Wire wizard GAS TRACKER User manual

INSTALLATION
& OPERATION
MANUAL
Installation, Maintenance
and Warranty Information
SHIP DATE SERIAL #
5750 Marathon Drive • Jackson, Michigan 49201
GAS TRACKER
PORTABLE OR IN-LINE GAS FLOW MONITOR


1
INTRODUCTION
Congratulations on your purchase of the Gas Tracker data collection system. Each Gas Tracker
unit is proudly made in the USA and quality tested and inspected prior to shipping. Please check
the box upon receiving the products for any damage that may have occurred during transit and
to ensure all components are accounted for.
Gas Tracker oers the capability to monitor the gas flow rate as a portable unit or as an inline system.
The unit has a built-in battery for easy transport without the need of nearby electrical outlets.
This guide is designed to assist the user whose primary responsibility is to operate and maintain
the Gas Tracker system. This manual provides specific information on the installation, safety,
basic operation, and maintenance. Please read, understand and follow all safety precautions
noted in this manual.
For customer service and support, contact ELCo Enterprises at 517.782.8040 or toll free 1.866.584.7281.
This manual and additional product information is available on our website at wire-wizard.com.
WARRANTY
ELCo Enterprises, Inc. (hereinaer “ELCo”) shall warrant this product to be free of defects in material
and/or workmanship for a period of one (1) year from the date of shipment to the buyer. The
warranty shall cover 100% of all parts and labor with the exception of misuse, abuse, neglect and
typical consumables as determined by ELCo. Failure to follow proper installation and/or maintenance
procedures specified in the operating instructions will void this warranty. ELCo will, at its option,
repair, replace or issue a credit for the value of the defective product within the warranty period.
Buyer accepts all responsibility for compliance with any/all Local, State and Federal Laws or
Regulations including Regulations of Foreign Governments.
No equipment shall be returned without a Return Authorization Number. Upon evaluation and validation
of warranty, replacements or repairs will be sent to the Buyer. If a replacement is needed immediately, a
purchase order is required to cover the cost of the product until the warranty is determined.
ELCo’s warranty is limited to replacing any goods that are proved to be defective and ELCo in no
event shall have any liability for paying incidental or consequential damages including and without
limitation, damages resulting in personal or bodily injury or death, or damages to, or loss of use of any
property. Notwithstanding any of these terms and conditions, the warranties set forth shall apply in
connection with any sales of goods, services or design by ELCo and are in lieu of all other warranties,
express or implied, including warranties of merchantability and fitness for a particular purpose.
PRODUCT REGISTRATION
Please register this product online or by phone within 14 days aer receipt to
validate warranty.
Register this product online by going to wire-wizard.com/register or scanning
the QR code on the right, or you may call 517.782.8040 to register by phone. Registering this
product will allow us to provide firmware and soware updates via email, as well as expedited
service should there be any problems potentially covered by this warranty in the future.
Please record the following information for this product and retain for your records:
Model #: ___________________ Lot #: _________________ Shipment Date: _______________
LIMITED ONE (1) YEAR WARRANTY
REGISTRATION REQUIRED: VISIT WIRE-WIZARD.COM/REGISTER

2GAS TRACKER INSTALLATION & OPERATION MANUAL
SAFETY NOTES/DISCLAIMER
The Gas Tracker system is designed to be safe to operate, provided the user reads, understands, and
adheres to the safety precautions listed below. Failure to adhere to these precautions may result in
personal injury and/or damage to the equipment.
WARNING: DO NOT USE WITH FLAMMABLE GASES
WARNING: AVOID EXTREME HEAT
WARNING: USE WITH DRY GAS ONLY
WARNING: EXCEEDING 50 PSI WILL DAMAGE UNIT
WARNING: USE CLEAN GAS ONLY
WARNING: NO PIPE DOPE SHOULD BE USED
ON THREADS
WARNING: ELECTRIC SHOCK HAZARD
Operators should always wear dry welding gloves and protective clothing when
welding. Do not contact electrically live parts. Keep welding guns and other
welding equipment away from moisture and water. Ensure ground connections
are secure and compatible with the required electric current. When welding
under wet conditions or where perspiration is a factor, the use of automatic
controls for reducing the no load voltage is recommended to reduce the risk of
electric shock. Accidental contact must be prevented with open circuit voltage
exceeding 80 volts AC, or 100 volts DC by using insulation or other means. When
welding gun is not in use, turn o power supply to prevent any accidental contact.
Welding equipment should be installed and maintained in accordance with
National Electrical Code (NFPA 70) and in compliance with local codes.
Equipment should only be serviced by qualified or trained personnel only.
Do not disassemble torch or change welding consumables with the power
supply on. See welding safety and operating references in section 2.1 for safety
guidelines and additional information.
WARNING: ARC RAYS AND SPARKS CAN CAUSE EYE
INJURY AND BURNS
Always wear a federally compliant welding helmet with the proper lens when
welding, along with protective welding gloves and protective clothing. Protective
clothing should cover all exposed skin to prevent burns and exposure to ultraviolet
rays. An approved welding curtain or solid wall must be used in areas where other
personnel may be exposed to arc rays. Other personnel in the work area exposed
to arc rays and sparks must also wear a welding helmet and protective clothing to
prevent eye injury and burns. Ear plugs should be worn to protect ears from sparks.
Avoid using flammable hair preparations when welding. Never attempt to weld
without a welding helmet, protective gloves and clothing. See welding safety and
operating references in section 2.1 for safety guidelines and additional information.

3
WARNING: COMPRESSED GAS CAN EXPLODE
Compressed gas cylinders contain gas under high pressure. If damaged, a
cylinder can explode. Since gas cylinders are normally part of the welding
process, be sure to treat them carefully.
Protect compressed gas cylinders from excessive heat, mechanical
shocks, physical damage, slag, open flames, sparks and arcs.
Install cylinders in an upright position by securing to a stationary
support or cylinder rack to prevent falling or tipping.
Keep cylinders away from any welding, cutting or other electrical circuits.
Never drape a welding electrode or cutting torch over a gas cylinder.
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 regulator when opening the valve.
Keep protective cap in place over valve except when cylinder is in use or
connected for use.
Use the right equipment, correct procedures and sufficient number
of persons to lift and move cylinders.
Read and follow instructions on compressed gas cylinders, associated
equipment, and Compressed Gas Association (CGA) publication P-1
listed in Safety Standards.
WARNING: WELDING WIRE CAN CAUSE INJURY
Keep hands and other body parts away from end of welding gun in case of
accidental activation of the trigger. Weld wire can puncture skin and cause
injury. Never point the gun toward the body or others when feeding wire.
1. Do not remove or deface any labels that are attached to the unit.
2. Ensure that all equipment in the area is disabled and a lockout/tagout procedure is
adhered to when required.
3. Never open or any remove any panels without first disconnecting and locking out power to
the system.
4. Never exceed the maximum rated gas pressures on the gas flow sensor.
5. Additional safety information can be found at the following websites:
osha-slc.gov/SLTC/robotics/index.html
ansi.org
nfpa.org

4GAS TRACKER INSTALLATION & OPERATION MANUAL
LEGAL DISCLAIMER
The Gas Tracker is designed to be a non-obtrusive unit upon installation. It is always the decision
of the end user if the equipment should have the capabilities of interrupting production. If the
end user chooses to integrate this unit with a PLC or any other means of communication that
could stop or interrupt production, they do so voluntarily. ELCo shall not be held responsible for
the loss of any production due to equipment interference, or any shutdown due to equipment
damage during installation or improper installation.
TECHNICAL SPECIFICATIONS
Hardware
Dimensions: 7" (178 mm) x
5.25" (134 mm) x 3.25" (83 mm)
Weight: 2.2 lbs (1 kg)
Input Power: 24 VDC
(Type A-style plug; 100 – 240 VAC
required for power supply)
Power Consumption: 2 A maximum
3.5" (89 mm) LED Touch Screen
Internal memory for up to 8,000 events
USB connection for exporting data
via PC connection
Four (4) programmable outputs
Accepts 1/4" NPT thread types
Modbus RTU interface for PLC
Normally-open relay contacts for
stacklight or PLC
Gas Flow Sensor Specifications
Range: 0 – 100 CFH (0 – 50 LPM)
Accuracy: +/- 3% (Full Scale)
Maximum operating pressure of
50 psi (350 kPa)
Gas Types:
Argon (Ar)
Nitrogen (N)
Carbon Dioxide (CO)
Helium (He)
C-2 (98% Ar/2% CO)
C-10 (90% Ar/10% CO)
C-15 (85% Ar/15% CO)
C-20 (80% Ar/20% CO)
C-25 (75% Ar/25% CO)
97-3 (97% Ar/3% O)
He-25 (25% He/75% Ar)
Soware Requirements
Microso Windows 7 or newer with
latest updates
At least one (1) USB 2.0 port
2 GB RAM
1 GB free disk space

5
SETUP & INSTALLATION
Setup for Portable Use
1. The Gas Tracker comes with a
rechargeable lithium ion battery.
Included is a 24 VDC power supply
(100 – 240 VAC required). Use the power
supply to completely charge the Gas
Tracker before initial use (complete
charge time is two (2) hours) (Fig. 1).
2. Note the gas flow direction on the front
of the unit (le to right) (Fig. 2).
3. Install the nozzle cone hose assembly
into the inlet (le hand side) of the
Gas Tracker (Fig. 3). This includes the
funnel/hose assembly and a filter which
screw into the brass fitting on the unit.
4. Install the exhaust screen fitting on
the outlet (right hand side) of the
Gas Tracker (Fig. 4).
Figure 2
Figure 1
Figure 4
Figure 3

6GAS TRACKER INSTALLATION & OPERATION MANUAL
Inline (Fixed) Installation
1. Permanently mount the Gas Tracker using the mounting tabs and four holes on the top and
bottom of the unit. The unit should be mounted in a location far enough away from the work
area to avoid damage from weld spatter, and a 100 – 240 VAC outlet is also required (within 59
in (1.5 m)) for powering the unit. Having the Gas Tracker installed near the inlet of the solenoid
or past the outlet of the solenoid will increase accuracy of the peak gas flow readings.
2. Connect the Gas Tracker inline to the gas supply. The Gas Tracker shall only be used on the outlet
side of the gas regulator. Ensure the inline filter provided with the unit is installed on the inlet
side of the sensor.
3. The Gas Tracker is designed to accept ¼ inch NPT thread types. Any gas rated fitting with
the correct thread type is acceptable. The Gas Tracker is not sent with any hose barbs. These
must be supplied by the customer. ELCo recommends the use of teflon tape on all threaded
fittings. Upon installation, ensure the teflon tape does not cover the orifice of the fittings.
4. Ensure the Gas Tracker is installed with the gas flowing from le to right, as indicated with
the arrows on the front of the unit (Fig. 2).
5. Using the 24 V power adapter, plug in the Gas Tracker to a 100 – 240 VAC outlet. Ensure the
cord is not in a location subject to getting pulled or damaged.

7
OPERATING INSTRUCTIONS
Power on the Gas Tracker using the power switch on the front cover.
The touch screen interface will now begin to load.
When the Gas Tracker is plugged into the 24 V power supply and charging, the text
Charging appears along the bottom of the display. When the battery is fully charged,
the text Charging disappears and is replaced by the text Fully Charged.
Initial Setup
Once the unit is powered on and the
touch screen has loaded it must be
configured. Configuration requirements
are completed in the Setup tab (Fig. 5).
Click Setup on the le hand side of the
touch screen interface.
Set the units by clicking the Units
button. The options are Metric and
Imperial. The current unit variation
selected is what the data will be
displayed in.
Select the timezone by clicking the
Timezone button. Options with NA are
for North American time zones
and options with EU are for European
time zones. Select from the following
options (Fig. 6): NA-Eastern, NA-Central,
NA-Mountain, NA-Arizona, NA-Pacific,
EU-Western, EU-Central, EU-Eastern,
EU-Fthr. East, Asia-China, Asia-Japan,
Asia-Korea, and Asia-India. If the
necessary timezone is not represented
here, the UTC oset can be used. Do
this by clicking the UTC Oset button.
Select the proper hour oset from
UTC. The range goes from -12 hours to +12 hours in 1 hour increments. Upon selecting the
time zone, the page will automatically save and return back to the Setup page. If the time
is incorrect it must be synced to a PC. Use the provided USB cable and the instructions in
the Soware section of the manual under Information to complete this task.
To set the Gas Type and Cylinder Capacity press the Gas Setup button.
Under the Gas Type text click Change to change the gas type. Select the proper gas
type from the menu. The options are as follows: Argon, CO, Helium, Nitrogen, 2% CO/Ar,
10% CO/Ar, 15% CO/Ar, 20% CO/Ar, 25% CO/Ar, 25% He/Ar, and 3% 0/Ar. Upon selecting
a gas mixture, the page will return back to the Gas Setup page.
Change the Cylinder Capacity by pressing the Change button under Cylinder Capacity.
The cylinder capacity options are configured on the keypad. A capacity from 1 – 500
CF (1 – 15,000 liters) can be established. The number entered will be in the selected
units (cubic feet if imperial and liters if metric) If using bulk gas select the Bulk option.
Upon selecting an option, the screen will return to the Gas Setup page. Click the backwards
arrows once the gas type and cylinder capacity have been configured.
Figure 6
Figure 5

8GAS TRACKER INSTALLATION & OPERATION MANUAL
Alerts Setup
To set up alerts, click the Alerts button on the Setup page. Six alerts can be configured.
The alerts are as follows: Peak Flow, Low Flow, Low Consumption, Cylinder Low,
High Flow, and High Consumption. Set the threshold by clicking on the appropriate alert.
Use the keypad to type the desired setting and click OK. Each of the alerts must be
configured separately from one another. Repeat the steps until the alerts are
established to the user’s preference.
Alerts can be disabled by clicking the disable button under each alert threshold configuration.
Alerts are updated at the completion of a weld.
Alerts will be seen on the Home page as they appear. Alerts that are in a green box
means there was no alert. Alerts that are represented in a yellow box show the value fell
out of the predetermined range.
Click the backwards arrow to return to the Setup page.
Outputs Setup
The Gas Tracker is capable of 4 outputs mimicking a normally-open relay.
Each output can be mapped to 1 of the 4 pins.
The output options are as follows: Always O, Always On, Heartbeat, High Flow,
Low Flow, Low/High Flow, High Peak Flow, Low Consumed, High Consumed,
Low/High Consumed, Cylinder Low.
Outputs are further discussed in Appendix B.
Modbus Setup
Modbus is the ability to query information from the unit. It Is best suited for interfacing
with a PLC.
The Modbus explanation and setup instructions are found in Appendix A.
Operation and Use
Viewing the Home page
Click the Home button on the screen to go to the main page. The main page shows the
most recent weld that has been completed.
The current flow rate is shown under the Gas Flow header along with the appropriate
units. This can be tested by purging the gas. The Gas Flow will show the real time gas
value. The Gas Tracker is designed to only record gas consumed when the flow rate is
above 5 CFH (2.3 LPM). The duration of the last event is only recorded when the gas
is above the 5 CFH (2.3 LPM) threshold.
Under the Last Weld header is the information for the most recent weld. This includes
Duration, Average Flow Rate, Peak Flow, and Gas Consumed. This information will show
data from the most recent gas flow event.
Viewing Alerts
The alerts are shown at the bottom of the Home page. If the box with the alert name is
green, there was no alert. If the box is yellow, it signifies there was an alert with that
weld. Any alerts that are triggered for the most recently completed weld will be shown
on the Home page.

9
Viewing the Totalizer
Each time an event is recorded the gas consumed is added to the totalized gas amount.
The totalized gas amount can be viewed by clicking the Totalizer tab on the le hand
side of the screen.
The totalized page shows the following information: Last Reset (Time and Date), Count
(event count since last reset), Consumed (amount of gas consumed since last reset),
and Average Flow (Average flow rate since last reset).
Viewing Historical Data
Historical data can be viewed under the History page. The History page shows the time
and date of each weld. It also shows the Duration, Average Flow Rate, Peak Flow, and
Gas Consumed for each specific weld.
The data can be toggled back and forth using the arrows at the bottom of the page.
Viewing Device Information
The About page shows the Soware Version, Build Date, Calibration Date, and Serial Number.
Access this data by clicking the About tab on the le hand side of the touch screen.
Editing/Refilling Gas Setup
There are two options to edit the gas settings.
Option 1 is by clicking the gas remaining bar graph on the right hand side of the touch screen.
Option 2 is by clicking the Setup tab and then clicking the Gas Setup button.
Once in the Gas Setup page, the Gas Type and Cylinder Capacity can be changed if
required. To keep the same Gas Type and Cylinder Capacity but just do a refill click the
Refill button. Click Yes or No accordingly on the pop up and use the back arrow to
reverse out to the Home page.
Clearing the Totalizer
The gas Totalizer has a clearing function to reset it to zero.
Complete this task by clicking on the Totalizer tab and then clicking the Reset Total
button at the bottom of the page.
The most recent reset time will update to the time the button was pressed. The Count,
Consumed, and Average Flow will all say 0 until the next time gas flows through the sensor.
All gas used aer a clear will be tallied and totaled until another clear is done.
The Reset Total button only clears the totalizer and no other data.
Clearing System Data
If all the weld data is to be cleared from the unit it can be done via the Clear Data
button found on the About tab.
The Clear Data button clears all previously saved events. The only thing not cleared by
this is the Alert and Output settings which have been previously configured.

10 GAS TRACKER INSTALLATION & OPERATION MANUAL
Changing Alert Settings
Alert settings are changed by going to the Setup tab and then clicking Alerts.
Each alert must be clicked individually and changed to the desired value.
Begin by clicking the desired alert (example: Low Flow).
In the keypad area press the double arrow to delete the preexisting value.
Type in the desired value on the keypad.
Press OK.
If an alert is to be disabled do so with the Disable button to the le of the keypad.
Changing Outputs
Output settings are changed by clicking the Setup tab and then clicking the Output button.
Each output can be modified by clicking the button under the output number.
When selected, the new output replaces the one that was previously configured.
Use the back button to go back to the Setup page.
Configuring signals via the Output information can be found in Appendix B of the manual.
Updating the Unit’s Time
Each Gas Tracker has multiple time zones that can be selected.
If the Timezone needs changed, click the Setup tab.
Press the Timezone button in the upper right hand corner.
Select the appropriate time zone.
If the time is out of sync for any reason the Gas Tracker must be connected to a PC. Do this
by following the instructions in the Soware Use section of the manual under Information.
Changing Units
If the units need changed from Metric to Imperial or vice versa do so on the Setup page.
Aer clicking the Setup tab, click the button under the text Units. The text that shows in
the box (ie. Imperial) are the units that are selected.

11
SOFTWARE
Soware Installation
The Gas Tracker unit works as delivered
as a portable measuring unit, but soware
is required for use with a computer if
monitoring and data exporting features
are desired. The Wire Wizard® Gas and
Wire Tracker soware is included on a
USB drive and can also be downloaded
on the Wire Wizard® website (wire-
wizard.com). The soware requires
Windows version 7 or greater. Install
the soware by double clicking the
installer folder. Follow the steps on the
screen to complete the installation.
Upon completion, press Finish and the
installation will be complete. Open the
newly installed application.
Using the Soware
A Gas Tracker must be connected to
the computer via a USB cable to be
detected by the soware. Plug in
the provided USB cable to both the
Gas Tracker and the computer with the
Gas and Wire Tracker soware installed
on it. If the Gas and Wire Tracker
soware is not installed, please do so
before proceeding.
The Gas Tracker must be powered on
in order for it to be recognized. Open
the Gas and Wire Tracker application.
Aer the USB cable is connected to both
the computer and Gas Tracker, click
Connect to Trackers. A new window
appears with the options of Cancel
or Connect to Trackers (Fig. 7). Click
Connect to Trackers. If the USB cable
becomes disconnected or the Gas
Tracker is powered o, the connection
will be lost. The connection must be
re-established by reconnecting the
USB cable, powering on the unit, and
clicking Connect to Trackers.
Figure 8
Figure 7
Product Registration
Product registration is required for warranty on
this product. The registration page comes up
automatically when the soware is installed. If
the page does not come up automatically it can
be found at wire-wizard.com/register.
The product must be registered 14 days from
purchase for the warranty to be valid.

12 GAS TRACKER INSTALLATION & OPERATION MANUAL
Any tracker that is connected will now appear on the screen (Fig. 8). Each tracker can be
denoted by the serial number in the center of the header (example: GT-XXXXXX). The number
on the le hand side shows the instantaneous gas flow rate. The bar across the bottom shows
how much gas is remaining in the gas cylinder. The green portion of the icon is the visual
amount of gas remaining. At the bottom right side of the screen are the options for Metric
and Imperial measurement units. The Gas Tracker and the Gas and Wire Tracker soware
can be simultaneously running in matching units or in mismatched units if desired. Click the
appropriate unit to see the instantaneous flow rate in Cubic Feet per Hour (CFH) (imperial) or
Liters per Minute (LPM) (metric).
There is a zoom in and zoom out function for the soware. This is located on the bottom right
side. There is also a product registration link in the corner. Clicking this link will open a browser
to the Wire Wizard® product registration page. Upon registering, new products and updates will
be readily available.
There are three buttons on the right side of the screen for each sensor which is connected:
Edit/Refill Gas
By clicking this icon the gas details can be viewed. On this page the gas type is selected
in the Gas Type dropdown box. The cylinder capacity can be adjusted by typing in the
correct number or using the up and down arrows to toggle. Aer a change in gas type, the
Update Gas Type and Capacity button must be clicked. This will update both the Gas
and Wire Tracker soware and the Gas Tracker unit. To refill the internal memory of gas,
click the blue Refill Gas icon. Upon completion of the changes, click OK.
Information
The Gas Tracker information can be found on this page. The page shows the type
of product, Serial Number, Firmware Version, Gas Capacity, Gas Remaining,
Manufacture Date, and Current Date. If the time on the Gas Tracker is incorrect, the
time may be synced with the computer time by clicking the Sync Time icon in the
bottom le corner. Upon completion, press OK to exit the page.
Historic Data
The Historic Data page shows a graphical representation of the average gas flow rates.
The Start and End dialog boxes represent the time frame displayed on the graph. These
can be adjusted by clicking the drop down arrow. Ensure that the start date is always
a prior date to the end date. The graph displays the data with the flow rate up the le
side (y-axis) and the time scale along the bottom (x-axis). The peak flow is represented
in blue and the average flow in green. When the page is scrolled down all of the
appropriate data is displayed in columnized form. The Date/Time, Duration (seconds),
Average Flow (CFH or LPM), Consumed (cf or l), and Gas Type are all displayed. A
CSV export can be performed on this page as well. Simply click the Export CSV button
to save a file. Select the appropriate file location and click Save. This file can now be
viewed using any application which can open CSV files (e.g., Microso Excel, etc.).

13
UPDATING THE SOFTWARE
There are two methods for updating the soware on your Gas Tracker. Option 1 is automatic
updates. These will be completed each time the Gas Tracker is connected to a PC with the
Gas and Wire Tracker soware installed. Upon connection to the PC, the steps for updating the
soware will automatically appear. The user has the choice to follow the steps and complete the
update or close the window and use the current soware. Option 2 is found on the Wire Wizard
website (wire-wizard.com). Download the newest soware of the Gas and Wire Tracker soware.
Follow the install steps as they appear. In both options, the new soware will locate and delete
the old soware files. Upon finishing either option, open the soware for continued use.
SENSOR CALIBRATION
The calibration on each Gas Tracker is certified for one (1) year. The Gas Tracker may be sent back to
ELCo Enterprises, Inc. to have the calibration renewed. Each sensor has a calibration sticker with a
date and the initials of the certification specialist. A Certificate of Calibration is included with each
Gas Tracker unit. Sensor recalibration is available through ELCo by ordering part number WC-1-GS-5.
DIMENSIONS

14 GAS TRACKER INSTALLATION & OPERATION MANUAL
PARTS LIST
Gas Line Adapter Fitting and Filter (part number WC-1-GS-S-001)
Power Adapter 24 V (part number WC-1-GS-S-PA)
Sensor Recalibration (part number WC-1-GS-RECAL)
USB Cable – 6 . (part number WC-1-GS-S-USB)
Hand Strap (part number WC-1-GS-S-STRAP)
Hose Assembly (part number WC-1-GS-RH)
Portable Use Outlet Filter (part number W0970530053U)

15
TROUBLESHOOTING
Name Description
Trouble
connecting
to a sensor
Ensure Gas and Wire Tracker soware is installed
Ensure the sensor is plugged in via the USB cable.
Ensure the unit is powered on.
If it is not saying “Connected to PC” it is likely a cable or driver issue.
The sensor uses generic Windows USB Serial drivers, which are included
with the Windows operating system. Verify a USB Serial device exists in
Device Manager.
Gas Tracker
will not
turn on
Ensure the power switch on the front cover is turned to "On."
Ensure the battery is charged or the unit is plugged in.
Ensure the power supply is plugged into a working outlet rated for the
proper voltage.
Screen is
frozen
Ensure the gas flow does not exceed the rated operating flow rate
(50 LPM, 100 CFH).
Perform a power cycle on the unit to reset the display.
Negative
number
on display
Ensure the gas is flowing the proper direction through the Gas Tracker.
Incorrect date
or time
Ensure the correct timezone is selected in the setup page of the Gas Tracker.
Sync Time to the Gas and Wire Tracker soware in the Information page.
Displaying the
wrong units
Change the units in the Setup page of the Gas Tracker.
Change the units at the bottom of the page on Gas and Wire Tracker soware.
Charging icon
not showing
Ensure the power adapter is plugged into a functional receptacle.
Ensure the barrel connector is fully inserted in the Gas Tracker.
Sensor is
giving false
readings
Ensure the sensor still falls within its calibration dates.
Check the Gas Tracker against a dierent sensor or gauge to check the
data validity.
Ensure the correct gas composition is selected in the Setup page.
Ensure the Gas Tracker is in the proper units
Low gas flow Check if there is adquate gas flow.
Ensure the inline filters are not plugged.

16 GAS TRACKER INSTALLATION & OPERATION MANUAL
APPENDIX A
Modbus Integration
Overview
The Gas Tracker supports integration with a PLC or personal computer through Modbus RTU over
RS-485 or USB. RS-485 is preferred for integrating with PLCs or other embedded devices. Using
the USB interface may be more convenient when integrating with a personal computer. This
interface allows the user to query unit status like gas flow rates, remaining gas in cylinder and to
retrieve alert statuses.
When connected to a personal computer through USB, thew device will appear as a COM port.
Modbus requests can be sent over this virtual serial port. Serial port settings such as baud
rate and parity have no influence on the virtual serial port and can be set to anything. The USB
interface always identifies as Modbus device ID 0x01.
The RS-485 interface provides more configuration options. The user can specify the baud rate
and parity options by clicking Setup in the le menu and then pressing Modbus on the Setup
page. The baud rate can be set to either 4800 or 9600. The parity can be None, Even or Odd. As
per the Modbus specification, two stop bits are used with None parity, and one stop bit is used
with Even and Odd parities. If the bus is shared, match the baud rate and parity to that of other
devices on the bus, otherwise a baud of 9600 and a parity of None are the best defaults.
Modbus has been an industry standard since 1979, and with minor changes in the early years,
has remained largely unchanged. Because of its longevity, it has a large presence in factory
automation and control.
Connector
The Modbus connector is Euro-style (also referred to as a Euro Block)
3.5mm pitch screw terminal connector. Replacements can be purchased
from a handful of suppliers.
Phoenix Contact, BCP Series #5441210
Adam Tech, EB Series #EBKA-03-A
MODBUS
D+
D–
GND

17
Overview
Modbus is a request/response protocol, where memory items are accessed by an identifier
number. Memory items come in four dierent types and are named for the legacy purpose of
controlling relay hardware.
Coils are used to trigger actions on the Tracker, in this way they function as commands.
Discrete inputs are used to read status and warning information.
Input registers contain measure values.
Holding registers contain configuration values which can be changed by the user
It should be noted that 16-bit registers can be signed or unsigned integers. Always refer to the
supporting documentation to verify if the data in a register should be treated as a signed or
unsigned quantity.
Larger values many need to be represented as long integers (32-bit). A special extension to the
Modbus specification is utilized to store these as two contiguous registers. As with 16-bit integers,
always check the supported documentation to understand if these quantities are signed or
unsigned. Values are stored with the least significant word in the lower addressed register.
The Tracker supports all Class 0 and Class 1 function codes except for Read Exception Status.
This code does not apply to the Tracker.
For more information about command formats, please review the following publicly-available
documents:
Modbus Application Protocol V1.1b3
Published by Modbus Organization, Inc.
http://www.modbus.org/docs/Modbus_Application_Protocol_V1_1b3.pdf
Modbus Protocol Reference Guide
Published by Modicon, Inc. (now Schneider Electric), Made Available by Modbus Organization, Inc.
http://modbus.org/docs/PI_MBUS_300.pdf
Type Access Data Type Address Range
Coil Read/Write Boolean 00001-09999
Discrete Input Read-Only Boolean 10001-19999
Holding Register Read/Write 16-bit 40001-49999
Input Register Read-Only 16-bit 30001-39999

18 GAS TRACKER INSTALLATION & OPERATION MANUAL
Coil Name Description
00001 Metric Units
Setting to 1 causes the display to show in Metric units. Setting to 0
causes the display to show in Imperial units. This does not aect data
available in Modbus registers, which are always in Imperial units.
00003 Restart Application Resets the Gas Tracker soware by triggering the unit to reboot itself.
00021 Store Gas Settings Persists the updated gas type and cylinder volume.
00022 Refill Gas Refills the gas remaining to 100% of the cylinder capacity.
00031 Persist Time Persists the current timestamp to a hardware RTC.
00041 Reset Totalizer Resets the totalizer to zero consumption.
00101 Clear Data Commands the unit to erase all weld events in its memory. This also
resets the totalizer and restarts the application.
Discrete
Input Name Description
10001 Charging Indicates that the AC power adapter is connected, and the unit is charging.
10002 Fully Charged Indicates that the AC power adapter is connected, and the unit has
completed charging.
10003 Heartbeat Toggles roughly every second to indicate the unit is running.
10011 Gas Flowing High whenever gas is flowing through the Gas Tracker.
10012 High Peak
Flow Warning
Triggered aer a weld completes, if the flow exceeded the peak
threshold. Resets with the next weld.
10013 Low Flow Warning Triggered aer a weld completes, if the average flow was less than
the threshold. Resets with the next weld.
10014 High Flow Warning Triggered aer a weld completes, if the average flow was more the
threshold. Resets with the next weld.
10015 Low Consumption
Warning
Triggered aer a weld completes, if the volume of gas consumed
was less than the threshold. Resets with the next weld.
10016 High Consumption
Warning
Triggered aer a weld completes, if the volume of gas consumed
was more than the threshold. Resets with the next weld.
10017 Low Cylinder
Warning
Triggers any time the amount of gas remaining in the cylinder is less
than the threshold. Resets when the cylinder is refilled.
Discrete Inputs
Modbus Register Definitions
Coils
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