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
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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%
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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.
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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.
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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.
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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.
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