IM3056 11/2017 REV01

LGA Interface

OPERATOR’S MANUAL

ENGLISH

Lincoln Electric Bester Sp. z o.o. ul. Jana III Sobieskiego 19A, 58-263 Bielawa, Poland

www.lincolnelectric.eu

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Declaration of conformity

Lincoln Electric Bester Sp. z o.o.

Declares that the device:

K14140-1 LGA Interface – PROFINET K14140-2 LGA Interface – DEVICENET K14140-3 LGA Interface – PROFIBUS

conforms to the following directives:

2014/30/CE

and has been designed in compliance with the following standards:

EN 60974-10:2014

15.11.2017 Piotr Spytek

Operations Director Lincoln Electric Bester Sp. z o.o., ul. Jana III Sobieskiego 19A, 58-263 Bielawa, Poland

07/11

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12/05

THANKS! For having chosen the QUALITY of the Lincoln Electric products. Please Examine Package and Equipment for Damage. Claims for material damaged in shipment must be notified

immediately to the dealer. For future reference record in the table below your equipment identification information. Model Name, Code &

Serial Number can be found on the machine rating plate.

Model Name:

………………...…………………………….………………………………………………………………………………………….. Code & Serial number:

………………….……………………………………………….. …………………………………………………….……………..

Date & Where Purchased:

…………………………………………………………………... ……………………….…………………………………………..

ENGLISH INDEX Technical Specifications .................................................................................................................................................. 3 Electromagnetic Compatibility (EMC) .............................................................................................................................. 3 Safety .............................................................................................................................................................................. 4 Introduction ...................................................................................................................................................................... 5 Installation and Operator Instructions .............................................................................................................................. 5 Appendix ........................................................................................................................................................................ 18 WEEE ............................................................................................................................................................................ 21 Spare Parts .................................................................................................................................................................... 21 Authorized Service Shops Location ............................................................................................................................... 21 Electrical Schematic ...................................................................................................................................................... 21 

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Technical Specifications

NAME INDEX

LGA Interface – PROFINET LGA Interface – DEVICENET LGA Interface – PROFIBUS

K14140-1 K14140-2 K14140-3

INPUT

Input Voltage U1 Input Amperes I1 EMC Class

40 Vdc 0.2 A A

DIMENSION

Weight Height Width Length

0.5 kg 170 mm 140 mm 50 mm

Protection Rating Operating Temperature Storage Temperature

IP20 from -10°C to +40°C from -25°C to 55°C

Electromagnetic Compatibility (EMC) 01/11

This machine has been designed in accordance with all relevant directives and standards. However, it may still generate electromagnetic disturbances that can affect other systems like telecommunications (telephone, radio, and television) or other safety systems. These disturbances can cause safety problems in the affected systems. Read and understand this section to eliminate or reduce the amount of electromagnetic disturbance generated by this machine.

This machine has been designed to operate in an industrial area. To operate in a domestic area it is necessary to observe particular precautions to eliminate possible electromagnetic disturbances. The operator must install and operate this equipment as described in this manual. If any electromagnetic disturbances are detected the operator must put in place corrective actions to eliminate these disturbances

with, if necessary, assistance from Lincoln Electric. Before installing the machine, the operator must check the work area for any devices that may malfunction because of electromagnetic disturbances. Consider the following. Input and output cables, control cables, and telephone cables that are in or adjacent to the work area and the

machine. Radio and/or television transmitters and receivers. Computers or computer controlled equipment. Safety and control equipment for industrial processes. Equipment for calibration and measurement. Personal medical devices like pacemakers and hearing aids. Check the electromagnetic immunity for equipment operating in or near the work area. The operator must be sure

that all equipment in the area is compatible. This may require additional protection measures. The dimensions of the work area to consider will depend on the construction of the area and other activities that are

taking place. Consider the following guidelines to reduce electromagnetic emissions from the machine. Connect the machine to the input supply according to this manual. If disturbances occur if may be necessary to take

additional precautions such as filtering the input supply. The output cables should be kept as short as possible and should be positioned together. If possible connect the

work piece to ground in order to reduce the electromagnetic emissions. The operator must check that connecting the work piece to ground does not cause problems or unsafe operating conditions for personnel and equipment.

Shielding of cables in the work area can reduce electromagnetic emissions. This may be necessary for special applications.

WARNING EMC classification of this product is class A in accordance with electromagnetic compatibility standard EN 60974-10 and therefore the product is designed to be used in an industrial environment only.

WARNING The Class A equipment is not intended for use in residential locations where the electrical power is provided by the public low-voltage supply system. There can be potential difficulties in ensuring electromagnetic compatibility in those locations, due to conducted as well as radio-frequency disturbances.

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Safety 01/11

WARNING This equipment must be used by qualified personnel. Be sure that all installation, operation, maintenance and repair procedures are performed only by qualified person. Read and understand this manual before operating this equipment. Failure to follow the instructions in this manual could cause serious personal injury, loss of life, or damage to this equipment. Read and understand the following explanations of the warning symbols. Lincoln Electric is not responsible for damages caused by improper installation, improper care or abnormal operation.

WARNING: This symbol indicates that instructions must be followed to avoid serious personal injury, loss of life, or damage to this equipment. Protect yourself and others from possible serious injury or death.

READ AND UNDERSTAND INSTRUCTIONS: Read and understand this manual before operating this equipment. Arc welding can be hazardous. Failure to follow the instructions in this manual could cause serious personal injury, loss of life, or damage to this equipment.

ELECTRIC SHOCK CAN KILL: Welding equipment generates high voltages. Do not touch the electrode, work clamp, or connected work pieces when this equipment is on. Insulate yourself from the electrode, work clamp, and connected work pieces.

ELECTRICALLY POWERED EQUIPMENT: Turn off input power using the disconnect switch at the fuse box before working on this equipment. Ground this equipment in accordance with local electrical regulations.

ELECTRICALLY POWERED EQUIPMENT: Regularly inspect the input, electrode, and work clamp cables. If any insulation damage exists replace the cable immediately. Do not place the electrode holder directly on the welding table or any other surface in contact with the work clamp to avoid the risk of accidental arc ignition.

ELECTRIC AND MAGNETIC FIELDS MAY BE DANGEROUS: Electric current flowing through any conductor creates electric and magnetic fields (EMF). EMF fields may interfere with some pacemakers, and welders having a pacemaker shall consult their physician before operating this equipment.

CE COMPLIANCE: This equipment complies with the European Community Directives.

ARTIFICIAL OPTICAL RADIATION: According with the requirements in 2006/25/EC Directive and EN 12198 Standard, the equipment is a category 2. It makes mandatory the adoption of Personal Protective Equipments (PPE) having filter with a protection degree up to a maximum of 15, as required by EN169 Standard.

FUMES AND GASES CAN BE DANGEROUS: Welding may produce fumes and gases hazardous to health. Avoid breathing these fumes and gases. To avoid these dangers the operator must use enough ventilation or exhaust to keep fumes and gases away from the breathing zone.

ARC RAYS CAN BURN: Use a shield with the proper filter and cover plates to protect your eyes from sparks and the rays of the arc when welding or observing. Use suitable clothing made from durable flame-resistant material to protect you skin and that of your helpers. Protect other nearby personnel with suitable, non-flammable screening and warn them not to watch the arc nor expose themselves to the arc.

WELDING SPARKS CAN CAUSE FIRE OR EXPLOSION: Remove fire hazards from the welding area and have a fire extinguisher readily available. Welding sparks and hot materials from the welding process can easily go through small cracks and openings to adjacent areas. Do not weld on any tanks, drums, containers, or material until the proper steps have been taken to insure that no flammable or toxic vapors will be present. Never operate this equipment when flammable gases, vapors or liquid combustibles are present.

WELDED MATERIALS CAN BURN: Welding generates a large amount of heat. Hot surfaces and materials in work area can cause serious burns. Use gloves and pliers when touching or moving materials in the work area.

SAFETY MARK: This equipment is suitable for supplying power for welding operations carried out in an environment with increased hazard of electric shock.

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CYLINDER MAY EXPLODE IF DAMAGED: 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. Always keep cylinders in an upright position securely chained to a fixed support. Do not move or transport gas cylinders with the protection cap removed. Do not allow the electrode, electrode holder, work clamp or any other electrically live part to touch a gas cylinder. Gas cylinders must be located away from areas where they may be subjected to physical damage or the welding process including sparks and heat sources.

The manufacturer reserves the right to make changes and/or improvements in design without upgrade at the same time the operator’s manual.

Introduction LGA Interface is an add-on module intended to be used with Lincoln Electric Arclink welders such as Power Wave R450 and S500,. The module attaches to the front of a machine in place of a User Interface. The LGA Interface add-on contains a Lincoln Electric L16616 Anybus board with an HMS Anybus CompactCom M30 module.. LGA works as a gate between an industrial network and the welder’s internal Arclink network. It also works as the welding sequencer for the welder and is capable of storing up to 1000 welding jobs. A welding job contains all necessary welding parameters: from PostFlow, to Striking, Ramping up, Welding, Ramping down, Crater fill, Burnback operation, and Post Flow. Configuration of the job can be done in one of two different ways, using the LGA Control Panel or through the Power Wave Manager software. The jobs are saved on the L16616 board in the LGA Interface module. When replacing a LGA Interface module or this board, the Jobs should be backed up first, and then restored when the new module/board is installed.

The LGA Interface is designed for ease of configure and use with a PLC. There are two modes of operation, Job Mode and Job Mode with Parameter Inputs. Each of these modes of operation requires that 12 bytes of data be sent to and from the Master to the welder. In its simplest implementation, Job Mode, all that is required to initiate welding is to send over a valid Job Number and then to set the Trigger input bit to true. All the welding parameters are contained from the Job setup parameters. With Job Mode with Parameters Inputs, the weld state inputs are obtained from IO inputs from the PLC interface to the welder. In this mode of operation, the Master has direct control of the weld state welding parameters and these inputs parameters can be changed during the weld. LGA is designed to work in different welding configurations. The LGA will control turn on and off the Wire Drive motor and Gas output automatically during the welding sequence.

Installation and Operator Instructions Read this entire section before installation or operation of the machine.

Connection Digram

Figure 1

Note: All welding parameters are stored in the LGA Interface and it can work without LGA Control Panel connected. It is recommended to connect/disconnect LGA Control Panel when Power Source is switched off. Connecting/disconnecting LGA Control Panel during operation will stop welding process and restart the system.

Requirements A Robotic Wire Drive must be present or the Module

will go fatal with a 0x5211 (Required Object Not Found), with an instance code of 1. A semi-automatic wire drive will not work.

A Power Wave Control board (“G4800”, “G6683”, or “L11088”) must be present or the Module will go fatal with a 0x5211 (Required Object Not Found), with an instance code of 2.

If an Autodrive SA or S is found, the Module will go fatal with a 0x5611 (Arclink Bad Object).

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Anybus Module LEDs - PROFINET

Figure 2

NS – Network Status

State Indication Off No Power/No connection with IO

Controller Green Online. Connection with IO Controller

Established, in Run State Green, Flashing

Online. Connection with IO Controller Established, in Stop State

MS – Module Status

State Indication Off Not Initialized Green Operating in Normal Condition Green (1 flash) Diagnostic Event Present Green (2 flashes) Blink, Used by tools to Identify

the node on network Red Exception Error Red, (1 flash) Configuration Error Red, (2 flashes) IP Address Error (Not Set) Red, (3 flashes) Station Name Error (Not Set) Red, (4 flashes) Internal Error.

Link/Activity

State Indication Off No Link, No Communication Present Green Link, Ethernet link Established, No

Communication Present Green, flickering

Activity, Ethernet link Established, Communication Present

Cable Use PROFINET cable 4x22AWG PVC GREEN.

AnyBus Modules LEDs & Connector IO - DeviceNet

Figure 3

IO Connector: Pin 1 = V- Pin 2 = CAN L Pin 3 = Drain Pin 4 = CAN H Pin 5 = V+

NS – Network Status

State Indication Off Not On-Line/ No Power Green On-Line, one or more connections

are Established Flashing Green (1Hz)

On-Line, no connections established

Red Critical link failure Flashing Red (1Hz)

One or more connections timed-out

Alternating Red/Green

Self Test

MS – Module Status

State Indication Off No Power Green Operating in Normal Condition Flashing Green (1Hz)

Missing or incomplete configuration, device needs commissioning

Red Unrecoverable Fault(s) Flashing Red (1Hz) Recoverable Fault(s) Alternating Red/Green

Self Test

Power Supply The total number of units that can be connected to the DeviceNet bus is limited by the maximum current that the power supply can deliver to the bus. Maximum current consumption per unit is specified in the DeviceNet specification to 750mA. If e.g. the supply can deliver 9A and all units consume maximum current, the maximum numbers of units allowed on the bus are 12 (12x750mA=9A). The anybus CompactCom 30 DeviceNet module accepts 11 – 25V on the industrial network side of the module. Maximum current consumption at 11 – 25V is 36 – 38 mA/module.

PE Connection Terminating Resistors The termonating resistor reduces reflections of the communication signals on the network. You must attach a terminating resistor equal to 121 ohms, 1%, 1/4W or greater wattage, to each end of the trunk cable. You must connect these resistors directly across the blue and white wires of the DeviceNet™ cable.

1 2 3 4 5

V-

CA

N L

Dra

in

CA

N H V-

Parameters of the Cable Use only Devicenet™ media that meet or exceed ODVA specifications. Wire Color Wire

Identity Usage Round

Usage Flat

White CAN_H Signal Signal Blue CAN_L Signal Signal Bare Drain Shield n/a Black V- Power Power red V+ Power Power

Link Activity

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You can connect components using three cable options: Use this cable For Round (thick) The trunk line on the DeviceNet™

network with a nominal outside diameter of 12.2mm. You can also use this cable for drop lines.

Round (mid) The trunk line on the DeviceNet™ network where smaller cable diameters and smaller bend radii are required. Its outside diameter is specified by the vendor. This cable can also be used for drop lines.

Round (thin) The drop line connecting devices to the main line with an outside diameter of 6.9mm. This cable has a smaller diameter and is more flexible than thick cable. You can also use this cable for the trunk line.

Note: these generic cable types are available in a variety of different offerings such as FLEX, HAZ-DUTY, CLASS I (600V), UV RESISTANT, etc. All deviceet™ cabling components selected shall be

suitable for the environment in which they are installed and in particular, corrosion resistance, IP rating and Ultra Violet stabilization. NOTE: DeviceNet™ cables are available in a variety of different types including: High Flexibility, Hazardous duty, Class I – 600 Volt, UV resistant. Consideration must be also given to environmental protection of the cable components when individual nodes are removed for maintenance and for testing.

Excessive bending of DeviceNet™ cables can reduce their ability to meet the DeviceNet™specification. Standard thick cables have a bending radius of greter than 75mm. standard thin cables have a bending radius of greater than 50mm.

Round shielded cable (thick, mid and thin) contains five wires: one twisted pair (red and black) for 24V dc power, one twisted pair (blue and white) for signal, and a drain wire (bare).

Network Topology Understand the Topoly. The DeviceNet™ cable system uses a trunk/drop line topology.

Trunk line

Drop Line

Device or node

Terminating resistor

You must terminate the trunk line at ends with 121 Ohms, 1%, 1/4 W terminating resistors.

Determine the Maximum Trunk Line Distance The maximum cable distance is not necessary the trunk

length only. It is the maximum distance between any two devices. The distance between any two points must not exceed the maximum cable distance allowed for the data rate used. Data rate Maximum

distance (thick cable)

Maximum distance (mid cable)

Maximum distance (thin cable)

125k bit/s 500m 300m 100m 250k bit/s 250m 250m 100m 500k bit/s 100m 100m 100m

Determine the Cumulative Drop Line Lenght The data rate you choose determines the maximum trunk line and the cumulative drop line lengths. The maximum cable distance from any device on a branching drop line to the trunk line is 6m. The cumulative drop line length refers to the sum of all drop lines, thick, thin, or mid cable, in the cable system. This sum cannot exceed the maximum cumulative length allowed for the data rate used. Data rate Cumulative drop line length 125k bit/s 156m 250k bit/s 78m 500k bit/s 39m

AnyBus Module LEDs - Profibus

Figure 4

Ref Item 1 Operation Mode 2 Status 3 Profibus Connector, 9-pin

female D-Sub

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OP – Operation Mode OP – Operation Mode State Indication Comments Off Not on line/ no

power -

Green Online, data exchange

-

Flashing Green

Online, clear -

Flashing Red (1flash)

Parameterization error

See "Parameterization Data Handing"

Flashing Red (2 flashes)

PROFIBUS Configuration error

See "Configuration Data Handing"

OP – Operation Mode State Indication Off Not On-Line/ No Power Green Data Exchange Flashing Green Clear Red Critical link failure Flashing Red (1 flash)

Parameterization Data Handling

Flashing Red (2 flashes)

Configuration Data Handling

ST - Status ST - Status State Indication Comments Off Not initialized Anybus

state="SETUP" or "NW_INIT"

Green Initialized Anybus module has left the "NW_INIT" state

Flashing Green

Initialized, diagnostic event(s) present

Extended diagnostic bit is set

Red Exception error Anybus state="EXCEPTION"

ST –Status State Indication Off Not Initialized Green Initialized Flashing Green

Initialized, Diagnostic Event Present

Red Exception Error

Profibus Connector (DB9F) Pin Signal Description 1 - - 2 - - 3 B Line Positive RxD/TxD,

RS485 level 4 RTS Request to send 5 GND Bus Ground (isolated) 6 +5V Bus Output +5V termination power

(isolated, short-circuit protected)

7 - - 8 A Line Negative RxD/TxD,

RS485 level 9 - - Housing Cable Shield Internally connected to

the Anybus protective earth via cable shield filters according to the PROFIBUS standard.

Cable specification it is recommended to use cable Type A Type A Technical specification: Impedance: 35 up to 165 Ohm at frequencies from 3

to 20 Mhz. Cable capacity: < 30 pF per meter. Core diameter: > 0,34 mm², corresponds to AWG

22. Cable type: twisted pair cable. 1x2 or 2x2 or 1x4

lines. Resistance: < 110 Ohm per km. Signal attenuation: max. 9 dB over total length of

line section. Shielding: CU shielding braid or shielding braid and

shielding foil. Max. Bus length: 200 m at 1500 kbit/s, up to 1,2 km

at 93,75 kbit/s. Terminators Terminators at both ends of the cable must be enabled. Termination of the bus prevents signal reflections on the PROFIBUS cable. Wrong or missing termination results in transmission errors when the worst case result is that the communication link is lost.

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I/O Format I/O from Welder to Master Cyclic I/O From Welder to Master Byte B7 B6 B5 B4 B3 B2 B1 B0 0 Misc

Module Fault

Wire Stick WC Fault Water Fault

WD Fault Gas Fault Touch Sense

Arc Detect

1 Anybus Fault

PM Limit PM Fault Weld Complete

Limit Error

2 Weld Sequencer Current State 3 4 Voltage Feedback, Low Byte (In Volts with 1 implied decimal places) 5 Voltage Feedback, High Byte 6 Current Feedback, Low Byte (In Amps with 1 implied decimal places) 7 Current Feedback, High Byte 8 Wire Drive Motor Current, Low Byte (Signed value In Amps with 2 implied decimal places) 9 Wire Drive Motor Current, High Byte 10 Wire Feed Speed Feedback, Low Byte 11 Wire Feed Speed Feedback, High Byte I/O Bit Description to Master Item Description Arc Detect A True value indicates sufficient arc voltage and arc current have been detected. Arc voltage and

arc current levels are addicted to mode. When there is no longer sufficient Arc current and Arc voltage then go to False.

Touch Sensed A True value indicates that the Touch Sense detected a short between the work piece and the electrode.

Gas Fault A True value indicates there is a failure in the gas controller. If a fault occurs the weld Power Wave will turn the output off and welding will not be possible until the problem is corrected and the fault is cleared.

WD Fault Asserted when there is a fault in the Wire Drive. This fault occurs also when Shutdown input is open on the external I/O connector Ref. Power Wave / Power Feed Wire Feeder Interconnections section describing External I/O Connector in the Operator’s Manual. If a fault occurs the weld Power Wave will turn the output off and welding will not be possible until the problem is corrected and the fault is cleared.

Water Fault True when Arclink Water Cooler reports an error. If a fault occurs the weld Power Wave will turn the output off and welding will not be possible until the problem is corrected and the fault is cleared.

WC Fault True when there is a Weld Controller fault. Refer to “Troubleshooting” in the Operator’s Manual for a list of possible errors. If a fault occurs the weld Power Wave will turn the output off and welding will not be possible until the problem is corrected and the fault is cleared.

Wire Stick True value indicates that after the welding output is turned off there is a short between the electrode and the workpiece. This will stay true until the welding output is turned on and the error is cleared or if a Touch Sense Command is asserted and the short has been cleared. This check is disabled by default and be enabled using the option “Enable Wire Stick Check”.

Misc Module Fault

True value indicates that a module, like the Advance Module, STT Switch, High Frequency Switch has a fault.

Limit Error Indicates that one of the Welding Job Parameters is out of limits. This will not stop welding process.

Weld Complete

Indicates that the weld has completed (subsequent to the trigger going false) including any downslope, crater, burnback and postflow times. Goes false when the next weld begins (trigger going true).

PM Fault This bit is used to indicate that the Production Monitoring object is faulty, a common cause is that the Production Monitoring object detected a limit error while welding and the Out of limit action was set to Alarm Latch. This faulty condition must be cleared before welding; toggling the PM Flt Reset bit to the welder should clear this condition.

PM Limit This bit is used to indicate that the Production Monitoring (PM) object detected a limit error. This bit is clear automatically when the trigger input goes on or when the PM Flt Reset bit to the welder goes on. This bit is basically just a status item indicating a PM limit fault occurred, but depending on how PM is configured, other behavior can occur when this bit goes on. If PM is set to Fault System, then PM will shut the Power Source output off automatically when a limit error occurs, this will cause the LGA sequencer to fault and stop welding. If PM is set to Alarm Latch and a limit error occurs, then the PM object will fault after the weld is over and welding can not resume until the PM fault is cleared (see the PM Fault bit).

Anybus Fault This bit is used to indicate that the Anybus module has a fault. This includes selecting a job with invalid Workpoint or Trim units, or selecting an invalid Job number.

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Weld Sequencer Current State

This 4-bit field returns the state that the welding sequencer is currently in, where 0=Idle (Not welding), 2=Preflow, 3=Strike, 4=Start, 5=Upslope, 6=Weld, 8=Downslope, 9=Crater, 10=Burnback, 11=Postflow, 12=Restrike.

Voltage Feedback

Returns the Voltage feedback value. This value is in Volts with an implied decimal place.

Current Feedback

Returns the Current feedback value. This value is in Amps with an implied decimal place.

WD Motor Current Feedback

Returns the Wire Drive Motor Current feedback value. This is a signed value In Amps with 2 implied decimal places. A negative value means that the motor is in reverse.

WFS Feedback

Returns the Wire Feed Speed feedback value. The units depend on the setting of the option WFS Feedback Units. This can be either in English (Inches per Minute) or in Metric (CM per Minute). The default settings is Metric.

I/O from Master to Welder I/O Format while in Job Mode Cyclic I/O To Welder From Master Byte B7 B6 B5 B4 B3 B2 B1 B0 0 Control Bit

1 Control Bit 0

Trigger

1 PM Flt Reset

Weld Disable

Touch Sense

CI Rev CI Fwd Gas Purge

2 Job Number (low byte) 3 Job Number (high byte) 4 5 6 7 8 Production Monitoring Profile Number (1 to 200) 9 10 11 Format while using I/O Parameter Inputs Cyclic I/O To Welder From Master Byte B7 B6 B5 B4 B3 B2 B1 B0 0 Control Bit

1 Control Bit 0

Trigger

1 PM Flt Reset

Weld Disable

Touch Sense

CI Reverse CI Forward Gas Purge

2 Job Number (low byte) 1 to 1000 3 Job Number (high byte) 4 WorkPoint, Low Byte 0 to 32767 (Low Limit to High Limit) 5 WorkPoint, High Byte 6 Trim, Low Byte 0 to 32767 (Low Limit to High Limit) 7 Trim, High Byte 8 Production Monitoring Profile Number (1 to 200) 9 10 Non-Synergic Welding Speed. Low Byte (0 – 3048 cm/min or 0 – 1200 IPM) 11 Non-Synergic Welding Speed, High Byte

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I/O Bit Description to Welder I/O Control Bits Cyclic I/O to Welder Control Bits

Control Bit #

Mode Description

1 0 0 0 Job Mode Uses Job Mode and all parameters from the stored settings.

0 1 Job Mode using I/O Parameter Inputs

Uses Job Mode, but welding parameters are from the inputs from the Cyclic I/O to the welder. Note that the Trim might not be relevant for all weld modes.

1 0 N/A Reserved for future use.

1 1 N/A Reserved for future use. Item Description

Trigger The trigger is used to enable/disable welding. Can not trigger on when a cold inching input or when the Touch Sense Input is on. Trigger will only come On when these inputs are off. If set Trigger to On when one of these are On, then when these go off, must set Trigger to Off, then set Trigger back On. Before trigger on, make sure a valid Job No is set.

Gas Purge Gas can be controlled directly by this bit if a preflow and postflow is desired. But Gas will come on and go off according to the sequencer’s machine state; regardless of this bit if the Job is set to use a Preflow/Postflow if the selected mode requires Gas.

Touch Sense This input will cause the power supply emit only a low current low voltage output used to detect a short or zero voltage condition indicating that the wire has touched the workpiece. The Touch Sense output bit is true when touching; false otherwise. This bit should not be set while the Trigger input is true.

Weld Disable When bit is true in the idle state, this will prevent any welding. If this is turned on during welding and “Enable Burnback on a Fault” is true, then weld sequencer will transition to the Burnback state and then disable the weld controller preventing any welding. If this is turned on during welding and “Enable Burnback on a Fault” is set to false, then the welding will be stopped immediately and the weld controller will be disabled preventing any welding.

CI Fwd CI Rev

Cold Inch Forward or Cold Inch in Reverse. These inputs will cause the wire to “cold inch”. The direction is determined by the true bit (the second bit set true is ignored). The wire feed speed is determined by the value of the Cold Inch Speed on the Wire drive. Note that these inch command inputs are ignored during welding (Trigger = true).

PM Flt Reset Production Monitoring Fault Reset. This bit is used when using Production Monitoring, to clear a production monitoring fault or alarm.

Job Number This input to the welder is used to select the desired Job Number to weld with. The valid range is from 1 to 1000. Note that there must be a valid job “programmed” for the inputted job number and the programmed Job WorkPoint and Trim units must match the present units for these items in order to weld. Job Number can be changed many times during the weld. If a job numbers changes during upsloping, upsloping will stop and the sequencer will go to the weld state. If a Job number changes during downsloping, downsloping will stop, and the sequener will proceed to the next enabled end state. If a Job number is actually updated, any new welding settings will not take effect during the welding. After the welding is complete, the job parameters will be updated with any new settings.

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Operation of Module There are two modes of operation for the module : Job Mode and Job Mode with Parameter Inputs. The I/O Control Bits on the Cyclic I/O to the welder controls which of these modes are operational. The two modes of operation assume that a “Job” or “Jobs” have been preconfigured using a pendant or perhaps by the Power Wave Manager. A Job is basically the welding sequence that will preformed when the trigger input is activated on the Cyclic I/O. The selected job will select the welding wave form (the weld mode), the welding parameters for the wave form, and the welding sequence. The welding sequence refers to things like ramping up or down, performing a crater fill, burnback, etc (see the section on LGA Weld Sequencer). During welding, the actual job number can be changed at any time, however there are some limitations of this, see the LGA Weld Sequencer, Sequencer Notes.

Modes of Operation Job Mode This is the most basic mode of operation for the interface. All what is required for a welding, provide that the jobs have been setup already, is to set a valid Job number, then assert the trigger bit. Then during welding monitor the digital feedback bits for any faults or possible issues like the Arc Detect bit not coming on. The interface will automatically turn on the gas controller if a weld mode “requires” gas and turn on the Wire Drive if the weld mode uses wire and a wire drive is present. Job Mode with Parameter Inputs This mode of operation is similar to the Job Mode, except for while in the Weld sequencer state (see LGA Weld Sequencer). When in the Weld sequencer state, the state wave form parameters will be set using I/O coming from the interface instead of the parameters from the Job setup. These I/O parameters can be changed as many times as desired. If the Job is setup to perform something like ramping or crater, it will still do it. If it is desired for the interface to perform these functions, then make sure that selected Job is not setup to perform them. Note that the Trim and Non-Synergic WFS input might not be relevant for all welding modes. The Non-Synergic WFS is active for Non-Synergic wave forms only. Note the actual internal units, limits, and decimal places of the parameters can vary depending on the welding mode. For example for Synergic pulse modes, Trim controls “Trim” with engineer units from 0.50 to 1.50 with a midpoint of 1.00, but for Synergic CV modes, Trim typically controls voltage that does not have a “midpoint”. The parameters inputs for the Workpoint and Trim do not use engineering units. These values range from 0 to 32767 where 0 will select the parameter low limit and 32767 will select the parameter high limit.

Weld Sequencer The LGA Interface has a built in welding sequencer that controls time and event related sequences of the welding process and operation of standard peripherals objects. For standardization purposes of application descriptions, communicating case and effects relationships, a generalized model (shown below) was

chosen for the sequencer. Sequencer states are shown on Figure 5.

Figure 5

Not all these sequencer states need to be used for a Job. For the Preflow, Up Slope, Down Slope, Crater, Burnback, and Post Flow states, these states are entered only if a state time is set for them. If their state time is 0, then the state will be bypassed. For the most basic welding, the only necessary states are Idle, Strike, and Weld; these states are always enabled. For the “welding” states (Strike, Upslope, Weld, Downslope, Crater, and Burnback), each of these states has their own parameters that control the wave form. For every welding state that is used, the state’s control parameters must be initialized before the welding. The only exception to this rule is if Job mode with Parameter Inputs is being used, then the welding state parameters are obtained from the I/O parameters inputs.

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Sequencer State Description State Purpose Exit

Conditions Equipment State

IDLE

Ready to weld. 1) Trigger On Output: Off Wire: Off Gas: Off

PREFLOW

Gas purge before welding. 1) Preflow Timer 2) Trigger Off

Output: Off Wire: Off Gas: On

STRIKE

Allow arc to establish. This is a Non-synergic state where Strike Speed is set independently of strike workpoint.

1) Arc Established 2) Strike Timer 3) Trigger Off

Output: On Wire: On Gas: On

START

Allow process to stabilize following initial arc establishment and prior to steady state.

1) Start Timer 2) Trigger Off 3) Arc Out

Output: On Wire: On Gas: On

UPSLOPE

Welding parameters are ramped (linearly) to their steady state welding (WELD) values.

1) Upslope Timer 2) Trigger Off 3) Arc Out

Output: On Wire: On Gas: On

WELD

Steady welding state. 1) Trigger Off 2) Arc Out

Output: On Wire: On Gas: On

DOWNSLOPE

Welding parameters are ramped (linearly) from their steady state welding values to arc ending values.

1) Downslope Timer 2) Trigger On 3) Arc Out

Output: On Wire: On Gas: On

CRATER

Allows the welding crater to be “filled”. 1) Crater Timer 2) Trigger On 3) Arc Out

Output: On Wire: On Gas: On

BURNBACK

Allows for proper wire stick out following a weld. 1) Burnback Timer 2) Trigger On 3) Arc Out

Output: On Wire: Off Gas: On

POSTFLOW

Gas purge after welding. 1) Postflow Timer 2) Trigger On

Output: Off Wire: Off Gas: On

RESTRIKE

Allows the arc to re-establish if extinguished unexpectedly during the weld. This is a Non-synergic state where “Restrike Speed” is set independently of strike workpoint.

1) Arc Established 2) Restrike Timer 3) Trigger Off

Output: On Wire: On Gas: On

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Sequencer State Transitions LGA Weld Sequencer State Transitions

Current State Trigger On Trigger Off Arc On Arc Off Time Expires (0) Idle If Preflow time goes

to Preflow, else go to Strike.

- - - -

(2) Preflow - Go to Idle - - When time expires, go to Strike

(3) Strike - Go to Idle If Start time go to Start, else if Upslope time go to Upslope , else go to Weld

- If Strike fault timer set, go to Idle

(4) Start -

if Burnback time go to BB, else if Postflow time go to Postflow, else go to Idle

-

Go to ReStike

if Upslope time go to Upslope , else go to Weld

(5) UpSlope - if Burnback time go to BB, else if Postflow time go to Postflow, else go to Idle

-

Go to ReStike

Go to Weld

(6) Weld -

If Downslope time go to D.S., else if Crater time go to Crater, else if Burnback time go to BB, else if Postflow time go to Postflow, else go to Idle

- Go to ReStike

-

(8) DownSlope Go to Weld - -

if Postflow time go to Postflow , else go to Idle

if Crater time go to Crater, else if Burnback time go to BB, else if Postflow time go to Postflow, else go to Idle

(9) Crater Go to Weld - -

if Postflow time go to Postflow , else go to Idle

if Burnback time go to BB, else if Postflow time go to Postflow, else go to Idle

(10) Burnback Go to Weld - - if Postflow time go to Postflow , else go to Idle

if Postflow time go to Postflow , else go to Idle

(11)PostFlow Go to Strike - - - Go to Idle (12) ReStrike - if Postflow

time go to Postflow, else go to Idle

Go back to previous state for the Start & Weld states, for the Upslope state go to Weld

- Go to Idle

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Sequencer Notes Item Description States The LGA Weld Sequencer supports the Idle, Preflow, Strike, Start, Upslope, Weld,

Downslope, Crater, Burnback, Postflow, and Restrike states. State Numbers The state numbers follow the standard Weld Sequencer state numbering – Idle (0),

Preflow (2), Strike (3), Start (4), Upslope (5), Weld (6), Downslope (8), Crater (9), Burnback (10), Postflow (11), and Restrike (12) states. This number is used only for certain events which might be logged when there is an issue.

Have a Downslope time, but no Crater time.

If have a Downslope Time, but no Crater time, then the Downslope time will be divided between the Downslope and Crater states.

Switching Jobs If change Jobs numbers during a state with a State timer, then the new settings will be switched too, but the interface will continue using the old state timer from the last Job # for the current weld.

Upslope/Downslope The time between slope updates is fixed at 100ms and the total slope time will always be rounded off to a 100ms. Always one step will be done, even if the slope time is less than 100ms.

The number of slope steps that are done is equal to the slope time divide by 100, with the reminder dropped. For example if a time of 240 ms is inputted, then 2 steps will be done.

WorkPoint, Trim, and WFS will be sloped. Sloping can go in a positive or negative direction for both Upslope and Downslope. Upslope goes from the Start settings to the Upslope settings.

Downslope goes from the Downslope Settings to the Crater settings. If Job numbers will be change during upsloping, upsloping will stop and it will go to the

welding state. If Job numbers will be change during downsloping, downsloping will stop, and it will proceed to the next enabled end state.

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Miscellanous Notes Item Description WorkPoint in Amps, Trim in Volts

These settings should be set to the desired values in the weld control before any jobs are setup. Once a job(s) is setup, these values must not be changed, else the job will be considered invalid. If these values are changed, then the welder must be reset in order to welding with the LGA Interface.

Sending an Invalid Job If an invalid job is sent to the board, it will be accepted and saved, but you can not weld with it. An invalid job is a job that has a non-existent welding mode or a WorkPoint or Trim value with the wrong units.

Updating the current Job Number in use.

If an updated Job is download to the board, any new setting will not take effect if that Job is currently in use and welding. When the welding goes to idle, it will be updated.

If weld mode uses gas If the welding mode has the Gas as a required, the gas will be turned on when the Preflow or Strike is entered first. So the user does not have to turn on the Gas Purge bit on the I/O.

Using GTAW processes When a GTAW process is currently selected and a Tig Gas object is detected in the system, then this Gas solenoid will be enabled when the Sequencer turns on gas or when the I/O Gas Purge bit is enabled. When a non-GTAW process is used, the gas solenoid found on the Wire Drive will be enabled. If a gas solenoid is on and a new job is selected and the process type is changed, the previous turned gas solenoid will stay on. After this solenoid is turned off, then the correct solenoid type will be turned on when commanded.

Setting Feedback Rate Used to set the feedback rate in the Weld Controller for the Current and Voltage and the WFS feedback rate in the Wire Drive. This takes effect only after reset. If this value is greater than the present setting, then no update will be done.

Enable Wire Stick Check After change this setting the system must be reset in order to take effect. Enable Burnback on a Fault

If Enable Burnback on a Fault is false, then if welding and a fault occurs, the sequencer should turn everything off and go to the Idle state immediately. If the Enable Burnback on a Fault is True, then if welding and a fault occurs, the sequencer will transition to the Burnback state if a Burnback state time is set. If it was the Weld controller that actually faulted, it stil will transition to the Burnback state, but the weld output will be off so no actual burnback will be done.

Production Monitoring Profile

The LGA Interface can be setup to select the Production Monitoring Profile number when a job is selected. The valid profiles numbers range from 1 to 200. If an invalid profile number is set in the job setup, then the LGA Interface will not write any profile number out and Production Monitoring should remain using the last valid profile number.

Job Mode with Parameter Inputs

The I/O control bit to put the interface into this mode must be set to True before the welding state is entered. If this not done the welder will use the values defined in the Job setup when the weld state is first entered. If the input is set to False when in the weld state, the welder will keep using the last inputted values that were sent over the I/O interface.

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Trace Function in Power Wave Manager Software Items displayed by Trace Function Item Description Time (in seconds) This is just a running counter that gets incremented approximately every millisecond. This can

be used to see the relative time when the events happened. Note: It is possible that this counter can roll over and new events have an older time stamp. Also since this is just a counter that gets updated, this might not actually reflect the true timing of some events.

I/O Out Shows the I/O bytes (in Hex) from the welder. See the section, for the meaning of this data. I/O In Shows the I/O bytes (in Hex) going to the welder. See the section to Welder, for the meaning

of this data. A520 Rq Displays the welding parameters that were sent to the welder’s weld controller. The set mask

is a bit mask (in hex) that shows what items were sent, where 0x01=Weld Mode, 0x02=WorkPoint, 0x04=Trim, 0x08=Wave Control 1, 0x01=Wave Control 2, 0x02=Wave Control 3, and 0x04=Wave Control 4.

A520 Rs Displays the response from the weld controller from receiving the welding parameters. The Syn WFS displays the calculated Synergic Wire Feed Speed for the given Workpoint for Synergic weld modes. If all parameters were in limit, the Error Mask will be 0, else it will be non-zero if an item was out of limit.

Arc Status Displays the present status of the arc, where 0=No Voltage or Current, 1=Voltage Only (OCV condition), 2=Current Only (Shorted Condition), 3=Both Voltage and Current present.

Weld State Displays the weld state that the machine went too. Set WFS Displays the Wire Feed Speed that went to the wire drive. Commands Displays when certain items were turned on or off, this includes: WC (Weld Controller) Output

On, WC Output Off, Gas On, Gas Off, WD (Wire Drive) Motor On, WD Motor Off. Events Show when some type of event happened. Use Power Wave Manager and the Lookup Error

section to interpret what the return code means. Trace Attributes Attribute Description Trace Logging Selects when the trace stops logging information. When “Stop when buffer full” is selected then

the trace will stop logging when the buffer can no longer store new logs. When “Continuous” is selected, then the trace will always keep inputting new information. When the end of the buffer is reached, it will roll-over and start to erase any old logs with new ones.

Filter Selects what is logged in the trace.

Using Trace Step Description 1. Setup Select the desired Trace Logging method and what to log with the Filter. 2. Start Click on the Start trace button to start logging. Note that the trace function has a limited buffer

space, so after the trace is started, it is best to cause the event you want to capture and stop the trace as quickly as possible.

3. Run Make a weld or cause the action you want to capture happen. 4. Stop Click on the Stop trace button to stop logging. 5. Read Click on the Read trace button to read in the trace data. 6. Save Click on the Save trace button if you want to save the trace to a file.

Appendix

PROFINET Configuration Item Value PROFINET Vendor ID 733 (0x2DD) Device ID 7 Lincoln Electric Bester Order Number K14140-1 GSD File GSDML-V2.31-LincolnElectric-K14140-1-

20141202.xml Default Device Name lincoln0001

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DeviceNet Configuration Item Value Vendor ID 346 (0x15A) Device ID/Product code 20 Lincoln Electric Bester Order Number

K14140-2

EDS File LGA_DN_1-1.EDS Default MAC ID  5 Default Baud Rate  AUTO  DeviceNet requires to configure module parameters with Power Wave Manager Software that You can downloadfrom http://powerwavesoftware.com or with LGA Control Panel (ref. IM3055).

Figure 6

MAC ID – unique node address (0 – 63), Baud rate – three bit rates are available: 125 Kbit/s,

250 Kbit/s and 500 Kbit/s. There is also the AUTO option – the bit rate is recognized and set automatically.

PROFIBUS Configuration Item Value Vendor Name HMS Industrial Networks Ident Number 0x1811 Lincoln Electric Bester Order Number

K14140-3

GSD File HMSB1811_LE.gsd Default Node Address  5  PROFIBUS requires to configure module parameters with Power Wave Manager Software that You can download from http://powerwavesoftware.com or with LGA Control Panel (ref. IM3055).

Figure 7

Node Address – unique node address (1 – 125),

Maintenance

WARNING For any repair operations, modifications or maintenance, it is recommended to contact the nearest Technical Service Center or Lincoln Electric. Repair and modification performed by unauthorized service or personnel will cause the manufacturer’s warranty to become null and void. Any noticeable damage should be reported immediately and repaired.

WARNING Do not touch electrically live parts.

WARNING Before the case of machine will be removed, the machine has to be turned off and the power lead has to be disconnected from mains socket.

WARNING Mains supply network must be disconnected from the machine before each maintenance and service. After each repair, perform proper test to ensure safety.

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Customer Assistance Policy The business of The Lincoln Electric Company is manufacturing and selling high quality welding equipment, consumables, and cutting equipment. Our challenge is to meet the needs of our customers and to exceed their expectations. On occasion, purchasers may ask Lincoln Electric for advice or information about their use of our products. We respond to our customers based on the best information in our possession at that time. Lincoln Electric is not in a position to warrant or guarantee such advice, and assumes no liability, with respect to such information or advice. We expressly disclaim any warranty of any kind, including any warranty of fitness for any customer’s particular purpose, with respect to such information or advice. As a matter of practical consideration, we also cannot assume any responsibility for updating or correcting any such information or advice once it has been given, nor does the provision of information or advice create, expand or alter any warranty with respect to the sale of our products. Lincoln Electric is a responsive manufacturer, but the selection and use of specific products sold by Lincoln Electric is solely within the control of, and remains the sole responsibility of the customer. Many variables beyond the control of Lincoln Electric affect the results obtained in applying these types of fabrication methods and service requirements. Subject to Change – This information is accurate to the best of our knowledge at the time of printing. Please refer to www.lincolnelectric.com for any updated information.

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WEEE 07/06

En

gli

sh

Do not dispose of electrical equipment together with normal waste! In observance of European Directive 2012/19/EC on Waste Electrical and Electronic Equipment (WEEE) and its implementation in accordance with national law, electrical equipment that has reached the end of its life must be collected separately and returned to an environmentally compatible recycling facility. As the owner of the equipment, you should get information on approved collection systems from our local representative. By applying this European Directive you will protect the environment and human health!

Spare Parts 12/05

Part List reading instructions Do not use this part list for a machine if its code number is not listed. Contact the Lincoln Electric Service

Department for any code number not listed. Use the illustration of assembly page and the table below to determine where the part is located for your particular

code machine. Use only the parts marked "X" in the column under the heading number called for in the assembly page (# indicate

a change in this printing). First, read the Part List reading instructions above, then refer to the "Spare Part" manual supplied with the machine, that contains a picture-descriptive part number cross-reference.

Authorized Service Shops Location 09/16

The purchaser must contact a Lincoln Authorized Service Facility (LASF) about any defect claimed under Lincoln's warranty period.

Contact your local Lincoln Sales Representative for assistance in locating a LASF or go to www.lincolnelectric.com/en-gb/Support/Locator.

Electrical Schematic Refer to the "Spare Part" manual supplied with the machine.