Lincoln Electric WAVE DESIGNER IM649 User manual

Wave DesignerTM
SOFTWARE OPERATOR’S MANUAL
IM649
May, 1999
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 thought-
ful 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.
Pulse Waveform Editor
Wire Feed Speed
Ramp Up Rate
Peak Amps
Peak Time ms
Tailout Time
Tailout Speed
Stepoff Amps
Backgrd Amps
Backgrd Time
Frequency
Ramp Overshoot %
26.4
33.4
21
40
.100
3.0
1.2
250
-20
600
Edit
Start
About
Adapt Short End
Wave Designer Pro Off Line - pulse.swf
700
600
500
400
300
200
100
00 3 6 9 12 15 18 21 24 27 30
File Tools Print Help
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50
Off Line Stand by
Status AC.sco loaded Adaptive
• Sales and Service through Subsidiaries and Distributors Worldwide •
Cleveland, Ohio 44117-1199 U.S.A. TEL: [phone] FAX: [phone] WEB SITE: www.lincolnelectric.com
World's Leader in Welding and Cutting Products Premier Manufacturer of Industrial Motors

WAVE DESIGNER
i
TABLE OF CONTENTS
Page
License Information ..................................................................................................... ii
Introduction .................................................................................................... Section 1
1.1 Product Overview .......................................................................................... 1-1
1.2 User Responsibility ....................................................................................... 1-1
1.3 Computer System Requirements .................................................................. 1-1
1.4 Software Release Data ................................................................................. 1-2
1.5 Welding Equipment Requirements ................................................................ 1-2
Software Installation ...................................................................................... Section 2
2.1 File Storage Locations ................................................................................. 2-1
2.2 Software Installation Procedure .................................................................... 2-1
2.3 Equipment Interface Connections ................................................................. 2-2
2.4 Equipment/Software Startup ......................................................................... 2-4
2.5 Upgrade Firmware ........................................................................................ 2-4
Software Operation ........................................................................................ Section 3
3.1 Synergic Welding and Workpoints ................................................................ 3-1
3.2 Working in Wave Designer ............................................................................ 3-2
3.3 Wave Design Process ................................................................................. 3-11
3.4 Downloading Wave Shapes ........................................................................ 3-12
3.5 Autosave ..................................................................................................... 3-13
ArcScope ........................................................................................................ Section 4
4.1 Introduction ................................................................................................... 4-1
Troubleshooting ............................................................................................ Section 5
5.1 Overview ....................................................................................................... 5-1
5.2 Wave Designer Troubleshooting Procedure ................................................. 5-1
Pulse Wave Shaping Principles ............................................................... Appendix A
A.1 Appendix Overview ...................................................................................... A-1
A.2 GMAW Pulse Overview ................................................................................ A-2
A.3 Adaptive and Non-Adaptive Mode ................................................................ A-4
A.4 Pulse Wave Design Process ........................................................................ A-5
A.5 Primary Pulse Waveform Components ...................................................... A-14
A.6 Secondary Waveform Parameters ............................................................. A-16
A.7 Application Exercise ................................................................................... A-17
STT Wave Shaping Principles .................................................................. Appendix B
B.1 Appendix Overview ...................................................................................... B-1
B.2 STT Overview ............................................................................................... B-2
B.3 STT (Surface Tension Transfer) ................................................................... B-4
B.4 STT Wave Design Process .......................................................................... B-6
B.5 Primary STT Waveform Components ........................................................ B-12
B.6 Secondary STT Waveform Components .................................................... B-14
B.7 Application Exercise ................................................................................... B-15
i

By clicking the acceptance button or installing the software, you are consenting to be bound by and are becoming
a party to this agreement. If you do not agree to all of the terms of this agreement, click the button that indicates
you do not accept the terms and do not install the software. (If applicable, you may return the product to the place
of purchase for a full refund.) If the copy of the software you received was accompanied by a printed or other
form of "hard-copy" end user license agreement whose terms vary from this agreement, then the hard-copy end
user license agreement governs your use of the software.
WAVE DESIGNER SOFTWARE LICENSE AGREEMENT
LICENSE:
Lincoln grants you the right to use the Wave Designer Software ("the Software"). You will not use, copy, modify, rent, sell or transfer this
Software, or any portion thereof, except as provided for in this Agreement. The Software includes and utilizes Java Runtime software owned
by Sun Microsystems, Inc. and this license is conditioned upon your agreement to the Sun Microsystems Binary Code License which is
attached and made a part of this license. There is no legal or commercial association between Lincoln and Sun Microsystems, Inc.
You may use the Software on a single computer and with any Lincoln arc welding equipment which you own or lease. If the software is
installed on a networked computer, only one (1) copy can be used at a time.
RESTRICTIONS: You may not:
1) Use the Software on more than one computer or with non-Lincoln arc welding equipment.
2) Sub-license the Software.
3) Reverse engineer, de-compile, disassemble, modify, or extract archived files from the Software.
4) Copy the Software, except for backup purposes.
5) Sell, license, or patent welding applications, waveforms, or other know how developed with this Software.
NON-DISCLOSURE:
You agree that the Software is and shall remain the property of Lincoln Electric, and that you will hold the Software in confidence for Lincoln.
You agree to make reasonable efforts to prevent unauthorized use of the Software, and to prevent disclosure to third parties.
ROYALTY-FREE:
Provided you have paid the initial license fee, you will be under no obligation to pay Lincoln a royalty for the use of the Software when used as
permitted under this license.
WARRANTY:
Lincoln warrants to the original purchaser that the Software will perform substantially as described in the Software documentation for a period
of 90 days from the date of purchase. Lincoln's liability under this warranty shall not exceed the amount you paid for the Software. No
warranty is made by Lincoln that the Software is free of errors or limitations. No warranty is made by Lincoln with respect to the Java Runtime
software.
THE ABOVE WARRANTIES ARE THE ONLY WARRANTIES OF ANY KIND EITHER EXPRESSED OR IMPLIED, INCLUDING
WARRANTIES OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE. LINCOLN SHALL NOT BE LIABLE FOR ANY
LOSS OF PROFITS, LOSS OF USE, INTERRUPTION OF BUSINESS, NOR FOR INDIRECT, SPECIAL, INCIDENTAL OR
CONSEQUENTIAL DAMAGES OF ANY KIND WHICH RELATE TO USE OF THE SOFTWARE. SELECTION AND APPLICATION OF THE
SOFTWARE IS YOUR SOLE RESPONSIBILITY AND NO WARRANTY IS GIVEN WITH REGARD TO WELDING CHARACTERISTICS
DESIGNED USING THIS SOFTWARE OR THE SUITABILITY OF WELDS PRODUCED USING SUCH CHARACTERISTICS.
TRANSFER:
You may transfer the Software, subject to this license, to another party if the receiving party also purchases from you the Invertec Power
Wave power source with which this Software is used. Prior to any such transfer, the transferee must agree to the terms of this license and
you must notify Lincoln, in writing, of the name and address of the party to whom the Software has been transferred. You must retain no
copies of the Software and accompanying documentation. Transfer of the license terminates your right to use the Software. This Software
may not be exported except as permitted by the export laws of the United States.
IMPROVEMENTS:
From time-to-time, Lincoln may make improvements in the Software. You agree that there is no obligation on the part of Lincoln to provide
you with or notify you of any improvements. Such improvements may be purchased by you from Lincoln under the terms of a separate
License Agreement or Maintenance Agreement for that Software. Additional charges for installing and trouble-shooting may apply.
POST-TERMINATION OBLIGATIONS:
If this Agreement is terminated, you must stop using the Software and, except in the case of transfer, destroy all copies. Your confidentiality
obligation shall survive termination and remain in effect for a period of five years following termination.
APPLICABLE LAW:
This License Agreement shall be interpreted and construed in accordance with the laws of the State of Ohio, and any litigation brought under
this License Agreement shall be filed in the State or Federal Courts in the State of Ohio. The United Nations Convention for the International
Sales of Goods is expressly excluded. Any claim arising out of this License Agreement will first be submitted for resolution by arbitration.
TERM AND TERMINATION:
This Agreement shall remain in effect for so long as the Wave Designer Software is in use as permitted under this license. The license may
be terminated by you at any time by removing and returning to Lincoln all copies of the Software.
ii ii
LICENSE INFORMATION
WAVE DESIGNER

JAVA RUNTIME ENVIRONMENT, VERSION 1.1.6, BINARY CODE LICENSE
This binary code license ("License") contains rights and restrictions associated with use of the accompanying Java Runtime Environment
software and documentation ("Software"). Read the License carefully before using the Software. By using the Software you agree to the
terms and conditions of this License.
1. License to Distribute. Licensee is granted a royalty-free right to reproduce and distribute the Software provided that Licensee: (i)
distributes the Software complete and unmodified (except for the specific files identified as optional in the Software README file), only as
part of, and for the sole purpose of running, Licensee's Java compatible applet or application ("Program") into which the Software is
incorporated; (ii) does not distribute additional software intended to replace any component(s) of the Software; (iii) agrees to incorporate
the most current version of the Software that was available 180 days prior to each production release of the Program; (iv) does not
remove or alter any proprietary legends or notices contained in the Software; (v) includes the provisions of Sections 2, 3, 5, 6, 8 and 9 in
Licensee's license agreement for the Program; and (vi) agrees to indemnify, hold harmless, and defend Sun and its licensors from and
against any claims or lawsuits, including attorneys' fees, that arise or result from the use or distribution of the Program.
2. Java Platform Interface. Licensee may not modify the Java Platform Interface ("JPI", identified as classes contained within the "java"
package or any subpackages of the "java" package), by creating additional classes within the JPI or otherwise causing the addition to or
modification of the classes in the JPI. In the event that Licensee creates any Java-related API and distributes such API to others for
applet or application development, Licensee must promptly publish broadly, an accurate specification for such API for free use by all
developers of Java-based software.
3. Restrictions. Software is confidential copyrighted information of Sun and title to all copies is retained by Sun and/or its licensors.
Licensee shall not decompile, disassemble, decrypt, extract, or otherwise reverse engineer Software. Software may not be leased,
assigned, or sublicensed, in whole or in part, except as specifically authorized in Section 1. Software is not designed or intended for use
in online control of aircraft, air traffic, aircraft navigation or aircraft communications; or in the design, construction, operation or
maintenance of any nuclear facility. Licensee warrants that it will not use or redistribute the Software for such purposes.
4. Trademarks and Logos. This License does not authorize Licensee to use any Sun name, trademark or logo. Licensee acknowledges
that Sun owns the Java trademark and all Java-related trademarks, logos and icons including the Coffee Cup and Duke ("Java Marks")
and agrees to: (i) comply with the Java Trademark Guidelines at http://java.sun.com/trademarks.html; (ii) not do anything harmful to or
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acquired by Licensee in any Java Mark.
5. Disclaimer of Warranty. Software is provided "AS IS," without a warranty of any kind. ALL EXPRESS OR IMPLIED
REPRESENTATIONS AND WARRANTIES, INCLUDING ANY IMPLIED WARRANTY OF MERCHANTABILITY, FITNESS FOR A
PARTICULAR PURPOSE OR NON-INFRINGEMENT, ARE HEREBY EXCLUDED.
6. Limitation of Liability. SUN AND ITS LICENSORS SHALL NOT BE LIABLE FOR ANY DAMAGES SUFFERED BY LICENSEE OR ANY
THIRD PARTY AS A RESULT OF USING OR DISTRIBUTING SOFTWARE. IN NO EVENT WILL SUN OR ITS LICENSORS BE LIABLE
FOR ANY LOST REVENUE, PROFIT OR DATA, OR FOR DIRECT, INDIRECT, SPECIAL, CONSEQUENTIAL, INCIDENTAL OR
PUNITIVE DAMAGES, HOWEVER CAUSED AND REGARDLESS OF THE THEORY OF LIABILITY, ARISING OUT OF THE USE OF
OR INABILITY TO USE SOFTWARE, EVEN IF SUN HAS BEEN ADVISED OF THE POSSIBILITY OF SUCH DAMAGES.
7. Termination. This license shall automatically terminate 180 days after production release of the next version of the Software by Sun.
Licensee may terminate this License at any time by destroying all copies of Software. This License will terminate immediately without
notice from Sun if Licensee fails to comply with any provision of this License. Upon such termination, Licensee must destroy all copies of
Software.
8. Export Regulations. Software, including technical data, is subject to U.S. export control laws, including the U.S. Export Administration Act
and its associated regulations, and may be subject to export or import regulations in other countries. Licensee agrees to comply strictly
with all such regulations and acknowledges that it has the responsibility to obtain licenses to export, re-export, or import Software.
Software may not be downloaded, or otherwise exported or re-exported (i) into, or to a national or resident of, Cuba, Iraq, Iran, North
Korea, Libya, Sudan, Syria or any country to which the U.S. has embargoed goods; or (ii) to anyone on the U.S. Treasury Department's
list of Specially Designated Nations or the U.S. Commerce Department's Table of Denial Orders.
9. Restricted Rights. Use, duplication or disclosure by the United States government is subject to the restrictions as set forth in the Rights in
Technical Data and Computer Software Clauses in DFARS 252.227-7013© (1) (ii) and FAR 52.227-19© (2) as applicable.
10. Governing Law. Any action related to this License will be governed by California law and controlling U.S. federal law. No choice of law
rules of any jurisdiction will apply.
11. Severability. If any of the above provisions are held to be in violation of applicable law, void, or unenforceable in any jurisdiction, then
such provisions are herewith waived or amended to the extent necessary for the License to be otherwise enforceable in such jurisdiction.
However, if in Sun's opinion deletion or amendment of any provisions of the License by operation of this paragraph unreasonably
compromises the rights or increase the liabilities of Sun or its licensors, Sun reserves the right to terminate the License.
iii iii
LICENSE INFORMATION
WAVE DESIGNER

iv iv
LICENSE INFORMATION
WAVE DESIGNER

1.1 PRODUCT OVERVIEW
Wave Designer is a visual, interactive software application used to modify wave shapes for use
with programmable waveform-controlled welding machines such as the Power Wave 455. The
Wave Designer software package includes a standard set of waveforms commonly used in
commercial and industrial welding applications.
The Wave Designer software package is intended for use by a weld application engineer in
concert with a skilled welding technician properly trained in welding applications.
This Instruction Manual guides you through the installation and operation of Wave Designer to
modify selected standard wave shapes and produce pulsed waveforms tailored to your specific
welding applications. The resulting custom waveforms automatically adjust your welding machine
to produce consistent weld transfers throughout a range of wire feed speeds and arc lengths.
1.2 USER RESPONSIBILITY
Section 1 1-1
INTRODUCTION
WAVE DESIGNER
Because design, fabrication, erection, and welding variables affect the results obtained in
applying this type of information, the serviceability of a product or structure is the
responsibility of the user. Variations such as plate chemistry, plate surface condition (oil,
scale), plate thickness, preheat, quench, joint fit-up, gas type, gas flow rate, and
equipment may produce results different than those expected. Some adjustments to
procedures may be necessary to compensate for unique individual conditions. When
possible, test all procedures, duplicating actual field conditions.
1.3 COMPUTER SYSTEM REQUIREMENTS
Wave Designer software is intended for use on Windows 95, Windows 98, or Windows NT 4.0.
It will not work with Windows NT 3.51, Windows 3.1, or Windows for Workgroups. The core of
this product is architecture-neutral (operating system independent). If you would like to have
Wave Designer on Solaris SPARC, Solaris x86, MAC OS, AIX, OS/2, or Linux, please notify us
at [email protected]. With Java Internationalization, Wave Designer can
support numerous European and Asian languages. Send your foreign language request to
[email protected].
We recommend a Pentium processor, 32 MB of RAM, and 6 MB of hard drive disk space for
efficient program operation. When running, Wave Designer occupies at least 10 MB of RAM. If
your computer is low in memory, we suggest you close other programs that consume large
memory. If you have less than 32 MB RAM, you may be able to run Wave Designer with “virtual
memory”. Set up virtual memory with one of the following command sequences.
In Windows 95 or 98 Start | Settings | Control Panel | System | Performance
Virtual Memory | Let me specify my own virtual memory settings
Minimum 100 | OK | Are you sure you want to continue? Yes | Close
Do you want to restart your computer now? Yes
KEY TOPICS
This symbol indicates the location of key concepts throughout this manual.

In Windows NT 4.0 log on as Administrator
Start | Settings | Control Panel | System | Performance
Virtual Memory Change... | Initial Size (MB): 100 | Set | OK
Do you want to restart your computer now? Yes
An RS-232 serial communication cable is required to use Wave Designer software with Power
Wave power sources. The Power Wave requires an RS-232 DB25 male connector. Most
computers feature an RS-232 DB-9 female connector as the COM serial port. (e.g. Radio Shack
cat no. 26-269 serial cable connects to this combination). Verify the set up on your computer as
it may differ.
We recommend using an 800 x 600 pixel or larger display monitor. A 640 x 480 display will not
show all the features of the Wave Designer Editor Screens.
1.4 SOFTWARE RELEASE DATA
Wave Designer is a product of The Lincoln Electric Company. Please send your comments,
questions, suggestions, and problem reports to [email protected].
Refer to the Wave Designer Welcome screen for the applicable release version of the Wave
Designer software package. Wave Designer is a JAVA (TM) application (applet) and it comes
bundled with Java Runtime Environment (JRE Version 1.1.6) from SUN Microsystems. You may
directly download JRE from http://java.sun.com/products/jdk/1.1/jre/index.html. More information
about JAVA technology can be found at the http://java.sun.com web site.
1.5 WELDING EQUIPMENT REQUIREMENTS
Wave Designer works only with the Power Wave 455 or similar Lincoln Electric Company
Programmable Waveform Controlled welding systems. The following welding equipment is
required to interface with Wave Designer and to produce sample welds.
• power source (Power Wave 455 or similar)
• wire feeder and associated gears and drive rolls (Power Feed 10 or similar)
• welding gun
• regulated supply of shielding gas
• continuous-feed electrode
• interconnecting hoses and cables
• sample weld materials
• oscilloscope (optional)
1-2 Section 1
INTRODUCTION
WAVE DESIGNER

2.1 FILE STORAGE LOCATIONS
The Wave Designer default home directory is C:\Program Files\WaveDesigner.
Subdirectories included with Wave Designer are as follows:
• arcScope - user data file for ArcScope traces (Wave Designer Pro option only)
• bin - system executables and support files, do not tamper with these files
• export - user waveform data table in ASCII text and html format
• firmware - bundled system firmware for PW455 machines
• jre - bundled Java Runtime Environment 1.1.6 from Sun Microsystems
• map - waveform editor template map files, do not tamper with them
• pictures - image files for GMAW droplet transfer movies
• systemWeldFile - user custom waveform files
• weldModeFile - copies of the weld mode directory (weld files for the welding machine)
2.2 SOFTWARE INSTALLATION PROCEDURE
Standard installation (CD ROM version): Start | Run | Browse; Run D:\setup.exe
Install the Wave Designer program as you would any Windows application. Select the Wave
Designer program icon from your START window to start up the program. Refer to Table 2-1 for
alternate installation procedures. On startup, the Wave Designer screens in Figure 2-1 will be
displayed.
NOTE: If upgrading a previous software release, save your data files (waveforms, scope traces,
etc.) and uninstall the previous software release before installing the new version.
TABLE 2-1. ALTERNATE INSTALLATION PROCEDURES.
Section 2 2-1
SOFTWARE INSTALLATION
WAVE DESIGNER
Application/
Operation Drive Command Sequence
Install Floppy Disk Version A Start | Run | Browse; Run setup.exe
Install Java Runtime All Create shortcut: <dir>\jrew.exe -ms12000000 -cp .\*.jar Pwgui
Executable Version Start Program: <dir>\Program Files\WaveDesigner\bin
Install Wave Designer Windows NT 4.0 Create Start Menu Shortcut; set icon for “All Users”
Icon
Start Wave Designer in a C Open C:\Program Files\WaveDesigner\bin
DOS Window Type: jre -ms12000000 -cp .\*.jar Pwgui
or:..\jre\bin\jre -ms12000000 -cp .\*.jar Pwgui
Start | Settings | Control Panel | Add/Remove Programs
Uninstall Program All Select Wave Designer in scroll window and click on
Add/Remove button. Use Windows Explorer or File Manager to
remove Wave Designer folder.

FIGURE 2-1.
WAVE DESIGNER
STARTUP SCREEN.
2-2 Section 2
SOFTWARE INSTALLATION
WAVE DESIGNER
Lincoln Electric Wave Designer Version 1.0
Copyright ©1998 The Lincoln Electric Company
All Rights Reserved
United States Patent Pending
Comments? Write to [email protected]
Initializing ... Please wait
27850002
Wave Designer
WARNING: This computer program is protected by copyright law
and international treaties. Unauthorized reproduction or
distribution of this program, or any part of it, may be prosecuted to
the maximum extent possible under the law.
Welcome to Wave Designer
2.3 EQUIPMENT INTERFACE CONNECTIONS
Wave Designer communicates welding parameter changes to the welding machine controller in
real time (on-the-fly). To enable communication with Wave Designer, reconfigure the welding
machine settings as follows:
1. Disconnect the electrical power to the welding machine.
2. Remove the control box LED display panel, Figure 2-2. Be careful not to pull hard on the
panel wiring harness.
3. Locate the bottom DIP switch block (SW2) on the user interface control board. Move the last
DIP switch (position #8) up and reinstall the LED display panel.
4. Toggle the control box SELECT switch up and down until the Weld Mode indicator lights up.
Toggle the SET switch to get an OFF readout on the LED display.
5. An RS-232 serial communication cable is required to use Wave Designer software with
Power Wave power sources. The Power Wave requires an RS-232 DB25 male connector.
Most computers feature an RS-232 DB-9 female connector as the COM serial port. (e.g.
Radio Shack cat no. 26-269 serial cable connects to this combination). Verify the set up on
your computer as it may differ.
6. Connect the RS-232 cable between the COM1 port of your computer and the mating
connector behind the front center panel of the power source, Figure 2-3.

Section 2 2-3
SOFTWARE INSTALLATION
WAVE DESIGNER
SW1
SW2
1
1
2
2
3
3
4
4
5
5
6
6
7
7
8
8
ON
ON CONTROL
BOX
CONTROL
BOARD
27850003
FRONT
PA N E L
POWER
SOURCE RS232
CABLE
COMPUTER
SYSTEM
27850004
FIGURE 2-2. CONTROL BOARD DIP SWITCH SETTING.
FIGURE2-3. INTERFACE CONNECTION.
PLEASE NOTE: Some IBM ThinkPads® by default have the serial port disabled and instead the port is used for infrared. The
following information describes the procedure to disable the infrared feature and enable the serial port. Follow the instructions
below to use COM1 to communicate with the PowerWave. More instructions at the end discuss how to use other ports, if
necessary.
The following information can also be found at the IBM website at
http://www.pc.ibm.com/qtechinfo/DSHY-3P5QW4.html
How to enable the external serial port on your ThinkPad
SYMPTOM:
The ThinkPad is not communicating with the PowerWave serial device.
CONFIGURATION:
Any ThinkPad trying to utilize the external serial port using any applicable operating systems.
RESOLUTION:
By default, currently available ThinkPads come with the external serial port disabled and Infrared enabled on COM 1. To use
the serial port on COM 1 you must either disable infrared or change infrared so that it uses alternate resources. If you are not
using infrared for printing or file sharing it is recommended that it be disabled.
To disable infrared and enable the serial port on COM 1 do the following:
1. Double-click your ThinkPad Features or ThinkPad Configuration icon located in the ThinkPad folder on your desktop.
2. Locate the Infrared button located on the left-hand side of this configuration screen and click it once.
(Note: If you hold your mouse pointer over any of the icons in this configuration screen the button will be identified at the
bottom in the status window.)
3. Change Infrared from "Enable" to "Disable" and click "OK".
4. Locate the serial port icon and click it once.
5. Select serial port "enable" and insure that the COM PORT setting is "COM 1" and click "OK".
6. Shut down and restart the computer.
More Information:
There are many different combinations of port settings that are possible. The following table indicates the standard settings for
the four available COM Ports:
COM 1 03F8 4 COM 2 02F8 3
COM 3 03E8 4 COM 4 02E8 3
Please note that COM 1 and 3 share IRQ 4 and COM 2 and 4 share IRQ 3. You can not configure multiple devices to the
same IRQ.
If not successful, try to use COM3. Follow the instructions above while substituting COM1 with COM3. Configure Wave
Designer by changing the properties of the Wave Designer icon (right click mouse when pointing to the icon), add "-port com3"
to the command line.

2.4 EQUIPMENT/SOFTWARE STARTUP
When the Wave Designer software installation is complete, Wave Designer is listed among the
programs you can start up from the Windows startup screen. Click on START, point to the
programs option, then click on the Wave Designer option. The Wave Designer Welcome
screen is displayed followed by the Pulse Waveform Editor screen. When the Pulse Waveform
Editor screen is displayed, the software is ready for use.
2-4 Section 2
SOFTWARE INSTALLATION
WAVE DESIGNER
Pulse Waveform Editor
Wire Feed Speed
Ramp Up Rate
Peak Amps
Peak Time ms
Tailout Time
Tailout Speed
Stepoff Amps
Backgrd Amps
Backgrd Time
Frequency
Ramp Overshoot %
26.4
33.4
21
40
.100
3.0
1.2
250
-20
600
Edit
Start
About
Adapt Short End
Wave Designer Pro Off Line - pulse.swf
700
600
500
400
300
200
100
00 3 6 9 12151821242730
File Tools Print Help
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50
Off Line Stand by
Status AC.sco loaded Adaptive
27850001
2.5 UPGRADE FIRMWARE
An ArcScope application is provided with Wave Designer Pro. In order to run the ArcScope
application, it may be necessary to upgrade the welding machine firmware. If the old firmware
does not support ArcScope, the ArcScope application will display garbled data rather than
waveforms. Wave Designer will automatically detect the firmware version and prompt you to
upgrade the firmware if required.

3.1 SYNERGIC WELDING AND WORKPOINTS
Prior to using Wave Designer it is important to have a good understanding of the concepts of
synergic welding and workpoints. Synergic welding is basically “one knob control” of a welding
process; all other variables of the process are adjusted by the power source based on the single
controlling variable. This single controlling variable is known as a workpoint. For example, in
synergic pulse welding (GMAW-P), the operator can adjust the wire feed speed (WFS). The
WFS is the workpoint. The synergic power source will then set all other GMAW-P variables
based on the WFS by “looking up” the other variables from a pre-programmed weld table. See
Figure 3-1.
Wave Designer is a program that lets you develop a customized weld procedure by letting you
program each variable for multiple workpoints into a weld “look up” table.
Power Wave power sources go even a step further than simply “looking up” pre-programmed
variables from a weld table. If a selected WFS is between two pre-programmed workpoints, the
Power Wave will interpolate values for each of the welding variables. The result is a precise and
continuous range of welding control.
Refering to Figure 3-1, lets examine how this interpolation works by looking at one welding
variable — background amps. The operator selects a wire feed speed of 175 in/min. This value is
between the pre-programmed workpoints of 150 and 200 in/min. The Power Wave interpolates
between the pre-programmed background amp values of 80 and 60 and adjusts the background
amps to 70.
FIGURE 3-1. WFS ENCODER AND WELD DATA TABLE.
Section 3 3-1
SOFTWARE OPERATION
WAVE DESIGNER
27850005
WFS/AMPS
ENCODER
NOTE: WFS ENCODER SETTING
DETERMINES WELDING
PROCESS VARIABLES PER
RELATED WELD TABLE.
WORK-
POINTS
(WFS)
PEAK CURRENT PULSE WIDTH BACKGROUND AMPS FREQUENCY
80
100
150
200
250
280
280
280
280
280
1.2
1.2
1.2
1.2
1.2
20
40
60
80
100
50
60
80
90
100
PRE-PROGRAMMED WELDING PROCESS VARIABLES INTERPOLATED
PARAMETER VALUE
10
0
20
30
40
50
60
70
80
90
100
1000 15050 200
INTERPOLATED
BACKGROUND AMPS
WFS = 175
WIRE FEED SPEEDS
BACKGROUND AMPS

3.2 WORKING IN
WAVE DESIGNER
3.2.1 WAVEFORM EDITOR WINDOW
Refer to the Waveform Editor window in Figure 3-2 and the related usage instructions.
FIGURE 3-2. WAVEFORM EDITOR WINDOW.
3-2 Section 3
SOFTWARE OPERATION
WAVE DESIGNER
Pulse Waveform Editor
Wire Feed Speed
Ramp Up Rate
Peak Amps
Peak Time ms
Tailout Time
Tailout Speed
Stepoff Amps
Backgrd Amps
Backgrd Time
Frequency
Ramp Overshoot %
26.4
33.4
21
40
.100
3.0
1.2
250
-20
600
Edit
Start
About
Adapt Short End
Wave Designer Pro Off Line - pulse.swf
700
600
500
400
300
200
100
00 3 6 9 12 15 18 21 24 27 30
File Tools Print Help










 








50
Off Line Stand by
Status AC.sco loaded Adaptive
1
2
5
3
6
7
4
27850006
1. Tool Bar Tool bar menus access alternate windows, open and save files, etc. Detailed
instructions are provided in paragraph 3.2.2.
2. Workpoint Selector/Editor The workpoint selector includes a pulldown window for
selecting a workpoint and an edit window for changing the listing of workpoint values. For
the Pulse Waveform Editor, the workpoints are wire feed speeds. The workpoint parameter
(peak voltage, current, etc.) varies with the welding mode (pulse, STT, etc.). Refer to
paragraph 3.2.3 for more detail on selecting and editing workpoints.
3. Variable Parameters The listing of variable parameters display the active parameter
values for the selected WFS. The parameter values are changed (edited) with the related
arrows and slide bars or by moving parameter nodes in the waveform graphic editor. See
paragraph 3.2.4 for more details on editing variable parameters and the wave shape.
4. Graphic Editor The graphic editor displays the active wave shape. The wave shape
changes when the parameter values are changed. The displayed wave parameter nodes
(boxes) can be selected with your mouse to edit the variable parameters. Pressing the
<F1> key will also toggle from one selected node to another. See paragraph 3.2.4 for more
details on editing variable parameters and the wave shape.

Section 3 3-3
SOFTWARE OPERATION
WAVE DESIGNER
5. Optional Windows The optional window buttons open additional windows used during
wave shaping. Optional windows in the pulse Waveform Editor include Start, Adapt, Short,
End, and About. Details about the use of most optional windows is covered in the applicable
appendix (i.e. Appendix A for Pulse Wave Shaping). We use the About window shown in
Figure 3-3 to record descriptive weld application data for custom wave shape files. This
information is stored with the program in the computer and in the Power Wave.
FIGURE 3-3. THE “ABOUT” EDIT WINDOW.
6. Wave Designer Status Bar This status bar provides a scrolled listing of recent program
events, error conditions, etc. Use the arrow keys ∂ƒto scroll through the listings. The status
bar includes three system status indicators: on line/off line, standby/welding, and
adaptive/non-adapt. The adaptive indicator is also a button that toggles between the
adaptive and non-adaptive mode.
7. Volts/Amps Display The Volts/Amps display, Figure 3-4, provides real time, oscilloscope
type displays of the voltage and amperage outputs from the connected power source.
Smaller display monitors (640 x 480 pixels or less) will not show the volts/amps display.
FIGURE 3-4. TYPICAL VOLTS/AMPS DISPLAY.
About the Procedure
About the Procedure
Process Type GMAW
Wire Type
Wire Size
Process Name
27850007
Steel Pulse A
Procedure
Gas super GAS
.035 Steel
6.3mm
Other










 








On Line Adaptive
27850008
Welding

3-4 Section 3
SOFTWARE OPERATION
WAVE DESIGNER
3.2.2 WAVEFORM EDITOR TOOL BAR
There are four menu selections available on the pulse waveform editor tool bar. The following
describes how to use the File, Tools, and Print menus. The Help menu is self explanatory.
3.2.2.1 FILE MENU
The File menu provides options for accessing
and managing waveform data files. The File
menu options include the following:
Open Waveform Ctrl+O
Use the Open Waveform option to open a
Wave Designer waveform or an in-house
custom waveform you created and saved
earlier.
Save Waveform As ...
Use the Save Waveform As ... option to save
an open waveform under a different filename.
Save Waveform Ctrl+S
The Save Waveform option saves all recent
changes to an open waveform file.
Open Scope Trace (Wave Designer Pro option only)
Use the Open Scope Trace option to open a graphical display of oscilloscope type waveforms
(volts, ohms, amps, etc.) for any stored waveform (.swf) file.
Save Scope As ... (Wave Designer Pro option only)
Use this option to save an open Scope Trace file under a different filename.
Save Scope (Wave Designer Pro option only)
The Save Scope option saves changes to the parameters in a .sco file caused by recent changes
to an open waveform file. Failure to actively open and save the Scope Trace file may result in an
inaccurate parameter record for a waveform undergoing design changes.
Export to Text File
Use the Export to Text File option to save a tabular record of the waveform variables data at
each of its design (Wire Feed Speed) workpoints.
Export to HTML Web Pages
Use the Export to Web Pages option to copy a custom waveform to a web page for transmission
of the waveform to Lincoln Electric for review.
Quit Ctrl+Q
Use the Quit option to exit the Wave Designer program.
File
Open Waveform Ctrl+O
Ctrl+S
Ctrl+Q
Save Waveform As ...
Save Waveform
Open Scope Trace
Save Scope As ...
Save Scope
Export to Text File
Export to HTML Web Pages
Import Text File
27850009
Quit
Tools Print Help

3.2.2.2 TOOLS MENU
The Tools menu includes waveform display
options and other tools required to operate
Wave Designer. The Tools menu options
include the following:
Pulse Editor Ctrl+P
Display the Pulse Waveform Editor screen.
STT Editor Ctrl+E
Display the STT Waveform Editor screen.
Simplify Editor
Display the primary wave shaping parameters
only. (See page A-1.)
ArcScope Ctrl+A
(Wave Designer Pro option only)
Display the Scope Trace screen for the currently displayed waveform.
Flash Custom Waveform Ctrl+F
Transmit selected waveforms to the welding
machine. This option requires that the
equipment interconnections are made and
that the welding machine is on-line
(communicating).
Browse Mode Directory Ctrl+B
Display the Weld Mode Directory screen. The
Weld Mode Directory lists the waveforms that
are presently downloaded into the welding
machine controller memory. You can
download up to ten custom waveforms to the
weld mode directory, memory slots (Modes)
155 through 164.
Upgrade Firmware
Use this option when installing new firmware on your welding machine. The new firmware is
required to run this Wave Designer software release. When later software releases are issued,
they may or may not include firmware upgrades. If firmware upgrades are included, you will use
the Upgrade Firmware option to install the upgrades.
Go Offline
Use the Go Offline option to temporarily interrupt and re-establish communications between the
welding machine / wire feeder and Wave Designer.
Section 3 3-5
SOFTWARE OPERATION
WAVE DESIGNER
27850011
Wave Designer Pro Off Line - pulse.swf
Search Weld Mode Directory
Off Line
Upload from Machine 0% done
Stand by
Status weldfile uploaded Adaptive
File Tools Print Help
Search for:
Mode 12: NST3510C.SWG: Steel Pulse, .035 Steel, Argon CO2 Blends
Mode 20: N45ST00C.SWG: Mig 3, .045 Steel, CO2
Mode 21: N45ST10C.SWG: Mig 3, .045 Steel, Argon CO2 Blends
Mode 22: NST4510C.SWG: Steel Pulse, .045 Steel, Argon CO2 Blends
Mode 24: N52ST00C.SWG: Mig 3, .052 Steel, CO2
Mode 25: N52ST10C.SWG: Mig 3, .052 Steel, Argon CO2 Blends
Mode 26: NST5210C.SWG: Steel Pulse, .052 Steel, Argon CO2 Blends
Mode 31: N35SS02.SWG: Mig 3, .035 Stainless, Argon Oxy Blends
Mode 32: NSS3502.SWG: Stainless Pulse2, .035 Stainless, Argon Oxy Blends
Mode 41: N45SS02.SWG: Mig 3, .045 Stainless, Argon Oxy Blends
Mode 42: NSS4502.SWG: Stainless Pulse2, .045 Stainless, Argon Oxy Blends
Mode 71: N48AL43.SWG: MIG 1, 3/64 4043, 100% Argon
Mode 72: NAL4843.SWG: Aluminum Pulse, 3/64 4043, 100% ARGON
Mode 73: N62AL43.SWGL MIG 1, 1/16 4043, 100% Argon
Mode 74: NAL6243.SWG: Aluminum Pulse, 1/16 4043, 100% Argon
Mode 75: N48AL56.SWG: MIG 1, 3/64 5356, 100% Argon
Mode 76: NAL4856.SWG: Aluminum Pulse, 3/64 5356, 100% Argon
Mode 77: N62AL56.SWG: MIG 1, 1/16 5356, 100% Argon
Mode 78: NAL6256.SWG: Aluminum Pulse, 1/16 5356, 100% Argon
Mode 81: N45MC10C.SWG: FCAW_GS, .045 MC-710, Argon CO2 Blends
Mode 82: NMC4510C.SWG: Pulse Metal Core, .045 MC-710, Argon CO2 Blends
Mode 90: N45OS00C.SWG: FCAW_GS, .045 FCAW-GS, 100% CO2
Mode 91: N45OS20C.SWG: FCAW_GS, .045 FCAW-GS, Argon CO2 Blends
Mode 200: mode200.SWG: CC TEST USING WP, 25A-600A,
Mode 201: MODE201.SWG: CV TEST USING WP, 10V-35V,
Mode 202: MODE202.SWG: CC TEST, NO WP, FIXED AT 10A,
Mode 203: MODE203.SWG: CC TEST, NO WP, FIXED AT 355A,
Mode 204: MODE204.SWG: CC TEST, NO WP, FIXED AT 455A,
Mode 205: MODE205.SWG: CC TEST, NO WP, FIXED AT 550A,
Mode 206: MODE206.SWG: CV TEST, NO WP, FIXED AT 30V,
Search Browse All
Tools Print
Pulse Editor Ctrl+P
Ctrl+E
Ctrl+A
Ctrl+F
Ctrl+B
STT Editor
ArcScope
Flash Custom Waveform
Browse Mode Directory
Upgrade Firmware
Go Offline
27850010
Simplify Editor
Help

3.2.2.3 PRINT MENU
Print menu options enable you to print out a waveform display, ArcScope screen, or tabular
waveform data listing as shown below. The Print menu options include the following:
3-6 Section 3
SOFTWARE OPERATION
WAVE DESIGNER
Wave Designer Pro Waveform Editor
Printed on Thu Jul 09 07:24:50 EDT 1998
..\systemWeldFile\pulse.swf
For Wire Feed Speed 150 inch / min
700
600
500
400
300
200
100
00 3 6 9 1215 182124 2730
Ramp Up Rate
Tailout Time
Peak Amps
Stepoff Amps
Backgrd Amps
Peak Time ms
Backgrd Time
Frequency
Tailout Speed
Ramp Overshoot %
Peak Voltage
Adaptive Type
Inductance
Short Detect Volt
Pinch Current Rise Rate
Arc Restablish Volt
End Amp
End Time
Open Circuit Volt
Strike Peak Time
Strike Peak Amps
Start Volt
Start Time
Start Amps
600
1.5
280
25
20
1.4
8.7
83.3
.100
-7
30.0
Fresa
2.625
5.0
55
15.0
550
2.5
48.0
2.5
550
28.0
87.5
172
Wave Designer ArcScope
Printed on Thu Jul 09 07:25:58 EDT 1998
Volt
---
Amp
---
dV/dt
.00
Ohm
1.0
Watt
7840
0 10 20 30 40
0
50
25
0
700
350
-100
100
0
0
1
.5
0
10000
5000
0 Amp
0.0 Volt
0.0 KW
0.0 KJ
0.0 Sec
Measured: N/A
Wave Designer Pro Data Table Created on Thu Jul 09 07:26:41 EDT 1998
..\systemWeldFile\pulse.swf
Weld Process: SMAW
Wire Type: Other
Wire Size: 6.3mm
Process Name: Steel Pulse A
Procedure: .035 Steel
Gas: super GAS
WireFeed inch / min 50 80 110 150 205 300 400 600 700 850 1000 1200
Ramp Up Rate
Tailout Time
Peak Amps
Stepoff Amps
Backgrd Amps
Peak Time ms
Backgrd Time
Frequency
Tailout Speed
Ramp Overshoot %
Peak Voltage
Adaptive Type
Inductance
Short Detect Volt
Pinch Current Rise Rate
Arc Restablish Volt
End Amp
End Time
Open Circuit Volt
Strike Peak Time
Strike Peak Amps
Start Volt
Start Time
Start Amps
600
3.0
250
40
21
1.2
33.4
26.4
.100
-20
24.00
Mora
2.999
5.0
55
15.0
550
2.5
48.0
1.5
550
28.0
50.0
50
600
3.0
250
45
28
1.4
20.2
40.2
.100
-17
26.0
Naranja
2.251
5.0
55
15.0
550
2.5
48.0
2.5
550
28.0
50.0
83
600
3.0
260
25
20
1.5
9.1
71.9
.100
-23
27.00
Manzana
2.251
5.0
55
15.0
550
2.5
48.0
2.5
550
28.0
75.0
145
600
1.5
280
25
20
1.4
8.7
83.3
.100
-7
30.0
Fresa
2.625
5.0
55
15.0
550
2.5
48.0
2.5
550
28.0
87.5
172
600
1.5
300
30
25
1.4
4.7
125.0
.250
-12
31.0
Sandia
2.999
5.0
55
15.0
550
2.5
48.0
2.5
550
28.0
100.0
200
600
1.5
350
70
45
.8
3.8
151.5
.250
-1
34.00
Mora
1.499
5.0
55
15.0
550
2.5
48.0
2.5
550
28.0
75.0
250
800
1.5
420
60
60
.8
3.0
175.4
.250
-10
39.50
Mora
-0.00
5.0
55
15.0
550
2.5
48.0
2.5
550
28.0
50.0
325
800
1.0
470
90
90
.8
2.3
222.2
.250
-13
41.0
Mora
-0.00
5.0
55
15.0
550
2.5
48.0
2.5
550
28.0
50.0
350
800
1.0
500
150
150
.8
2.2
227.3
.250
-6
41.50
Mora
-0.00
5.0
55
15.0
550
2.5
48.0
2.5
550
28.0
50.0
425
800
1.0
535
190
190
.8
2.0
238.1
.250
-5
43.0
Mora
-0.00
5.0
55
15.0
550
2.5
48.0
2.5
550
28.0
50.0
438
800
1.0
520
230
230
.9
1.7
256.4
.250
-10
43.5
Mora
-0.00
5.0
55
15.0
550
2.5
48.0
2.5
550
28.0
50.0
450
800
1.0
540
270
270
.9
1.7
256.4
.250
-6
44.00
Mora
-0.00
5.0
55
15.0
550
2.5
48.0
2.5
550
28.0
50.0
475
27850012
Print
Waveform Ctrl+W
Help
ArcScope Capture
Variable Table Ctrl+T
Ctrl+C

3.2.3 EDITING AND SELECTING WORKPOINTS
For each custom welding application, unique wave shapes are developed for specific workpoints
within the range of workpoints defined for the application. In Wave Designer the range of
workpoints and the specific workpoint values are defined in a Workpoint Editor window. After the
workpoints are defined, we use a workpoint pulldown menu to select a specific workpoint for
wave shaping. The following describes how workpoints are defined (edited) and selected for a
Pulse (GMAW) mode welding application.
Section 3 3-7
SOFTWARE OPERATION
WAVE DESIGNER
Pulse Waveform Editor
Wire Feed Speed
Ramp Up Rate
Peak Amps
Peak Time ms
Tailout Time
Tailout Speed
Stepoff Amps
Backgrd Amps
Backgrd Time
Frequency
Ramp Overshoot %
26.4
33.4
21
40
.100
3.0
1.2
250
-20
600
Edit
Start
About
Adapt Short End
Wave Designer Pro Off Line - pulse.swf
700
600
500
400
300
200
100
00 3 6 9 12151821242730
File Tools Print Help




700
350
0
60
30
0
0 102030405060
60
700
0
0
30
350
0
0
50
Off Line Stand by
Status AC.sco loaded Adaptive
27850013
80
110
205
300
400
600
700
150
WORKPOINT
PULLDOWN
MENU
WORKPOINT
EDITOR WINDOW
WorkPoint Editor
WorkPoint Editor
1
0
2
3
4
5
6
7
8
9
10
11
80 700
80 700
110 700
150 700
205
300
400
600
inch / min meter / min
Go Figure

3.2.3.1 EDITING WORKPOINTS
Clicking on the Edit button in the waveform Editor window opens a Workpoint Editor window. The
Workpoint Editor window displays a listing of workpoints for the selected standard waveform. Use
the Workpoint Editor window according to the following descriptions and guidelines:
• Each workpoint value must be equal to or greater
than the preceding workpoint value.
• The workpoints range is from the lowest defined
workpoint to the highest.
• Successive workpoint boxes can share the same
value. Equivalent workpoints will share the same
wave shape. Wave Designer selects the last
workpoint of equal value as the controlling
workpoint.
• You can click on the related check box to lock (fix)
the wave shape variables for a developed
workpoint.
• You can click on the Go Figure button to
extrapolate/interpolate fixed workpoint parameter
values for all non-checked workpoints.
• When only one workpoint is fixed (checked), Go
Figure copies the workpoint (sets the wave shape
parameters for all other defined workpoints equal
to those of the fixed workpoint). This function
should be used just after the wave shape for the
first workpoint is fully developed.
• When two or more workpoints are developed and
fixed, selecting Go Figure performs a linear
interpolation of the wave shape parameters
between checked workpoints and extrapolation to
unchecked workpoints outside the checked ones.
3-8 Section 3
SOFTWARE OPERATION
WAVE DESIGNER
WorkPoint Editor
WorkPoint Editor
1
0
2
3
4
5
6
7
8
9
10
11
80 700
80 700
110 700
150 700
205
300
400
600
inch / min meter / min
Go Figure
28750014
WorkPoint Editor
WorkPoint Editor
1
0
2
3
4
5
6
7
8
9
10
11
80 700
80 700
110 700
150 700
205
300
400
600
inch / min meter / min
Go Figure
28750015
WORKPOINT
WORKPOINT VARIABLE
FIXED VALUE
INTERPOLATED/
EXTRAPOLATED VALUE
WorkPoint Editor
WorkPoint Editor
1
0
2
3
4
5
6
7
8
9
10
11
80 700
80 700
110 700
150 700
205
300
400
600
inch / min meter / min
Go Figure
28750016
WP0, 1
WP2 WP3
WP5
WP6
WP7
WP8, 9, 10, 11
WP4