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SAFETY PRECAUTIONS – READ BEFORE USING 

 

Welding is not particularly hazardous when certain safety practices are followed.  Everyone using this 

equipment should be thoroughly trained in safe welding practices.  Failure to observe safe practices may cause 

serious injury. 

 

Handling welding torches presents no danger if the appropriate safety regulations are strictly adhered to. For 

example: 

  Starting procedures must be reserved for those fully conversant with processes relating to arc 

welding equipment. 

  Arc welding can prove damaging to eyes, skin, and hearing! It is therefore imperative that both 

management and operators understand and follow the ANSI Standard Z49.1, SAFETY IN 

WELDING ANDCUTTING. All Personal Protective Equipment (PPE) shall be in place in 

accordance with this referenced specification and all other applicable and governing regulations. 

  The operating data provided in the Specifications are maximum values. Overloading the welding 

torch will inevitably damage the product and void any and all warranties. 

  Before changing any parts on the torch or control box, disconnect the torch from the welding 

power source and disconnect the control box input power source. Unplug the control box from the 

electrical outlet.  

  The operating instructions for all other welding components - e.g. power source, wire feed and 

cooling unit must be followed per the manufacturer’s recommendations. 

  Never pull the cable assembly across sharp edges or set down on a hot surface.  

  Never move the torch by pulling or dragging by the welding torch or cable. 

  Curtains or partitions shall be installed to protect other workers or observers from arc radiation. 

  When handling gas cylinders, consult the instructions issued by 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 attached to lead, 

cadmium, copper, zinc, and beryllium. Take appropriate precautions to ensure that the legal 

maximum levels of toxic concentrations are not exceeded. 

 

  Do not touch the welding torch with bare skin until it has had adequate time to cool down. 

 

Wait to adjust the rotation diameter until the torch has cooled to room temperature.

 

 

Fume and Gases 

 

FUMES AND GASES can be hazardous. Welding and cutting 

produces fumes and gases. Breathing these fumes and gases 

can be hazardous to your health

 

 

  Keep your head out of the fumes. Do not breathe the fumes. 

  If inside, ventilate the area and/or use local forced ventilation at the arc to remove welding and 

cutting fumes and gases. The recommended way to determine adequate ventilation is to sample 

for the composition and quantity of fumes and gases to which personnel are exposed. 

  If ventilation is poor, wear an approved air-supplied respirator. 

  Read and understand the Safety Data Sheets (SDSs) and the manufacturer’s instructions for 

adhesives, coatings, cleaners, consumables, coolants, degreasers, fluxes and metals.  

  Work in a confined space only if it is well ventilated, or while wearing an air-supplied respirator. 

Always have a trained watch-person nearby. Welding fumes and gases can displace air and 

lower the oxygen level causing injury or death. Be sure the breathing air is safe. 

  Do not weld or cut in locations near degreasing, cleaning, or spraying operations. The heat and 

rays of the arc can react with vapors to form highly toxic and irritating gases. 

Содержание Computer Weld Technology DMC II

Страница 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 ...

Страница 2: ......

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 10: ......

Страница 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 ...

Страница 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...

Страница 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 ...

Страница 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...

Страница 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 ...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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 ...

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

Страница 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...

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

Страница 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 ...

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

Страница 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 ...

Страница 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 ...

Страница 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 ...

Страница 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 ...

Страница 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 ...

Страница 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 ...

Страница 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 ...

Страница 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 ...

Страница 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...

Страница 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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