Computer Weld Technology Micro ADM User manual

10702 Old Bammel N Houston Rd.
Houston, TX 77086
Phone: [phone]
Fax: [phone]
Email: [email protected]
Computer Weld Technology, Inc.
Micro ADM
Micro Arc Data Monitor
Operation / Installation Manual
Manual Part Number: A8M5022
Revised: 7/24/2008

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

APPENDIX B MICRO ADM™ ASSEMBLY PARTS LIST................................................ 38
B.1 MICRO ADM™ SENSOR ASSEMBLY P/N: A3A0226 REV: 0............................................................. 38
B.2 MICRO ADM™ SENSOR ASSEMBLY P/N: A3A0226 REV: A.............................................................41
B.3 MICRO ADM™ SENSOR 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: A3A0226 REV: A.............................................................51
C.3 MICRO ADM™ SENSOR ASSEMBLY P/N: A3A0226 REV: B.............................................................52
C.4 MICRO ADM™ SENSOR ASSEMBLY P/N: A3A0226 REV: C............................................................. 53
APPENDIX D DEVICE ID MSB AND LSB DECODE TABLE.......................................... 54

1.0 SYSTEM OVERVIEW
1.1 General Overview
The Micro ADM™ Sensor (A3A0226) is a lightweight; compact, multi-sensor unit
designed for monitoring, Parameter Testing and telemonitoring service purposes
in a welding environment. The Micro ADM™ Transducer includes an embedded
micro-controller to provide the necessary data acquisition, signal processing and
communications firmware to allow remote logging/testing of the following basic
welding parameters.
Arc Current
Arc Voltage
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.
The unit is powered by a user supplied external 24 VDC power source via the
sensor interface cable (A3W0327). This cable also provides an RS-485 Full-
Duplex serial communications port to an external system (data acquisition or
PLC). A second Remote I/O cable (X3W5102) is provided to allow an external
PLC/Robotic controller to control and monitor the sensors’ embedded fault
testing routines.
1.2 General Specifications
Listed below are the general system specifications:
Dimensions: 3.81” H x 5.38" W x 5.25" L (97mm x 137mm x 133mm)
Weight: 2.7 lbs (1.2 kg)
Power Input: 24 vdc @ 0.2 amp, ripple 200 mv
Operating Temp: -12°C to +60°C
Remote Input: 5 – 24 vdc @10ma current limited
Remote Outputs: Non isolated 24 vdc @ 75 ma Sourcing Open emitter
Transistor output with current limit
Serial Communication Modbus™ RTU slave mode protocol
1

1.3 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 ± 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 ± 1.8 % of reading ± 1.8 % of reading
Band Width at ± 1db 250 Hz 250 Hz
Wire Speed Sensor English Units Metric Units
Wire diameter (min/max) .030 - .062 inch 0.8 mm / 1.6 mm
Speed range 10 – 1000 ipm 4 – 420 mm/s
Relative precision on Range ± 3% ± 3%
2

2.0 INSTALLATION
2.1 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™:
Mount the Micro ADM™ in a location that is convenient for
installation of the welding wire and will not cause any binding
of the wire or the wire liner. It is recommended that the
Micro ADM™ be mounted as close to the wire feeder as
possible (not to exceed 1 meter).
The Positive welding cable must pass through the Micro
ADM™ sensor opening. Make 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 routing of the
Shielding Gas hose to prevent any restriction of gas flow.
The Sensor cable must be mounted in such a manner as to
prevent stress on the sensor cable connector.
The two 18 gage conductors supplied with the Micro ADM™
are used to provide the + and – of the Voltage Sense. These
conductors must be routed so as not to produce stress on
the Voltage Sense terminal strip.
When mounting the Micro ADM™, position it so the operator
or maintenance personnel can see the sensor LEDs if
possible.
If using the optional mounting brackets to mount the Micro
ADM™, an insulating liner must be used for support of the
wire from the sensor to the back of the wire feeder inlet
guide.
3

2.2 Sensor Installation Guidelines
Installation of the Micro ADM™ is a simple 5-step process regardless of the
selected mounting method.
1. Feed the Positive welding cable through the Micro ADM™ Current
Sensor opening. The diameter of the opening will accommodate a 22
mm cable. If the crimp terminal is too large to fit through the opening
then it must be removed and another terminal installed after the cable
is passed through the opening.
2. Feed the wire through the Micro ADM™ Wire Feed Speed Sensor
inlet. Push down on the pressure release lever located on the top of
the sensor while feeding the wire through the guide rollers and out the
other side of the sensor. Feed the wire into the wire drive motor as
you would normally. If using the quick disconnect fittings to mount the
sensor, connect one end to the wire drive motor quick disconnect
fitting. Insert the wire liner quick disconnect fitting into the other end of
the sensor. If using the optional mounting brackets, install the
sensor at the desired location. Install an insulated wire liner or conduit
assembly (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” NPT 90° elbow. User to
supply the necessary adaptor. Make sure to check for gas leaks after
the hose clamps are installed.
4. Use the two Conductors (18 gage, 600V) provided with the Micro
ADM™ Sensor to connect the Micro ADM™ Voltage Sensor to the
welding system. Route the RED conductor (3’ long) from the Positive
(+) terminal of the Voltage Sense Terminal block to the Positive
welding cable connection point (at the Torch or Wire Feeder). Route
the BLACK conductor (25’ long) from the Negative (-) terminal of the
Voltage Sense Terminal block to the Negative welding cable
connection point (at the Work piece ground point).
5. To connect the Sensor Cable (A3W0327) to the Micro ADM™, insert
the connector into the Micro ADM™ Sensor Cable receptacle until it
“Clicks” and locks into place. Connect the other end to the appropriate
weld data acquisition system or PLC. To remove the Micro ADM™
Sensor Cable, pull back on the locking barrel of the connector plug
while pulling the plug from the receptacle. A diagram of the
connections for the cable can be found in Appendix B.
4

2.3 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. Locate the LSB and MSB rotary switches. Set the
binary address by rotating the switches to the desired address. The
Switch is Binary encoded and has a range of “0 - F”. Reinstall the hole
plug after setting the Device ID number. The maximum Device ID is
restricted to 247 as specified by the ModBus Protocol standard. See
Appendix D for Device ID MSB and LSB Decode Table.
5

3.0 OPERATION
3.1 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” condition. When the Voltage
or Current falls below the user specified value the sensor would set an “Arc Off”
condition and stop data logging. The user must activate this input by setting the
corresponding mode via the serial communication port.
If the “Auto Arc On” mode is disabled the user can force a arc on condition by
asserting the “Remote Arc On” input. This signal is the “Black” wire provided in
the sensor serial communication cable P/N A3W5042. Asserting a 5-24 VDC
signal from the common (Grey) and the remote arc on input (Black) will force a
sensor arc on condition.
3.2 Embedded Firmware
The embedded firmware has basic scaling and averaging capabilities as well as
Slave mode ModBus RTU Communications protocol support. The sensor will
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 analog data will be
sampled at a 5 kHz rate. The Sensor will average 5 samples to produce a 1khz
data rate for all analog sensors. The Wire feed conversion time will be based on
the actual wire feed rate (16.6 Hz – 16.6 KHz).
Configuration of scaling and averaging parameters will be possible through the
ModBus network port. The user may specify the number of samples (X) to be
averaged before saving the data point in memory for later play back. The
SENSOR will also generate a weld summary for each weld, which will be the
average of all sampled data during the last weld cycle. The Data will be
Date/Time stamped and stored in NV-RAM. Up to 1300 weld summaries may be
stored before downloading. The sensor provides continuous averaging of the X
most recent data values, and queries by the host system at lower frequencies of
either last data value or last average value.
3.3 Host System Serial Interface
The sensor will provide a RS-485 compatible serial port and will support the
ModBus RTU protocol. The Sensor default baud rate is 19.2K Baud.
6

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. The sensor provides a user
configurable 120-ohm termination 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 an
input voltage of 12 – 36 Vdc @ 3.6 watts. The sensor will provide polarity and
over current protection. The sensor terminal connector Pin out is as follows:
Pin Wire Color Function
1 Brown Sensor (12 – 24 vdc) Positive Input
2 White Net_High RS-485 Signal High
3 Blue Net_Low RS-485 Signal Low
4 Black Remote Arc Active Input (5 – 24 vdc)
5 Grey Sensor (12 – 24 vdc) Common
Shield Sensor Cable Shield – Not Connected at Sensor
7

4.0 Micro ADM™ MODBUS MEMORY MAP
4.1 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. The controller provides the slave side communications routines
for the RTU mode. The user must define the Slave ID to a unique ID number
from 1 – 247. Default Baud 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 0-26
05 Force Single Coil 0-15
06 Preset Single Register 0-26
15 Force 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 Active – Set when Weld Arc is detected
2 1 Save Average Data – When set Weld Summary Data is stored
in NVRAM
3 2 Clear Summary Counter – When set the Average Data Counter
is reset to 0 and Average Memory is cleared
4 3 Clear Part Fault Counter – When set the Fault Counter will be
reset to 0
5 4 Enable Metric units of measure. When set the sensor use
metric units of measure. (Wire = mm/sec; Gas = kpa)
6 5 Enable Auto Arc Detect – When set the Arc On condition is
detected by sensing the arc voltage and arc current. When
cleared the sensor can be forced into an arc on condition by
asserting CR 1.
7 6 Read Memory – When set the Weld Summary data specified
by Register 19 will be read into Register 2-12. Coil will be reset
when summary has been loaded. Function is executed only
8

when the arc is off.
8 7 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.
9 8 Learn Mode Enabled – When set the user defined Learn input
is active.
10 9 New Part Enabled – When set the user New Part Input is
active.
11 10 AAD Fault – When set the sensor has detected an
Accumulated Arc Density Fault condition. This output will only
be set when the weld is complete or when the part input is
cleared.
12 11 TIME Fault – When set the sensor has determined an arc time
fault has occurred. If set when the Part input is cleared the
sensor indicates an accumulative arc time fault for the part.
13 12 VOLT Fault – When set the sensor has detected a volt
parameter fault during the previous weld. If set when the Part
input is cleared it indicates an arc density fault has occurred.
14 13 AMP Fault – When set the sensor has detected an amp
parameter fault during the previous weld. If set when the Part
input is cleared it indicates an arc density fault has occurred.
15 14 GAS Fault – When set the sensor has detected a gas pressure
fault during the previous weld.
16 15 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 following is the Register definitions address 0-26:
REGISTER ADDRESS DESCRIPTION
1 0 Arc On Status – When the arc is active the value will be
greater then 1. When the arc is off the value will be 0
2 1 Arc Time – Weld on timer in 0.1-second intervals. Value is
incremented during a weld cycle and 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)
3 2 Volts – During the Arc on Time the value represents the
actual arc voltage. The value is in 0.1-volt increments
(100=10.0 volts). When the weld cycle is complete the
value will be the statistical average for the last weld.
4 3 Amps- – During the Arc on Time the value represents the
actual arc current. The value is in 1amp increments
(100=100 amps). When the weld cycle is complete the
value will be the statistical average for the last weld.
5 4 Gas Pressure - – During the Arc on Time the value
represents the actual gas pressure. The value is in 0.1 PSI
or 1KPa increments (100=100Kpa/10.0 PSI). When the
weld cycle is complete the value will be the statistical
average for the last weld.
6 5 Wire Speed - – During the Arc on Time the value
represents the actual wire feed speed. The value is in 1-
9

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.
7 6 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. (MSB = seconds; LSB =
Minutes)
8 7 RTC BCD 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. (MSB = Hour; LSB = Day)
9 8 RTC BCD MN:YR - The value is the arc start Month and
Year based on the Real Time Clock. This value is set when
an arc on condition is detected. (MSB = Month; LSB =
Year)
10 9 Arc Time Mean – Arc Time mean value for in-process limits
11 10 Arc Voltage Mean – Voltage mean value used for in-
process limits.
12 11 Arc Current Mean – Amperage mean value used for in-
process limits.
13 12 Gas Pressure Mean – Gas pressure mean value used for
in-process limits.
14 13 Wire Speed Mean – Wire speed mean value used for in-
process limits.
15 14 Spare – Not Used
16 15 Weld Count – Total number of weld since last reset. If weld
counter reaches the max count of 65535 the counter will
reset to 0.
17 16 Weld Summary Count – Value indicates the number of weld
summaries stored in memory (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 to Register 2-12.
Range of Value 1-500.
20 10 Arc On Amps – The value set in this Register is the welding
current that must be exceeded to establish an arc on
condition. Value is in 1-amp increments (10 = 10 amps).
21 20 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 in 0.1-volt increments (100 =10.0 volts).
22 21 SAMPLE COUNT: TIME Sigma – The MSB byte indicates
the number of raw data samples to average to produce a
single sample value as stored in Register 3-5. The LSB
byte sets the Arc Time sigma value used by sensor for
process limits Setting the Sigma value to 0 will disable the
test function. (Arc Time Sigma = LSB/24; i.e. 55 =2.29)
23 22 VOLT: AMP Sigma – The MSB byte sets the Voltage sigma
value used by the sensor for process limits. The LSB byte
sets the Amp sigma value used by sensor for process limits
Setting the Sigma value to 0 will disable the test function.
(Sigma = MSB, LSB/24; i.e. 55 =2.29)
24 23 GAS: WIRE Sigma – The MSB byte sets the Gas Pressure
sigma value used by the sensor for process limits. The
LSB byte sets the Wire Speed sigma value used by sensor
for process limits. Setting the Sigma value to 0 will disable
10

the test function. (Sigma = MSB, LSB/24; i.e. 55 =2.29)
25 24 DENSITY: VOLUME Sigma – The MSB byte sets the Arc
Density sigma value used by the sensor for process limits.
The LSB byte sets the Weld Volume sigma value used by
sensor for process limits. Setting the Sigma value to 0 will
disable the test function. (Sigma = MSB, LSB/24; i.e. 55
=2.29)
26 25 DELAY: WELDS – The MSB byte sets the start/end Test
delay time. The value is in 0.1 second increments and sets
the delay time from arc start to begin testing and the end
time, prior to arc off, to stop testing. The LSB indicates the
number of welds per part. This value is set during the learn
mode.
The 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
Bit3-7 = 0
4 Firmware 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 used as
internal bit flags to perform specific functions. Only 1-8 of the simulated coils is
used. Setting the coils 8-16 will not have any effect on the Micro ADM™
controller. However, they are reserved for future expansion. The Micro ADM™
supports both single and group force coil commands. Refer to Section 4.3 for
summary of the Coil functions.
To clear the Micro ADM™ weld and average counters or reset the total arc timer,
force the specific coil to the “ON” condition. The Micro ADM™ will clear the
requested counter or timer and then reset the coil to the “OFF” condition
signifying a successful 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.
To set the Real time clock perform the following steps:
11

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.
4. Enable Coil 2 to resume automatic arc detection.
To read a stored weld data summary perform the following steps:
1. Set Coil 2 to the “ON” condition to disable automatic arc detection.
2. Load the desired weld summary number into Registers 19. This value
must be equal to or less than the total number of saved welds as
indicated by Register 17.
3. Set Coil 6 to the “ON” condition. The Micro ADM™ will load the stored
data into Registers 2-12 and will clear the coil after 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 indicate when a welding arc has been detected. When this
register is a 1 the Micro ADM™ controller is updating the welding parameters
with new measured values.
Register 2–6: Contains the current value for each of the welding parameters:
The following table shows the value and units of measure for each weld
parameter register:
REGISTER MEASURED PARAMETERS UNITS OF MEASURE
2 Arc On time – Time in 0.1 seconds from arc
detection (Value /10) sec.
3 Arc Voltage – Voltage measured by Volt sensor (Value/10) vdc
4 Arc Current – Welding amps measured by
Hall Sensor Value = Amps DC
5 Gas Pressure – Shielding Gas pressure from
Torch (Value * 0.1)=Kpa (psi)
6 Wire Speed – Linear wire speed measured by
encoder Value = mm/sec (ipm)
12

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. The Time and Date parameters are in BCD
format. The low nibble is the 1’s units and the upper nibble is the 10’s units.
Note: When setting the Real time Date and Time the values loaded into the
Registers 7-9 must be in a BCD format.
Register 10–14: Used to indicate the statistical mean values as calculated
during the Learn Mode for each weld within the learned part. The value is an
integer value and represents mean value that is used with the sigma value to set
the upper and lower control limits for parameter testing. These values have the
same scaling as Register 2-6 (see above table).
Register 15: Spare Register - Not used at this time.
Register 16: The current weld count since the last weld count reset. This
counter is incremented when the total arc time for a weld is greater then 0.5
seconds. This prevents false arc starts from being counted as a valid weld.
Register 17: Indicates 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 weld number
location. The Welds will only be saved if the Save Weld summary coil (2) has
been set and the minimum weld time is greater than 0.5 seconds.
Register 18: This register sets the number of raw data points to be averaged to
generate a single sampled value. The minimum value is 1 and the maximum
value is 255. Setting this value to 0 will disable the Analog Data collection
routines.
Register 19: This register is used to read a previously stored weld summary
from memory. Set the desired weld summary number in this register then set the
Read Weld Memory Coil 7. The value will be written to Register 2 – 12.
Maximum value is 1024.
Register 20-21: These registers are used to specify the conditions required to
establish an arc on signal. To set the auto arc on signal the Voltage and current
sensor values must exceed both values stored in the these registers. If any
single sensor input drops below this level the arc on signal will be reset.
Register 22-26: These registers are used to specify the process control limits
used for in process monitoring. The MSB and LSB bytes are used as
independent byte size variables and have a Byte size decimal range of 0-255.
13

5.0 Micro ADM™ ASCII TERMINAL MODE PROTOCOL
5.1 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.
The user can use any terminal program to perform the programming function. All
program command functions are case sensitive. The serial port is configured for
the following data format:
Baud Rate: 19.2K, Full Duplex
Word Length: 8 Data Bits, One Stop and no parity
Hand Shaking: None
5.2 TERMINAL PROTOCOL
The protocol consists 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 indicate that data is being sent to the selected parameter by the host
controller. The "?" will indicate a request for data from the Micro ADMto the
host controller. If the host is sending data to the Micro ADMthe data will be
placed after the "=" character and will be an ASCII string terminated with an
ASCII "cr" (0dh). The following is an example of reading a parameter value from
the Micro ADM™:
From Host type: V1? (cr)
Response from Micro ADM™: ##
Where: ## is the current value for the parameter and
(cr) is the enter key
The following is an example of how to modify a value in the Micro ADM™ using
the terminal commands:
From Host type: V1=#### (cr)
Where: ## is the new value for the parameter and
(cr) is the enter key
14

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™: hh:mm:ss
Where: hh is the current hour, mm is the current
minute and ss is the current second. (cr) is
the enter key
To set the time (hour/minute/second) type: T=10:17:35 (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 command:
From Host type: D? (cr)
Response from Micro ADM™: mn:dd:yy
Where: mn is the current month, dd is the current
day and yy is the current year, (cr) is the
enter key
To set the date (year/month/day) type: D=99/06/01 (cr). The Entire field must be
completed as explained below:
Type February 4, 1999 as D=99/02/04(cr)
Type November 23, 2000 as D=00/11/23(cr)
Note: “cr” denotes carriage return (Enter)
15

5.3 TERMINAL COMMANDS
The following is a summary of the Terminal Commands supported by the Micro
ADM:
Command DESCRITION RANGE
C0 Voltage zero offset calibration value. (128 = 0 offset)
Negative offset < 128 > Positive offset 0-255
C1 Current zero offset calibration value (128 = 0 offset)
Negative offset < 128 > Positive offset 0-255
C2 Gas Pressure zero offset calibration value (128 = 0
offset)
Negative offset < 128 > Positive offset
0-255
C3 Gas pressure Gain value (Gain = Value/32) 0-255
D Sets or reads the Real Time Clock date parameters
Format = YY/MM/DD 8 Bytes
T Sets or Reads the Real Time Clock Time parameters
Format = HH:MM:SS 8 Bytes
M0 ModBus Coils 1-8 Set/Read. Binary Bit’s are set by
decimal value. CR1=1, CR2=2, CR3=4, CR4=8,
CR5=16, CR6=32, CR7=64, CR8=128
0-255
M1 ModBus Coils 9-16 Set/Read. Binary Bit’s are set by
decimal value. CR1=1, CR2=2, CR3=4, CR4=8,
CR5=16, CR6=32, CR7=64, CR8=128
0-255
M2 Baud Rate – Sets the serial communications Baud
Rate 0=38.4Kb, 1=19.2Kb, 2=9600buad, 3=4800 baud 0-3
M3 Sample Count – Number of raw samples to averaged
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. (Note: Sigma = Value/24) 0-255
M6 Gas Sigma value. When set to zero parameter testing
is disabled. (Note: Sigma = Value/24) 0-255
M7 Wire Speed Sigma value. When set to zero parameter
testing is disabled. (Note: Sigma = Value/24) 0-255
M8 Arc Density Sigma value. When set to zero parameter
testing is disabled. (Note: Sigma = Value/24) 0-255
M9 Weld Volume Sigma value. When set to zero
parameter testing is disabled. (Note: Sigma =
Value/24)
0-255
M10 Start/End Test time value. The value specifies the
delay time from Arc On to begin parameter testing and
the time prior to arc off to stop all parameter testing.
0 – 25.5
M11 Number of welds per Part. This value indicates the
number of welds per part as determined by the Learn
mode.
V1 Arc On Status – When the arc is active the value will be
greater 1. When the New Part input is active, the value
will be the calculated End Test time for the current
weld. When the arc is off the value will be 0
0-65535
V2 Arc Time – Weld on timer in 0.1-second intervals.
Value is incremented during a weld cycle. And 0-65535
16