HF25 Datacom Technical Manual
Contents
1. PERIOD W RUN MENU ENERGY HF25 ADVANCED SERIAL DATACOM COMMUNICATIONS INTERFACE DOS B 4 990 331 APPENDIX B HOST ORIGINATED COMMANDS HF25 ADVANCED SERIAL DATACOM COMMUNICATIONS INTERFACE DOS 990 331 B 5 APPENDIX B HOST ORIGINATED COMMANDS command 25 State description command 25 State description ALARM READ CLEAR SET error number DISPLAY alarm message string lt crlf gt lt lf gt Any Provides access to the HF25 alarm logic When used with the READ keyword the current error condition value is returned See Appendix A for list of alarm messages When the CLEAR keyword is used all alarm conditions are canceled When the SET keyword is used the host may invoke an error identified by error number When the DISPLAY keyword is used an error condition can be created with any message desired The length of the error message must be limited to 40 characters or less No help message will be available in connection with this created error message SCHEDULE READ SET lt crlf gt parameter name value lt crlf gt parameter name value lt c lf gt It Any except while welding Provides control over the HF25 schedule parameters When used with the READ keyword all parameters pertaining to the currently loaded schedule are returned see SCHEDULE under HF25 ORIGINATED COMMANDS When the SET keyword is used the host may set change the value of one or more of2. CONDITION3 WELD END ALARM OUT lt crlf gt ACTIVE4 HIGH LOW lt crlf gt CONDITION4 WELD END ALARM OUT lt crlf gt Any Reports the relay settings MONITOR schedule_number lt crlf gt MONTYPEI KA V KW j lt crlf gt limit_value lt crlf gt LOWER1 limit_value lt crlf gt none STOP INHIBIT j lt crlf gt MONTYPE2 KA V KW j lt crlf gt UPPER limit value lt crlf gt LOWER limit value lt crlf gt ACTION2 none STOP INHIBIT j lt crlf gt If Any Reports the settings of the basic weld monitor of the currently loaded HF25 schedule The schedule number variable identifies which schedule is currently loaded and may be any value from 000 to 127 The possible value for all variables listed after their parameter name correspond to the values listed under MONITOR the Appendix B Host Originated Commands HF25 ADVANCED SERIAL DATACOM COMMUNICATIONS INTERFACE DOS 990 331 C 3 APPENDIX C HF25 ORIGINATED COMMANDS Command 25 State Description Command 25 State Description Command 25 State Description SYSTEM lt crlf gt LIGHT light_value lt crlf gt BUZZER OFF ON lt crlf gt LOUDNESS loudness_value lt crlf gt DISPLAY AVG lt c lf gt SWTYPE MECHANICAL OPTO PLC lt crlf gt SWITCH OPEN CLOSED lt crlf gt CTTYPE MECHANICAL OPTO PLC lt c
3. is the energy of pulse 2 If HF25 ADVANCED SERIAL DATACOM COMMUNICATIONS INTERFACE DOS 990 331 11 APPENDIX A WELD STATUS MESSAGES The last field in the report packet represents the status of the weld made Status numbers and definitions are listed below Status Status Message GOOD CHECK CONTROL SIGNALS INPUT STATUS CHECK INPUT SWITCH STATUS FIRING SWITCH BEFORE FOOT SWITCH EMERGENCY STOP ON CONTROL SIGNALS INPUT POWER TRANSISTOR OVERHEATED EMERGENCY STOP OPERATOR ACTIVATED FIRING SWITCH DIDN T CLOSE IN 10 SECOND WELD TRANSFORMER OVERHEATED VOLTAGE SELECTION PLUG IS MISSING INHIBIT CONTROL SIGNALS ACTIVATED LOW BATTERY NO CURRENT READING NO VOLTAGE READING LOAD RESISTANCE TOO HIGH NO WELD TRANSFORMER DETECTED WELD SWITCH IN NO WELD POSITION CALIBRATION RESET TO DEFAULT LOWER LIMIT GREATER THAN UPPER LIMIT COOL TIME ADDED FOR DIFFERENT FEEDBACK SYSTEM amp SCHEDULE RESET TO DEFAULTS SAFE ENERGY LIMIT REACHED UPSLOPE REQUIRED FOR LOWER LIMIT INPUT TOO LARGE INPUT TOO SMALL PRESS RUN BEFORE WELDING ACCESS DENIED SYSTEM SECURITY ON ON A Q tS Oo a CO Nre N ON 5 WWW un iS 25 ADVANCED SERIAL COMMUNICATIONS INTERFACE DOS 990 331 1 APPENDIX A WELD STATUS NUMBERS Status 40 47 65 66 69 71 72 73 74 75 76 77 78 80 Status Message ILLEGAL SECURITY CO
4. the host may set change the value of one or more of the parameters of the basic weld monitor settings pertaining to the currently loaded schedule HF25 ADVANCED SERIAL DATACOM COMMUNICATIONS INTERFACE DOS 990 331 B 7 APPENDIX B HOST ORIGINATED COMMANDS The following is a list of valid literal substitutions for the parameter_name and value variables MONTYPE1 KAIVIKW Monitor Type for pulse 1 UPPER1 limit_value Upper Limit for pulse 1 LOWERI limit value Lower Limit for pulse 1 ACTIONI none STOP INHIBIT y Out of Limit Action for pulse 1 MONTYPE2 KAIVIKW Monitor Type for pulse 2 UPPER2 limit value Upper Limit for pulse 2 LOWER2 limit value Lower Limit for pulse 2 ACTION2 none STOP INHIBIT Out of Limit Action for pulse 2 limit value is the parameter that specifies the range of the valid readings If the reading was within the range of the limit value no alarm will occur If the reading was out of the valid range an alarm will occur If the monitor type is KA the limit value is in unit of 1A If the monitor type is V the imit value is in unit of ImV If the monitor type is KW the imit value is in unit of IW The valid number for limit value is 1 through 9999 and 0 is for none command SYSTEM READ I SET lt crlf gt parameter name value lt crlf gt parameter name value lt crlf gt it HF25 State Any description Provides control over HF25 system parameters When used with
5. 2nd weld pulse The average voltage of 2nd weld pulse The control capacity needed to reach the 2nd weld pulse The status of the weld 9o Y AS ade tur 49 Example of a Weld Report 3 205 217 12 513 452 22 0 The above weld report represents the following information 1 Schedule number 3 Average current of the Ist weld pulse 205 A Average voltage of the 1st weld pulse 217 mV control capacity of the Ist weld pulse 12 Average current of the 2nd weld pulse 513 A Average voltage of the 2nd weld pulse 452 mV control capacity of the 2nd weld pulse 22 Status of the weld 0 GOOD a m Qux n d UD d For the list of the weld status codes see Appendix A Weld Status Numbers HF25 ADVANCED SERIAL DATACOM COMMUNICATIONS INTERFACE DOS 8 990 331 OPERATING INSTRUCTIONS Simple Data Collection In order to do the simple data collection the host only needs to send ID REPORT NEW number command JD is the identification number of the HF25 number is a number greater than the number of welds made since the last data collection Then the HF25 then send all the weld reports since the last data collection and erases all the weld data sent from the weld data buffer The host should parse the weld report The weld reports are separated with lt crlf gt The fields within the report are separated with acomma See SECTION 3 amp 4 for additional remote data collection commends Examples of Remote Data Collection Commands 1
6. available in HF25 The total number of weld data that the HF25 holds in the buffer is 3000 Command SCHEDULE schedule number lt c lf gt lt If gt HF25 state Any Description Returns the current schedule number to the host schedule number may be any number from 0 to 127 Command REPORT number of reports lt crlf gt report lt crlf gt report lt crlf gt report lt crlf gt lt lf gt HF25 state Any Description Returns the requested number of weld reports First field is the number of reports to sent Then follows the packets of report One report pack hold all the information about a weld Each report packet is separated by lt crlf gt and this command ends with lt crlf gt lt If gt number of reports This is the number of reports that shall be included in this command If the host computer requests more weld data than is available in the weld data buffer the HF25 sends only the weld reports in the weld buffer and the number of reports is the number of weld reports available in the weld data buffer After the report is sent to the host computer the HF25 erases the weld data sent to the host from the weld data buffer report schedule number current 1 voltage 1 current 2 voltage 2 control 1 pulse width 9o control 2 weld status HF25 ADVANCED SERIAL DATACOM COMMUNICATIONS INTERFACE DOS 990 331 C 1 APPENDIX HF25 ORIGINATED COMMANDS Command HF25 State Description Command HF
7. the READ keyword all system parameters are returned see SYSTEM under HF25 ORIGINATED COMMANDS When used with the SET keyword the host may set change the value of one or more of the system parameters The following is a list of valid literal substitutions for the parameter name and value variables LIGHT light value y LCD contrast LOUDNESS loudness value y Buzzer Loudness BUZZER OFF ON end of cycle buzzer DISPLAY PEAK AVG Display mode SWTYPE MECHANICAL PLC Input Switch Type SWITCH OPEN CLOSED Input Switch mode CTTYPE MECHANICAL OPTO PLC Control Signals CONTROL OPEN I CLOSED Control Signals mode FIRESW AUTO I OPTO NONE Firing Switch Type GRAPH OFF Update Graph WELDABORT OFF Footswitch weld abort DEBOUNCE 10110120130 Switch debounce time in msec HF25 ADVANCED SERIAL DATACOM COMMUNICATIONS INTERFACE DOS B 8 990 331 command HF25 State description Command HF25 state Description Command HF25 state Description Command 25 state Description APPENDIX B HOST ORIGINATED COMMANDS These parameters pertain to the settings of the option menus available via the front panel user interface light value is a number 0 to 99 for brightness of the LCD 0 is dark and 100 is the brightest loudness value is a number 0 to 99 for buzzer loudness 0 is off and 100 is the loudest SYNC lt crlf gt lt If gt Any
8. 25 State Description Command 25 state Description Command The fields in the report packet are separated with a comma and all fields are in integer format There are always 8 fields in report packet schedule_number The schedule number of the weld current 1 The average current of pulse 1 in A voltage The average voltage of pulse 1 in mV control l The capacity control needed to reach the pulse 1 current 2 The average current of pulse 2 in A voltage 2 The average voltage of pulse 2 in mV control 2 capacity control needed to reach the pulse 2 weld_status The status of the weld STATE state_name lt crlf gt lt If gt Any Identifies the current state of operation of the sentry May be in response to the STATE READ command sent by the host or may be sent as a result of a state change from the sentry front panel state_name may be any of RUN PROGRAM or MENU SCREEN TEXT ATTRIBUTE lt crlf gt screen_dump lt crlf gt lt lf gt Any state Returns the request screen dump from the HF25 If TEXT is specified the HF25 is sending 320 bytes of the text screen dump If ATTRIBUTE is specified the HF25 is sending 320 bytes of attribute screen dump COUNTER number lt crif gt lt lf gt Any Returns the requested current HF25 weld counter number SCHEDULE schedule number lt crlf gt FEEDBACKH KA V KW lt crlf gt FEEDBACK KA V KW lt crlf gt SQUEEZEsqueeze_time l
9. 485 card the RS 485 to RS 232 converter is necessary to connect a host computer to the RS 485 port of HF25 Control s Use TELEBYTE Model 285 Superverter or equivalent The followings are the description for how to setup using TELBYTE Model 285 Superverter using 3 wires connection HOST MODEL 285 COMPUTER SERIAL CABLE Set the jumpers as following HF25 ADVANCED SERIAL DATACOM COMMUNICATIONS INTERFACE DOS 990 331 7 OPERATING INSTRUCTIONS Section 2 Remote Data Collection The HF25 data communication protocol includes the capability of collecting basic weld information for each individual weld The HF25 stores weld information for the last 3000 welds Weld Report When DATACOM ROLE of the HF25 Control is set to MASTER the 25 sends out the weld report via the serial ports after each weld is made When DATACOM ROLE of the HF25 Control is set to SLAVE the HF25 sends out the weld report only if it is requested by the host computer With SLAVE setting the host computer should periodically poll the 25 to collect the weld data before 3000 welds are reached Otherwise data over run occurs and weld data will be lost starting with the oldest data The following information is included in the HF25 weld report 1 The schedule number of the weld The average current of 1st weld pulse The average voltage of 1st weld pulse The control capacity needed to reach the Ist weld pulse The average current of
10. DE ENTERED ACCESS DENIED SCHEDULE LOCK ON SCHEDULES ARE RESET SYSTEM PARAMETERS ARE RESET WELD TIME TOO SMALL CURRENT GREATER THAN UPPER LIMIT CURRENT LOWER THAN LOWER LIMIT VOLTAGE GREATER THAN UPPER LIMIT VOLTAGE LOWER THAN LOWER LIMIT POWER GREATER THAN UPPER LIMIT POWER LOWER THAN LOWER LIMIT RESISTANCE GREATER THAN UPPER LIMIT RESISTANCE LOWER THAN LOWER LIMIT WELD STOP LIMIT REACHED HF25 ADVANCED SERIAL DATACOM COMMUNICATIONS INTERFACE DOS 2 990 331 APPENDIX B HOST ORIGINATED COMMANDS These are the commands sent by the host computer via RS 485 or RS 232 to an HF25 Command STATUS lt crIf gt lt If gt 25 state Any Description Requests the 25 to report the status of the weld data buffer HF25 returns STATUS with either or OVERRUN Command COUNT lt erlf gt lt lf gt HF25 state Any Description Requests the HF25 to report the number of weld data accumulated since the last data collection HF25 returns the COUNT even if there is no weld data available Command LOAD schedule number lt crlf gt lt lf gt HF25 state RUN state Description Selects the schedule number as the currently loaded schedule schedule number may be any number from 0 to 127 There must be a space between LOAD and schedule number Command SCHEDULE lt crIf gt lt If gt HF25 state Any Description Requests the HF25 to return the currently selected schedule number command COUNTER TOTAL
11. HIGH LOW GOOD lt crif gt lt lf gt HF25 state Any Description Requests the HF25 to return the HF25 weld counter contents TOTAL returns the total number of weld counter HIGH returns the out of limits high counter LOW returns the out of limits low counter GOOD returns the within limits counter Command REPORT OLD NEW number lt crlf gt lt lf gt HF25 state Any Description Requests the HF25 to send the weld report OLD requests to send the number of oldest weld reports since the last data collection The reported weld data will be erased NEW requests to send the number of newest weld reports All the weld data will be erased after reported number the number of weld data to be sent HF25 ADVANCED SERIAL DATACOM COMMUNICATIONS INTERFACE DOS 990 331 B 1 APPENDIX B HOST ORIGINATED COMMANDS If the number is greater than the number of weld data in the buffer less than the number of weld data will be sent There must be a space between two fields HF25 ADVANCED SERIAL DATACOM COMMUNICATIONS INTERFACE DOS B 2 990 331 Command 25 state Description Command HF25 State command HF25 State description command HF25 State description command HF25 State description APPENDIX B HOST ORIGINATED COMMANDS ERASE lt crlf gt lt If gt Any Requests the 25 to erase all the weld reports STATE READ RUN PROGRAM MENU lt erlf gt lt lf gt Any Descri
12. Provides synchronization of the commands The HF25 return SYNC command back to the host computer CURRENT lt crIf gt lt If gt Any Requests the HF25 to report the sampled Current data of the last weld HF25 shall return with CURRENT report See CURRENT command under HF25 Originating Commands section VOLTAGE lt crlf gt lt lf gt Any Requests the HF25 to report the sampled Current data of the last weld HF25 shall return with VOLTAGE report See VOLTAGE command under HF25 Originating Commands section POWER lt c lf gt lt If gt Any Requests the HF25 to report the sampled Current data of the last weld HF25 shall return with POWER report See POWER command under HF25 Originating Commands section HF25 ADVANCED SERIAL DATACOM COMMUNICATIONS INTERFACE DOS 990 331 B 9 APPENDIX C HF25 ORIGINATED COMMANDS These are commands sent from a HF25 to a host computer Command STATUS state name lt crlf gt lt If gt HF25 state Any Description Identifies the current status of the weld data buffer May be in response with OK or OVERRUN OK means that the HF25 weld buffer did not over run since the last data collection and all the data are intact OVERRUN means that the HF25 weld buffer did over run since the last data collection and only the latest 3000 weld data are available to report Command COUNT number lt crif gt lt lf gt HF25 state Any Description Returns the number of weld data
13. REPORT OLD 10 lt crlf gt lt 1f gt Host is requesting the HF25 with id 1 to send 10 weld reports from the accumulated weld reports The weld data counter in the HF25 is decremented by 10 The corresponding HF25 with id 1 will response with 1 REPORT 10 lt crlf gt 3 205 217 12 513 452 22 0 lt crlf gt weld report 1 3 211 216 13 511 451 22 0 lt crlf gt weld report 2 3 202 212 14 512 453 22 0 crlf weld report 3 3 203 217 12 513 456 22 0 lt crlf gt weld report 4 3 207 218 11 513 457 22 0 crlf weld report 5 3 206 222 12 514 458 22 0 lt crlf gt weld report 6 3 205 214 14 513 461 22 0 lt crlf gt weld report 7 3 208 212 13 512 439 22 0 lt crlf gt weld report 8 3 209 218 15 515 451 22 0 crlf weld report 9 3 202 218 16 512 455 22 0 lt crlf gt weld report 10 If 1 REPORT NEW 1 lt crlf gt lt lf gt Host is requesting the HF25 with id number 1 to send the latest weld reports The weld data counter is reset to 0 The corresponding HF25 with id 1 will response with 1 REPORT 1 lt crlf gt 3 205 217 12 513 452 22 0 lt crlf gt weld report 1 If HF25 ADVANCED SERIAL DATACOM COMMUNICATIONS INTERFACE DOS 990 331 9 OPERATING INSTRUCTIONS Section 3 Remote Programming The portions of the protocol that include the physical layer hardware electrical interconnect the link layer framing data encoding duplex control the network layer source destination identification and the transport layer packet f
14. Turn off the HF25 Control 2 Connect the 9 pin to 9 pin cable to RS 232 connector on the rear panel of the HF25 Control to the RS232 connector on a host computer Use 9 pin to 25 pin adapter if necessary The cable and adapter are part of the HF25 DATACOM kit 3 Insert DATACOM diskette to the floppy drive of the computer The data collection software included in 25 DATACOM kit provides a simple way of collecting weld reports from a 25 4 INSTALL to install the data collection software Follow the screen instructions After the installation is complete type DATACOM from DOS prompt 6 Select SETUP and set COM port to serial port to which the serial cable is connected Set baud rate to 9600 baud Set HF25 Communication Role to SLAVE COLLECTING HF25 WELD DATA gt COMMUNICATION SETUP gt 9608 Bl COM1 ENAME TEST TXT HF25 DATACOM ROLE SLAVE Select 4 Change or press ESC to return 7 Turn on HF25 Weld Head Control HF25 ADVANCED SERIAL DATACOM COMMUNICATIONS INTERFACE DOS 990 331 3 OPERATING INSTRUCTIONS 8 Set the baud rate of the HF25 Control to 9600 The HF25 serial communication baud rate setting is listed under the HF25 Control COMMUNICATIONS menu lt COMMUNICATION gt TION ROLE SLAY ER Bl 9600 SORE RII RAE REE REE REE RIE RAR RIE RAR IERIE EEE N X22222 RAR RAR RARA ROE ROE RIEKIE RAE 9 Set the ROLE option in the HF25Weld Head Contr
15. USER S MANUAL ANUNITEK PEC0 990 331 WORLD LEADER IN RESISTANCE WELDING REVISION B January 2002 MODEL HF25 ADVANCED SERIAL DATACOM COMMUNICATIONS INTERFACE DOS VERSION Copyright 1997 2002 Unitek Miyachi Corporation The engineering designs drawings and data contained herein are the proprietary work of UNITEK MIYACHI CORPORATION and may not be reproduced copied exhibited or otherwise used without the written authorization of UNITEK MIYACHI CORPORATION Unitek Miyachi 1820 South Myrtle Avenue P O Box 5033 Monrovia CA 91017 7133 Telephone 626 303 5676 FAX e mail 626 358 8048 info unitekmiyachi com Printed in the United States of America REVISION RECORD Revision EO Date Basis of Revision A 2 97 Original Release B 19146 01 02 Updated data and format HF25 ADVANCED SERIAL DATACOM COMMUNICATIONS INTERFACE DOS 990 331 OPERATING INSTRUCTIONS Table of Contents Page Section 1 General Description 24242 22 22 1 HF25 Serial Communication aan ee Bene eek 1 HF25 Communication Options er 1 HE25 Datacom Kill anne an 2 RS 232 Data Communication Operation Ad 2 liqui o 2 Making RS 232 Connections HN 3 RS 232 Serial Connector Information uus nase 4 RS 485 Data Comm
16. amples Current and Voltage every 50 us For a weld less than 100 ms weld time the number of data should be total weld time 50 us This number will be always less than 2000 data an integer number in unit of W HF25 ADVANCED SERIAL DATACOM COMMUNICATIONS INTERFACE DOS 990 331 5
17. eter_name value lt crlf gt parameter_name value lt crlf gt It Any except while welding Provides control over the HF25 schedule parameters for relay settings When used with the READ keyword the relay settings of the currently loaded schedule are returned see RELAY under HF25 ORIGINATED COMMANDS When the SET keyword is used the host may set change the value of one or more of the relay settings of the currently loaded schedule The following is a list of valid literal substitutions for the parameter name and value variables ACTIVEI HIGH LOW Relay 1 Active High or Active Low CONDITIONI WELD END ALARM OUT Relay 1 Active Conditions ACTIVE2 HIGH LOW Relay 2 Active High or Active Low CONDITION2 WELD IEND I ALARM OUT Relay 2 Active Conditions ACTIVE3 HIGH LOW Relay 3 Active High or Active Low CONDITION3 WELD IEND I ALARM OUT Relay 3 Active Conditions ACTIVEA HIGH LOW Relay 4 Active High or Active Low CONDITION4 WELD IEND I ALARM OUT Relay 4 Active Conditions MONITOR READ SET lt crlf gt parameter_name value lt crlf gt parameter_name value lt crlf gt R lt gt Any except while welding Provides control over the basic weld monitor settings of the HF25 schedule When used with the READ keyword the basic weld monitor settings of the currently loaded schedule are returned see MONITOR under HF25 ORIGINATED COMMANDS When the SET keyword is used
18. kets of data Each data is separated by lt crlf gt and this command ends with lt crlf gt lt lf gt number of data This is the number of data that shall be included in this command The HF25 Control samples current every 50 us For a weld less than 100 ms weld time the number of data should be total weld time 50 us This number will be always less than 2000 data an integer number in unit of A VOLTAGE number of data lt crlf gt data lt crlf gt data crlf2 data lt c lf gt lt If gt Any Returns the Voltage reading of the last weld First field is the number of data to be sent Then follows the packets of data Each data is separated by lt crlf gt and this command ends with lt crlf gt lt lf gt number of data This is the number of data that shall be included in this command The HF25 Control samples Voltage every 50 us For a weld less than 100 ms weld time the number of data should be total weld time 50 us This number will be always less than 2000 data an integer number in unit of mV POWER number data lt c lf gt data lt crlf gt data crlf2 data lt crlf gt lt If gt Any Returns the Power reading of the last weld First field is the number of data to be sent Then follows the packets of data Each data is separated by lt crlf gt and this command ends with lt crlf gt lt If gt number of data This is the number of data that shall be included in this command The HF25 Control s
19. mputer To use the RS 232 communication refer to RS 232 Data Communication Operation The RS 485 communication provides a way of collect weld reports from one or more HF25 Controls using one host computer To use the RS 485 communication refer to RS 485 Data Communication Operation There is no difference between the operations of RS 232 communication and RS 485 communication other than that RS 485 can be daisy chained and RS 232 can not RS 232 COMMUNICATION RS 232 COMPUTER RS 485 COMMUNICATION UP TO 30 HF25 s RS 485 TERMINATOR OUT RS 485 RS 232 CONVERTER HOST COMPUTER HF25 Communication Options To establish communication through the Serial Port connector the Communication options should be set to match the communication configuration of the host computer The communication options are set from the HF25 COMMUNICATION menu HF25 ADVANCED SERIAL DATACOM COMMUNICATIONS INTERFACE DOS 990 331 1 OPERATING INSTRUCTIONS Baud Rates Parity Datacom Role I D Number The baud rate of the HF25 Weld Control can be configured at 1200 2400 4800 9600 14 4K 19 2 or 28 8K The default setting is 9600 The 25 always communicates in 8 bits with no parity and 1 stop bit The 25 be configured as a MASTER or SLAVE When MASTER is selected for the DATACOM ROLE the HF25 sends out the weld repo
20. ol COMMUNICATIONS menu to SLAVE LD NUMBER does not matter at this time RS 232 Serial Connector Information The serial port pin assignment is as follows CTS Clear to Send RTS Request to Send RI Ring Indicator RS 232 Connector on the back panel of the HF25 HF25 ADVANCED SERIAL DATACOM COMMUNICATIONS INTERFACE DOS 4 990 331 OPERATING INSTRUCTIONS RS 485 Data Communication Operation Purpose The purpose of the RS 485 ports are to enable remote data collection and remote programming via a half duplex multi drop RS 485 communications line between HF25s and a serial data collecting device or host computer The protocol will be implemented using printable ASCII characters to allow ease of protocol translation comprehension and debugging in control systems development UP TO 30 HF25 s RS 485 TERMINATOR OUT RS 485 RS 232 CONVERTER HOST COMPUTER Making RS 485 Connections 1 2 Turn off the HF25 Control s Connect the serial connector on a host computer to RS 232 RS 485 converter using 9 pin to 9 pin cable provided with HF25 DATACOM kit Use 9 pin to 25 pin adapter if necessary Connect the RS 485 IN connector on the rear panel of each HF25 Weld Head Control to the RS 485 connector on the RS 485 to RS 232 converter There is no standard cable for RS 485 therefore special cabling is req
21. onding 25 with ID 1 will respond with 1 COUNTER 9999 lt erlf gt lt If gt where is the current total weld counter 5 SCHEDULE lt crlf gt lt If gt Host is requesting the HF25 with ID 5 to send the current schedule number selected The corresponding HF25 with ID 5 will respond with 5 SCHEDULE lt crlf gt lt If gt where is the current schedule number of HF25 5 SCHEDULE READ crIf gt lt If gt Host is requesting the HF25 with ID 5 to send the current schedule information The corresponding 25 with ID 5 will respond with 5SCHEDULE lt crlf gt where is the current schedule number of HF25 lt crlf gt where is the feedback of pulse 1 FEEDBACK lt crlf gt where is the feedback of pulse 2 SQUEEZE lt crlf gt where is the squeeze time ms lt crlf gt where is the upslope time of pulse 1 in 100 us WELDI lt crlf gt where is the weld time of pulse 1 in 100 us DOWN I lt crlf gt where is the downslope time of pulse 1 in 100 us COOL lt crlf gt where is the cool time in 100 us UP2 lt crlf gt where is the upslope time of pulse 2 in 100 us WELD2 lt crlf gt where is the weld time of pulse 2 in 100 us DOWN2 lt crlf gt where is the downslope time of pulse 2 in 100 us HOLD lt crlf gt where is the hold time in ms ENGI lt crlf gt where is the energy of pulse 1 ENG2 lt crlf gt where
22. ption Commands sentry to identify its current state READ keyword see STATE under HF25 Originated Commands or go to either RUN state or PROGRAM state SECURITY OFF SCHEDULE SYSTEM CALIBRATION lt crIf gt lt If gt Any Allows control of the Sentry security mode OFF sets all security status HF25 to OFF SCHEDULE sets the schedule lock to ON SYSTEM sets the system lock to ON CALIBRATION sets the calibration lock to ON COPY from_schedule_number to schedule number lt crlf gt lt lf gt Any state Allows one schedule to be copied to another schedule number From schedule number and to schedule number may be any number from 0 to 127 Copying a schedule to itself has no effect other than to invoke a schedule printout when PRINT SCHEDULES PROGRAMS is enabled SCREEN TEXT ATTRIBUTE lt crlf gt lt lf gt Any state Requests the HF25 to send screen dump If TEXT is specified the HF25 sends 320 bytes of the text screen dump If ATTRIBUTE is specified the HF25 sends 320 bytes of attribute screen dump HF25 ADVANCED SERIAL DATACOM COMMUNICATIONS INTERFACE DOS 990 331 B 3 APPENDIX B HOST ORIGINATED COMMANDS Command KEY key code lt crlf gt lt lf gt HF25 state Any Description Process the key code as if it was pressed from the front panel The following the codes SQUEEZE WELD 1 DOWN 1 COOL UP 2 WELD 2 DOWN 2 HOLD UP DOWN
23. raming amp token control are implemented in the HF25 The HF25 must always be in the Slave Mode to send data in a polled request response synchronous operation utilizing a packetized token passing like control amp accepting input commands The multi drop signal synchronization control utilizing a token passing like algorithm uses the unit identification portion of the command screen as the token which is the pound sign followed by the unit ID number When no information is being passed the host passes an empty token which is a packet consisting of the token followed by the end of packet sequence lt crlf gt lt If gt If the HF25 has a message to return it sends the message along with the token to the host Otherwise if the HF25 has no message to return it returns an empty token A message consists of any command and its parameters or other data accompanying the command Each token message packet must conclude with an end of packet sequence The HF25 ignores any packet beginning with a unit ID that does not match it s programmed value up to the point that an idle line is detected Thus at least one character time of idle line is required between packets to wake up all HF25 Weld Controls on the communication line in order to recognize any subsequent packet that may be addressed to them Command Summary Packet format ID KEYWORD parameters lt crlf gt lt lf gt unit identification amp token D ID is any number from 0 to 255 mus
24. rlf gt CONTROL CLOSED lt crlf gt FIRESW AUTO NONE lt crlf gt GRAPH OFF ON lt crlf gt WELDABORT OFF ON lt crlf gt DEBOUNCE 01 10 120 130 lt crlf gt If Any Reports the current settings of the HF25 system parameters light value is a number 0 to 99 for brightness of the LCD 0 is dark and 100 is the brightest loudness value is a number 0 to 99 for buzzer loudness 0 is off and 100 is the loudest ALARM error_message lt crlf gt lt If gt Any Identifies the current error condition of operation of the HF25 May be in response to the ALARM READ command sent by the host or may be sent as a result of an error condition occurring in the HF25 error message is a text string describing the error message which is the same error message that is displayed to the screen SYNC lt crlf gt lt lf gt Any The HF25 return SYNC command back to the host computer when the SYNC command is received from the host computer HF25 ADVANCED SERIAL DATACOM COMMUNICATIONS INTERFACE DOS 6 4 990 331 Command 25 state Command 25 state Description Command 25 state Description APPENDIX C HF25 ORIGINATED COMMANDS CURRENT number_of_data lt crlf gt data lt crlf gt data lt crlf gt data lt crlf gt lt lf gt Any Description Returns the Current reading of the last weld First field is the number of data to be sent Then follows the pac
25. rt via the Serial Port after each weld is made When SLAVE is selected for the DATACOM ROLE the 25 sends out the weld report only if it is requested by the host computer The default setting is SLAVE To identify each HF25 Weld Control connected to one RS 485 communication line the host computer needs to know the identification number of each HF25 The I D Number can be any number from 0 to 99 The default setting of I D NUMBER is 1 HF25 Datacom Kit 10 347 01 The HF25 DATACOM KIT provides all the tools necessary to collect weld data from the HF25 Control using a host computer It should be consist of 1 9 pin male to 9 pin female cable 2 9 pin to 25 pin serial adapter 3 RS 485 terminator 4 DATACOM manual 5 HF25 data collection software RS 232 Data Communication Operation Purpose The purpose of the RS 232 port is to enable remote data collection and remote programming via a RS 232 serial communication line from one HF25 Control to a serial data collecting device or host computer This protocol provides a simple way of reporting weld information from a HF25 Control to a computer Using a RS 232 communication remote programming is also allowed However this section describes simple remote data collection method only RS 232 COMPUTER HF25 ADVANCED SERIAL DATACOM COMMUNICATIONS INTERFACE DOS 990 331 OPERATING INSTRUCTIONS Making RS 232 Connections 1
26. t be left justified or zero padded to left command keywords BOLD variable to be replaced by literal italics required parameters enclosed in braces one required and only one parameter allowed optional parameters enclosed in brackets zero or more allowed required optional parameters enclosed in braces and brackets one or more allowed choice of parameters separated by vertical bar indicates one OR another of choices presented range of parameters ow end high end separated by hyphen end of parameter line lt crlf gt carriage return followed by newline end of packet lt 1 gt line must be preceded by the end of parameter line lt crlf gt Each component token keyword and parameters will and must be separated by one or more non printing characters spaces or tabs except the end of packet lf must follow the end of parameter line lt crlf gt immediately Non printing characters immediately preceding the end of parameter line lt crlf gt are ignored HF25 ADVANCED SERIAL DATACOM COMMUNICATIONS INTERFACE DOS 10 990 331 OPERATING INSTRUCTIONS Examples Of Remote Programming Commands 1 LOAD 10 lt crlf gt lt If gt Host is requesting the HF25 that has ID 1 to load schedule 10 The corresponding HF25 with ID 1 will response with 1 lt crlf gt lt If gt 1 COUNTER TOTAL lt crlf gt lt lf gt Host is requesting the HF25 with ID 1 to send the total weld counter The corresp
27. t c lf gt UPIweld time lt c lf gt WELDIweld time lt c lf gt DOWN 1weld_time lt crlf gt COOL weld_time lt crlf gt UP2weld_time lt c lf gt WELD 2weld_time lt c lf gt DOWN2weld_time lt crlf gt HOLDhold_time lt c lf gt ENG1weld_energy lt crlf gt ENG2weld_energy lt crlf gt HF25 ADVANCED SERIAL DATACOM COMMUNICATIONS INTERFACE DOS C 2 990 331 25 State Description Command 25 State Description Command 25 State Description APPENDIX C HF25 ORIGINATED COMMANDS Any Reports the settings of the currently loaded HF25 schedule parameters The schedule_number variable identifies which schedule is currently loaded and may be any value from 0 to 99 squeeze_time and hold_time are the parameter that defines the time for the given period in 1 msec Valid range is from 0 to 999 weld_time is the parameter that defines the time for the given period in 0 1 msec Valid range is from 0 to 990 weld_energy is the parameter that specifies the amount of weld energy In the current feedback mode weld_energy is in unit of 0 001KA In the voltage feedback mode weld_energy is in units of 0 001V In the power feedback mode weld_energy is in units of 0 001KW RELAY lt crIf gt ACTIVE HIGH LOW lt crlf gt CONDITIONI WELD END ALARM OUT lt crlf gt ACTIVE2 HIGH LOW lt crlf gt CONDITION2 WELD END ALARM OUT lt crlf gt ACTIVE3 HIGH LOW lt crlf gt
28. the parameters pertaining to the currently loaded schedule The following is a list of valid literal substitutions for the parameter name and value variables ENG1 weld_energy energy amount for pulse 1 FEEDBACK1 KAIV IKW feedback type for pulse 1 ENG2 weld_energy energy amount for pulse 2 FEEDBACK2 KAIV IKW feedback type for pulse 2 SQUEEZE squeeze_time squeeze time UPI weld_time up slope time of pulse 1 WELD1 weld_time weld time of pulse 1 DOWN1 weld_time down slope time of pulse 1 COOL weld_time cool time UP2 weld_time slope time of pulse 2 WELD2 weld_time weld time of pulse 2 DOWN2 weld_time down slope time of pulse 2 HOLD hold_time hold time HF25 ADVANCED SERIAL DATACOM COMMUNICATIONS INTERFACE DOS B 6 990 331 command 25 State description command 25 State description APPENDIX B HOST ORIGINATED COMMANDS squeeze_time and hold_time are the parameter that defines the time for the given period in 1 msec Valid range is from 0 to 999 weld_time is the parameter that defines the time for the given period in 0 1 msec Valid range is from 0 to 990 weld_energy is the parameter that specifies the amount of weld energy In the current feedback mode weld_energy is in unit of 0 001KA In the voltage feedback mode weld_energy is in units of 0 001V In the power feedback mode weld_energy is in units of 0 001KW RELAY READ SET lt crlf gt param
29. uired Refer to the cabling information in RS 485 CABLING INFORMATION section If the host computer have a RS 485 communication port there is no need to use the RS 232 to RS 485 converter Daisy chain the HF25 Controls if more than one HF25 Controls are to be connected Use standard 9 pin female to 9 pin female serial cables Turn on the HF25 Control s Set the baud rate of the HF25 Control s and the host computer to the same baud rate The HF25 serial communication baud rate setting is listed under the HF25 Weld Head Control COMMUNICATIONS menu Set the ROLE option in the HF25 Control COMMUNICATIONS menu to SLAVE Set the unit ID number in the HF25 Control COMMUNICATIONS menu Each HF25 unit should have its own unique ID number to be identified by the host computer HF25 ADVANCED SERIAL DATACOM COMMUNICATIONS INTERFACE DOS 990 331 OPERATING INSTRUCTIONS RS 485 Cabling Information The HF25 Control RS 485 OUT port and RS 485 IN port have following pin assignments for RS 485 communication There is no difference between RS 485 OUT port and RS 485 IN port m ee mem RS485 Transmit Dat 9 TXD RS485 Transmit Data The RS 485 cabling method using 2 wires and a shield RS 485 Connector on the back panel of the HF25 HF25 ADVANCED SERIAL DATACOM COMMUNICATIONS INTERFACE DOS 6 990 331 OPERATING INSTRUCTIONS RS 485 to RS 232 Interface Converter Information Unless the host computer has a RS
30. unication Operation une 5 P rpsse o 5 Making RS 485 Connections ee 5 RS 485 Cabling Information at 6 RS 485 To RS 232 Interface Converter Information 7 Section 2 Remote Data Collection a ea aaa 8 Weld C9 s EP 8 Ez mpl eof a Weld BODOP ouo udi ores areas eee SEDES 8 Simple Data Colleetion D 9 Examples of Remote Data Collection Commands ana 9 Section 3 Remote Programming 10 Command Summary un 10 Examples of Remote Programming Commands nen 11 Appendix A Weld Status Messages 1 Appendix Host Originated Commands 1 Appendix C HF25 Originated Commands C 1 Section 1 General Description HF25 Serial Communication The purpose of the HF25 Control serial port is to enable remote data collection and remote programming via a serial communications line between the HF25 Control s and a serial data collecting device or host computer The HF25 Control has two ways of reporting weld information or programming remotely using RS 232 and RS 485 The RS 232 communication provides a simple way of reporting weld information from a HF25 Control to a co
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