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Computer Weld Technology Micro ADM Operation & Installation Manual

Micro arc data monitor
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Computer Weld Technology, Inc.
10702 Old Bammel N Houston Rd.
Houston, TX 77086
Phone: (713) 462-2118
Fax: (713) 462-2503
Email: cwt@cweldtech.com
Micro ADM
Micro Arc Data Monitor
Operation / Installation Manual
Manual Part Number: A8M5022
Revised: 7/24/2008

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  • Page 1 Computer Weld Technology, Inc. 10702 Old Bammel N Houston Rd. Houston, TX 77086 Phone: (713) 462-2118 Fax: (713) 462-2503 Email: cwt@cweldtech.com Micro ADM Micro Arc Data Monitor Operation / Installation Manual Manual Part Number: A8M5022 Revised: 7/24/2008...

  • Page 3: Table Of Contents

    SUPPORTED MODBUS COMMANDS..................... 8 MEMORY MAP FOR SENSOR ......................... 8 COIL DEFINITIONS AND OPERATION....................11 REGISTER DEFINITIONS........................12 5.0 MICRO ADM™ ASCII TERMINAL MODE PROTOCOL ..........14 GENERAL DESCRIPTION........................14 TERMINAL PROTOCOL .......................... 14 TERMINAL COMMANDS......................... 16 6.0 MICRO ADM™ REMOTE I/O USER INTERFACE ............19 GENERAL DESCRIPTION........................
  • Page 4 APPENDIX B MICRO ADM™ ASSEMBLY PARTS LIST..........38 MICRO ADM™ SENSOR ASSEMBLY P/N: A3A0226 REV: 0 ............. 38 MICRO ADM™ SENSOR ASSEMBLY P/N: A3A0226 REV: A............. 41 MICRO ADM™ SENSOR ASSEMBLY P/N: A3A0226 REV: B............. 44 MICRO ADM™ SENSOR ASSEMBLY P/N: A3A0226 REV: C............. 47 APPENDIX C SCHEMATIC DIAGRAMS ................

  • Page 5: System Overview

     Wire Feed Speed  Shielding Gas Pressure The light weight, easy to install design allows the user to install the Micro ADM™ at the wire drive motor inlet using industry standard quick disconnect conduit fittings or to a fixed surface with the optional mounting brackets (A2A0025). The LED indicators provide the operator or maintenance personnel with a quick visual indication of sensor activity.

  • Page 6: Sensor Specifications

    Sensor Specifications Current Sensor Current range 0-600 A (DC) Relative precision on Range ± 1% Max Linearity error ± 0.9 % of reading Band Width at ±1db 2.5 Khz Voltage Sensor Voltage range 0-100 V (DC) Relative precision on Range ±...

  • Page 7: Installation

    2.0 INSTALLATION General Guidelines The Micro ADM™ can be mounted two different ways. It can be installed at the wire feeder using the quick disconnect fittings or mounted to a fixed surface. Listed below are some things that should be taken into consideration when selecting a place and method for mounting of the Micro ADM™:...

  • Page 8: Sensor Installation Guidelines

    (Maximum length of 1 meter) for support of the wire from the Micro ADM™ to the wire feeder inlet. 3. Connect the Shielding Gas line to the Micro ADM™ Gas inlet. A barb T-fitting is provided to facilitate the installation of the Gas Line. Cut the Gas hose and install each end on to the 1/8”...

  • Page 9: Configure Modbus™ Device Id

    Configure ModBus™ Device ID Two BCD switches are provided to allow external definition of 0 to 247 ModBus addresses. Prior to operation the user must set the desired Device ID number for the ModBus communications. Each address must be unique. To set the Device ID remove the Black hole plug from the bottom of the unit.

  • Page 10: Operation

    3.0 OPERATION Arc Detection “Auto Arc On” is not available if firmware is Version 2.31 and later. If the “Auto Arc On” mode is enabled the sensor will use the Arc Voltage and Current to determine when to log welding data. Both parameters must exceed the user defined threshold values to set an “Arc On”...
  • Page 11 The following is the general specification for the RS-485 port: Serial Port Specification Description Physical support Twisted Pair Connector Turck Eurofast 5 pin circular Network RS 485 – Full Duplex Data exchange protocol Modbus RTU The RS-485 is a Turck Eurofast connector and will provide the RS-485 connections and the power to operate the sensor.

  • Page 12: Micro Adm™ Modbus Memory Map

    General Description This document provides the basic ModBus memory map and command structure for the Micro ADM™ RS-485 communications port. The Micro ADM™ supports the ModBus Protocol as specified in the Modicon Technical publications “ModBus Protocol” (intr7.html). The Micro ADM™ control does not support the Broadcast mode.
  • Page 13 when the arc is off. Set Clock – When set the Date and Time values set in Register 7 – 12 will be loaded to the Real Time Clock. The Coil will be reset after the RTC is set. This function will only execute when the arc is off.
  • Page 14 mm/sec increments (100=100 MM/Sec/100 IPM). When the weld cycle is complete the value will be the statistical average for the last weld. RTC BCD SEC:MIN – The value is the arc start SEC:MIN based on the Real Time Clock. This value is set when an arc on condition is detected.

  • Page 15: Coil Definitions And Operation

    To disable the auto arc on detection mode force coil 2 to the “ON” condition. When set the Micro ADM™ will only log data when the remote on input is active. To allow normal arc on detection Coil 2 must be in the “OFF” condition.

  • Page 16: Register Definitions

    1. Set Coil 2 to the “ON” condition to disable automatic arc detection. 2. Load the BCD formatted Time and Date into the value Registers 6-12. 3. Set Coil 8 to the “ON” condition. The Micro ADM™ will clear the coil after completing the function.
  • Page 17 When the Arc is in the off condition the Registers will display the statistical average for the last weld. Registers 7-9: Contains the BCD coded Time and Date at the start of the last weld. These registers will only update when a new weld is detected or a weld summary is loaded from memory.

  • Page 18: Micro Adm™ Ascii Terminal Mode Protocol

    5.0 Micro ADM™ ASCII TERMINAL MODE PROTOCOL General Description If the Device ID is set to zero when the power is applied then the Micro ADM Terminal mode is active and can be used to off-line program the user configurable parameters and operating modes. The protocol is a simple ASCII command string that allows the user to upload or download the various data.
  • Page 19 The following is a summary of the two special command functions. They are used to set and read the Micro ADM™ Real Time Clock (RTC). To read the current Time type the following command: From Host type: T? (cr) Response from Micro ADM™:...

  • Page 20: Terminal Commands

    TERMINAL COMMANDS The following is a summary of the Terminal Commands supported by the Micro ADM: Command DESCRITION RANGE Voltage zero offset calibration value. (128 = 0 offset) 0-255 Negative offset < 128 > Positive offset Current zero offset calibration value (128 = 0 offset) 0-255 Negative offset <...
  • Page 21 measures the Arc On time for each weld. When the weld cycle is complete the total time for the weld will be set. (Note 100 = 10.0 sec) Volts – During the Arc on Time the value represents 0-102.3 the actual arc voltage. The value is in 0.1 volt increments (100=10.0 volts).
  • Page 22 welding current that must be exceeded to establish an arc on condition. Value is in 1-amp increments (10 = 10 amps). Arc On Volts - The value set in this Register is the 0-102.3 welding voltage that must be exceeded to establish an arc on condition.

  • Page 23: Micro Adm™ Remote I/O User Interface

    Micro ADM™ uses this input to establish when a new part is being welded. When the input is cleared the Micro ADM™ will perform a final analysis of all the welds made and set the pass/fail Part output signals. The pass-fail outputs will be set based on weld volume, weld counts and work-applied calculations.

  • Page 24: Operational Description

    Part” signal that must be asserted at the beginning of the part weld sequence. This input must be held during the complete part weld cycle. The Micro ADM™ will count and test each weld as the part is welded. Each weld will then be verified based on AAD process algorithms.

  • Page 25: Setting Process Control Limits

    Complete Part SETTING PROCESS CONTROL LIMITS The Micro ADM™ has a learn mode that is used to establish the Part and weld process control limits. This mode is used to calculate the required AAD limits and to establish the base-line weld data limits. The user must first validate the process parameters and be assured that the parts are conforming to applicable codes and design specification.
  • Page 26 The “CR3-Fault” is reset when a new weld is detected or the “INP1-Learn” input is asserted. After completing the “Learn” the Micro ADM™ will not begin testing until the “INP2- New Part” has been cleared then asserted indicating a new part.

  • Page 27: Appendix A Micro Adm™ Installation Specifications

    Appendix A Micro ADM™ Installation Specifications Micro ADM™ Sensor Mounting Dimensions 4.75 4.00 4X Ø0.31 TWO OPTIONAL 3.88 0.40 MOUNTING BRACKETS BOTTOM VIEW OUTPUT SIDE PANEL VIEW WIRE SPEED SENSOR FITTING 5.25 5.38 3.00 WIRE SPEED 4.73 SENSOR FITTING LEFT END VIEW...

  • Page 28: Sensor Cables And Wire Speed Sensor Installation

    Sensor Cables and Wire Speed Sensor Installation To Wire Feed Drive Wire Outlet Quick Disconnect Fitting From Wire Spool Wire Inlet Quick Disconnect Fitting Communications Connector Remote Connector Positive Welding Cable Installation To Wire Feed Drive From Welding Positive Power Source Welding Cable...

  • Page 29: Gas Pressure Hose Installation

    Gas Pressure Hose Installation CWT Supplied 1/4” or 3/8” I.D. gas hose barb tee fittings Splice into Customer’s supplied 1/4” OR 3/8” I.D. gas hose CWT supplied 1/4” x 6” long gas hose Voltage Sensor Installation Route the RED 18 gauge, 600V conductor (3’...

  • Page 30: Single Unit Installation

    P/N: C3A5023 – To be Computer connected to the COM Port on your Personal Computer Power Supply 110VAC - P/N: X3T5036 220VAC - P/N: X3T5047 Micro ADM P/N: A3A0226 Communications Cable P/N: A3W0327 (6 meter long) SYSTEM INSTALLATION DIAGRAM RS-485 CABLE HOOKUP...
  • Page 31 Echo Duplex Baud Rate Jumpers Jumpers Jumpers (JP1) (JP2) (JP3) RS-485 Terminal Block (TB1) RS-232 Connector Internal Power Jumper (JP4) Power Supply Connector ECHO JUMPERS (JP1) POWER JUMPERS (JP4) BAUD RATE JUMPERS (JP3) ECHO JUMPER POWER JUMPER BAUD JUMPER External** 1200 Off** Internal...

  • Page 32: Multiple Unit Network Installation

    (Order by the Foot) NetHub Assembly 110VAC - P/N: A3A0214 220VAC - P/N: A3A0219 RS-485 Cable Power Cable P/N: X3W5042 (Order by the Foot) Micro ADM Communications Cable P/N: A3A0226 P/N: A3W0327 (6 meters long) SYSTEM INSTALLATION DIAGRAM RS-485 CABLE HOOKUP TERMINAL...
  • Page 33 Echo Duplex Baud Rate Jumpers Jumpers Jumpers (JP2) (JP1) (JP3) RS-485 Terminal Block (TB1) RS-232 Connector Internal Power Jumper (JP4) Power Supply Connector ECHO JUMPERS (JP1) POWER JUMPERS (JP4) BAUD RATE JUMPERS (JP3) POWER JUMPER ECHO JUMPER BAUD JUMPER External** On** 1200 Internal...
  • Page 34 Terminal Block Jumper JMP1 Terminal Block Fuse F1 TB1 - AC Power 1 Amp 110/220 AC TB4 - Remote I/O Terminal Block Terminal Block TB3 - Net In TB2 - Net Out Terminal Block Terminal Block Terminal Block Terminal Block Terminal Block Terminal Block TB9 - Port 5...

  • Page 35: Nethub Mounting Dimensions

    NetHub Mounting Dimensions...

  • Page 36: Communications Cable P/N: A3W0327

    Communications Cable P/N: A3W0327 This part includes both a cable and a strain relief. The strain relief is to be used for a NetHub installation. WIRE LIST WIRE COLOR FROM REFERENCE BROWN ITEM 1 PIN 1 +24 VDC WHITE ITEM 1 PIN 2 NET+ BLUE ITEM 1 PIN 3...

  • Page 37: Typical External Powered Plc I/O System Integration

    SUPPLY FOR ALL SENSORS CONNECTED TO PLC I/O MODULE. TO SENSOR NET- P1 - I/O COMM 4. RS-485 CONVERTER MAY BE REPLACED WITH OPTIONAL NETHUB PROVIDING TO SENSOR NET+ POWER AND COMMUNICATIONS FOR 6 SENSORS. TYPICAL SENSOR POWERED PLC TO MICRO ADM INTERFACE...

  • Page 38: Typical Sensor Powered Plc I/O System Integration

    OPTIONA L NETHUB CONNECTION POWER AND COMMUNICATIONS FOR 6 SENSORS. NET HUB PORT (1-6) TB5 - TB10 +12 VDC NET+ SENSOR COMM TO SENSOR NET- CABLE P/N A3W0327 I/O COMM PORT RMT ON TYPICAL SENSOR POWERED PLC TO MICRO ADM INTERFACE...

  • Page 39: Normal Weld Cycle Process Control Flow Chart

    WELD OPERATIONAL SEQUENCE: COMPLETE 32. Set Micro ADM sensor “PART” input Bit O:1/1. 33. Delay 80 msec for sensor I/O debounce time. 34. Test the sensor “NEW PART” output I:1/0 for low level indicating new part active. If High then clear DELAY 150 MSEC the sensor “PART”...

  • Page 40: Group Weld Cycle Process Control Flow Chart

    Only one output “Fail” or “Pas s” will be set if neither output is set handle sensor fault error. Note: The actual Input/Output bits assigned to the Micro ADM sensor will depend on actual system integration to PLC controller.

  • Page 41: Learn Weld Cycle Process Control Flow Chart

    LEARN COMPLETE START WELD EVENT LEAR N MODE OPERATIONAL SEQUENCE: Set the “Learn” input O:1/0. Warning: When “Learn input is set the Micro ADM will clear all previous limits. WELD Set the sen sor “PART” input Bit O:1/1. COMPLETE Delay 80 msec for sensor I/O debounce time.

  • Page 42: Appendix B Micro Adm™ Assembly Parts List

    Appendix B Micro ADM™ Assembly Parts List Micro ADM™ Sensor Assembly P/N: A3A0226 Rev: 0...
  • Page 44 Wire, 24 AWG CSA Type Tr-64 Yellow 14” Wire, 24 AWG CSA Type Tr-64 Green A5A0117 I-Dart I/O PCB Assembly X6S5023 Spacer, M-F #6-32 x 1/2” long #8250 HH Smith #6-32 x 5/8” long Pan Head Screw Micro ADM Sensor Serial Number Label Warning #1 Label...

  • Page 45: Micro Adm™ Sensor Assembly P/N: A3A0226 Rev: A

    Micro ADM™ Sensor Assembly P/N: A3A0226 Rev: A...
  • Page 47 Wire, 24 AWG CSA Type Tr-64 Yellow 14” Wire, 24 AWG CSA Type Tr-64 Green A5A0117 I-Dart I/O PCB Assembly X6S5023 Spacer, M-F #6-32 x 1/2” long #8250 HH Smith #6-32 x 5/8” long Pan Head Screw Micro ADM Sensor Serial Number Label Warning #1 Label...

  • Page 48: Micro Adm™ Sensor Assembly P/N: A3A0226 Rev: B

    Micro ADM™ Sensor Assembly P/N: A3A0226 Rev: B...
  • Page 50 Wire, 24 AWG CSA Type Tr-64 Yellow 14” Wire, 24 AWG CSA Type Tr-64 Green A5A0117 I-Dart I/O PCB Assembly X6S5023 Spacer, M-F #6-32 x 1/2” long #8250 HH Smith #6-32 x 5/8” long Pan Head Screw Micro ADM Sensor Serial Number Label Warning #1 Label...

  • Page 51: Micro Adm™ Sensor Assembly P/N: A3A0226 Rev: C

    Micro ADM™ Sensor Assembly P/N: A3A0226 Rev: C...
  • Page 53 Wire, 24 AWG CSA Type Tr-64 Yellow 14” Wire, 24 AWG CSA Type Tr-64 Green A5A0117 I-Dart I/O PCB Assembly X6S5023 Spacer, M-F #6-32 x 1/2” long #8250 HH Smith #6-32 x 5/8” long Pan Head Screw Micro ADM Sensor Serial Number Label Warning #1 Label...

  • Page 54: Appendix C Schematic Diagrams

    Appendix C Schematic Diagrams Micro ADM™ Sensor Assembly P/N: A3A0226 Rev: 0 +VARC -VARC VOLT SENSE NET+ PCB? NET- N.C. 1 +24 I-DART PCB 2 NET+ SENSOR A5A0109 3 NET- 4 INP1 5 COM -VARC 2 +VARC 1 CR1 1...

  • Page 55: Micro Adm™ Sensor Assembly P/N: A3A0226 Rev: A

    Micro ADM™ Sensor Assembly P/N: A3A0226 Rev: A +VARC -VARC VOLT SENSE NET+ ADM? NET- N.C. 1 +24 I-DART PCB 2 NET+ SENSOR A5A0109 3 NET- 4 INP0 5 COM -VARC 2 +VARC 1 CR1 1 1 AMP+ CR3 2...

  • Page 56: Micro Adm™ Sensor Assembly P/N: A3A0226 Rev: B

    Micro ADM™ Sensor Assembly P/N: A3A0226 Rev: B +VARC -VARC VOLT SENSE NET+ ADM? NET- N.C. 1 +24 I-DART PCB 2 NET+ SENSOR A5A0109 3 NET- 4 INP0 5 COM -VARC 2 +VARC 1 CR1 1 1 AMP+ CR3 2...

  • Page 57: Micro Adm™ Sensor Assembly P/N: A3A0226 Rev: C

    Micro ADM™ Sensor Assembly P/N: A3A0226 Rev: C +VARC -VARC VOLT SENSE NET+ ADM? NET- PSEL 1 +24 I-DART PCB 2 NET+ A5A0109 SENSOR 3 NET- 4 INP0 5 COM -VARC 2 +VARC 1 CR1 1 1 AMP+ CR3 2...

  • Page 58: Appendix D Device Id Msb And Lsb Decode Table

    Appendix D Device ID MSB and LSB Decode Table Node ID Node ID Node ID Node ID...

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