XM Controls Tandem-Wire User manual

Revision 0 May 2007
Tandem-Wire SAW System
Operation Manual
Advanced Manufacturing Engineering Technologies
X
M Controls

1 Foreword
Throughout this manual, these icons will highlight specific information related to each
category.
Icon Function
Note - Highlights or reviews important information and general
points of interest.
Caution - Highlights items, which can cause damage to the system
and/or injury to operators.
Tip - Identifies programming suggestions and operational
information for the XM.
Safety - Identifies specific safety concerns. These items may vary
depending on how the system is equipped; however, general safety
practices remain constant in all situations and environments.

Table of Contents
1FOREWORD .......................................................................................................................................2
2GENERAL SAFETY...........................................................................................................................4
3XM TANDEM-WIRE SAW SYSTEM............................................................................................10
4XM TANDEM-WIRE SAW SYSTEM MODULE CABINET......................................................12
5TANDEM WIRE SAW OPERATION QUICK START................................................................13
5.1 Power .........................................................................................................................................13
5.1.1 Main Disconnect...............................................................................................................13
5.1.2 Lincoln Power Supply ......................................................................................................13
5.1.3 Meta Cabinet.....................................................................................................................13
5.1.4 Weld Engineering.............................................................................................................13
5.1.5 Meta Software...................................................................................................................13
5.1.6 XM Controller ..................................................................................................................13
5.2 Set-Up ........................................................................................................................................14
5.2.1 XM Controller ..................................................................................................................14
5.2.2 Tracking Laser Calibration (Longitudinal).......................................................................14
5.2.3 Tracking Laser Calibration (Circumferential) ..................................................................15
5.3 Start the weld..............................................................................................................................16
5.4 Restart ........................................................................................................................................16
6XM CONTROLLER .........................................................................................................................17
6.1 XM Controller Features .............................................................................................................17
6.2 Controller Components..............................................................................................................18
6.2.1 Emergency Stop................................................................................................................19
6.2.2 Soft Buttons......................................................................................................................19
6.2.3 Sequence Buttons..............................................................................................................19
6.2.4 Programming Knobs.........................................................................................................19
6.2.5 Function Buttons...............................................................................................................20
6.2.6 Joystick Controls ..............................................................................................................22
6.2.7 LCD Display.....................................................................................................................22
6.3 Mode Of Operation Select..........................................................................................................23
6.3.1 Weld Mode.......................................................................................................................23
7TANDEM WIRE SAW SYSTEM....................................................................................................27
8SAW SYSTEM OPERATIONS OVERVIEW................................................................................29
8.1 Boom & Mast Manipulator with Travel Car..............................................................................29
8.1.1 Boom ................................................................................................................................29
8.1.2 SAW Welding Head.........................................................................................................29
8.1.3 Mast & Travel Car............................................................................................................30
8.1.4 Turning Rolls....................................................................................................................31
8.1.5 Flux-delivery/recovery System.........................................................................................31
8.1.6 Lincoln Power Wave Power Supplies...............................................................................31
9META SEAM TRACKING & JOINT SCANNER OPERATION ...............................................32
9.1 Application Software..................................................................................................................32
9.2 Components of the main display................................................................................................33
10 ADDENDUM A: QUICK REFERENCE CHARTS.......................................................................40

2 General Safety
Arc Welding Safety Precautions
ARC WELDING MAY BEHAZARDOUS.
PROTECT YOURSELF and others from possible serious injury or death!
KEEP CHILDREN AWAY at all times!
PACEMAKER WEARERS KEEP AWAY until such time as you have consulted your doctor.
Welding exposes you to certain hazards. However, welding is safe when
precautions are taken. The following safety information only summarizes
the more complete safety information found in the Principal Safety
Standards manuals listed at the end of this section (p. 6).
Read and follow all Safety Standards!
DANGEROUS LASER BEAM
It is dangerous to look directly into the laser beam.
Ensure that suitable precautions are taken so that
direct viewing of the beam or viewing of direct
reflections from shiny surfaces is not possible.
1. A key switch is provided to allow the laser to be disabled.
2. The laser should be disabled before any maintenance is performed nearby the sensor head or
welding head.
3. The sensor head and control unit contain no serviceable parts. No work should be undertaken on
these items except by or under the direct guidance of appropriately trained personnel.
WARNING
VISIBLE LASER LIGHT
AVOID EXPOSURE TO BEAM
CLASS 3B LASER PRODUCT

ELECTRIC SHOCK CAN KILL
Touching live electrical parts may cause fatal
shocks or severe burns. The electrode and work
circuit are electrically live whenever the output is
on. The input power circuit and machine internal
circuits are also live when power is on. In automatic
wire welding, the wire, wire reel, drive roll housing,
and all metal parts touching the welding wire and
torch are electrically live. Incorrectly installed or
improperly grounded equipment is a hazard.
1. Do not touch live electrical parts.
2. Wear dry, hole-free insulating gloves and body protection.
3. Use dry insulating mats or covers to insulate yourself from work and ground.
4. Disconnect input power before installing or servicing the equipment.
5. Properly install and ground any equipment according to its Owner’s Manual and national, state,
and local codes.
6. Turn off all equipment when not in use.
7. Ground the work piece to a good electrical (earth) ground.
8. Do not touch electrodes while you are in contact with the work (ground) circuit.
9. Use only well maintained equipment. Repair or replace damaged parts at once.
10. Keep all panels and covers securely in place.
ARC RAYS CAN BURN EYES AND SKIN
NOISE MAY DAMAGE HEARING
Arc rays from the welding process produce intense
heat and strong ultraviolet rays that will burn eyes
and skin. Noise from some processes can damage
hearing.
1. Wear a welding helmet fitted with a proper shade of filter (see ANSI Z49.1 listed in the Safety
Standards) to protect your face and eyes when welding or watching.
2. Wear approved safety glasses. Face shields are recommended.
3. Use protective screens or barriers to protect others from flash and glare; warn others not to watch the arc.
4. Wear protective clothing made from durable, flame-resistant material (wool and leather) and foot protection.
5. Use approved earplugs or earmuffs if the noise level is high.
FUMES AND GASES CAN BE HAZARDOUS
TO YOUR HEALTH
Welding produces fumes and gases. Breathing these
fumes and gases can be hazardous to your health.

1. Keep your head out of the fumes. Do not breathe fumes.
2. If indoors, ventilate the area and/or exhaust welding fumes and gases from the arc.
3. If ventilation is poor, use an approved air-supplied respirator.
4. Read the Material Safety Data Sheet (MSDS) and the manufacturer's instructions for metals,
consumables, coatings, and cleaners.
5. Work in a confined space only if it is well ventilated, or while wearing an air-supplied respirator. Shielding
gases used for welding can displace air, causing injury or death. Be sure the breathing air is safe.
6. Do not weld in locations near degreasing, cleaning, or spraying operations. The heat and rays of the arc
can react with vapors to form highly toxic and irritating gases.
7. Do not weld on coated metals (such as galvanized, lead, or cadmium plated steel) unless the
coating is removed from the weld area, the area is well ventilated, and if necessary, while
wearing an air-supplied respirator. The coating and any metals containing these elements can
give off toxic fumes if welded.
FLYING SPARKS AND HOT METAL CAN
CAUSE INJURY
Chipping and grinding cause flying metal. As welds
cool, they can throw slag.
1. Wear approved face shields or safety goggles. Side shields are recommended.
2. Wear proper body protection to protect skin.
WELDING CAN CAUSE FIRE OR
EXPLOSION
Sparks and spatter fly off from the welding arc. The
flying sparks and hot metal, weld spatter, hot work
piece, and hot equipment can cause fires and burns.
Accidental contact of electrode or welding wire to
metal objects can cause sparks, overheating, or fire.
1. Protect yourself and others from flying sparks and hot metals.
2. Do not weld where flying sparks can strike flammable material.
3. Remove all flammables within a minimum of 35 ft. (10.7m) of the welding arc. If this is not possible,
tightly cover them with approved covers.
4. Be alert that welding sparks and hot materials from welding can easily go through small cracks and
openings to adjacent areas.
5. Watch for fire and keep a fire extinguisher nearby.
6. Be aware that welding on a ceiling, floor, bulkhead, or partition can cause fire on the hidden side.
7. Welding sealed containers such as tanks or drums is very dangerous. Expanding gases within the
container can cause explosions.
8. Connect work cable to the work as close to the welding area as practical to prevent welding current from
traveling long, possibly unknown paths and causing electric shock and fire hazards.
9. Remove stick electrode from holder or cut off welding wire contact tip when not in use.
10. Wear oil-free protective garments such as leather gloves, heavy shirt, cuff-less trousers, high shoes, and a cap.

NON
FLAMMABLE GAS
CYLINDERS CAN EXPLODE IF DAMAGED
Shielding gas cylinders contain gas under high
pressure. If damaged, a cylinder can explode. Since
gas cylinders are normally part of the welding
process, be sure to treat them carefully.
1. Protect compressed gas cylinders from excessive heat, mechanical shocks, and arcs.
2. Install and secure cylinders in an upright position by chaining them to a stationary support or equipment
cylinder rack to prevent falling or tipping.
3. Keep cylinders away from any welding or other electrical circuits.
4. Never allow a welding electrode to touch any cylinder.
5. Use only correct shielding gas cylinders, regulators, hoses, and fittings designed for the specific
application; maintain them and associated parts in good condition.
6. Turn face away from valve outlet when opening cylinder valve.
7. Keep protective cap in place over valve except when cylinders are in use or connected for use.
8. Read and follow instructions on compressed gas cylinders, associated
equipment, and CGA publication P-1 listed in Safety Standards.
9. Near the top of the tank each cylinder has a label, which identifies
its contents by name, and a brief symbol, which identifies safety
concerns.
It is very important you read and understand all the
Material Safety Data Sheets (MSDS) for all substances you work with and around.
This is your responsibility!
MOVING PARTS CAN CAUSE INJURY
Moving parts, such as fans, rotors, and belts can cut
fingers and hands or catch loose clothing.
1. Keep all doors, panels, covers, and guards closed and secured in place.
2. Have only qualified people remove guards or covers for necessary maintenance and troubleshooting.
3. To prevent accidental starting during servicing, shutdown the entire system, which includes turning off
the power supply.
4. Keep hands, hair, loose clothing, and tools away from moving parts.
5. Reinstall panels or guards and close doors when servicing is finished and before starting equipment.
NON-FLAMMABLE GAS

HOT PARTS CAN CAUSE SEVERE BURNS
Avoid any contact with all HOT materials and
substances.
1. Allow a cooling period before *handling* moving or servicing.
2. Use approved techniques, tools, and safety clothing (gloves, shields, shoes, eye protection, etc.).
STEAM AND PRESSURIZED HOT COOLANT
CAN BURN FACE,EYES,AND SKIN
The coolant in the radiators and pressurized hoses is
under pressure and can be very hot.
1. Wear gloves and put a rag over cap area when accessing system.
2. Allow pressure to escape before completely opening system.
3. Treat all hoses, hot or cold, with caution. Pressure can cause injury.
ELECTRICAL SHOCK CAN KILL
This identification label is used to call attention to
immediate or imminent conditions, which if not
avoided, will result in serious injury or death. Have
only QUALIFIED personnel install, operate, repair,
or perform any maintenance on this equipment.
AUTOMATED AND ROBOTIC EQUIPMENT
MAY MOVE UNEXPECTEDLY AND CAUSE
SERIOUS INJURY OR DEATH AT ANY TIME
Observe all perimeter boundaries for all
automated equipment at all times.
1. Keep all guards, doors, covers, panels, and shields securely attached at all times.
2. Stop entire system when performing any maintenance, repair, installation, or inspections.

3. Observe all Safety Lines and Limits at all times.
4. Wear appropriate safety gear when operating any function of this equipment.
5. If a malfunction occurs:
A. Shut down the entire system.
B. Contact the system manager immediately.
6. If the standard system motion becomes obstructed, DO NOT ATTEMPT to clear the obstruction
yourself. Follow procedures described in #5.
7. Shortcuts can cause serious injury or death and may damage the system.
8. In all situations THINK before you act.
Principal Safety Standards
Safety in Welding and Cutting, ANSI Standard Z49.1, from American Welding Society, 550 N.W. LeJeune
Rd, Miami FL 33126
Safety and Health Standards, OSHA 29 CFR 1910, from Superintendent of Documents, U.S. Government
Printing Office, Washington, D.C. 20402
Recommended Safe Practices for the Preparation for Welding and Cutting of Containers That Have Held
Hazardous Substances, American Welding Society Standard AWS F4.1, from American Welding Society,
550 N.W. LeJeune Rd, Miami, FL 33126
National Electrical Code, NFPA Standard 70, from National Fire Protection Association, Batterymarch
Park, Quincy, MA 02269
Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-1, from Compressed Gas Association,
1235 Jefferson Davis Highway, Suite 501, Arlington, VA 22202
Code for Safety in Welding and Cutting, CSA Standard W117.2, from Canadian Standards Association,
Standards Sales, 178 Rexdale Boulevard, Rexdale, Ontario, Canada M9W 1R3
Safe Practices For Occupation And Educational Eye And Face Protection, ANSI Standard Z87.1, from
American National Standards Institute, 1430 Broadway, New York, NY 10018
Cutting And Welding Processes, NFPA Standard 51B, from National Fire Protection Association,
Batterymarch, Quincy, MA 02269

3 XM Tandem-wire SAW System
The illustrations below shows the XM Tandem-wire SAW System: column & boom,
pneumatic control box, travel car & track, control stand and pendant, XM Controller,
SAW welding head, electronic cabinets, turning rolls.
XM Tandem-wire SAW System 1

4 XM Tandem-wire SAW System Module Cabinet

5 Tandem Wire SAW Operation Quick Start
5.1 Power
5.1.1 Main Disconnect
1. Power the entire system with the main disconnect lever.
5.1.2 Lincoln Power Supply
1. Check to ensure both Lincoln Power Supply cabinets are on.
5.1.3 Meta Cabinet
1. Turn on the Meta Cabinet power supply with the red switch on the outside of the
cabinet.
2. Turn on the Sola Power Supply on the inside of the Meta Cabinet.
5.1.4 Weld Engineering
1. Turn on the Weld Engineering Mighty Mac X.
2. Turn on the Weld Engineering AV-3000.
3. Turn on the Weld Engineering Main Control.
5.1.5 Meta Software
1. Turn the Meta Software Laser Key Switch to the On Position
2. If the Meta Software does not automatically boot, open the Meta Software File
(MAF).
5.1.6 XM Controller
1. Ensure the XM Controller is connected in order for it to turn on.

5.2 Set-Up
5.2.1 XM Controller
1. Enter Weld Mode on the XM Controller.
2. Make sure the E-stop is cleared on the XM Controller.
3. Load the appropriate longitudinal or circumferential weld program.
5.2.2 Tracking Laser Calibration (Longitudinal)
1. Feed the wire to a desired stick out length.
2. Turn the Laser on with the XM Controller Laser On Function Button.
3. Move the wire tip to the starting point in the weld groove until the Meta Display
shows an acceptable image.
4. Adjust the Meta Tracking Laser manual adjusting screws until the Meta Tracking
Laser Display shows the lowest point of the weld centered on the crosshairs.
5. Position the 1st Weld Wire tip on the top left or top right of the groove.

6. Select the corresponding top left or top right Soft Button on the XM Controller.
7. Move the wire to the other corner and check the Meta Tracking Laser Display to
ensure the image displays a mirror image.
8. Position the torch at a starting point.
5.2.3 Tracking Laser Calibration (Circumferential)
5.2.3.1 Adjust the Scribe Camera
In addition to the above steps, in order to do a circumferential weld, you must do the
following:
1. Place the calibration tool in view of the camera and parallel to the groove.
2. Press the LTS Calibration button on the Meta Display.
Left and right sides are determined by looking at the front of the weld
head.

3. Follow onscreen instructions.
5.3 Start the weld
1. Press the Start Sequence Button to begin the weld.
2. Observe the Meta Tracking Display.
5.4 Restart
1. If camera position changed, recalibrate the laser camera or scribe camera with the
above steps; press the Restart Soft Button
2. If cameras are the same, continue the weld by pressing the Restart Soft Button.
Restart – This continues a weld from an operator’s previous stop point.
This will restart the weld at the point in the program when the stop
button was pressed.
Pressing the Start Sequence Button will begin the weld from the
beginning of the segment. The Restart Soft Button begins the weld from
the point in the segment that the program was stopped.

6 XM Controller
6.1 XM Controller Features
•Lightweight Ergonomic Controller: The XMController is easy to handle and
comes with a pendant package for mounted use.
•Powerful Graphical Programming Interface: The interface uses the latest
electronic and manufacturing technologies for programming. Simply select and
dial a value.
•*Easy Plug and Weld Connection: The XMController immediately detects any X
module (AVC, Wire Feed, Oscillation, etc.).
•Brilliant 6.4” LCD Display: An outstanding backlit TFT LCD operator display
offers clear readability.
•Dedicated Buttons: Designed for the most commonly used welding functions.
•3 Programmable Joysticks: The joysticks control up to 6 axis of motion.
•4 Programming Knobs: Easily program parameters and offer override control in
welding programs.
•Integrated Power Supply Control: For virtually any arc welding supply.
*Build or expand your own system with the industry’s first Plug and Weld modules. The
XM Controller automatically recognizes XM modules. Simply plug in a module and
the Add Weld Capability will instantly be detected.
This manual uses the term AVC (Automatic Voltage Control) and the
AMET product name XVC interchangeably. Both referring to the
hardware and software assembly that automatically controls arc voltage.

LCD Display
(4.7)
6.2 Controller Components
Soft Buttons
(4.2)
Emergency Stop
(4.1) Mode Buttons
(4.8)
Sequence Buttons
(4.3)
Soft Control
Knobs
(4.4) Joystick Controls
(4.6)
Function Buttons
(4.5)

6.2.1 Emergency Stop
The Emergency Stop button immediately stops current flow from the power supply and
all servo-controlled motion. The system remains inactive until an operator pulls the
Emergency Stop button and pushes the CLEAR E-STOP Soft Button.
The Emergency Stop button should be used to avoid damaging the
system or to avoid injuries. It is not intended as a common
procedure for stopping the system.
6.2.2 Soft Buttons
Each Soft Button has a corresponding label on the LCD screen. According to the Mode
selected (WELD, EDIT, OR SETUP), each Mode changes the function and label of the
Soft Buttons.
6.2.3 Sequence Buttons
The Sequence buttons (Start, Stop, and Next) are used with the weld program. The
Start button begins the current weld program. The Stop button terminates any running
process or operation. If used during a weld program, the Stop button will either end the
current weld segment and go to the post weld segment or terminate the program if
already in the final segment. The Next button’s function depends on the weld program
and requires an operator to advance to the next programmed event. The Next button
illuminates when it can be used to advance a sequence in the program.
6.2.4 Programming Knobs
Programming Knobs - Override weld program parameters in WELD mode. In EDIT
and SETUP Mode, the knobs navigate up and down the screen and adjust the settings. By
rotating a knob clockwise or counter-clockwise, the operator can scroll through the
display to reach a desired item and then increase or decrease a value. Each knob also acts
as a pushbutton by pressing down on the knob.

6.2.5 Function Buttons
6.2.5.1 Flux System Button
Flux Recovery - Activates the flux recovery system.
Flux Valve Open – Opens the valve for the flux system
6.2.5.2 Track
Laser On – Turns the Meta Tracking laser on.
6.2.5.3 Jog Buttons
Sub Arc Lead Wire – Jogs the Sub Arc Lead Wire.
Sub Arc Trail Wire – Jogs the Sub Arc Trail Wire.
Scribe Line - Activates the plasma gas at the default flow rate.
Plasma Gas will flow at this rate until the button is deactivated.
Set Reference – Opens the screen to calibrate the tip of the wire on
the Top Left or Top Right edge of the weld.