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Table of Contents

1.0

SYSTEM OVERVIEW .................................................................................................... 1

1.1

GENERAL OVERVIEW .............................................................................................................................. 1

1.2

GENERAL SPECIFICATIONS ................................................................................................................... 1

1.3

SENSOR SPECIFICATIONS ..................................................................................................................... 2

2.0

INSTALLATION.............................................................................................................. 3

2.1

GENERAL GUIDELINES............................................................................................................................ 3

2.2

SENSOR INSTALLATION GUIDELINES.................................................................................................. 4

2.3

CONFIGURE MODBUS™ DEVICE ID ..................................................................................................... 5

3.0 OPERATION .................................................................................................................... 6

3.1

ARC DETECTION....................................................................................................................................... 6

3.2

EMBEDDED FIRMWARE........................................................................................................................... 6

3.3

HOST SYSTEM SERIAL INTERFACE...................................................................................................... 6

4.0 MICRO ADM™ MODBUS MEMORY MAP .................................................................... 8

4.1

GENERAL DESCRIPTION......................................................................................................................... 8

4.2

SUPPORTED MODBUS COMMANDS..................................................................................................... 8

4.3

MEMORY MAP FOR SENSOR ................................................................................................................. 8

4.4

COIL DEFINITIONS AND OPERATION.................................................................................................. 11

4.5

REGISTER DEFINITIONS........................................................................................................................ 12

5.0 MICRO ADM™ ASCII TERMINAL MODE PROTOCOL ............................................. 14

5.1

GENERAL DESCRIPTION....................................................................................................................... 14

5.2

TERMINAL PROTOCOL .......................................................................................................................... 14

5.3

TERMINAL COMMANDS......................................................................................................................... 16

6.0 MICRO ADM™ REMOTE I/O USER INTERFACE ...................................................... 19

6.1

GENERAL DESCRIPTION....................................................................................................................... 19

6.2

OPERATIONAL DESCRIPTION.............................................................................................................. 20

6.3

SETTING PROCESS CONTROL LIMITS............................................................................................... 21

APPENDIX A

MICRO ADM™ INSTALLATION SPECIFICATIONS................................ 23

A.1

MICRO ADM™ SENSOR MOUNTING DIMENSIONS.......................................................................... 23

A.2

SENSOR CABLES AND WIRE SPEED SENSOR INSTALLATION..................................................... 24

A.3

POSITIVE WELDING CABLE INSTALLATION ...................................................................................... 24

A.4

GAS PRESSURE HOSE INSTALLATION .............................................................................................. 25

A.5

VOLTAGE SENSOR INSTALLATION..................................................................................................... 25

A.6

SINGLE UNIT INSTALLATION ................................................................................................................ 26

A.7

MULTIPLE UNIT NETWORK INSTALLATION....................................................................................... 28

A.8

NETHUB



MOUNTING DIMENSIONS .................................................................................................. 31

A.9

COMMUNICATIONS CABLE P/N: A3W0327......................................................................................... 32

A.10

REMOTE I/O CABLE P/N: X3W5102 ...................................................................................................... 32

A.11

TYPICAL EXTERNAL POWERED PLC I/O SYSTEM INTEGRATION ................................................ 33

A.12

TYPICAL SENSOR POWERED PLC I/O SYSTEM INTEGRATION .................................................... 34

A.13

NORMAL WELD CYCLE PROCESS CONTROL FLOW CHART ........................................................ 35

A.14

GROUP WELD CYCLE PROCESS CONTROL FLOW CHART........................................................... 36

A.15

LEARN WELD CYCLE PROCESS CONTROL FLOW CHART............................................................ 37

Содержание Micro ADM

Страница 1: ...ston Rd Houston TX 77086 Phone 713 462 2118 Fax 713 462 2503 Email cwt cweldtech com Computer Weld Technology Inc Micro ADM Micro Arc Data Monitor Operation Installation Manual Manual Part Number A8M5...

Страница 2: ......

Страница 3: ...REMOTE I O USER INTERFACE 19 6 1 GENERAL DESCRIPTION 19 6 2 OPERATIONAL DESCRIPTION 20 6 3 SETTING PROCESS CONTROL LIMITS 21 APPENDIX A MICRO ADM INSTALLATION SPECIFICATIONS 23 A 1 MICRO ADM SENSOR MO...

Страница 4: ...ASSEMBLY P N A3A0226 REV B 44 B 4 MICRO ADM SENSOR ASSEMBLY P N A3A0226 REV C 47 APPENDIX C SCHEMATIC DIAGRAMS 50 C 1 MICRO ADM SENSOR ASSEMBLY P N A3A0226 REV 0 50 C 2 MICRO ADM SENSOR ASSEMBLY P N A...

Страница 5: ...A2A0025 The LED indicators provide the operator or maintenance personnel with a quick visual indication of sensor activity The unit is powered by a user supplied external 24 VDC power source via the...

Страница 6: ...e 1 Max Linearity error 0 5 of reading Band Width at 1db 2 5 Khz Pressure Sensor English Units Metric Units Pressure range 2 5 14 5 PSI 15 100 Kpa Relative precision on Range 3 3 Max Linearity error 1...

Страница 7: ...sure that there is no stress on the sensor as a result of movement of the welding cable The Shielding Gas line must be attached to the gas inlet of the sensor Consideration must be given to the routin...

Страница 8: ...r 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 Lin...

Страница 9: ...To set the Device ID remove the Black hole plug from the bottom of the unit Locate the LSB and MSB rotary switches Set the binary address by rotating the switches to the desired address The Switch is...

Страница 10: ...provide user defined average and data collection mode to allow Run time and or average data storage The Run time data will be generated based on the averaging sample time specified by the user The Raw...

Страница 11: ...resistor for the RS 485 serial cable The Host controller will provide the necessary power to operate the sensor The power will be connected to the sensor through the RS 485 cable The sensor requires a...

Страница 12: ...orce Multiple Coils 0 15 16 Preset Multiple Registers 0 26 17 Report Slave ID 5 bytes 4 3 Memory Map for Sensor The following is the Coil definitions address 0 15 COIL ADDRESS DESCRIPTION 1 0 Arc Acti...

Страница 13: ...WIRE Fault When set the sensor has detected a wire speed parameter fault during the previous weld If set when the Part input is cleared it indicates a total volume applied fault has occurred The follo...

Страница 14: ...mory Max Count 500 18 17 Part Fault Counter Total number of faulted parts since last fault count reset 19 18 Read Weld Number the value is used to select the stored Summary data to be read from memory...

Страница 15: ...mware Version Number BCD Format MSB Major ISB Minor 5 Firmware Version Number BCD Format MSB LSB Release 4 4 Coil Definitions and Operation The Micro ADM has 16 simulated output coils These coils are...

Страница 16: ...completing the function The data will remain in the register until the next arc on or stored weld request 4 Enable Coil 2 to resume automatic arc detection 4 5 Register Definitions Register 1 Used to...

Страница 17: ...ndicates the number of weld summaries stored in the weld memory The maximum number of welds stored is 1024 Writing a new value to this register will cause the next collected weld to be written to that...

Страница 18: ...of a command string and optional data bytes The command string is an alpha character and an option number followed by a or followed by optional data and terminated with an ASCII cr 0dh The will indic...

Страница 19: ...7 35 cr Entire field must be completed as explained below Type 6 45 am as T 06 45 00 cr Type 7 25 PM as T 19 25 00 cr Note cr denotes carriage return Enter To read the current Date type the following...

Страница 20: ...for a single parameter sample 0 255 M4 Voltage Sigma value When set to zero parameter testing is disabled Note Sigma Value 24 0 255 M5 Amp Sigma value When set to zero parameter testing is disabled No...

Страница 21: ...cted 0 65535 V8 HR DAY The value is the arc start Hour and Day based on the Real Time Clock This value is set when an arc on condition is detected 0 65535 V9 MN YR The value is the arc start Month and...

Страница 22: ...ish an arc on condition Value is in 1 amp increments 10 10 amps V21 Arc On Volts The value set in this Register is the welding voltage that must be exceeded to establish an arc on condition Value is i...

Страница 23: ...asserted the Micro ADM will perform a final analysis of the entire first Group A welds and will assert the pass fail Part output signals The Group A pass fail outputs will be set based on total weld...

Страница 24: ...the INP 2 New Part signal and must be asserted at the end of the Part A weld cycle At the end of each weld the previous test status will be asserted by the CR2 NO Fault or CR3 Fault outputs One of the...

Страница 25: ...d 10 parts using the normal interface sequence If the optional INP3 Part B input is used it should be asserted at the end of Part A welds and cleared when the INP2 New Part input is cleared after comp...

Страница 26: ...completing the Learn the Micro ADM will not begin testing until the INP2 New Part has been cleared then asserted indicating a new part The following is the Micro ADM Learn Mode I O timing diagram Wel...

Страница 27: ...IEW LEFT END VIEW INPUT SIDE PANEL VIEW TOP VIEW SENSOR COMMUNICATIONS CONNECTOR REMOTE I O CONNECTOR 4 73 WIRE SPEED SENSOR FITTING WIRE SPEED SENSOR FITTING 3 00 5 38 TWO OPTIONAL MOUNTING BRACKETS...

Страница 28: ...ire Feed Drive Wire Outlet Quick Disconnect Fitting A 3 Positive Welding Cable Installation Positive Welding Cable From Welding Power Source To Wire Feed Drive Communications Connector From Wire Spool...

Страница 29: ...ation 1 2 Ring Terminals Route the BLACK 18 gauge 600V conductor 25 long from the Negative terminal of the Voltage Sense Terminal Block to the Negative welding cable connection point at the Work piece...

Страница 30: ...N X3T5047 Communications Cable P N A3W0327 6 meter long Personal Computer SYSTEM INSTALLATION DIAGRAM RS 485 CABLE HOOKUP TERMINAL LABEL WIRE COLOR 1 PWR Brown 2 RD N C 3 RD N C 4 TD White 5 TD Blue 6...

Страница 31: ...JUMPERS JP1 ECHO JUMPER On A BAUD RATE JUMPERS JP3 Off B Denotes the default jumper DUPLEX JUMPERS JP2 DUPLEX JUMPER Full None Half A and B Denotes the default jumper BAUD JUMPER JUMPER External Yes...

Страница 32: ...2 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 LABEL WIRE COLOR 1 PWR Orange 2 RD N C 3 RD N C 4 TD B...

Страница 33: ...On A Off B Denotes the default jumper DUPLEX JUMPERS JP2 DUPLEX JUMPER Full None Half A and B Denotes the default jumper BAUD RATE JUMPERS JP3 BAUD JUMPER 1200 A 2400 B 4800 C 9600 D 19200 E 38400 F...

Страница 34: ...wered A NetHub Powered A and B JUMPER JP2 NCOM POWER JUMPERS External Powered A NetHub Powered A and B TERMINAL BLOCK TB1 AC POWER PIN REFERENCE WIRE COLOR 1 HOT BLU 2 EARTH GRN YEL 3 NEU BRN TERMINAL...

Страница 35: ...A 8 NetHub Mounting Dimensions 31...

Страница 36: ...ITEM 1 PIN 3 NET BLACK ITEM 1 PIN 4 PSEL GRAY ITEM 1 PIN 5 24VDC GROUND SHIELD CABLE SHIELD 6 Meter Long Cable A 10 Remote I O Cable P N X3W5102 WIRE LIST WIRE COLOR FROM REFERENCE WHITE ITEM 1 PIN 1...

Страница 37: ...1 3 SPARE 1 O 1 5 SPARE 3 O 1 4 SPARE 2 O 1 7 SPARE 5 O 1 6 SPARE 4 1 2 3 4 5 6 7 8 9 0 1 P LC24 VDCOUTP UT M ODULE WHT GRN YEL GREY PINK BLU RED BRN BLU WHT BRN GRY 1 2 3 4 5 6 7 8 1 2 3 4 5 6 PWR R...

Страница 38: ...SPARE 4 1 2 3 4 5 6 7 8 9 0 1 P LC24 VDCOUTP UT M O DULE WHT GRN YEL GREY PINK BLU RED BRN BLU WHT BRN GRY 1 2 3 4 5 6 7 8 1 2 3 4 5 6 PWR RD RD TD TD COM CONVERTER JUMPERS J1 B J2 A B JP3 E JP4 ON BR...

Страница 39: ...Weld Fault error condition 39 Test the sensor Pass Output I 1 1 to validate proper sensor operation Only one output Fail Pass will be set if neither output is set handle sensor fault error Note If th...

Страница 40: ...fore setting sensor fault error 22 Test for last weld on Group A Part If not last w go to step 13 23 Set the sensor Group input O 1 2 When set the perform Group A validation test 24 Test the sensor Gr...

Страница 41: ...g new part active If High then clear PART input Bit O 1 1 and Learn it O 1 0 Then handle sensor Off Line Start fixture weld cycle eld cycle complete for 150 msec to allow sensor validation of ld arc o...

Страница 42: ...Appendix B Micro ADM Assembly Parts List B 1 Micro ADM Sensor Assembly P N A3A0226 Rev 0 38...

Страница 43: ...39...

Страница 44: ...Dowel Pin 0 093 diameter long D2 6 Berg 28 1 X6B5025 Retaining Ring External 5100 25 Thruarc 29 1 X6B5054 Shaft Collar DSCA 5 Small Parts 30 2 X6B5055 Locator Button CL 1 SLB Carr Lane 31 1 X6F5090 Fi...

Страница 45: ...B 2 Micro ADM Sensor Assembly P N A3A0226 Rev A 41...

Страница 46: ...42...

Страница 47: ...7 Dowel Pin 0 093 diameter long D2 6 Berg 28 1 X6B5025 Retaining Ring External 5100 25 Thruarc 29 1 X6B5054 Shaft Collar DSCA 5 Small Parts 30 2 X6B5055 Locator Button CL 1 SLB Carr Lane 31 1 X6F5090...

Страница 48: ...B 3 Micro ADM Sensor Assembly P N A3A0226 Rev B 44...

Страница 49: ...45...

Страница 50: ...7 Dowel Pin 0 093 diameter long D2 6 Berg 28 1 X6B5025 Retaining Ring External 5100 25 Thruarc 29 1 X6B5054 Shaft Collar DSCA 5 Small Parts 30 2 X6B5055 Locator Button CL 1 SLB Carr Lane 31 1 X6F5090...

Страница 51: ...B 4 Micro ADM Sensor Assembly P N A3A0226 Rev C 47...

Страница 52: ...48...

Страница 53: ...7 Dowel Pin 0 093 diameter long D2 6 Berg 28 1 X6B5025 Retaining Ring External 5100 25 Thruarc 29 1 X6B5054 Shaft Collar DSCA 5 Small Parts 30 2 X6B5055 Locator Button CL 1 SLB Carr Lane 31 1 X6F5090...

Страница 54: ...SB PCB MICRO ADM PCB 1 BRN 2 WHT 3 BLU 4 BLK 5 GRY P1 SENSOR 1 WHT 2 BRN 3 GRN 4 YEL 5 GRY 6 PNK 7 BLU 8 RED P2 I O WHT GRN RED YEL BLU PNK GRY BRN WHT BLU BRN GRY CR1 CR2 CR3 INP1 INP2 COM 24 ICOM 24...

Страница 55: ...ORG ORG ORG YEL YEL GRN GRN BRN RED ORG YEL GRN BRN RED ORG YEL GRN BRN RED ORG 1 2 TB7 VOLT SENSE RED BRN GAS ACOM 5 VDC AMP AMP ACOM 15 VDC 15 VDC N C N C COM CHB CHA 5 VDC DCOM VARC VARC TB3 TB1 T...

Страница 56: ...ORG ORG ORG YEL YEL GRN GRN BRN RED ORG YEL GRN BRN RED ORG YEL GRN BRN RED ORG 1 2 TB7 VOLT SENSE RED BRN GAS ACOM 5 VDC AMP AMP ACOM 15 VDC 15 VDC N C N C COM CHB CHA 5 VDC DCOM VARC VARC TB3 TB1 T...

Страница 57: ...D ORG ORG ORG YEL YEL GRN GRN BRN RED ORG YEL GRN BRN RED ORG YEL GRN BRN RED ORG 1 2 TB7 VOLTSENSE RED BRN GAS ACOM 5 VDC AMP AMP ACOM 15 VDC 15 VDC N C N C COM CHB CHA 5 VDC DCOM VARC VARC TB3 TB1 T...

Страница 58: ...88 5 9 150 9 7 213 D 5 28 1 C 89 5 A 151 9 8 214 D 6 29 1 D 90 5 B 152 9 9 215 D 7 30 1 E 91 5 C 153 9 A 216 D 8 31 1 F 92 5 D 154 9 B 217 D 9 32 2 0 93 5 E 155 9 C 218 D A 33 2 1 94 5 F 156 9 D 219...

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