AUTO ARC 255 Installation manual

Computer Weld Technology, Inc.
10702 Old Bammel N Houston Rd.
Houston, TX 77086
Phone: (713) 462-2118
Fax: (713) 462-2503
Email: cwt@cweldtech.com
TM
ATC II
AUTOMATIC TORCH CONTROL
Operation / Installation Manual
P/N: S8M5018
Revised: September 4, 2009
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 .......................................................................................... 4
CABLES....................................................................................................................... 7
REMOTE CONTROL FUNCTIONS ............................................................................ 9
OPERATION................................................................................................................. 10
OPERATIONAL SEQUENCES................................................................................. 10
ATC II OFF-LINE SERIAL TERMINAL PORT PROTOCOL...................................... 13
SERIAL TERMINAL PORT INTERFACE.................................................................. 13
PORT PROTOCOL.................................................................................................... 13
TERMINAL COMMANDS.......................................................................................... 13
ATC II PROGRAMMABLE SEQUENCE PROTOCOL .............................................. 16
PROGRAMMABLE SEQUENCES ........................................................................... 16
SPECIFIC COMMAND FUNCTION .......................................................................... 16
RELAY OUTPUTS..................................................................................................... 16
AVAILABLE COMMAND ........................................................................................... 17
FACTORY DEFAULTS.............................................................................................. 24
APPENDIX A ATC II SYSTEM DRAWINGS ..................................................................... 26
A.1
A.2
A.3
A.4
A.5
A.6
A.7
ATC II CONTROL ENCLOSURE .............................................................................. 26
MICROSTEP MOTOR CABLE P/N: S3W5034......................................................... 28
VOLTAGE SENSOR CABLE P/N: S3W5044 ........................................................... 28
CURRENT SENSOR CABLE P/N: S3W5045........................................................... 29
POWER CABLE P/N: S3W5043 ............................................................................... 29
TERM CABLE P/N: S3W5050 ................................................................................... 30
REMOTE I/O CABLE P/N: E3W5045 ........................................................................ 30
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. The Thru-Arc sensor provides two modes of Torch Height Control. Mode 4
provides Torch Height Control using Arc Voltage Control (AVC). Mode 5 provides torch height control
using Arc Current Control (ACC). The entire Torch tracking information is derived from the welding arc.
The arc voltage and welding current is measured with an external voltage probe and Hall-Effect clamp
on current sensor provided with the system.
The ATC II provides a user definable 50 sequence Programmable Logic Controller (PLC) with four 24vdc inputs and two N.O. relay contacts. Using the PLC the user can provide external program control
and simple power source interface. A RS-232 serial port is provided for off-line programming and
system configuration. The RS-232 port can also be used to remote control the ATC II.
The Automatic Torch Control (ATC II) provides the necessary command signals to the stepper motor
powered drive to permit the selection of the following functions from the front panel of the ATC Control
box.
CONTROL
RUN
TRACK
JOG
SPEED
GAIN
FUNCTION
Enable Slide Home and AVC/ACC operation
Enable/Disable Thru-Arc AVC/ACC tracking
Jog the Torch slide position p or down
Control the speed of the slide
Provide sensitivity control for all tracking functions
The Linear Slide Assembly (LSA) is a stepper motor driven mechanical assembly that provides the
motion for weld torch manipulation. The standard LSA provides 7” of vertical motion and has a weight
capacity of 25 lbs @ 3” from the face of the carriage. The Torch Slide Assembly module can be
installed in any position using the mounting bracket. The mounting bracket can be installed on the
bottom or in the center of the back of the slide.
ATC II™ ENCLOSURE SPECIFICATIONS
Dimensions
Weight
Power Requirements
Velocity
Motor Torque
6.62”H X 4.12”W X 8.75”L (168mm X 105mm X 222mm)
5.5 lbs (2.5kg)
115 vac or 42 vac 50/60 Hz @ 220 va
0.2 - 15 inch/min
120 oz-in max (Holding Torque
LIGHT DUTY SLIDE SPECIFICATIONS
Dimensions
Max Travel
Weight
Velocity
Weight Capacity
13.25”H x 4.7”W x 3.5”D (336mm X 102mm x 89mm)
7.25” (184mm)
7 lbs (3.18kg)
0.2 – 1.5 inch/sec
10 lbs @ 3” from slide face
1
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 – 1.5 inch/sec
45 lbs @ 3” from slide face
2
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.
FIGURE 1 - Control Physical Dimensions
3
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 2- Light Duty Slide Physical Dimensions
4
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.

Mount the Current Sensor such that the welding ground cable passes through the
sensor (Fig 5). The two RED dots should point toward the power supply for GMAW
applications and toward the work piece for GTAW and Plasma applications. Connect
the Current Sensor Cable to the Sensor Cable Connector and to the CURRENT
mating connector on the rear panel of the ATC II (Fig 5).
CABLE
CONNECTOR
NEGATIVE WELDING
CABLE TO NEGATIVE
TERMINAL OF
WELDING POWER
SUPPLY
RED DOTS
FIGURE 5 - Current Sensor Installation

Connect the RED and BLACK leads of the Voltage Sensor in accordance with Table
1 below. Connect the lead for the Electrode as close as possible to the welding torch.
Connect the Voltage Sensor Cable to the mating connector on the Voltage Sensor
and connect the other end to the ATC II rear panel VOLTAGE Connector.
APPLICATION
GMAW
P-GMAW
GTAW
P-GTAW
PAW
P-PAW
RED (+) LEAD
Electrode
Electrode
Work
Work
Work
Work
BLACK (-) Lead
Work
Work
Electrode
Electrode
Electrode
Electrode
Table 1 - Voltage Sensor Installation

If the ATC II is to be used to control the welding power source connect the Remote
Control Cable to DB9 I/O connector on the rear panel of the ATC II (Fig 6). (Remote
Control Cable is not part of the base unit and must be purchased separate) Refer to
Appendix D for samples interconnect drawings for various weld power supplies.
7

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.
RED WIRE
1/2” RING
TERMINAL
BLACK WIRE
1/2” RING
TERMINAL
VOLTAGE
CABLE
P/N: S3W5044
CURRENT SENSOR
P/N: X3Q5010
VOLTAGE SENSOR
P/N: S3A5053
CURRENT CABLE
P/N: S3W5045
VOLTAGE CABLE
P/N: E3W5045
TERM CABLE
P/N: S3W5050
ATC II
ENCLOSURE
P/N: S3A5127
POWER CABLE
P/N: S3W5043
MIRCOSTEP
CABLE
P/N: S3W5034
LINEAR SLIDE
FIGURE 6 – System Layout
8
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.
1
6
2
7
3
8
4
9
5
REMOTE I/O
INPUT 1
CR1 N.O.
INPUT 2
CR1 COM
INPUT COM
CR2 N.O.
INPUT 3
CR2 COM
INPUT 4
R1
4.7K 1/2W
(10 - 28) VDC INPUT
INPUT COM
1
2
A
C
C
E
16
15
LOGIC +5
INP1
R2
4.7K
TYPICAL INPUT CIRCUIT
LOGIC COM
CR1 N.O.
5
CR1 COM
8
+
1
16
RELAY DC24V
TYPICAL OUTPUT CIRCUIT
FIGURE 7 - Remote Input/Output Configuration
2.4
REMOTE CONTROL FUNCTIONS
All input and output functions are defined and controlled using he ATC II PLC Program
The following is a functional description of the remote control specifications:
PIN
1
2
3
4
5
6
7
8
9
FUNCTIONS
INP1 - 24 vdc remote input 1 (24vdc @ 5.0 ma. Active High)
INP2 - 24 vdc remote input 1 (24vdc @ 5.0 ma. Active High)
INP COM - Digital input signal common
INP3 - 24 vdc remote input 1 (24vdc @ 5.0 ma. Active High)
INP4 - 24 vdc remote input 1 (24vdc @ 5.0 ma. Active High)
CR1-A - CR1 relay Normally Open (N.O.) output (Default weld contactor)
CR1-B - CR1 common output (Default Weld contactor)
CR2-A - CR2 relay Normally Open (N.O.) output (Default arc active)
CR2-B - CR2 common output (Default arc active)
9
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.
AVC SETTING
CONTROL
AVC
DISPLAY
SPEED
CONTROL
GAIN
CONTROL
RUN
SWITCH
TRACKING
SWITCH
SLIDE JOG
SWITCH
POWER
SWITCH
FIGURE 8 - Front Control Panel Layout

To operate the control, turn the main power switch to the "Up" position. The power
switch will illuminate indicating that the unit is operational. The AVC Display will
illuminate and display the active AVC setting.
10

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. Holding the "JOG" switch in the
"UP" direction will move Torch Slide in the up direction. Holding the "JOG" switch in
the "DOWN" position will move the torch slide in the down direction. The "JOG"
switch is disabled when the "TRACKING" Switch is on and the "ARC IS ACTIVE".

How to Set and Save the Torch Start Weld Position.
1. With the "RUN" switch in the "OFF" position use the "JOG" Switch to move the Torch
to the desired START WELD position.
2. To Save the START WELD position set the “RUN” switch to the “ON” position. By
performing this operation the ATC will store the START WELD position of the torch
slide.

After the START WELD position is saved it can be restored to the saved START
WELD position by toggling the “RUN” switch to the “Off” position. After the START
WELD position has been restored move the "RUN" switch back to the "ON" position.

To operate the ATC II without saving a START WELD position place the “RUN”
switch in the “ON” position.

Using the “JOG” switch set the torch to the desired weld start position.

To enable the AVC tracking set the “TRACKING” switch to the “ON” position.

Start the welding arc and the AVC control will begin operation when the arc is
detected. To adjust the AVC set point, adjust the “AVC” control to the desired level.

To halt the AVC torch tracking toggle the “TRACKING” switch to the “OFF” position.
When the Tracking switch is “OFF” the “JOG” switch will be enabled and the operator
can manually adjust the torch position.
To start a welding sequence using the DEFAULT PLC PROGRAM:

Turn the "RUN" switch to the "ON" position.

The ATC II will activate the CR1 output relay (connected to the Power Source
Contactor through the optional Remote I/O Cable) and will wait for an arc on
condition.

An arc on condition is set when the current is greater than 8 amps and the
voltage is greater than 3.0 volts as detected by the Voltage and Current Sensor
of the ATC II. The arc active signal will be reset if current or voltage falls below
preset values and tracking will stop.

When the arc is active CR2 will be set.
11

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.
NOTE: If excessive "GAIN" is used the torch slide will over-correct and the weld bead
will wander. Decrease the gain to obtain stable torch tracking.

The control will start the tracking from the last position as determined when the "RUN"
switch is set to the "ON" position.

When the "TRACKING" switch is set to the "OFF" position the AVC control will be
disabled. When the "TRACKING" switch is in the "OFF" position the Torch position
can be moved by activating the "JOG" switch in the "UP" or "DOWN" position. When
the "JOG" is returned to the center position the control will use the new torch position
as the new start location.
12
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:
4.2
9600, Full Duplex
8 Data Bits, One Stop and no parity
None
PORT PROTOCOL
The Protocol consists of a command string and optional data bytes. The command string is an
Alpha character and 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 select
parameter by the host controller. The "?" will indicate a request for data from the ATC II to the
Host controller. If the host is up-loading data to the ATC II 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 sending a new step motor speed to the ATC II:
V1=1000(cr)
- Sent from Host
To read the ATC II step motor speed, send the following command:
V1?(cr)
1000(cr)
4.3
- Sent from Host
- Received from ATC II
TERMINAL COMMANDS
The following is a summary of the RS-232 serial Commands supported by the ATC II:
COMMAND
DESCRIPTION
A1 - A4 Read ATC II Analog Inputs. The following is a summary of the analog command functions:
A1 - AVC Control Pot input (1 to 255 = 0.01 to 25.5 on the display).
A2 - Speed Pot input (255 = 5.12 vdc Step Rate = Value * Rate Multiplier (M5)).
A3 - Not Used.
A4 - Not Used.
A5 - Not Used.
A6 - Gain Pot analog input (255 = 5.12 vdc).
A7 - Current sensor excitation current (255 = 255 ma.)
A8 - Set motor Excitation current reference (255 = 2.55 amps).
13
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).
BIT 0 = Relay CR1 (value= 1)
BIT 1 = Relay CR2 (value= 2)
M3 -
Set Step motor current value #.## amps (.55 - 2.55 amps).
M4 -
Set Current sensor excitation value (1 - 255).
M5 -
Set motor step rate multiplier value. Motor speed = [1 / (Value x Rate)].
M6 -
Step motor scale factor (Steps / Distance).
M7 -
Analog input automatic scan starting parameter (0 - 5). When the value is set to zero
the front panel pot values will be used. To disable the pot controls set the scan value
to 6. This will enable off-line programming of the oscillator parameters.
M8 -
CWT LAN ID number. Setting a LAN ID value will disable the RS-232
communications and enable the LAN communications routines (Range 1 - 4).
M9 -
Enable ATC II auto sequence routines.
Command
M9=1
M9=2
M9=3
M9=4
Function
Enable Auto sequence input
Clear Auto sequence input
Set Initialize sequence input
Calculate maximum position based on external limit switch inputs.
M10-
Tracking gain.
M11-
Set the Auto Arc On detection current level (0 – 255 amps).
M12-
Enable/Disable tracking data up-load (1 = Enable, 0 = Disable).
M13-
Set Tracking mode:
0 = Center line Tracking.
1 = Width control tracking.
2 = Left side Tracking with constant width
3 = Right side tracking with constant width.
********* Firmware Version 1.22 or higher *********
4 = AVC torch height control (Ver 1.22 or greater)
5 = ACC Torch Height control (Ver 1.22 or greater)
M14-
Depth of penetration value used for tracking modes 1 - 2. The value controls the depth
of penetration of the arc into the sidewall of the welding bevel.
M15
Torch height correction sample time period (10 – 255 msec)
S1 - S50 Programmable Sequence Commands - See Section 5.0 for description of programmable
sequence commands and data format.
14
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.
V10= Maximum cross seam correction limit.
V11= Maximum torch to work correction limit.
***************** Firmware Version 1.22 or higher *******************************
V12= Torch to work reference voltage used in tracking mode 4 and 5
V13= Torch to work reference current used in tracking mode 4 and 5
V14= Actual Arc Voltage value (0.1 volt increments, 100 = 10.0 volts)
V15= Actual Arc Current value (1 amp increment, 100 = 100 amps)
In addition to the terminal commands the ATC II supports several special control key functions.
These functions are used to save the programmed data in the EEPROM and to clear any
pending terminal commands. The following commands are generated by pressing the CTRL"
and specified letter key at the same time. When sending any of the following control codes,
the ATC II will respond with an ASCII "CR". The following is a summary of the special control
character function supported by the ATC II:
Control Code
Command Function
^W
Save current parameters and sequence values to ATC II EEPROM
^C
Reset the terminal serial port and clear any pending terminal commands
^S
Up-load stored sequence commands from ATC II to terminal.
^R
Load sequence commands from EEPROM to RAM
15
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 colon will cause the MSB and LSB byte to concatenate to form a single twobyte value.
5.2
SPECIFIC COMMAND FUNCTION
When setting MSB and LSB bytes for specific command function the MSB and LSB byte may
be separated by a ":" or the total value may be specified by the decimal equivalent of the two
bytes. To set the decimal value for the MSB and LSB bytes use the following equation:
Decimal Value = (MSB x 256) + LSB
The following is an example of how to set sequence 4 to the "SWITCH ON" command (1) and
branch to sequence number 10 when "OFF" (MSB) and to test switch input 1 (LSB):
Decimal Value = (MSB x 256)+LSB = (10 x 256)+1 = 2561
Decimal Command sent to ATC II:S4=1,2561
Optional Command format:
S4=1,10:1
5.3
RELAY OUTPUTS
When Setting / Resetting the relay outputs the individual relays are selected by setting the
decimal value for each relay and use the result as the value for the command. The following is
an example of programming sequence 5 to set relay CR1 and CR2 using the "SET RELAY"
command (2):
Decimal Value for CR1 = 1 and CR6 = 3
Decimal Value = 1 + 2 = 3
Command sent ATC II: S5=2,3
16
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
5.5
DECIMAL
1
2
4
8
16
32
64
128
RELAY
CR1
CR2
N/A
N/A
N/A
N/A
N/A
N/A
SWITCH INPUT SWITCH
INP1
INP2
Slide Home Limit
INP4
"JOG UP" Switch
"JOG DOWN" Switch
"RUN" Switch
“TRACK” Switch
AVAILABLE COMMAND
The following is summary of the available commands and the required values:
COMMAND
0
DESCRIPTION
NOP - No Operation increment to next sequence
Example:
1
S20=2,0:1
S20=2,40:1
;Wait for input 1 "OFF".
;If input 1 is "ON" branch to SEQ40. If "OFF" increment
to next sequence
S20=3,2
S20=3,3
;Set CR2 relay output.
;Set CR1 and CR2 relay output
CLEAR RELAY - Clear relay output specified by LSB byte (CR1 = 64 and CR2 =
128).
Example 1:
Example 2:
5
;Wait for input 1 "ON".
;If input 1 is "OFF" branch to SEQ40. If "ON" increment
to next sequence
SET RELAY - Set relay output specified by LSB byte (CR1 = 64 and CR2 = 128).
Example 1:
Example 2:
4
S20=1,0:1
S20=1,40:1
SWITCH OFF - LSB selects switch input, MSB is branch to sequence number if
switch is "ON". If MSB is zero, function will wait for switch "OFF" condition then
increment to next sequence.
Example 1:
Example 2:
3
;Skip sequence - No operation.
SWITCH ON - LSB selects switch input MSB is branch to sequence number
if switch is "OFF". If MSB is zero, function will wait for switch "ON" condition
then increment to next sequence.
Example 1:
Example 2:
2
S20=0,0
S20=4,2
S20=4,3
;Reset CR2 relay output.
;Reset CR1 and CR2 relay output
DELAY TIME - Delay program execution by time specified by the value. The value
specified is in 10 msecond increments. (Example: 13,50 Set delay time to 0.50
seconds)
Example:
S20=5,20
;Delay for 0,20 seconds.
17
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.
S20=13,0
;Restore save position and move oscillator to the saved
position.
S20=14,1000
;Move oscillator to position specified.
S20=15,10000
;Set oscillator maximum to position 10000.
LOAD POSITION TO MAX - Set maximum position limit to current position.
Example:
17
;Set motor speed to low speed ( [1 / (Value * Rate)] ).
SET MAXIMUM POSITION - Set maximum position limit to value specified.
Example:
16
S20=10,20
MOVE TO POSITION - Move to position and increment to next sequence.
Example:
15
;Halt current move command and stop motor drive.
RESTORE POSITION - Move to position saved in temporary position register and
increment to next sequence.
Example:
14
S20=9,0
SAVE POSITION - Save current position encoder count to temporary position
register and increment to next sequence.
Example:
13
;Clear Initialize Flag.
SET POSITION - Set current position to value specified by [MSB:LSB].
Example:
12
S20=8,0
SET SPEED - Value equal new drive velocity [LSB] (1 - 255).
Example:
11
;If the initialize flag is set jump to SEQ 20 else jump to SEQ
10.
HALT MOVE - Halt current move command and stop stepper drive motor.
Example:
10
S20=7,10:20
CLEAR INITIALIZE - Clear initialize input.
Example:
9
;If the auto active flag is set jump to SEQ 20 else jump to
SEQ 10.
INITIALIZE - If the Initialize input is active branch to LSB sequence. If the Initialize
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:
8
S20=6,10:20
S20=16,0
;Load current oscillator position to Max position.
JOG POSITION CW - Add value specified to current position and move to new
position.
18
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. If a return subroutine command is executed
with out a "jump subroutine " the sequence counter will be incremented to the next
sequence.
Example:
27
S20=21,1
JUMP SUBROUTINE - Jump to specified sequence number subroutine. The
sequence subroutine must be terminated with a return from subroutine command
(32). The ATC II allows nesting of up to 5 subroutines. All commands may be used in
subroutines.
Example:
26
;Load Loop counter 1 with a value of 25.
JUMP TO SEQUENCE - Jump to sequence specified by LSB byte.
Example:
25
S20=20,25:1
CLEAR LOOP COUNTER - Clears the selected loop counter (0 - 4). The LSB byte
selects the desired loop counter to be cleared and sets the condition code register.
Example:
24
;Wait for oscillator move complete
;Is oscillator move complete? No - Branch to SEQ 40
DECREMENT LOOP COUNTER - Decrement the selected counter (0 - 4) and set
the condition code register. The LSB byte selects the loop counter to decrement.
Example:
23
S20=19,0
S20=19,40:0
INCREMENT LOOP COUNTER - Increment the selected counter (0 - 4) and set the
condition code register. The LSB byte selects the loop counter to Increment.
Example:
22
;Jog current position 100 steps in the CCW direction.
SET LOOP COUNTER - Load selected loop counter (0-4) with starting value. MSB
byte is the value to load and the LSB byte is the selected counter. There are 5 Loop
counters available.
Example:
21
S20=18,100
MOVE COMPLETE - Has drive completed the last move command? If the MSB byte
is set the function will jump to the selected sequence number if the move is not
complete. If the LSB byte is zero the function will wait for the move to be completed
then increment to the next sequence or branch to the sequence number set by the
LSB.
Example 1:
Example 2:
20
;Jog current position 100 steps in the CW direction.
JOG POSITION CCW - Subtract value specified from current position and move to
new position.
Example:
19
S20=17,100
S20=26,0
;Return from subroutine.
COMPARE VALUE TO POSITION - Compares the value (MSB, LSB) to the current
position and set the condition code register. The comparison is a subtraction of the
current position from the command value (CURRENT POSITION - COMMAND
19
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:
29
S20=27,1000
S20=29,10:1
;Compare Loop counter 1 to 10 and set condition code
registers.
BRANCH NOT EQUAL - Branch to sequence specified by LSB byte as a result of the
previous parameter value not being equal to command value or not equal zero. As
specified by the condition code register. If not zero increment to next sequence
number.
Function: (Parameter != Compare) then Branch to Seq #
Example:
31
S20=30,40
;If comparison parameter is not equal to value branch to
SEQ 40.
RANCH IF LOWER - Branch to sequence specified by LSB as a result f the previous
parameter value being less than the command value. As specified by the condition
code register. If not less than stored value increment to next sequence number.
Function: Parameter < Compare then Branch to Seq #
Example: S20=31,40
32
;If comparison parameter < value branch to SEQ 40.
BRANCH IF HIGHER - Branch to sequence specified by LSB byte as a result of the
previous parameter value being greater than the command value. As specified by the
condition code register. If not greater than parameter value increment to next
sequence number.
Function: Parameter > Compare then Branch to Seq #
Example: S20=32,40
33
;If comparison parameter > value branch to SEQ 40.
BRANCH IF EQUAL - Branch to sequence specified by LSB byte as a result of the
previous parameter value being 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.
Function: Parameter = Compare then Branch to Seq #
Example: S20=33,40
34
;If comparison parameter = value branch to SEQ 40.
BRANCH IF HIGHER OR EQUAL - Branch to sequence specified by LSB byte as a
result of the previous parameter value being greater than or equal to the command
value. As specified by the condition code register. If not greater than command value
increment to next sequence number.
Function: Parameter >= Compare then Branch to Seq #
20
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.
Function: Parameter <= Compare then Branch to Seq #
Example: S20=35,40
36
;If comparison parameter <= to value branch to SEQ 40.
START OSCILLATOR - Start the mechanical oscillation based on current width,
speed, and dwell parameters.
Example: S20=36,0 ;Start oscillation.
37
STOP OSCILLATOR - Halt the current oscillation and move oscillator to the current
center position.
Example: S20=37,0 ;Stop oscillation.
38
START TRACKING - Start centerline tracking with the mode specified by the [LSB]
byte. The following are the valid tracking mode commands: 0 = Centerline tracking,
1 = Width control tracking, 2 = Right side tracking, 3 = Left side tracking.
Example 1: S20=38,0
Example 2: S20=38,1
Example 3: S20=38,2
Example 4: S20=38,3
39
STOP TRACKING – Disable the centerline tracking functions.
Example: S20=39,1
40
Start tracking using the centerline mode
Start tracking using the width mode
Start tracking using the Right side mode
Start tracking using the Left side mode
Disable center line tracking
CR1 ON/OFF - Activate CR1 based on the [LSB] specified input. If the [LSB] input is
active set CR1,. If the [LSB] byte specified input is inactive reset CR1.
Example: S20=38,1 ;Set/Reset CR1 based on input 1 status
41
CR2 ON/OFF - Activate CR2 based on the [LSB] specified input. If the [LSB] input is
active set CR2,. If the [LSB] byte specified input is inactive reset CR2.
Example: S20=39,1 ;Set/Reset CR2 based on input 1 status
42
OSCILLATOR ON/OFF – Activate the Oscillator based on the [LSC] specified input.
If the [LSB] input is active start the Oscillator. If the [LSB] byte specified input is
inactive stop the oscillator.
Example: S20=40,1 ;Start/Stop the oscillator based on input 1 status
43
TRACK ON/OFF - Activate the tracking mode specified by the [MSB] based on the
[LSB] specified input. If the [LSB] input is active, start the tracking mode specified by
the [MSB] byte. If the [LSB] byte is inactive disable the tracking function. The
following are the valid tracking mode [MSB] values: 0 = Centerline tracking, 1 = Width
control tracking, 2 = Right side tracking, 3 = Left side tracking.
Example 1: S20=43,0:1
Example 2: S20=43,1:1
Example 3: S20=43,2:1
Example 4: S20=43,3:1
If INP 1 is active start tracking using the centerline mode
If INP 2 is active start tracking using the width mode
If INP 1 is active start tracking using the Right side mode
If INP 2 is active start tracking using the Left side mode
21
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.
Example: S20=41,10:1
45
;If INP 1 is active increment center position 10 steps in the CW
direction
JOG CCW ON/OFF - Jog the oscillator center position in the CCW 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.
Example: S20=42,10:1
46
;If INP 1 is active increment center position 10 steps in the CCW
direction
WAIT FOR ARC ON CONDITION - Wait for valid arc condition defined by arc voltage
greater then 2.5 volts and current greater then 10 amps. If MSB byte is set the
function will branch to the selected sequence number while the ARC ON Flag is clear.
If the LSB is set and the "ARC ON" flag is set the function will branch to the specified
sequence. If the LSB is zero the function will increment to next sequence.
Example 1: S20=46,0
Example 2: S20=46,40:30
47
Wait for Arc Active.
If Arc is not active branch to SEQ 40. If Arc is active branch to SEQ 30
SET WIDTH - Set oscillation width control to [LSB] (0 - 255) value. This function is
used to set a default width Pot value when the auto scan function is set to 5 to disable
user Pot controls.
Example:
S20=47,20
;Set oscillation width to LSB value.
************ Only Available In Firmware Version 1.21 Or Greater *************
48
SET RIGHT DWELL - Set oscillation Right Dwell control to [LSB] (0 - 255) value. This
function is used to set a default Right Dwell Pot value when the auto scan function is
set to 5 to disable user Pot controls.
Example:
49
S20=49,20
;Set oscillation Left Dwell to LSB value.
SET CENTER DWELL - Set oscillation Center Dwell control to [LSB] (0 - 255) value.
This function is used to set default Center Dwell Pot value when the auto scan
function is set to 5 to disable user Pot controls.
Example:
51
;Set oscillation Right Dwell to LSB value.
SET LEFT DWELL - Set oscillation Left Dwell control to [LSB] (0 - 255) value. This
function is used to set a default Left Dwell Pot value when the auto scan function is
set to 5 to disable user Pot controls.
Example:
50
S20=48,20
S20=50,20
;Set oscillation Center Dwell to LSB value.
SET TRACKIN GAIN - Set Cross Seam Tracking Gain control to [LSB] (0 - 255)
value. This function is used to set default Tracking Gain Pot value when the auto scan
function is set to 5 to disable user Pot controls.
Example:
S20=51,20
;Set Tracking Gain to LSB value.
******************************** Firmware
22
Version 1.22 or Higher
*********************************
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.
MOVE SLIDE CW BY INPUT VALUE – Move slide in CW direction based on Input
Value specified by the [LSB] at the speed specified by the [MSB]. This function moves
the slide in the CW Direction when the Input Value is equal to the Value in the [LSB] at
the speed indicated in the [MSB].
Example:
59
; 100 step retract and 2 step down increment .
SET CURRENT REF TO POT - Set Current reference, for torch height tracking, to the
Pot value specified by the [LSB]. This function is used to set torch tracking reference
current to the value controlled by the selected control panel pot. The auto scan
function must be enabled. The [LSB] sets the control panel pot that is used (0 = A1…
5 =A6).
Example:
58
S20=54,100:2
SET VOLT REF TO POT - Set Volt reference, for torch height tracking, to the Pot
value specified by the [LSB]. This function is used to set torch Tracking reference
voltage to the value controlled by the selected control panel pot. The auto scan
function must be enabled. The [LSB] sets the control pot that is used (0 = A1… 5
=A6).
Example:
57
;Set Torch height to 220 amps.
HOME SLIDE – Find Upper home position of a vertical slide assemble. Requires
external N.C. upper limit switch to indicate home position. The [LSB] byte specifies
the remote input used to indicate the Home position. This command will set the
current slide position to the user defined V4 max position limit and will move the slide
up until the selected remote input [LSB] is inactive or the max position step count has
been reached.
Example:
56
S20=53,220
TOUCH-RETRACT – This command provides an automatic touch retract torch
routine. The [MSB} byte sets the retract distance and the [LSB] sets the step down
increments. When this command is executed the Torch slide will be move down until
the sensed arc voltage falls below 0.8 volts. The command will then halt the down
ward motion and back up the number of steps set in the [MSB] byte. This routine
requires an external voltage source be applied to the torch and is normally used with
GTAW application.
Example:
55
;Set Torch tracking voltage to 23.0 volts.
SET CURRENT REFERANCE - Set Current 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 1-amp increments (i.e. 100 = 100 amps).
Example:
54
S20=52,230
S20=58,200:16
;If Input Value Equals 16 (Input 5 is Active) Move
Slide Down at Speed of 200.
MOVE SLIDE CCW BY INPUT VALUE – Move slide in CCW direction based on
Input value specified by the [LSB] at the speed specified by the [MSB]. This function
23
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. The centerlinetracking mode will be activated when the operator activates the "TRACKING" switch. The
PLC code is divided into three sections. The first section is the non-welding routine and
consists of Sequence 1 - 5. This section checks the various input control switches and will jog
the oscillator center, start/stop the oscillator and start the welding sequence. The second
section is the welding routines. When the "RUN" switch is active the CR1 relay is set and the
PLC code will wait for an arc on condition. When the arc is established the oscillator will
automatically start. When the "TRACKING" switch is activated the ATC II will begin centerline
tracking. To change the mode of tracking the user will need to change line S10 to reflect the
desired tracking mode. The operator can also jog the oscillation center position using the
"JOG" control switch. The following is a listing of the default PLC program provided:
;======== ATC II AVC TRACKING SYSTEM CONFIGURATION PARAMTERS ========
;
CR1 - Cycle Start Latch Relay Output
;
CR2 - ARC Active Travel Start Relay
;
INP1 - Not Used
;
INP2 - Not Used
;
INP3 - Slide Home Input
;
INP4 – Not Used
;
;=========================== ATC II Default PLC ===========================
S1=25,30
; Jump to Initialize Subroutine S30
;=============== Idle Switch Test Routine===================================S2=25,25
; Jump to Jog Up/Down Subroutine S25
S3=1,2:64
; IS RUN SWITCH ON - NO GO TO SEQ 2
;================== WELD "ON" ROUTINE =================================
S4=12,0
; Save Current Position
S5=3,1
; SET RELAY 1 "CYCLE ON"
S6=1,16:64
; Is RUN Switch still active? No End Weld
S7=25,25
; Check JOG switch inputs
S8=46,6:9
; IS ARC ACTIVE? NO - GO TO S8 AND RECHECK
;------------------- ARC Active Scan Routine -------------------------S9=3,2
; SET ARC ACTIVE RELAY CR2
S10=43,4:128
; START/STOP CENTER LINE TRACKING BASED ON SWITCH?
S11=2,13:128
; IF Tracking on THEN skip Jog Switch Test
S12=25,25
; ELSE - Check for Jog Switch Command
S13=56,0
; Load A1"Volt" pot to Volt Reference
S14=1,16:64
; IS WELD SWITCH STILL ON - NO GOTO S16 END WELD
S15=46,16:9
; IS ARC STILL ACTIVE - NO GOTO S22 ELSE GOTO S16
;=================== END WELD CYCLE ==================================
S16=39,4
; STOP CENTER LINE TRACKING
S17=4,2
; RESET CR2 "ARC ACTIVE" RELAYS
S18=2,6:64
; Wait for Input Off
S19=3,1
; Reset "Cycle On" Relay
S20=10,255
; Set Speed
S21=13,0
; Restore Position
S22=19,0
; Wait for Move Complete
S23=24,2
; JUMP TO SEQ 2
24
;=============== 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
S37=26,0
; Return from Subroutine
25
APPENDIX A
A.1
ATC II SYSTEM DRAWINGS
ATC II CONTROL ENCLOSURE
26
27
A.2
MICROSTEP MOTOR CABLE P/N: S3W5034
A.3
VOLTAGE SENSOR CABLE P/N: S3W5044
28
A.4
CURRENT SENSOR CABLE P/N: S3W5045
A.5
POWER CABLE P/N: S3W5043
29
A.6
TERM CABLE P/N: S3W5050
A.7
REMOTE I/O CABLE P/N: E3W5045
30