CLOOS Schweißtechnik GmbH

MC3 PC-Software Vx.x

Copyright 2000

Index...................................................................................................................Page

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1.0 INTRODUCTION ................................................................................................................................3

2.0 SYSTEM REQUIREMENTS ..............................................................................................................3

3.0 INSTALLATION..................................................................................................................................3

RS422 INTERFACE...................................................................................................................................5

4.0 OPERATION OF PC SOFTWARE....................................................................................................5

5.0 CONFIG ................................................................................................................................................6

5.1 MACHINE NUMBER ..................................................................................................................................65.2 INTERFACE ..............................................................................................................................................65.3 INFO ........................................................................................................................................................7

6.0 DIAGNOSIS..........................................................................................................................................7

6.1 MEMORY MANAGEMENT .........................................................................................................................7

7.0 MC3 .......................................................................................................................................................8

7.1 CHARACTERISTIC CURVES .......................................................................................................................87.1.1 Modification of an existing characteristic curve .............................................................................87.1.2 Synergy On/Out ...............................................................................................................................97.1.3 Adjust characteristic curve data (gas preflow, gas postflow etc.) ..................................................97.1.4 Adjustment of a special characteristic curve .................................................................................10

7.2 ACTUAL VALUES ...................................................................................................................................117.3 JOB DATA ..............................................................................................................................................11

7.4 SURVEY..............................................................................................................................................11

7.5 DOCUMENTATION..................................................................................................................................117.5.1 Display range of consuming data ..................................................................................................137.5.2 Documentation data mask .............................................................................................................137.5.3 Memory administration mask ........................................................................................................147.5.4 The configuration window.............................................................................................................147.5.5 File name.......................................................................................................................................147.5.6 Function „Automatic storage after each seam“............................................................................15

7.5.7 THE ASCII FILE ............................................................................................................................15

8.0 BACKUP .............................................................................................................................................16

8.1 TOTAL BACKUP MC3 -> PC ..................................................................................................................168.2 JOB DATA MC3 -> PC ...........................................................................................................................178.3 CHARACTERISTIC CURVES MC3 -> PC..................................................................................................178.4 TOTAL BACKUP PC -> MC3 ..................................................................................................................178.5 JOB DATA -> MC3.................................................................................................................................188.6 CHARACTERISTIC CURVES PC -> MC3..................................................................................................188.7 CHANGE DIRECTORY – SET STANDARD DISK DRIVE ...............................................................................18

9.0 PRINT..................................................................................................................................................19

9.1 CURRENT CHARACTERISTIC CURVE .......................................................................................................19

10.0 END....................................................................................................................................................19

11.0 ERROR MESSAGES .......................................................................................................................20

12.0 COPY RIGHT...................................................................................................................................21

13. 0 COMPATIBILITY WITH FORMER MC 3 SOFTWARE VERSIONS....................................21

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1.0 Introduction

The MC3 PC software enables you to generate your own characteristic curves (special),to change the existing characteristic curves or to backup all parameters on a floppy diskor hard disk. The characteristic curves have 2 to 20 supporting points. Each supportingpoint comprises the following parameters:

Normal Pulse• Wire feed speed • Wire feed speed• Voltage • Frequency• Choke effect • Pulse time• CurrentSet (welding current to be

expected)• Pulse amplitude

• Plate thickness • Base current• Pulse edge steepness• CurrentSet (welding current to be

expected)• Plate thickness

The supporting point parameters can individually be changed and stored in the weldingmachine memory. In addition it is possible to create your own characteristic curves withnew parameters which are particularly adopted to the welding task. A serial interface isused to combine the ”MC3” and the ”PC”. An interface card (033 25 02 00) in thewelding machine is required.

2.0 System requirements

PC• PC-AT 286, 386, 486, Pentium• 640 KB main memory• 1 serial interface• DOS 3.XX and up• VGA monitor• The use of a computer mouse is helpful, but not indispensable.

Welding machine• Interface card 033 25 07 00

3.0 Installation

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Software :Before installation the following must be observed:

1. During installation, a system file ( MC318.SYS ) for a complete version or.( DMC318.SYS ) for a demonstration version ( limited operation time ) is generatedin your PC. This file is “hidden” and must be deleted prior to another (e.g. morerecent) installation.Please proceed as follows:• Start your PC in DOS mode.• Enter the command: attrib -r -h -s C:\MC318.SYS bzw. attrib –r –h –s

C:\DMC318.SYS and confirm with the return key.• Enter then the command: del C:\MC318.SYS or. del C:\DMC318.SYS and

confirm again with the return key. The system file is deleted now.2. Please make sure that the original disk is not write-protected.3. Never start the installation program from a supervised software

(Dosshell, Norton etc....).4. Please read chapter 12.0„Copy protection“

Insert the original disk in drive A: or B:, start the program ”INSTALL” and follow theinstructions shown on the screen. As soon as the program has been successfully started,activate the keys ”Alt” and ”K” to select the menu point ”CONFIG”. Press the key ”S”for serial interface. Activate the keys ”Alt” and ”P” in the dialogue window and selectthe required interface port (COM1 or COM2) using the cursor keys. Connect thewelding machine calculator to this interface port. After pressing the ”ENTER KEY” theset configuration is automatically stored under the file name ”MC3.KON” on the hard orfloppy disk drive. This interface configuration is only required for the first programstart.

Hardware:• Linking is not possible• RS232 interface

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• Maximum cable length = 5 metres• Interface parameter :

Baud rate = 38400Stop bit = 1Parity = none

• Interface card 033.25.07.00 required in the welding machine.The jumpers on the interface card must be configured as follows: J4, J17, J18

Insert the interface cable (RS232) into the 9 pole socket ”X3” of the interface card andconnect with the serial connection plug for the PC (COM1 or COM2).The interface cable is a tree-core cable with a 9 pole DSUB plug and a 9 pole DSUBsocket.Pins 2, 3 and 5 are used.

9 pole plug 9 pole socket

Pin 2 ←→ Pin 2Pin 3 ←→ Pin 3Pin 5 ←→ Pin 5

RS422 interface• required for longer cables or when linking several MC3 welding machines.• Interface parameter:

Baud rate = 38400Stop bit = 1Parity = none

• Interface card 033.25.07.00 required in the welding machine.The jumpers on the interface card must be configured as follows: J5, J17, J18.

When linking several welding machines it is important that the jumpers J17 and J18must be applied in maximally 2 welding machines. These jumpers must be removed inall other welding machines.At the distributor output, a plug with a terminating load resistor (120 Ohm) and acapacitor (100nF) must be applied.

Connect the interface converter (033.52.19.40) to the PC serial connection plug(COM1 or COM2).The interface converter output is directed via a serial connection cable to a multipledistributor. The welding machines are connected to this distributor.

Please take care that all welding machines connected to the network have differentmachine numbers.

4.0 Operation of PC software

After program start the main menu of the MC3 PC software is shown on the display.The individual items are shown on the top line of the screen. A letter in the description

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of these menu items is highlighted (in bold or red). Take the menu item ”CONFIG” asan example. The letter ”C” is highlighted. To call up the CONFIG menu, the ”Alt” and”C” keys must be pressed simultaneously. When using the mouse you only need tomove the mouse cursor to the selected menu item and press the left mouse key. Asmaller window with further submenus is displayed on the screen. Individual letters inthe description of these submenus are also highlighted. The submenu required is calledup by pressing the corresponding key; in our example the letter ”G” for machinenumber. It is also possible to select the required menu using the cursor keys (up, down).Pressing the ”ENTER KEY” calls up the chosen submenu. In the individual submenusvarious selection boxes and entry fields are shown with their appropriate descriptions.Letters are marked in bold or yellow. The boxes and entry fields are selected bysimultaneously pressing the keys ”Alt” and the highlighted letter. When using a mouse,press the left mouse key. Pressing the ”TABULATOR KEY” selects the next entry fieldor the next selection box. By pressing the ”SHIFT” and ”TABULATOR” keyssimultaneously, the previous entry field or selection box is selected. After new data hasbeen entered or existing data changed, this is confirmed by pressing the ”ENTER KEY”.The range is then automatically checked and the new value is only displayed in the entryfield if it is within the valid parameter range. An invalid value is ignored.

5.0 Config

Various basic configurations can be carried out in the menu „CONFIG“. The“CONFIG” menu is divided into 2 submenus:

• Machine number (see 5.1 Machine number)• Interface (see 5.2 Interface)• Info (see 5.3 Information)

5.1 Machine number

Each type "MC3" welding machine has its own machine number. The factory setting is„1“. The machine number in the PC must also be set to „1“ to ensure a communicationbetween PC and welding machine via the serial interface.If further welding machines are connected to the PC (network), the machine number inthe PC must always be the same as the number of the welding machine with which thePC is intended to communicate.

5.2 Interface

In this menu you can tell the PC to which interface port the power source computer isconnected and what the transmission speed is for the data exchange between PC andpower source. If you call up the submenu ”INTERFACE”, a window called ”Interfaceconfiguration” appears on the screen. In the left half of the window a selection box

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called ”Port” is shown. Press the key ”P” and select the corresponding interface port(COM1 or COM2) by using the cursor. In the right half of the window a selection boxcalled ”Baud rate” is shown. This is set at our factory at ”38400”; this setting cannot bealtered. To quit the menu press the ”ENTER KEY” or select the control field ”OK”. Thesettings are stored together with the machine number in the file ”MC3.KON”. To quitthe menu without saving the settings, select the control field ”ESCAPE”.

5.3 Info

In this menu the version type of the PC software actually installed and the currentinterface status are displayed.

6.0 Diagnosis

The menu ”DIAGNOSIS” has another submenu:• Memory management(see 6.1 Memory management)

6.1 Memory management

The welding machine memory has a total of three memory ranges:

1. Job memory2. Characteristic curve memory3. Basic data memory

The display field ”Max. jobs” shows the job memory size available. The MC3 has amemory capacity for 50 job data sets (Display: Max-Jobs = 50).The display field ”Max. characteristic curves” shows the number of maximum availablesupporting points. 2 to 20 support points can be programmed in each characteristiccurve. A total of 500 support points can actually be stored in the MC3. (Display: Max.characteristic curves = 500).

The display field ”Max. basic data” shows the basic data memory size available. Eachcharacteristic curve has a basic data set where the parameters such as ”Creeping in”,”Gas preflow”, ”Gas postflow” etc. are saved. A total of 80 basic data sets can actuallybe stored in the MC3 (Display: Max. basic data = 80).

When switching the welding machine on the welding machine calculator checksautomatically the complete memory range. Possible memory errors are displayed in thecorresponding display fields in the memory administration menu (error jobs, error

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characteristic curves, error basic data). The displayed value shows the number of thedamaged data records. However, it cannot be deduced from that which data records havebeen damaged.If damaged data records are to be displayed, the operator has the possibility of eithernewly formatting the corresponding memory range by selecting the keys "delete jobmemory", "delete characteristic curve" or "delete basic data memory" or the completememory range by selecting "delete everything". CAUTION; all stored data in thesememory ranges is deleted at the same time. The error displays on the PC screen are resetto "0". The deleted data can be loaded again by means of a previously made backup.However, it has to be observed that the backup has been made at a time when thewelding machine memory was still faultless. If the backup is not available, the standardbackup on the original floppy disk can be used. The machine is then again in the state attime of supply.All eventual modifications made by the customer have to be added manually.

To quit the submenu "Memory administration" press the control field "ESCAPE".

7.0 MC3

The menu ”MC3” has five further submenus:

• Characteristic curves (see 7.1 Supporting points)• Actual values (see 7.2 Actual values)• Job data (see 7.3 Job data)• Survey (see 7.4 Survey)• Documentation (see 7.5 Documentation)

7.1 Characteristic curves

In this submenu there is the possibility of modifying the characteristic curves of MC3welded at Cloos or programming new special characteristic curves. A characteristiccurve consists of at least 2 to a maximum of 20 characteristic curve supporting points.Characteristic curve supporting points are working points which are welded withdifferent welding powers. Afterwards, the welding machine calculator calculates thecharacteristic curve by means of a linear interpolation between the individual supportingpoints . At least 2 supporting points have to be stored so that the welding machinecalculator can calculate a valid characteristic curve.

7.1.1 Modification of an existing characteristic curve

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Adjust the requested characteristic curve with the keys "Material", "Gas", "Wirediameter" and "Process" at the welding machine and call up the submenu "Characteristiccurves" at the PC.In the upper part of the screen the current characteristic curve is now displayed. In theleft lower screen half a selection box with the supporting points of the adjustedcharacteristic curve is shown. The supporting points are displayed - ascending accordingto the wire feed speed - in the selection box. To set a new supporting point the requestedwire feed value has to be adjusted in the entry field "Wire". The parameters "Voltage","Choke" or "Frequency", "Pulse time", "Pulse amplitude", "Basic current" and "Pulseslope" have to be adjusted accordingly. A test welding has to be made and parametershave to be corrected if necessary. Note the current value in the display instrument duringthe welding process. Afterwards, enter this value in the entry field "CurrentSet". This isnecessary in order to obtain a meaningful current pre-display (ASet) later on. Pleaseenter the plate thickness which corresponds to the welding current in millimetres intothe entry field "Plate thickness". These parameters are also necessary in order to obtain ameaningful plate thickness display (mm) later on.Store the supporting point by selecting the control field "Store". The supporting pointjust generated appears in the selection box now. If you want to look at, correct or deletethe parameters of an existing supporting point, select this supporting point in theselection box. The supporting point parameters are displayed in the corresponding entryfields. In case of a parameter correction the supporting point has to be stored againafterwards. To delete a supporting point select the control field "Delete". After the safetyinquiry select the control field "Yes" in order to delete the supporting point completely.

7.1.2 Synergy On/Out

If you call up the submenu "Characteristic curves" at the PC, the synergy function isautomatically switched off. From now on the welding machine calculator does not makeany characteristic curve calculations. The state of the synergy function (synergy on orsynergy out) is displayed below the selection box. If a welding process is started whenthe synergy function is switched off, the machine welds with the current supportingpoint parameters. This enables you to make test weldings with the individual supportingpoints. Therefore you only have to select the requested supporting point in the selectionbox. If you have welded several supporting points and if you want to test thecharacteristic curve afterwards, switch the synergy function on. The welding machinecalculator calculates the new characteristic curve based on the individual supportingpoints. Make a test welding and alter the power potentiometer at the wire drive duringthe welding process. The left limit stop of the potentiometer corresponds to the weldingefficiency of the lowest supporting point. The right limit stop corresponds to thewelding efficiency of the highest supporting point.

7.1.3 Adjust characteristic curve data (gas preflow, gas postflow etc.)

Every characteristic curve has its own characteristic curve data set. This data setincludes the parameters ”Gas preflow”, ”Gas postflow”, ”Creeping in ”, ”Burnback” andthe ”Characteristic curve description”. With a PULSE characteristic curve the parameter"Controller type" is available additionally.

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Adjust the requested characteristic curve with the keys "Material", "Gas", "Wirediameter" and "Process" at the welding machine and call up the submenu "Characteristiccurves" on the PC in order to change the basic data set of a characteristic curve.Afterwards, select the control field "Basic data". A window with the basic data of theadjusted characteristic curve is displayed at the screen. The current characteristic curveadjustment is shown in the selection boxes "Material" and "Wire". If you have adjusteda "Special" characteristic curve at the operating panel of the welding machine, you cannow adjust the requested special material and the requested special wire diameter in thecorresponding selection boxes. Afterwards, enter the requested values in the entry fields"Gas preflow", "Gas postflow", "Creeping in" and "Burnback". Any text string can beentered in the entry field "Characteristic curve description". This text string is used astitle when printing the current characteristic curve out.Regarding the controller type you can choose between U/I- and I/I-controller. If thecontroller type of an existing characteristic curve is changed later, all supporting pointshave to be welded newly. Select the control field "OK" in order to quit the menu and tostore the basic data.

7.1.4 Adjustment of a special characteristic curve

If you want to adjust a special characteristic curve, you first have to choose a "Special"adjustment at the operating panel of the welding machine with the keys "Material" and"Wire diameter". With the keys "Gas" and "Process" you can choose the correspondingprotecting gas and the requested welding process (N-Synergy or P-Synergy).Now call up the submenu "Characteristic curves". Select the control field "Basic data"and adjust the requested parameters in the selection boxes "Material" or "Wire".Afterwards, choose the corresponding controller type (U/I- or I/I-controller) and enter

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the requested values in the entry fields "Gas preflow", "Gas postflow", "Creeping in"and "Burnback". Any text string can be entered in the entry field "Characteristic curvedescription" (e.g. ”Special FE 82/18. 1.2mm”). This text string is used as title whenprinting the current characteristic curve out. Quit the basic data menu by selecting thecontrol field "OK" and enter your supporting point parameters afterwards (sameprocedure as in chapter 7.1.1. "Modification of an existing characteristic curve"). Afterhaving entered and test welded all supporting points, switch the synergy function on andtest your new characteristic curve (see chapter 7.1.2 ”Synergy on/out”).Select the control field "OK" in order to quit the submenu "Characteristic curve".

7.2 Actual values

This submenu is a pure information window. In the upper screen part the adjustment ofthe current characteristic curve is displayed (material, gas, wire diameter and process).Afterwards, the current welding parameters are displayed. If you change the adjustmentof the power or fine alignment potentiometer at the wire drive, you can see at the screen,which set parameters the welding machine calculator calculates from the programmedsupporting points. The current welding voltage and welding current are displayed belowthese parameters. Quit the menu by selecting the control field "ESCAPE".

7.3 Job data

In the job data menu all parameters of the currently active job are displayed clearly. Thejob data window is a pure information window whose data is made topical cyclically. Inthe upper screen part the parameters "Material", "Gas", "Wire diameter", "Process" and"Operating mode" are displayed. The parameters "Creeping in", "Gas preflow", "Gaspostflow", "Burnback" and depending on the programming also "Upslope","Downslope" and "Spot welding time" are displayed below these selection boxes. In thelower part of the screen a table with the parameters "Power" and "Fine alignment" or"Wire feed", "Voltage" and "Choke effect" are displayed. Depending on the operatingmode 1, 2 or 5 power stages are displayed correspondingly. Quit the menu by selectingthe control field "ESCAPE".

7.4 Survey

In this submenu the job names of all jobs are displayed.New job names can be entered or existing job names can be changed..Jobs can also be selected and called up.

7.5 Documentation

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In this submenu the documentation mask is shown on the display. The followingparameters are shown in this mask:

- The number of the welding machine with the current date and thecurrent time.

- The basic data “Material, Gas, Wire Diameter and Process”.

- The nominal parameters of the active welding task (wire feed speed, voltage andchoke during MAG Normal and MAG Normal Synergy process or the wire feedspeed, frequency, pulse amplitude, pulse time, base current, pulse flank and arclength during MAG Pulse Syn process or the current during TIG andELECTRODE).

- The real values of voltage, current, gas flow and wire feed speed during thewelding process. At the end of welding the average values of the last weldseam are shown in the same display panels. These values do not match to the“Hold values” shown in the welding machine.“Hold values” are momentary values

- The parameters “Gas Consumption, Wire Consumption, ElectricalEnergy and Welding Time” as consuming values for the last weldseam and the total consuming value are shown. In order to determinethe heat input it is essential to enter the weld seam length in “cm”in the input field “DISTANCE”. The heat input is then displayedin „kJ/cm“. It is possible to delete the total consuming values. Todo this, the relating parameter must be clicked via mouse. Actuatethen the “RESET key” to delete the selected parameters.

In addition, a documentation data set can be saved in an ASCII file by pressing the keyor automatically after each weld seam. The preselection (pressing the key orautomatically) and the file name are determined before in a configuration window. Aconfiguration file is automatically produced and administered to ensure that this data isstill available after a restart of the PC.

Fig 1: The documentation mask

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7.5.1 Display range of consuming data

Per weld seam Range DisplayWeld time Up to 59.99 seconds

From 1 minutex x . x x sx x x : x x min

Electrical work Up to 999.99 WhFrom 1 kWh

x x x . x x Whx x x x . x x kWh

Gas quantity Up to 99.99 litres100 to 999.9 litresFrom 1000 litres

x x . x x lx x x . x lx x x x x x l

Wire quantity Up to 99.99 meters100 to 999.9 metersFrom 1000 meters

x x . x x mx x x . x mx x x x x x m

Total Range DisplayWeld time Up to 999.59.59 hours

From 1000 hoursx x x : x x . x x hx x x x x x . x x h

Electrical work U to 99.99 kWh100 to 999.9 kWhFrom 1000 kWh

x x . x x kWhx x x . x kWhx x x x x x x kWh

Gas quantity Up to 9999 litresFrom 10000 litres

x x x x lx x x x x x x . x x m3

Wire quantity Up to 9999 metersFrom 10000 meters

x x x x mx x x x x x x . x x km

7.5.2 Documentation data mask

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The configuration window is opened as soon as the control field “ADJUSTMENT” hasbeen pressed. The control field “Storage” is only shown when the function “Automaticstorage after each seam” has been deactivated before in the configuration window seeFig. 2).

7.5.3 Memory administration mask

By pressing the control field all consumer values can be set to Zero. This measure isessential for commissioning a new welding machine.

Fig 2. The configuration window

7.5.4 The configuration window

Three text fields “Component”, Order Number” and “Comments” are shown in theconfiguration window. Any text with a maximum of 40 digits can be entered here. Theinput field for the file name of the ASCII file as well as the selection field for thefunction “Automatic storage after each seam” are also available in this window.

7.5.5 File name

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The documentation data is stored under the file name on the current disk. The file namemust not exceed the maximum of 8 digits and must not contain any special characters(such as öäü/ß). The extension “asc” is automatically added..

7.5.6 Function „Automatic storage after each seam“

The function „Automatic storage after each seam“ is activated and deactivated with thekeys “Alt and” or with a mouse click. An activated function is marked with an “X” inthe brackets of the selection field. The serial data protocols are exchanged between thewelding machine and the PC in a time–slot pattern of 300 ms. Consequently, thewelding time of a seam must at least be 300 ms so that the automatic weld datadocumentation can by carried out via PC.

With activated functionAt the end of each weld seam the documentation data is automatically stored in thecorresponding ASCII file. The display fields for “Seam length” and “Heat input” areextracted because these values are not yet available at the moment of storage.

With deactivated function

The control field “Storage” (see fig. 1) is additionally shown in the documentation datamask. By pressing this control field the storage process for the documentation data canbe started manually.

7.5.7 The ASCII file

The documentation data is stored in the ASCII file in the following format:

Line 1: “Date“;“Time“;“Seam counter“;“Component“;“Order number.“ etc...Line 2: “29.01.1999“;“10.03.58“; etc...

When generating a new ASCII file, the designation of the data fields is entered first (seeline 1). Then the data sets are only completed (line 2). A data set has a total of 41 datafields. The data fields are entered in the following sequence:

Date, Time, Seam counter, Component, Order No., Comments1, Comments2,Comments3, Material, Gas, Wire, Process, Wire feed speed, Voltage, Choke,Frequency, Pulse current, Pulse voltage, Pulse time, Base current, Pulse flange, Arclength, Current, Real value Voltage, Average value Voltage, Real value Current,Average value Current, Real value Gas, Average value Gas, Real value Wire Averagevalue Wire, Gas consumption Seam [l], Gas consumption Total [l], Wire consumptionSeam [m], Wire consumption Total [m], Electrical energy/Seam [kWh], Electricalenergy/Total [kWh], Welding time/Seam, Welding time/Seam [h], Welding time/Total[h], Seam length [cm], Heat input [KJ/cm].

The maximum size (volume) of the ASCII file depends on the storage capacity which isavailable on a data carrier (storage medium). No data is stored if the free storagecapacity on a data carrier is less then 20 KB. A relating error message is displayed.

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8.0 Backup

In the menu ”BACKUP” there is the possibility of saving or loading the completewelding machine memory (total backup) or individual memory ranges (job orcharacteristic curve memory) on the standard disk drive (hard disk or floppy disk) orfrom the standard disk drive. As already described in chapter 6.0 ”Diagnosis”, the MC3welding machine memory is subdivided into three memory ranges (job, characteristiccurve and basic data memory). If you make a new backup, every memory range isautomatically stored in an own file. The PC marks these files with a 3-digit reference atthe end. So e.g. a backup file of the job memory has the reference ”MCJ”, a backup fileof the characteristic curve memory has the reference ”MCK” and a backup file of thebasic data memory has the reference "MCG".A total backup MC3 -> PC saves the complete welding machine memory and generatesthree new files on the standard disk drive. These 3 files have always the same name.They only differ from the 3-digit reference.A job data backup MC3 -> PC saves only the job memory and generates a new file withthe reference ”MCJ” on the standard disk drive .A characteristic curve backup MC3 -> PC saves the complete characteristic curve andbasic data memory and generates two new files with the references ”MCK” and ”MCG”on the standard disk drive.It is generally recommended to only use the total backup method, as e.g. job data can bebased on different characteristic curves and therefore also on different characteristiccurve basic data.

If you want to make a backup, call first of all the menu "Backup" and select therequested backup method.

• Total backup MC3 -> PC (see chapter 8.1)• Job data MC3 -> PC (see chapter 8.2)• Characteristic curves MC3 -> PC (see chapter 8.3)• Total backup PC -> MC3 (see chapter 8.4)• Job data PC -> MC3 (see chapter 8.5)• Characteristic curves PC -> MC3 (see chapter 8.6)• Change directory (see chapter 8.7)

8.1 Total backup MC3 -> PC

In this submenu the complete welding machine memory (job, characteristic curve andbasic data memory) is stored on the adjusted standard disk drive. After calling the menuup a window with the indication ”MC3 DATA -> PC” appears on the screen. In the leftlower part of the window a selection box with the indication "FILE" is displayed. In thisselection box all backup files, which have already been stored on the standard diskdrive, are listed. If backup files have not been generated before, the message ”empty”appears in the selection box. Enter a file name with max. 8 digits in the entry field"Name" in order to make a new backup. Take e.g. the name ”DEMO”. After selectingthe control field ”OK” the backup function is started. The PC reads one after another thecontents of the welding machine’s job, characteristic curve and basic data memory andstores it in the files ”DEMO.MCJ”, ”DEMO.MCK” and ”DEMO.MCG” on the standarddisk drive.

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8.2 Job data MC3 -> PC

In this submenu the job memory of the welding machine is stored on the adjustedstandard disk drive. After calling the menu up a window with the indication "MC3DATA -> PC” appears on the screen. In the left lower part of the window a selectionbox with the indication "FILE” is displayed. In this selection box all backup files("MCJ"), which have already been stored on the standard disk drive, are listed. If backupfiles have not been generated before, the message "empty" is displayed in the selectionbox. Enter a file name with max. 8 digits in the entry field "Name" in order to make anew backup. Take e.g. the name ”TEST”. After selecting the control field ”OK” thebackup function is started. The PC reads the contents of the welding machine's jobmemory and stores it in the file ”TEST.MCJ” on the standard disk drive.

8.3 Characteristic curves MC3 -> PC

In this submenu the characteristic curve and characteristic curve basic data memory ofthe welding machine is stored on the adjusted standard disk drive. After calling themenu up a window with the indication ”MC3 DATA -> PC” appears on the screen. Inthe left lower part of the window a selection box with the indication "FILE" isdisplayed. In this selection box all backup files ("MCK"), which have already beenstored on the standard disk drive, are listed. If backup files have not been generatedbefore, the message "empty" is displayed in the selection box. Enter a file name withmax. 8 digits in the entry field "Name" in order to make a new backup. Take e.g. thename "ATTEMPT". After selecting the control field ”OK” the backup function isstarted. The PC reads one after another the contents of welding machine’s characteristiccurve and characteristic curve basic data memory and stores it in the files”ATTEMPT.MCK” and ”ATTEMPT.MCG” on the standard disk drive.

8.4 Total backup PC -> MC3

In this submenu there is the possibility of transferring backup files, which are stored onthe standard disk drive, to the welding machine. After calling this menu up a windowwith the indication ”PC-DATA-> MC3” appears on the screen. In the left lower part ofthe window a selection box with the indication "FILE" is displayed. In this selection boxall backup files ("MCJ", "MCK" and "MCG"), which have already been stored on the

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standard disk drive, are listed. Before the data transmission to the welding machine canstart, the requested file has to be selected first of all. You have to observe that at leastthree files with the same name (e.g. ”DEMO.MCJ”, ”DEMO.MCK” and”DEMO.MCG”) are listed in the selection box. As you have chosen the total backupmethod, the PC tries to transfer three files in any case. These files must have the samefile name with max. 8 digits. If a file cannot be found, the PC finishes the backupfunction with an error message. Select one of the three requested files and press thecontrol field "OK" afterwards. The backup function is started and the PC transfers oneafter another the selected backup files to the welding machine.

8.5 Job data -> MC3

In this submenu there is the possibility of transferring job backup files, which are storedon the standard disk drive, to the welding machine. After calling this menu up a windowwith the indication ”PC-DATA-> MC3” appears on the screen. In the left lower part ofthe screen a selection box with the indication "FILE" is displayed. In this selection boxall backup files ("MCJ"), which have already been stored on the standard disk drive, arelisted. Now select the requested backup file and press the control field "OK" afterwards.The backup function is started and the PC transfers the contents of the selected backupfile to the welding machine.

8.6 Characteristic curves PC -> MC3

In this submenu there is the possibility of transferring characteristic curve backup files,which are stored on the standard disk drive, to the welding machine. After calling thismenu up a window with the indication ”PC-DATA-> MC3” appears on the screen. Inthe left lower part of the window a selection box with the indication "FILE" isdisplayed. In this selection box all backup files (”MCK”), which have already beenstored on the standard disk drive, are listed. Select the requested backup file and pressthe control field ”OK” afterwards. The backup function is started and the PC transfersthe contents of the requested backup file to the welding machine. As you have chosenthe characteristic curve backup method, the PC transfers after the characteristic curvefile (”MCK”) also the characteristic curve basic data (”MCG)”.

8.7 Change directory – Set standard disk drive

In this menu the current standard disk drive or current directory is set.

Example:You want to configure the disk drive ”A” as current standard disk drive. Call up thesubmenu ”Change directory”. Select ”DRIVES” in the selection box ”TREE” and thenpress the ”ENTER KEY”. A list of all disk drives connected to the PC appears on thescreen. Insert a formatted disk in disk drive ”A”, select disk drive ”A:” and press the

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”ENTER KEY”. In the selection box only the disk drive ”A:\” with the probabledirectory paths is shown. Select the control field ”OK” to quit the submenu ”Changedirectory”. The disk drive ”A:” is configured now as standard disk drive. All access tothe standard disk drive (see chapter 8.0 ”BACKUP”) is diverted to disk drive ”A:\”.

Example:The disk drive ”C:” (hard disk) has been configured as standard disk drive. You want tochange the current directory ”C:\MC3” and configure ”C:\” as current directory path.Call up the ”Change directory” submenu, select ”C:\” in the selection box ”TREE” andthen press the ”ENTER KEY”. The ”C:\” directory with all existing subdirectories isshown on the screen. The directory actually selected (C:\) is highlighted in green. Selectthe control field ”OK” to quit the submenu. The directory ”C:\” is now configured as thecurrent directory. All access to the standard disk drive (see chapter 8.0 ”BACKUP”) isdiverted to disk drive ”C:\”.

For both examples mentioned any alterations made up to this point can be rejected andthe original state re-established before exiting the menu "Change directory". Simplyselect the control field "REVERT". Then select the control field "OK" and the menu"Change directory" is exited unaltered.

9.0 Print

The ”PRINT” menu has another submenu:

• Current characteristic curve (see 9.1 Current characteristic curve)

It is possible to print out the supporting point parameters of the currentcharacteristic curve. Connect a commercial printer (EPSON LQ or EPSON FXcompatible) to the parallel interface port LPT1 of the PC (e.g. ”OKI Microline 390”,”Citizen Swift 200” etc.)

9.1 Current characteristic curve

In the submenu ”Current characteristic curve” the current characteristic curve supportingpoints with the relating characteristic curve basic data can be printed out.

10.0 End

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To finish the program select the menu point ”FINISH PROGRAM” in the ”END” menuor press the ”Alt” and ”X” keys simultaneously. The main menu of the MC3 PCsoftware is exited and you return to the DOS operating system.

11.0 Error messages

Error message Possible error causeNo user licence available !!! • Prior t o installation the original disk has

been write-protected; therefore the userlicence has not been transferred.

Cannot find file „MC3.SPR“ ! • File „MC3.EXE“ has been started in thewrong directory. Change to correctdirectory (e.g.. C:\MC3) and recallMC3.EXE .

Machine does not respond ! • Welding machine switched off• Interface cable incorrectly connected or

faulty• Wrong machine number set on PC. Factory

setting = 1Faulty transfer ! • After a total of 5 attempts the serial data

records could not be correctly transferred.Interference on serial data lines probablytoo great

• Too many drivers are installed on thecomputer at one time

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12.0 Copy right

The MC3 PC software is supplied on a copy protected disk with connection cableRS232 and service manual. The purchase of the program entitles the buyer to use theprogram on one computer only. The user licence on the original disk is automaticallytransferred when file ”INSTALL.BAT” is installed. The program can be installedsimultaneously on several computers, but can only be started on the computer where theuser licence was installed. Using the original disk it is possible to move the user licencefrom one computer to another. Use the ”EVMOVE” program on the original disk. Withthe command ”EVMOVE C: A:” the user licence is moved back from hard disk drive”C:” to floppy disk drive ”A:”, i.e. to the original disk. The original state of the disk hasbeen restored and you can now install and re-install the program on any computer.

Example :The MC3 PC software has been installed on the hard disk drive ”C:” on computer No. 1.You wish to install and start it now on the hard disk drive ”C:” on computer No. 2.Please proceed as follows:Insert the original disk in drive ”A:” of computer No. 1. Change to disk drive ”A:\” andenter the command ”EVMOVE C: A:”. After pressing the ”ENTER KEY” thefollowing message appears on the screen:

Moving Authorization FROM drive C to drive A - Confirm (Y/N) ? Y

Press the ”ENTER KEY” again. The user licence is then transferred from hard diskdrive ”C:” to floppy disk drive ”A”. You can now insert the original disk in drive ”A:”on computer No. 2. Install the software using the command ”Install deutsch A:C:”(Install German A.C). The installation procedure starts after the ”ENTER KEY” ispressed. Enter the command ”MC3” to start the program.

CAUTION !!!

Before using commercial defragmentation programs (e.g.. MSDOS-DEFRAG) on thehard disk of your computer the user licence should be transferred back to the originaldisk. After defragmentation the user licence can be transferred again to the hard diskusing the command ”EVMOVE A: C:”.

13. 0 Compatibility with former MC 3 software versions

The MC 3 PC software is downward compatible with all former MC 3 softwareversions. However, the new functions cannot be used.When calling up a function which is not implemented in the welding machine software,a corresponding error message appears on the PC monitor. The welding machine must atleast be provided with the V1.62 in order to use all functions of the V1.8 PC software.