireless Network Guidelines: A wire le ss networ k r e quir e s an 802.11 bridge. Several cu stomers
have had success using a NETGEAR wireless a dapter (Model: ENCE2001).
System Limitat ions
Table 1.1 compares the two recent versions with r e spe ct to limitations. While Production Monitor ing™ is a
great tool for monitoring your welding operations, please m a k e no te o f the fo llo w ing limitations:
Welds with a tot a l duration less than 0.2 seconds will not be recorde d in Pro duc tion
Monitoring™ 2.2.
Welds wit h a duration less than th e su m o f the Sta rt De la y 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., w e lds wit h 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 P ower S ource itself is 1000. The
oldest rec or d s w ill be replaced with a new recor d w h e n a new record is generated.
NOTE | In the event there is an Ethernet co nnection issue with the
Welding Power Source, the Production Monitoring™ weld
records will be stored in the Welding Power Source up to
the maximum num ber of records. The power s ource will
transfer the data to the Production Monitoring™ database
once the connec tion has been reestablished. Please keep in
mind that if t he W elding Power Source is powered down or
reset for any reason, these stored wel d rec ords 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 select ing W e ld Profiles. (Please refer t o
the Power Wave® Manager User Manual for more details on this method.)
1.6 P ro d uction Monitoring™ User Manual IM8001
Requirements and Limitations Chapter 1. General Information
FANUC® Se r vo To r c h Wire Fe e d Speed (WFS) will not be recorded for olde r soft w are versions of
ArcTool® software and older versions of the Welding Po w e r Sourc e ’s firm w a re. Start ing with the
V7.70P/07 release of the ArcTool® softw are, Ser voTor ch WFS feedbac k is support e d.
The robotic analog interface is not recommended when you use the Last Digit of Workpoint
method for selecting Weld Profiles. (Please refe r to t he Power Wave® Manager User Manual for
more details on this method.)
Production Monitoring™ does not support consumable pac ka ge tracking or the calculation of
Wire Deposition with Dual-Head Wire Fee ders.
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 wit h memory pane ls co nne cte d 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 the ir weld. You c ould 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 (sec onds) 6,553 429,496,729
Maximum weld re c ords in Welding Power
Source memory
Shortest weld duration that can be
recorded (seconds)
Minimum total delay (i.e ., S tar t De la y plus
End Delay) (seconds)
Maximum serial number length 16 32
Maximum out-of-lim it tolerance time
(seconds)
TIG and stick welding supported No Yes
WeldScore™ supported No On third-generation We lding
5,000 1,000
0.5 0.2
0.7 0.2
1310.7 85,899,345
Power Sources
IM8001 Production Monitoring™ User Manua l 1.7
Chapter 1. General Information Requirements and Limitations
THIS PAGE INTENTIONALLY LEFT BLANK.
1.8 P ro d uction Monitoring™ User Manual IM8001
Chapter 2
Upgrading from Production Monitoring™ 2.1
If you already have Production Monitor ing™ 2.1 installed a nd simply nee d t o upgr a de to version 2.2, this
section provides simple information for you to accomplish this as quickly as possible.
STOP | If you have Producti on M onitoring™ 2.0 or l ow er ( or you
need to install for the first time), you must refer to Chapter
3 for instruc tions. Upgrading to t he new v ersion requires
that you unins t all all older versions and install the ne w
version fresh.
System Requirements
The system must meet the requirements liste d on pa ge 1.4 to install and r un t he Product ion Monitoring™
2.2 application. If on e of these requirements is missing, th e installation will fail. For assist ance with these
requirements, please cont act your loca l IT department or contact support at
support@lincolnproductionmonitoring.com
.
Preparing for the Upgrade
To upgrade from Production Mo nit o ring™ 2.1 t o Produc tion Monitoring™ 2.2, you will need the following:
Administ rator permissions o n y o u r server computer.
Production Monitoring™ 2.2 Patch
If you do not have the Production Monitoring™ 2.2 Patch, contact Production Monitor ing™
support at support@lincolnproductionmonitoring.com
software.
A standard installation of Product ion Monit oring™ 2.1 running on the se rve r comput er.
STOP | If your Production Monitoring™ 2.1 insta llation is non-
standard, you will need to contact s upport for assistance
with the upgrade pr oc ess.
A non-stan dard installation wo uld include any instal lation
where the Pro duc t ion Monitoring™ database has been
moved to a diffe rent server or the password for the
Productio n Monitoring™ databa s e has been changed within
Microsoft ® S Q L E nt erprise Manager.
for assistance with obtaining the
IM8001Production Monitoring™User Manual2.1
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 Produc t ion Monit or ing™ 2.1 softw are to the late st
Production Monitoring™ 2.2.x rele a se .
NOTE | If you do not have the patc h file and do not know how to
obtain it, contact Production M onitoring™ support a t
support@lincolnproductionmonitoring.com
Lincoln sales representative.
NOTE | These instructio ns ma y v ary depending on the operat ing
system installed on the server computer.
Procedure Details
or your loca l
1. Locate the Production Monitoring™ 2.2 patch
file you saved on your computer.
2. Right-click the patch file a nd select Extract All
from the pop-up menu.
3. Double-click the setup.exe file to begin the
installation of the Production Monitoring™
2.2 Patch.
4. When the installation process finishes, c lick
OK to close the applic a tion.
TIP | To find the files easily, crea te an empty
folder on your Desktop and extract the files to that
folder.
This process is aut om a ted and should not require
user involvement once the application begins to run.
The title bar of the a pplic ation should now read
Production Monitoring™ 2.2.
NOTE | If the patch encounters an error duri ng
install or th e s y s t em does not appear to be running
version 2.2, y ou should contact support for
assistance.
2.2Production Monitoring™User ManualIM8001
Chapter 3
Installing Production Monitoring™
If you have a new installation or you need to upgrade from Production Monit or ing™ 2.0 or lower , the
information in th is c hapter provides easy-to-follow instruc tions.
Installation Preparation
This section will guide yo u through the step-by-step proc e ss o f ho w to prep a r e the server compute r fo r th e
Production M onitoring™ software install. This installation section also includes how t o determine which
version is currently running in th e event you are performing a n upgr a de.
Prerequisit es f or Installing Production Monitoring™ 2.2
Before you can begin insta lling Production Monitoring™, you need to make sure that you have met certain
requirements and have certa in informa tion available to you. This helps ensure you have as efficient an
installation a s po ssible.
You must be logged on as an Administrator to the server computer .
Determine the current version being used if you ar e per forming a Pr oduction Monit or ing™
upgrade. Refer to page 3.2 to determine the version installed on your serve r co mputer .
STOP | If you need to upgrade from P roduction Monitoring™ 2.0,
you must completely uninstal l t his v ersion prior to installing
Production Monitoring™ 2.2. Refer to page 3.2 for uninst all
instructions.
If you need to upgrade from Productio n M onitoring™ 2.1,
you must run the P roduction Monitoring™ 2.2 patch. Refer
to Chapter 2 for instructions on running the patch.
The computer name must not contain any underscores (_). Exam ple : If the computer name is
“My_ Computer”, it should be changed to something like “MyComput e r”.
During installatio n , it is best to turn off any Firewalls o r se curity software on the
server computer.
Microsoft Inte r net Information Server (IIS) must be insta lle d before installing Production
Monitoring™. Refer to page 3.7 for information on how to install IIS for your ope rat ing sy st em.
If you are installing the soft w a re on a Windows Se r ver 2003 operating system, che c k to make
sure that Servic e Pa c k 1 or greater is installed. (Right-clic k the My Computer or Computer icon
on the desktop or Start menu and select Properties.)
For the Windows Server 2003 operating system, ver ify t ha t CO M+ is ena ble d. Refer to page 3.16
for information o n ho w to verify if this is enabled.
If your server computer is Windows Ser ve r 2008, Pow e r S hell must be inst a lle d ma nually. Refer
to page 3.18 to install P o w e rShell.
IM8001Production Monitoring™User Manual3.1
Chapter 3. Installing Production Monitoring™ Uninstalling Production Monitoring™ 2.0
Determini ng the Prod uction Monitoring™ Version
To determine the version of Production Monitor ing™ installe d on your se rver computer, simply launch
Production Monitoring™ on that computer and look at the Inter net browser tab for the applicat ion (Figure
3.1).
Figure 3.1 Verify Production Monitoring™ Version Number
In the event your browser does not display tabs, the applica tion 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 P r o duction M onitoring™ 2.1, you will then proceed as if your
Production Monitoring™ version is 2.0.
Uninstalling Production Monitoring™ 2.0
This section descr ibe s ho w to uninstall Production Monitoring™ 2.0. You m ust do this prior to installing
Production Monitoring™ 2.2.
STOP | Uninstalling will erase all previous da t a c ollected with
Productio n M onitoring™ 2.0. If you want t o s ave any
previously c ollected data, then d o not c ontinue. Contact
Productio n Monitoring™ suppo rt for assistance in sa v ing
your data. For P roduction 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@lincolnelectricproductionmonitor ing.com
Support will need to log in to the server computer remotely
in order to bac k up the previous database from Production
Monitoring ™ 2 .0.
3.2 P ro d uction 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 P r oduc tion Monitoring™ 2.0, you will uninstall various applic ations that comprise
the Production Monitoring™ “system”. This section explains how to remove the Production Monitoring™
2.0 software application. Ke e p in mind these steps may va ry depending on t he compute r Operating
System.
Figure 3.2 Uninstalling Software
Procedure Details
1. Select the Start > ControlPanel from the
computer’s main program menu.
2. Double-click the Add or Remove Programs icon.
3. Locate Lincoln Production Monitoring in the list
of software.
4. Click the Remove button.
5. Select the Uninstall button.
6. Click the Close button when the system finish es
uninstalling Product ion Monit or ing™ 2.0.
In newer versions of the Windows operating
system, the option is called Programs and Features.
See Figure 3.2.
The system prompts you to confirm that you want
to uninstall the software.
The system uninstalls the program and will inform
you when it is co mp le te.
IM8001 Production Monitoring™ User Manua l 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 Product ion Monit or ing™ 2.0 files from the default
installation location on the serve r comput er. Keep in mind t he se inst ructions ma y va ry depending on the
operating system installed on your computer.
Procedure Details
1. Open the Start menu and click My Computer.
2. Double-click the Local Disk (C:) icon.
3. Open the Program Files folder.
4. Open the Lincoln Electric folder.
5. Right-click the Production Monitoring folder
and select Delete from the pop-up me nu.
6. Click Yes.
Depending on your operating system, the option
could be called Computer . The contents of the
computer display.
The syste m d isp lays the folders sto r ed on your
local drive.
TIP | If there is no Production Monitoring folder
when you open the Lincoln Electric folder, you can
move to the next s ec t ion a nd skip the remaining
steps.
The system prompts you to confirm the deletion of
the folder.
Uninstalling SQL Management Studio
You must uninstall SQL Management Studio if you have it inst a lle d on your comput e r.
Procedure Details
1. Select the Start > ControlPanel from the
computer’s main program menu.
2. Double-click the Add or Remove
Programs icon.
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.
3.4 P ro d uction Monitoring™ User Manual IM8001
In newer versions of the Windows operating system,
the option is calle d P rog ra ms a nd Features.
The system proceeds with uninstalling Microso ft SQL
Server Management Studio Express.
Uninstallin g Production Monitoring ™ 2.0 Chap t er 3. Installing P r oduction Monitoring™
Uninstalling the SQL Server Instance
After you uninstall Microsoft SQL Se rver Manage me nt St udio Expr e ss, 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 Details
1. Select the Start > ControlPanel from the
computer’s main program menu.
2. Double-click the Add or Remove
Programs icon.
3. Locate Microsoft SQL Server 2005 in the list
of software.
4. Click the Remove button.
In newer versions of the Windows operating system,
the option is calle d P rog ra ms a nd Features.
The system proceeds to uninstall t he insta nc e.
During th e process, the syste m st ops and displays
the Component Selection window.
5. Choose LINCOLN: Database Engine and
click Next.
6. Click Finish to continue.
7. Exit the Add or Remove Programs window
when the process is complete.
IM8001Production Monitoring™User Manual3.5
STOP | Only remove the LINCOLN: Database
Engine entry. DO NOT remove any other
databases.
The syste m di splays a confirmatio n m essage.
The syste m completes the uninst all process.
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 Details
1. Select the Start > ControlPanel from the
computer’s main program menu.
2. Double-click the Administrative Tools icon.
3. Double-click the Internet Information
Services shortcut.
4. Click the plus sign ( + ) next to Machine
Name (local computer) to expand it.
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 .
The Control Panel opens.
The Administrative Tools window opens.
The system opens the Internet Information Services
window.
Where MachineName is the name of your computer
7. Right-click the LincolnPM option and select
Delete from the pop-up menu.
8. Click Yes to delete the item.
9. Right-click the IGear.Lincoln.Configuration
option and select Delete from the popup menu.
3.6Production Monitoring™User ManualIM8001
The system prompts you to confirm the deletion.
The system prompts you to confirm the deletion.
Installing Microsoft Internet Information Services (IIS) Chapter 3. Installing Production Monitoring™
Procedure Details
10. Click Yes to delete the item.
11. Restar t your computer .
After uninstalling a nd r e m oving a ll pr evious items, you
must restart your computer before continuing.
Installing Microsoft Internet Information Services (IIS)
Production Monitoring™ is an int ernal w e b-based applica tion that allows you and other users to access
data collected from the Welding P ower Sources co nne c ted to the applica t ion. 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 Micr o soft’s Internet Information Service s (or IIS) components.
TIP | When installing IIS on o lder computers, please be sure you
have the Windows installation C D for your operating
system. Check w it h y our local IT department for more
information.
The instructions are slight ly diffe r e nt de pending on th e Opera t ing S ystem (OS) of your Production
Monitoring™ server comput er. 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 Prof essional IIS Installation
With Windows XP P r o fe ssio nal, IIS is not installed by default. Follow the instructions below to inst a ll IIS.
Procedure Details
1. Log in to the server computer as the
administrator user.
2. Insert the original Microsoft Operating
System d isk .
3. Choose the Install Windows XP option under
the What do you want to do? question.
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 Manua l 3.7
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