Computer Weld Technology, Inc. 10702 Old Bammel N Houston Rd. Houston, TX 77086 Phone: (713) 462-2118 Fax: (713) 462-2503 Email: cwt@cweldtech.
Table of Contents 1.0 OVERVIEW..................................................................................................................... 1 2.0 INSTALLATION.............................................................................................................. 3 2.1 2.2 2.3 2.4 3.0 3.1 4.0 4.1 4.2 4.3 5.0 5.1 5.2 5.3 5.5 5.6 ATC CONTROL ........................................................................................................... 3 ATC SLIDE ASSEMBLIES .....................
1.0 OVERVIEW The Computer Weld Technology Automatic Torch Control (ATC II) is a compact, lightweight, weld torch manipulation control system comprised of the micro-controller based Automatic Torch Control (ATC II) and a stepper motor driven Linear Slide Assembly (LSA). This system is capable of providing independent control of all torch movements in the vertical plane. The ATC II provides automatic torch Height control using Computer Weld Technology's patented ThruArc sensing technology.
MEDIUM DUTY SLIDE SPECIFICATIONS Dimensions Max Travel Weight Velocity Weight Capacity 16.66”H x 3.38”W x 2.88”D (423mm X 86mm x 73mm) 7.25” (184mm) 7 lbs (3.18kg) 0.2 – 1.5 inch/sec 25 lbs @ 3” from slide face HEAVY DUTY SLIDE SPECIFICATIONS Dimensions Max Travel Weight Velocity Weight Capacity 17.08”H x 5.00”W x 2.63”D (434mm X 127mm x 67mm) 7.25” (184mm) 9-1/2 lbs (4.32kg) 0.2 – 1.
2.0 INSTALLATION 2.1 ATC CONTROL The ATC Control assembly should be located to allow easy operator access to the front panel. The control is provided with four 10-32 captive PEM nuts located on the left side of the enclosure. Figure 1 shows the physical mounting dimensions.
2.2 ATC SLIDE ASSEMBLIES See Figure 2, 3 and 4 for mounting locations and physical dimensions for light, medium and heavy duty slides.
FIGURE 3- Medium Duty Slide Physical Dimensions 5
FIGURE 4- Heavy Duty Slide Physical Dimensions 6
2.3 CABLES Perform the following to install the cables and sensors for the ATC II. WARNING Do not connect or disconnect the SLIDE MOTOR CABLE from the Slide or ATC II back panel with Power Applied to the control. Doing so will damage the control and slide assembly. Connect the ATC Slide Motor Cable to the Motor mating connector on the rear of the control enclosure (Fig 5) and to the Motor mating connector on the Slide Assembly.
Connect the Power Cable to the rear mating POWER connector on the rear panel of the ATC II (Fig 6). This completes the cable installation.
The ATC Control has a DB-9S remote control connector located on the rear panel of the ATC II (Fig 6). The remote inputs can be used to provide remote control of the ATC II and the outputs can be used to control a device through the ATC II (such as Power Source Weld Contactor to start the weld process). These functions are based on the configuration of the ATC II PLC Program. Figure 7 shows the pin-out for the remote connector and the Input/Output configuration for the I/O port.
3.0 OPERATION 3.1 OPERATIONAL SEQUENCES The following operational sequence is based on the DEFAULT PLC program provided with the unit. The operation may vary based on user defined PLC code. Refer to Section 5 for PLC programming information. Figure 8 shows the location of the operator controls.
To initialize the slide, turn the "RUN" switch to the "On" position. The Torch slide will move to the upper slide limit switch and stop. Turn the “RUN” switch to the “Off” position. This operation must be performed every time the ATC II is powered on. The front panel controls will remain inoperable until the slide is initialized. To change the Slide speed, adjust the "SPEED" control. To change the AVC set point value adjust the "AVC" control. To move the Torch Slide use the "JOG" switch.
To activate the selected tracking mode set the "TRACKING" switch to the "ON" position. To disable the selected tracking mode set the "TRACKING" switch to the "OFF" position. While tracking the "GAIN" control can be used to adjust the sensitivity of the tracking. If the Torch is moving UP and DOWN too much the GAIN may be too HIGH. If the Torch moves too little the GAIN is too LOW. Adjust the GAIN until the Torch movement is stable.
4.0 ATC II OFF-LINE SERIAL TERMINAL PORT PROTOCOL 4.1 SERIAL TERMINAL PORT INTERFACE The RS-232 communications port is used to off-line program the ATC II PLC sequences drive motor parameters and the operating parameters for the ATC II. The Protocol is a simple ASCII command string that allows the user to up-load or download the various parameters. The serial port is configured for the following data format: Baud Rate: Word Length: Hand Shaking: 4.
M0 - M5 Set system control mode functions: M0 - Set programmable sequence number to value. M1 - Read Switch input status (1 = on, 0 = off) BIT 0 = Remote INP1 (value= 1). BIT 1 = Remote INP2 (value= 2). BIT 2 = Slide Home Limit (value= 4). BIT 3 = Remote INP4 (value= 8). BIT 4 = "JOG UP" switch input (value= 16). BIT 5 = "JOG DOWN" switch input (value= 32). BIT 6 = "RUN" switch input (value= 64). BIT 7 = “Track” switch input (value= 128). M2 - Set output relays CR1 - CR2 (1=on, 0=off).
V1 - V9 Write/Read double byte variables: V1 = Motor speed value. V2 = Current Drive Position (Scaled step motor count). V3 = Move position value. Decrement by the step motor drive command. V4 = Maximum oscillator position limit. V5 = Slide center position. V6 = Slide Oscillator width. V7 = Maximum Slide Oscillation width limit used by the adaptive width tracking mode 1. V8 = Minimum Slide Oscillation width limit used by the adaptive width tracking mode 1. V9 = Current torch to work position.
5.0 ATC II PROGRAMMABLE SEQUENCE PROTOCOL 5.1 PROGRAMMABLE SEQUENCES The ATC II programmable sequence consists of a 3-byte command. The First byte is the command byte followed by a two-byte value: {Byte1}, {Byte2 (MSB)(:)Byte3 (LSB)} The value bytes must be set even if not required by the command. The value bytes may be branch addresses or real data passed to the selected function. The Command and value must be separated by a comma. The MSB byte and LSB byte of the value may be separated by a colon (":").
The following is the decimal value for individual bits used for the relay outputs and switch inputs: BIT NUMBER BIT 0 BIT 1 BIT 2 BIT 3 BIT 4 BIT 5 BIT 6 BIT 7 5.
6 AUTO EXECUTE - If the Auto execute input is active branch to LSB sequence. If the Auto Execute input is not active branch to sequence number specified by the MSB. If MSB is 0 the function will wait until the input becomes active. If input is active the function will branch to the sequence number specified by the LSB byte. If the LSB is 0 the function increment to the next sequence. Example: 7 S20=11,1000 ;Set current position to 1000. S20=12,0 ;Save current position.
Example: 18 ;Increment Loop counter 1 and set condition code register. S20=22,1 ;Decrement Loop counter 1 and set condition code register. S20=23,1 ;Clear Loop counter 1 and set condition code register. S20=24,40 ;Jump to sequence S40. S20=25,40 ;Jump to subroutine at sequence S40. RETURN FROM SUBROUTINE - Returns the sequence counter to the "jump subroutine " sequence number plus 1.
Example: 28 S20=28,3 ;Compare input to 3 (Input 1 and 2 active) and set condition code register. COMPARE LOOP VALUE - Compares the loop counter specified by the LSB byte to VALUE). Example: 30 ;Compare current position to 1000 and set condition code register. COMPARE SWITCH INPUT - Compares the current ATC II switch inputs to the binary value specified in the LSB byte (SWITCH - VALUE) and sets the condition code register.
Example: S20=34,40 35 ;If comparison parameter => to value branch to SEQ 40. BRANCH IF LESS THEN OR EQUAL - Branch to sequence specified by LSB byte as a result of the previous parameter value being less than or equal to the command value (Note: result of comparison is zero). As specified by the condition code register. If not equal to parameter value increment to next sequence number.
44 JOG CW ON/OFF - Jog the oscillator center position in the CW direction by the value specified in the [MSB] byte. The [LSB] specifies the input to test. If the [LSB] specified input is active jog the center position by the value specified in the [MSB] byte. If the [LSB] byte is inactive the change center position is unchanged.
52 SET VOLT REFERANCE - Set Voltage reference to the value and increment to the next sequence. This value is used as a reference for torch height control tracking mode 4 or 5. The units are in 0.1-volt increments (i.e. 100 = 10.0 volts) Example: 53 S20=55,1 ;Home vertical slide using INP1 as home limit. S20=56,1 ;Set Volt Reference to the Width Pot. S20=56,3 ;Set Current Reference to the Center Dwell Pot.
Example: 5.6 S20=58,200:16 ;If Input Value Equals 16 (Input 5 is Active) Move Slide UP at Speed of 200. FACTORY DEFAULTS As shipped from the factory the ATC II has a basic operation PLC program. The PLC code allows the user to start/stop the welding process using the "RUN" switch. By connecting the CR1 relay output to the "Gun Switch" input on the wire feeder the ATC II will activate the welding system. When an arc is established the oscillator will be activated.
;=============== Jog Up/Down Subroutine =================================== S25=58,200:32 ; IF CW SWITCH ON - JOG CW S26=5,5 ; Delay S27=59,200:16 ; IF CCW SWITCH ON - JOG CCW S28=26,0 ; Return from Subroutine ;=============== Initialize Routine =========================================S30=1,64 ; Wait for "RUN" switch on S31=4,3 ; Reset all Relays S32=5,1 ; Delay S33=55,4 ; Home Slide and wait for Input 3 S34=19,0 ; Wait for Move Complete S35=11,1 ; Reset position Register S36=2,64 ; Wait for Run Switch Off
APPENDIX A A.
27
A.2 MICROSTEP MOTOR CABLE P/N: S3W5034 A.
A.4 CURRENT SENSOR CABLE P/N: S3W5045 A.
A.6 TERM CABLE P/N: S3W5050 A.
