Lincoln Electric Computer Weld Technology DMC II Operation & Installation Manual Download Page 1

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DMC II

DC DRIVE MOTOR CONTROL

Operation / Installation Manual

Manual Part Number: S8M5021

April 24, 2019

Computer Weld Technology

A Lincoln Electric Brand

10702 Old Bammel N Houston Rd.

Houston, TX 77086

Phone: (713) 462-2118

Fax: (713) 462-2503

Email: [email protected]

Summary of Contents for Computer Weld Technology DMC II

Page 1: ...OL Operation Installation Manual Manual Part Number S8M5021 April 24 2019 Computer Weld Technology A Lincoln Electric Brand 10702 Old Bammel N Houston Rd Houston TX 77086 Phone 713 462 2118 Fax 713 462 2503 Email cwt cweldtech com ...

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Page 3: ...y the manufacturers and the suppliers of the pressurized gas Work pieces that have been degreased using chlorinated solvents must be sprayed down with clean water before welding starts to avoid the risk of phosgene forming For the same reason no degreasing baths containing chlorine must be placed close to the welding point All vapors given off by metals can cause harm and a special warning is atta...

Page 4: ...se sparks explosion overheating or fire Check and be sure the area is safe before doing any welding or cutting Remove all flammables within 35 ft 10 7 m of the welding or cutting arc If this is not possible tightly cover them with approved covers Do not weld or cut where flying sparks can strike flammable material Protect yourself and others from flying sparks and hot metal Be aware that welding s...

Page 5: ...t work alone Disconnect input power or stop engine before installing or servicing equipment Lockout tagout input power according to OSHA 29 CFR 1910 147 see Safety Standards Properly install ground and operate this equipment according to its Owner s Manual and national state provincial and local codes Always verify the supply ground check and be sure that input power cord ground wire is properly c...

Page 6: ... Never allow a welding electrode or cutting torch to touch any cylinder Never weld on a pressurized cylinder explosion will result Use only the correct compressed gas cylinders regulators hoses and fittings designed for the specific application maintain them and associated parts in good condition Turn face away from valve outlet when opening cylinder valve Do not stand in front of or behind the re...

Page 7: ...g to minimize the possibility of interference California Proposition 65 Warnings Welding or cutting equipment produces fumes or gases that contain chemicals known to the State of California to cause birth defects and in some cases cancer California Health Safety Code Section 25249 5 et seq This product contains chemicals known to the State of California to cause cancer and birth defects or other r...

Page 8: ...t Miami FL 33125 Free download at http www aws org technical AWS_Z49 pdf ANSI Standard Z41 1 STANDARD FOR MEN S SAFETY TOE FOOTWEAR obtainable from the American National Standards Institute 1430 Broadway New York NY 10018 ANSI Standard Z49 2 FIRE PREVENTION IN THE USE OF CUTTING AND WELDING PROCESSES obtainable from the American National Standards Institute 1430 Broadway New York NY 10018 OSHA SAF...

Page 9: ...EGISTER AND OPERATION 10 4 7 MEMORY MAP FOR SLAVE ID MODBUS COMMAND 17 11 APPENDIX A SYSTEM DRAWINGS 12 A 1 DMC II LOW VOLTAGE ENCLOSURE ASSEMBLY 110VAC P N S3A5160 12 A 2 DMC II LOW VOLTAGE ENCLOSURE ASSEMBLY 220VAC P N S3A5169 14 A 3 DMC II HIGH VOLTAGE ENCLOSURE ASSEMBLY 110VAC P N S3A5161 16 A 4 MILLER A1D4 MOTOR CONTROL CABLE P N S3W5059 18 A 5 STANDARD W O TACH MOTOR CONTROL CABLE P N S3W506...

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Page 11: ... remote direction control The control provides an optional isolated encoder output signal A remote I O connector located on the rear of the enclosure provides all user control connections 1 2 Motor Output The standard DMC II can be used with 24 VDC permanent magnet motors up to 150 watts The DMC II HV can be used with 90 VDC permanent magnet motors up to 250 watts A motor connector located on the ...

Page 12: ... 25 0khz Forward Input 24 vdc 20ma Active High Reverse Input 24 vdc 20ma Active High Speed Reference Input 0 10 vdc 0 1 ma The following are the electrical specifications for the DMC II LV Power Input 120 vac 10 2 5amps Armature Current 0 5 6 5 amps Armature Voltage 0 24 vdc Encoder Input 5 or 15 vdc 100 lines rev max frequency 25 0khz Forward Input 24 vdc 20ma Active High Reverse Input 24 vdc 20m...

Page 13: ...t allows easy access to the front and rear panel Figure 2 1 shows the mounting pattern for the control enclosure FIG 2 1 Enclosure Mounting Dimensions POWER Computer Weld Technology Inc DMC I O PWR TORQUE READY DRIVE ON FWD CW REV CCW NET PWR 3 6V 12V 36V TM COMM I O 10 250 0 375 11 000 9 250 0 87 1 250 0 477 2 250 4X Ø0 281 4 750 MOTOR MAX 6 FOR CABLE CLEARANCE TOP VIEW SIDE VIEW FRONT VIEW REAR ...

Page 14: ...ed E Not used F Chassis Ground G Encoder Pulse input TTL or 15 Volt Pulse H Encoder Common J Motor Field K Motor Armature L Motor Field M Motor Armature Figure 2 2 Motor Connector Pin out 2 2 Optional Encoder Connections The DMC II can use a 5 volt or 15 volt encoder Both power outputs are provided on the connector Connect the optional motor encoder to the correct voltage output Use Pin A for a 15...

Page 15: ...e DMC HV can be used with a permanent magnet or shunt field motors with an armature rating of 90 100 volt dc The DMC II LV can be used with a permanent magnet motors with an armature rating of 10 24 volt dc The following is the connection diagram for a permanent magnet motor ARM ARM Fig 2 4 Permanent magnetic motor wiring A B C D E F G H J K L M A B C D E F G H J K L M ...

Page 16: ...mon 4 Speed input signal 0 10 vdc 5 Drive Forward command input 24 vdc 10 ma 6 Drive Reverse command input 24 vdc 10 ma 7 Motor Tachometer output 24 vdc 8 Frame ground Cable Shield connection Fig 2 6 Remote I O connector pin out A remote I O cable S3W5058 is available for interfacing the DMC II to the CWT controller or for direct interface to user supplied PLC controller The following is an exampl...

Page 17: ...r input When an encoder is installed on the motor shaft the DMC II can be set for encoder feedback by installing a jumper on JP3 When the jumper is installed the controller uses the tachometer to regulate motor speed When the jumper is removed the controller will use the motor back EMF for speed regulation 3 2 Control Calibration The DMC II controller is factory calibrated to produce 2300 rpm with...

Page 18: ...8 5 Disable the forward direction input Turn the power off and reinstall the DMC cover ...

Page 19: ... rate is 19 2 K Baud 4 2 Supported Modbus Commands The following ModBus commands are supported CODE DESCRIPTION ADDRESS RANGE 01 Read Coil Status 0 15 03 Read Holding Registers 0 19 05 Force Single Coil 0 15 06 Preset Single Register 0 19 15 Force Multiple Coils 0 15 16 Preset Multiple Registers 0 19 17 Report Slave ID 5 bytes 4 3 Memory Map for Coils Modbus Command 01 05 15 The following is the C...

Page 20: ... bit defined input only Bits 0 5 are defined 15 14 Encoder Scale in PPR used to calculate Motor RPM 16 15 Node Iref MSB DevID 1 247 LSB Max Motor Amp 17 16 EMF Kd Kp DO NOT MODIFY WARNING Changing this value may result in a catastrophic failure of the controller 18 17 TACK Kd Kp DO NOT MODIFY WARNING Changing this value may result in a catastrophic failure of the controller 19 18 PWMHZ Accel DO NO...

Page 21: ...following is a summary of the Report Slave ID and Status Code 17 Response Data fields Byte Contents 1 Sensor ID Number 10 Hex Version 1 Rev0 2 Run Indicator 0 OFF FF On 3 Status Byte Bit 0 Ram Full Bit 1 Battery Ok Bit 2 Self Test Ok Bit 3 7 0 4 Firmware Version Number BCD Format MSB Major ISB Minor 5 Firmware Version Number BCD Format MSB LSB Release ...

Page 22: ...12 APPENDIX A SYSTEM DRAWINGS A 1 DMC II Low Voltage Enclosure Assembly 110VAC P N S3A5160 ...

Page 23: ...ess Motor Encoder 9 1 S3W5163 Harness I O 10 1 S3W5164 Harness Comm 11 1 S5A5076 PCB Assembly DMC 2 36V Drive 12 1 X3P5841 Connector Housing 8 Circuit 13 1 X3P5875 Connector Housing 3 Circuit 14 1 X3S5078 Switch Rocker 15 1 X3T5096 Supply Power AC DC 28VDC 120W 16 2 S2M5212 Pad Thermal 17 10 Screw 6 32 x 1 4 Pan Head w Internal Lock Washer 18 4 Screw 4 40 x 1 4 Pan Head w Internal Lock Washer 19 1...

Page 24: ...14 A 2 DMC II Low Voltage Enclosure Assembly 220VAC P N S3A5169 ...

Page 25: ...Harness Motor Encoder 9 1 S3W5163 Harness I O 10 1 S3W5164 Harness Comm 11 1 S5A5076 PCB Assembly DMC 2 36V Drive 12 1 X3P5841 Connector Housing 8 Circuit 13 1 X3P5875 Connector Housing 3 Circuit 14 1 X3S5078 Switch Rocker 15 1 X3T5096 Supply Power AC DC 28VDC 120W 16 2 S2M5212 Pad Thermal 17 10 Screw 6 32 x 1 4 Pan Head w Internal Lock Washer 18 4 Screw 4 40 x 1 4 Pan Head w Internal Lock Washer ...

Page 26: ...16 A 3 DMC II High Voltage Enclosure Assembly 110VAC P N S3A5161 ...

Page 27: ...0 Harness Power Switch 7 1 S3W5162 Harness Motor 8 1 S3W5163 Harness I O 9 1 S3W5164 Harness Comm 10 1 S5A5086 PCB Assembly DMC 2 HV2 11 1 X3P5841 Connector Housing 8 Circuit 12 1 X3P5875 Connector Housing 3 Circuit 13 1 X3S5078 Switch Rocker 14 2 S2M5212 Pad Thermal 15 10 Screw 6 32 x 1 4 Pan Head w Internal Lock Washer 16 1 Nut Hex 6 32 17 1 Label Serial Number ...

Page 28: ...ale 5 4 X3P0303 Terminal Socket 22 awg 6 2 X3P0302 Terminal Socket 18 awg 7 1 X3Z5054 Clamp Cable 8 25 X3W5020 Cable 6 Conductor DESCRIPTION WIRE TYPE FROM TO 15VDC 22 AWG RED ITEM 1 PIN A ITEM 4 PIN 7 GROUND 22 AWG GREEN ITEM 1 PIN F ITEM 4 PIN 5 ENC 22 AWG BLUE ITEM 1 PIN G ITEM 4 PIN 9 COM 22 AWG BROWN ITEM 1 PIN H ITEM 4 PIN 8 ARM 18 AWG BLACK ITEM 1 PIN M ITEM 4 PIN 1 ARM 18 AWG WHITE ITEM 1 ...

Page 29: ...ON 1 1 X3P5586 Connector Plug 12 Circuit Male 2 1 X3P5589 Clamp Cable 3 1 X3P5505 Boot Cable Clamp 4 25 X3W5079 Cable 4 Conductor 16 awg DESCRIPTION WIRE TYPE FROM ARM 16 AWG RED ITEM 1 PIN M ARM 16 AWG BLACK ITEM 1 PIN K FIELD 16 AWG GREEN ITEM 1 PIN J FIELD 16 AWG WHITE ITEM 1 PIN L ...

Page 30: ...05 Boot Cable Clamp 4 1 X3P5663 Connector Plug 6 Circuit Female 5 1 X3P5503 Clamp Cable 6 1 X3Z5085 Boot Cable Clamp 7 25 X3W5079 Cable 4 Conductor 16 awg DESCRIPTION WIRE TYPE FROM TO ARM 16 AWG RED ITEM 1 PIN M ITEM 4 PIN A ARM 16 AWG BLACK ITEM 1 PIN K ITEM 4 PIN B FIELD 16 AWG GREEN ITEM 1 PIN J ITEM 4 PIN C FILED 16 AWG WHITE ITEM 1 PIN L ITEM 4 PIN D ...

Page 31: ...Cable Clamp 4 25 X3W5025 Cable 3 Conductor 22 awg 5 25 X3W5079 Cable 4 Conductor 16 awg DESCRIPTION WIRE TYPE FROM TO 5VDC 22 AWG RED ITEM 4 PIN B GROUND SHIELD ITEM 4 ITEM 4 PIN F ENC 22 AWG CLEAR ITEM 4 PIN G COM 22 AWG BLACK ITEM 4 PIN H ARM 16 AWG BLACK ITEM 4 PIN M ARM 16 AWG WHITE ITEM 5 ITEM 4 PIN K FIELD 16 AWG RED ITEM 4 PIN L FILED 16 AWG GREEN ITEM 4 PIN J ...

Page 32: ...8 Open Ended Remote I O Cable P N S3W5219 DESCRIPTION WIRE TYPE CONNECTOR CW WHITE PIN 1 24 I O BROWN PIN 2 CCW GREEN PIN 3 DRVON YELLOW PIN 4 RDY GRAY PIN 5 REF PINK PIN 6 I O COM BLUE PIN 7 WIPER RED PIN 8 ...

Page 33: ...ielded 4 2 X3P5257 Terminal Ring 5 6 Wire 22 awg Green Yellow DESCRIPTION WIRE TYPE FROM TO CW WHITE ITEM 1 PIN 1 ITEM 2 PIN 1 24 I O BROWN ITEM 1 PIN 2 ITEM 2 PIN 2 CCW GREEN ITEM 1 PIN 3 ITEM 2 PIN 3 DRVON YELLOW ITEM 1 PIN 4 ITEM 2 PIN 4 RDY GRAY ITEM 1 PIN 5 ITEM 2 PIN 5 REF PINK ITEM 1 PIN 6 ITEM 2 PIN 6 I O COM BLUE ITEM 1 PIN 7 ITEM 2 PIN 7 WIPER RED ITEM 1 PIN 8 ITEM 2 PIN 8 ...

Page 34: ...t Switcher I O MOTOR PWR RD TD DMC II Enclosure RS 485 Comm Cable P N C3W5079 RS 232 RS 485 Ethernet Converter P N C3A5049 Ethernet Cable P N X3W5117 6 5 4 3 2 1 RD RD PWR RD TD I O MOTOR Personal Computer DMC II Enclosure RS 232 RS 485 Converter P N C3A5023 To be connected to the COM Port on your Personal Computer Power Supply P N X3T5036 RS 485 Comm Cable P N S3W5220 ...

Page 35: ...rter P N C3A5023 Personal Computer WIRE LIST COLOR FROM TO DESCRIPTION ORG NETHUB TB3 1 NETHUB TB3 1 PWR WHT ORG NETHUB TB3 4 NETHUB TB3 4 COM BLU NETHUB TB3 2 NETHUB TB3 2 TD WHT BLU NETHUB TB3 3 NETHUB TB3 3 TD SHIELD NETHUB TB3 5 NETHUB TB3 5 EARTH I O MOTOR I O MOTOR I O MOTOR I O MOTOR NetHub Comm Cable P N S3W5221 DMC II System Option WIRE LIST COLOR FROM TO DESCRIPTION ORG J1 9 NETHUB TB3 1...

Page 36: ... A3A0214 220VAC P N A3A0219 RS 232 RS 485 Ethernet Converter P N C3A5049 Ethernet Cable Ethernet Switcher RS 485 Cable P N X3W5042 WIRE LIST COLOR FROM TO DESCRIPTION ORG NETHUB TB3 1 NETHUB TB3 1 PWR WHT ORG NETHUB TB3 4 NETHUB TB3 4 COM BLU NETHUB TB3 2 NETHUB TB3 2 TD WHT BLU NETHUB TB3 3 NETHUB TB3 3 TD SHIELD NETHUB TB3 5 NETHUB TB3 5 EARTH I O MOTOR I O MOTOR I O MOTOR I O MOTOR NetHub Comm ...

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