Home

DC25 UB25 Datacom Technical Manual

1. L Fexcum gri NOTE You can select up to 4 files mom mom mae E GR GE 3 NOTE You can not assign graphs to specific buttons like you can in the View mode As shown in the screen on the right the Datacom Compare function automatically assigns graphs to the Graph Display Buttons from right to left when you click Open NOTE You may turn each graph display ON or OFF by pushing the corresponding display button Test This 15 used to test or verify that Controls are communicating properly with the computer Test 15 only active if the software is connected and Controls are communicating with the computer Test may be performed any time the computer is Connected to the Control s The computer issues a Status command to all Controls connected to the computer from 0 to 30 then status reports from each Control will be displayed 1n the Communication View Window From the Menu Bar press the Communication View Window icon so you will be able to see test results 2 From the Menu Bar press the Test icon then watch the Communication View Window for test results DC25 UB25 WELD STAT ADVANCED SERIAL DATACOM COMMUNICATIONS INTERFACE 990 661 37 APPENDIX HISTORY DATA Data And Display Formats The history of each weld 15 stored in two different files different formats e Binary Data DAT format e Text Data TXT format
2. T 11 A 11 bun A 12 PU DOW E Em 12 13 Section VI Setup M 14 Comum e a EE dcn Ds 14 SLAVE NOO P E 15 MASTER Mode Monitor a Single Control 15 MASTER Mode Monitor Controls 16 DC25 UB25 WELD STAT ADVANCED SERIAL COMMUNICATIONS INTERFACE 990 661 li Table of Contents Continued Page CONOS 16 LO oro PRO RR 16 CI M 17 E 18 Section Operating Instructions delude 19 bi RR me 19 iB 19 Communication 19 ner ee 20 Connect Software to the Serial Port
3. V kW lt crlf gt weld energy lt crlf gt V kW lt crlf gt squeeze time lt crlf gt weld time lt crlf gt weld time lt crlf gt weld time lt crlf gt weld time lt crlf gt weld time lt crlf gt weld time lt crlf gt weld time lt crlf gt hold time lt crlf gt pid gain lt crlf gt pid gain lt crlf gt If your UB25 Control has a software version lower than 1 22 you will see VMULT This parameter 15 not used ignore If your UB25 Control has a software version lower than 1 23 you will not see either PIDG1 or PIDG2 Any Continued Next Page DC25 UB25 WELD STAT ADVANCED SERIAL DATACOM COMMUNICATIONS INTERFACE 990 661 C 17 APPENDIX PROGRAMMING CODES Description Command Reports the settings of the currently loaded Control 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 15 from 0 to 999 weld time is the parameter that defines the time for the given period in 0 01 msec For the UB25 the valid range is from 0 to 9900 0 to 99 00ms For the DC25 the valid range 15 from 0 to 990 0 to 9 90ms CONTROL Ran Time Range Weld Time for UB25 0 99 ms Weld Time for DC25 0 9 9 ms weld energy is the parameter that specifies the amount of w
4. nives er vicium This 15 used for weld history retrieval storage graphic displays and remote EN HE weld schedule programming see Section em CONVERTER ms IV RS 485 Operation 1 TERMINATION TO 30 DC25 UB25 CONTROLS _ HOST COMPUTER a The only difference between RS 232 operation and 5 485 operation is that RS 485 be Daisy Chained for multiple controls and RS 232 cannot Datacom software 15 used to retrieve store import and export weld history data display weld history graphs and to perform remote weld schedule programming Installation instructions and software description are in Section V Datacom Software Instructions on using Datacom functions are listed in Section VII Operating Instructions DC25 UB25 WELD STAT ADVANCED SERIAL DATACOM COMMUNICATIONS INTERFACE 990 661 1 OPERATING INSTRUCTIONS Datacom Kit Contents QTY ITEM QTY ITEM Datacom Operator Manual 990 661 Computer Requirements General Operating System Windows 95 Windows 98 Windows NT 4 or Windows NT 2000 NT 5 Serial Port RS 232 RS 485 or both Available Hard Drive Space 1 Megabyte minimum RAM 64 Megabytes minimum Monitor Screen and Video Card capability 800 x 600 or larger 256 colors RS 232 Operation No special requirements The Control is confi
5. The Datacom software re formats raw data and T 3 UM displays the weld count schedule peak and gt IV m average values and welds status as shown on the 001 003577 02 1028A 4 01 0035722 02 gt 10254 DODOmV right Weld data appears in the order the Control 00 0035723 02 gt 1028A 00007 44 receives it S Delte HORIZONTAL VERTICAL SCROLL SCROLL BAR BAR Use the horizontal slider bar to view the complete width of a data line e Use the vertical scroll bar to scroll up or down through the complete list of data To save a weld history follow the SAVE Data File or SAVE AS Data File instructions below If you Print the weld history you can select the pages you want printed or select all welds to be printed not just those shown in the window From the Menu Bar click on File 2 Fromthe File pull down menu click on Print select your print options then click on OK NOTE Each page can contain up to 50 weld histories File SAVE Data File This function saves the file that 1s currently open To save data received from the Control s since the file was opened 1 From the Menu Bar click on File 2 From the File pull down menu click on Save 3 Close the window by clicking on the X on the top right of the window 4 If you want to clear the open file click on the File pull down menu then click on Purge Data DC25 UB25 WELD STAT ADVANCED SERIAL DATACOM
6. 7 e e e m m 4 V mom mpm mm mom V i i i i i b 2 4 4 E REL 4 4 4 m am am oam um om oce sno cm ae qe i i i Lj amm mm je bee ede ee eb 7 After you have selected a Graph Display Button click OK Example In the screen on the right the Fixcurr graph was loaded then the Current button was pressed to assign the eraph to the first Graph Display Button and the Fixpower graph was loaded then the Voltage button was pressed to assign the graph to the second Graph Display mm Button 303m 131m 8 Repeat steps 1 7 to load up to four eraphs and assign them to the Graph Display Buttons NOTES e Inthe View mode you may Update and Save any selected graph using the active buttons ims e You may turn each graph display ON or OFF by pushing the corresponding display button DC25 UB25 WELD STAT ADVANCED SERIAL DATACOM COMMUNICATIONS INTERFACE 990 661 35 OPERATING INSTRUCTIONS Compare Stored Weld Pulse Graphs This 15 a quick easy way to
7. 7 display reference lines on the graph placea next to Maximum and or Mean by clicking on the appropriate box 8 To save the waveform traces click on the Save button pop up box will allow you to select the waveform traces that are to be saved NOTES e Clicking on all of the four boxes will select all the waveforms A Comments box opens which allows you to enter one line of comments After closing this window the File Open window opens which allows you to name the file or files When you name a file the character C for current V for voltage P for power or R for resistance will automatically be added to the end of the name Example If you saved the current graph as Unitek GRF the computer will save it as UNITEKC GRF e The Compare function allows you to compare up to four saved waveform traces e To store weld pulse graph follow the SAVE AS Data File procedures DC25 UB25 WELD STAT ADVANCED SERIAL DATACOM COMMUNICATIONS INTERFACE 990 661 33 OPERATING INSTRUCTIONS 34 To print the weld pulse graph click on the File icon on the toolbar From the File pull down menu click on Print select your print options then click on OK NOTE To verify what the weld pulse graph will look like before printing click on File from the File pull down menu click on Print Preview look at the histogram then click on Close View Stored Weld Pulse Graphs 1 Click on the W
8. gt none STOP INHIBIT KA V KW crlf2 value lt gt limit value lt gt none STOP lt crlf gt PROGRAMMING CODES lt crlf gt NOTE If your UB25 Control has a software version lower than 1 22 you will not the parameters below PILDLY1 PILDLY2 PIUDLYI PIUDLY2 P2LDLY1 P2LDLY2 P2UDLYI P2UDLY2 lt gt Control State Any delay value crlf2 delay value crlf2 delay value crlf2 delay value crlf2 delay value crlf2 delay value crlf2 delay value lt gt delay value crlf2 Description Reports the settings of the weld monitor of the currently loaded Control schedule The schedule number variable identifies which schedule is currently loaded and may be any value from 0 to 99 The possible value for all variables listed after their parameter name correspond to the values listed under MONITOR Host Originated Commands of this manual DC25 UB25 WELD STAT ADVANCED SERIAL DATACOM COMMUNICATIONS INTERFACE 990 661 19 APPENDIX PROGRAMMING CODES Command SYSTEM lt crlf gt LIGHT Light value lt crlf gt BUZZER OFF ON lt crlf gt LOUDNESS loudness_value lt crlf gt DISPLAY PEAK AVG lt crlf gt SWTYPE MECHANICAL PLC lt crif gt SWSTATE OPEN CLOSED lt crlf gt CTTYPE MECHANICAL OPTO PLC lt crlf gt CTSTATE OPEN CLOSED lt crlf gt FIRESW AUT
9. 00 2 1 6600000000000000000000050 8000000000000 4 000023 20 Disconnect Software Omir tic Serial 21 21 27 22 arr dg 23 te E 23 Open Au Data File 24 es Mio MT crs sats se csc cts ON 24 qoo Mc 25 ESTER 26 cand odie E E E 2 Remotely Program Weld Schedules 28 How to Use Schedule Name and Schedule Library 30 fs TERRENT 30 sisi E cue descr ERE 30 Restore a Weld Schedule from the Library 1 1 00 000000000 000000000550 0005000 30 Remotely Prosram System Settings 31 32 View Graph OF Last Made 34 34 Compare Stored Weld Pulse Graphis 36 37 Appendix Weld History Data A 1 Appendix B
10. 19214 2 02 Software Upgrade DC25 UB25 WELD STAT ADVANCED SERIAL DATACOM COMMUNICATIONS INTERFACE 990 661 Table of Contents Page Section I Introduction ET 1 2 Computer RE qUITO PHI DS 2 2 2 NIN RN 2 DEOS tin AIO 2 Section II RS 232 Control To Printer Operation Equipment onnechonand 3 uci A 3 Section III RS 232 Control To Computer Operation GU Tp iment COMME and 4 ecc 4 Section IV RS 485 Operation Eg ipment CONNCCHOM and aE 5 Succ a 6 Section V Datacom Software Q re sce 7 9 Mou 10 lai snes seca anes E 10 10 M 11
11. 4 UNITEK 28 License Agreement ee License Grant Organization This is a license not a sales agreement between you the end user and Unitek Miyachi Corporation grants to you a non exclusive non transferable except as provided below icense to use the copy of the software enclosed in this lenvelone and the accomnanving documentation in accord Lo not accept the tenme in ther agreement lt Back Next gt Cancel Back Cancel 4 Select accept then click on Next to 5 When this screen appears enter your Name continue If you do not accept the license and Organization in the appropriate boxes agreement installation will stop then click Next iD Unitek WeldStat InetallS hield Wiz d 2 UNITEK MIYACHI ick Net bo ta thes folder or click Change to install to a different 28 minor 99 OR PORATIoOW decise Cheb Cancel t CProgram gange aa Folder Ci Prog am Undteb edet at User Inlonmabion Company Cancel lt Back 6 Installation creates the folder C Program 7 Ifyou need to make changes click on Back Files Unitek WeldStat for the software until the desired screen appears make the Click on Next or click on Change select changes then continue the installation To a different
12. From the Menu Bar click on File 2 From the File pull down menu click on Purge Data 22 ovi AS Print Print Preview Print Setup Import Purge Data 1 SERIES 25 dat Exit HE Import Export Data 1 SERIES 2S dat Exit Ctlen Cul 5 Girle Ctri E thE Cuneo Cries Ctri R oreo DC25 UB25 WELD STAT ADVANCED SERIAL DATACOM COMMUNICATIONS INTERFACE 10 990 661 OPERATING INSTRUCTIONS setup Setup The Setup button on the Menu Bar gives you the pull down menu on the right that offers the same Connect Disconnect and Test options as the Toolbar icons Connect Disconnect Setup procedures for Communication are described in Section Operating Instructions Test File Printer Setup The Datacom software uses the standard Windows Print Setup window Printer Default printer IIT Cancel Before printing verify that desired currently HP Lasewet 2100 Series PCL 6 on LPT1 Printer is selected If not use the pull Specific printer Options down menu to select it HP LaserJet 2100 Series PCL 6 on LPT1 Hep 2 Verify that the page Orientation is moron 1 Netwok i ize correct If not click on the Portrait or c Panel x11 in C Landscape Sour
13. From the Menu Bar click on File 2 From the File pull down menu click on Import 3 If you want another type of file clickon _ 2154 the List files of type menu button to Look jn Gy Datacom Software display the pull down menu then click type of you want New Data txt 4 open a file e Double click on a displayed name OR e Type a name in the File name box File name then click on Open TexFiles TXT Cancel Continued on next page ooo Fees LUE DC25 UB25 WELD STAT ADVANCED SERIAL DATACOM COMMUNICATIONS INTERFACE 24 990 661 OPERATING INSTRUCTIONS e To look for files in other folders click on the icon in the Folders column then click on the folder you want e Click on the Open button in the Import window Open performs the Import function File Export A File This allows you to take an existing weld data file and write it in the text TXT format which can then be used by Excel or similar spreadsheet programs This 15 useful if you have been collecting data from multiple Controls in the Master mode Using Excel you can sort the data by Control I D numbers in order to have a record of welds made by specific Controls Fromthe Menu Bar click on File 2 File pull down menu click on Export Type in the new name in the File name window 3 Tochange the file type click on the Menu Button next to the Fi
14. USER S MANUAL 990 661 2 Revision B February 2002 UNITEK PECO WORLD LEADER IN RESISTANCE WELDING Operator Manual DC25 UB25 Weld Stat Advanced Serial Datacom Communications Interface Version 1 10 Revision B Sener 25 Station DC 25 Humber 1 a a Nisi am m 0000032 01 0000093 01 n 00000734 01 00000796 mn 0000096 a 75 Humes red 14 47 109 Leper Conta Lami 3 1 Limit Tegma Pul Poles Ange pe Sep firm 1 Coren 1 Prem Pungspinnca 2h 1 F a p t 1 1 p 1 13 cat gm m ma zm y du bem Se uem xa w T a 1 i LI L EN o E mm Li 1 7 4 a a a 2480 TETTED cwummdumsemas a Li a i L a 4 a i a a ee i esu ep petente a a L a i 1
15. Datacom software reads DAT data and formats it for display like this Series 25 Station UB 25 Number ER Slave Total Weld 1205 Count AvgCurent _ 0035710 10284 0035711 3 10284 0035712 12 1028 0035713 2 10284 0035714 1028A 0035715 2 gt 10284 0035716 1028A 0035717 gt 10284 0035718 1028 0035719 2 gt 1028 0035720 gt 10284 0035721 3 10284 0035722 10284 0035723 gt 10284 Datacom Weld History Window In the T XT format each line of data represents a single weld Each value is separated by comma and the line ends with a hard return This allows the data to be used in Microsoft Excel and similar programs for sorting grouping and other data processing When a Control 15 connected to a serial printer weld histories are printed in the unformatted T XT format which looks like this 1 1 0 550 549 913 914 408 833 88 121 O O 931 1246 1250 1941 1475 2427 124 17 7 0 0 551 552 908 920 410 835 89 123 0 0 931 1246 1250 1941 1476 2427 122 15 9 551 550 908 920 409 835 89 123 O 0 932 1248 1250 1941 1478 2427 122 15 9 6 5 6 1 0 0 0 0 0 1 1 1 1 0 1 1 0 551 550 912 914 410 829 89 121 0 0 932 1249 1250 1941 1479 2427 124 16 1 1 0 550 550 912 914 409 833 89 119 0 0 931 1246 1250 1941 1476 2427 122 16 Weld History Text TXT Data The top line of data shown above is
16. 2 Click ona Unit the far left column to select an individual schedule 3 Use the Shift or Control key on the PC keyboard to select multiple schedules 4 Select a weld schedule or schedules to copy from database to Schedule programming menu uy 31 2001 Time 08 03 06 DC25 UB25 WELD STAT ADVANCED SERIAL DATACOM COMMUNICATIONS INTERFACE 30 990 661 OPERATING INSTRUCTIONS 5 Click on the To Schedule button The Copy To dialog box pops up asking you to input the schedule from which to start COPY TO Copying Series 25 Starting NOTE If you copy multiple schedules Station 01 Schedule 15 they will be copied numerical order from the schedule number you select M 6 Now that you have the schedules from the database in the Schedule window you can send them to a Control as described earlier Remotely Program System Settings From the Menu Bar click on Setup Communication Settings 2 Setup pull down menu click on Communication EM Baud Rae 50 sn 3 Highlight the number in the Series 25 I D window Welders Role Series 25 4 Enter I D number of Control you DC 25 want to program then click the Series 25 D button Display All Units Refresh Rate a Seconds Verify that the ID number is correct Click on Menu icon to get the
17. COMMUNICATIONS INTERFACE 22 990 661 SAVE AS Data File OPERATING INSTRUCTIONS This allows you to save open data file with a new name such as Day Date project name etc The original data file remains in memory unchanged 1 2 3 From Menu Bar click on File From the File pull down menu click on Save As Type in the new name in the File name window Save in Datacom Software a e E If you want to change the folder for the 3 5eries25 dat file click on the Menu button next to the Look In window then select a new folder If you want to change the file type click on the Menu button next to the Files of type window then click on a new file 29 type Save as dat Cancel 2 omm dat When you have made your choices click All Files on the Save button Close the History window by clicking on the X on the top right of the window If you want to clear the open file click on the File pull down menu then click on Purge Data File Create A New Data File From the Menu Bar click on File Look jn Gy WeldStat 2 From File pull down menu click on New 3 MARTY 25 Type in the new name in the File name window If you want to change the folder for the file click on the Menu Button next to the Look In window then select a new Filename _ folder Files of type 4 Cancel If you
18. Control Originating Commands section VOLTAGE lt crlf gt lt lf gt Any Requests the Control to report the sampled Current data of the last weld Control shall return with VOLTAGE report See VOLTAGE command under Control Originating Commands section POWER lt crlf gt lt lf gt DC25 UB25 WELD STAT ADVANCED SERIAL DATACOM COMMUNICATIONS INTERFACE C 4 990 661 Control State Description Command Control State Description Command Control State Description Command Control State Description Command Control State Description APPENDIX C PROGRAMMING CODES Any Requests the Control to report the sampled Current data of the last weld Control shall return with POWER report See POWER command under Control Originating Commands section COUNTER TOTAL HIGH LOW GOOD lt crlf gt lt lf gt Any Requests the Control to return the Control 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 REPORT OLD NEW number lt crif gt lt lf gt Any Requests the Control to send the weld report 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 s
19. GOOD i 1 1 1 10674 2mM 2 04 OmV GOOD incoming data in real time 2n mV Geel GOOD 10674 2 04 GOOD 10694 2mV 2 04 GOOD 1067A 2mM 2 04 GOOD 10684 2mM 2 04 GOOD 10674 2mV 2 04 OmM GOOD 10674 2mV 2 04 Omi 0A GOOD 10674 2mV 2 04 04 Om GOOD 10674 2m 2 04 GOOD 10684 2 2 04 GOOD 106574 2mV 2 04 0 Om GOOD OL M CH CH CH CH CH CH CH CH CH CH CH SCH 02 SCH 02 SCH 02 SCH 02 SCH 02 SCH 02 SCH 02 SCH 02 SCH 02 SCH 02 SCH 02 SCH 02 DC25 UB25 WELD STAT ADVANCED SERIAL DATACOM COMMUNICATIONS INTERFACE 990 661 21 OPERATING INSTRUCTIONS Weld History IE History x If the computer is Connected you may press the 5 Series 25 Station UB 25 Number Sla History icon on the Menu Bar any time you want xh to see the collected Weld Histories as they are Unt Count Schedule Pulse1 gt AvgCument AvgVollage 4 01 0035710 02 gt 10284 0000 being received If the computer is Disconnected 003571 02 gt 1028A 0000 01 0035712 02 gt 10284 0000 from the Control s this window be used to 00573 02 5 1028A 0000 j 357 2 gt 2 view stored weld history files Nes oe 01 0035716 02 gt 1028
20. NOTES The maximum number of Controls that can be connected and supported by the software at any single time is 30 even though the I D numbers can go up to 99 If communicating to a single Control the software and the control unit I D must match in order to communicate and collect data DC25 UB25 WELD STAT ADVANCED SERIAL DATACOM COMMUNICATIONS INTERFACE 16 990 661 OPERATING INSTRUCTIONS From the COMMUNICATIONS MENU screen press the 2 key to get the 1 0 I D NUMBER 01 NUMBER entry screen 1 0 NUMBER 2 Enter a two digit number from 01 to 99 in 1 0 NUMBER field NUMBER Change MENU Previous menu 3 Press the MENU key to get the COMMUNICATION menu screen This time the 1 0 NUMBER line will display your I D number entry Baud Rate From the COMMUNICATION menu BAUD RATE press the 3 key to get the BAUD RATE 1 1200 6 19 2K selection screen 7 28 8 5 the numeric keypad to select baud rate of the receiving device The display automatically returns to the NUMBER Change MENU Previous menu COMMUNICATION menu which shows the new baud rate 6 Press MENU to return to the MAIN MENU 5 14 4K DC25 UB25 WELD STAT ADVANCED SERIAL DATACOM COMMUNICATIONS INTERFACE 990 661 17 OPERATING INSTRUCTIONS Computer Setup Use the Datacom software Setup Communication menu to match each Control to the computer s settings COM port and Baud Rate If you are using multiple Co
21. Peak C Curent 6 Voltage Power Resistance HIGHEST RECORDED 1 2300 NEST LEVEL 2100 y vw icu 8 WELDS WELDS WELDS RECORDED gt BEEN A ATA gen 70 Bo SLIDER 4 16 BAR WELDS WELDS WELDS WELDS INDIVIDUAL WELDS Weld History Graph Each point on the graph is a separate weld Selector buttons allow you to choose which values to graph The software automatically calculates the highest and lowest levels recorded then plots those values on the graph The bottom of the graph shows the actual weld count numbers in groups of ten Selector buttons are provided to allow visual minimum and maximum limits to be set 1 Highlight the default limit and enter a limit value 2 Press Tab to display a green limit line on the graph This feature is useful as a visual indictor when a monitor 1s used to view the data in a production environment To save a weld history graph follow the SAVE Data File or SAVE AS Data File instructions If you Print the weld history graph only the portion of the graph in the window will be printed however you may move the slider bar on the bottom of the graph to move to any portion of the weld history beginning middle end To Preview which part of the graph will be printed the slider to the point where you want the graph to start 2 From Menu
22. RS 232 RS 485 1 5 220000020000000 1 Appendix Datacom Programming Codes C 1 DC25 UB25 WELD STAT ADVANCED SERIAL DATACOM COMMUNICATIONS INTERFACE IV 990 661 Section Introduction Overview For the rest of this manual the DC25 UB25 Weld Stat Advanced Serial Datacom Communications Interface will be referred to simply as the Datacom For the rest of this manual the DC25 and UB25 Linear DC Welding Control will be referred to simply as the Control The Datacom Kit allows you to connect a single Control or multiple Controls to a printer or a computer in order to Compile store view and print weld history data for detailed analysis e Remotely program weld schedules on the Control s e Remotely program menu items on the Control s There are three types of Datacom connections 5 232 connection between a single Control and a printer This 15 used to print out weld history data No computer or Datacom software 15 sim required see Section II RS 232 Control To Printer Operation 8 SERIAL CABLE CONTROL SERIAL PRINTER 5 232 connection between a single Control to a computer This 15 used for weld history retrieval storage graphic Se displays and remote weld schedule programming see Section Zu CAL III RS 232 Control To Computer Operation CONTROL COMPUTER PRINTER
23. System menu window shown below Ul System SYSTEM WAVEFDRM CHECK RELAY ACTIVE CONDITION 0 i m 1 ALARM Graph Switch Mechanical Stability 7 NL v 2 ALARM WeldAbot Switch State Open T Delay 2 21 Mechanical 3 ALARM Control Type Mechanical E gt Control State Open xj hm ALARM zj Fire Switch AUTO es Datacom System Menu 7 Click on the Receive button to read the existing settings in the Control DC25 UB25 WELD STAT ADVANCED SERIAL DATACOM COMMUNICATIONS INTERFACE 990 661 31 OPERATING INSTRUCTIONS NOTE When either SEND or RECEIVE is pressed the System menu will disappear Click on the MENU icon again to continue 8 Tochange the settings e Use the mouse to highlight a setting number then type in the new number e Use the pull down menus to select setting options Press the SEND button to send the new settings to the Control 9 Repeat Steps 1 through 8 to change the settings on other Controls For descriptions of the fields and their use refer to the UB25 or DC25 manual NOTE Depending on the type of Control and version of Control software some of these options may not be available Waveform Trace This feature works independently of the Weld History data When Connected to the Control s this displays a waveform graph of
24. a computer equipped with Datacom software up to 30 Controls may use all of the Datacom functions at one time Collect and store Weld History Data from the Control s Print export and display Weld History Data in different graphic formats Remotely select and modify Weld Schedules and System settings the Control s connected to the host computer Remote programming of menu items NOTE Individual Controls can be given unique unit I D numbers so that the software knows which Control it is communicating with To set the Control s ID number follow the procedures listed in the Control s Operator Manual Section VII Operating Instructions DC25 UB25 WELD STAT ADVANCED SERIAL DATACOM COMMUNICATIONS INTERFACE 6 990 661 OPERATING INSTRUCTIONS Section V Datacom Software Installation begin installation insert the Datacom disk into your computer s CD ROM drive fe Unitek WieldStal Wizard fe Unitek WieldS tat InstallShield Wizard Welcome bo the Installshield Wizard for Unitek Weldstat une abeo iae we MN a Weise on UNITEK MIYA CHI 29 29 REOR PO RATIO KAONE EUREN and Datacom Software br for UB 25 25 Weld Stat 2 The nstallShield Wizard window will appear 3 on the monitor click Next to continue Uritek WeldStat InstallShield Wizard iG Unitek WoldStat InstallShield Wizard poco
25. 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 Control samples Current and Voltage every 40 us For a weld less than 80 ms weld time the number of data will be approximately total weld time 40 us This number will be always less than 2000 da a Aninteger number in unit of W DC25 UB25 WELD STAT ADVANCED SERIAL DATACOM COMMUNICATIONS INTERFACE C 16 990 661 Control State Description Command Control State Description CHECKx ccrlf ENABLE STABILITY DELAY CAPACITY lt gt APPENDIX C PROGRAMMING CODES OFF ON lt crlf gt stability value crlt gt delay value crlt value crlt Any except while welding Returns the parameters for the waveform check stability value is the limit of the allowable average deviation from the set point for the weld pulse after the delay period delay value is the delay period in milliseconds This delay period at the start of the pulse will not be used when the average deviation is calculated capicity value is the capacity limit This limit 15 the below the set point the energy is allowed to be at the end of the weld pulse SCHEDULE ENGI FEEDBACKI ENG2 FEEDBACK2 SQUEEZE WELDI DOWNI COOL UP2 WELD2 DOWN2 HOLD PIDGI PIDG2 lt lf gt NOTES schedule number lt crlf gt weld energy lt crlf gt
26. are defined below COOL TIME ADDED FOR DIFFERENT FEEDBACK forso o DC25 UB25 WELD STAT ADVANCED SERIAL DATACOM COMMUNICATIONS INTERFACE 990 661 3 0 2 _ EMEN __ __ omo APPENDIX WELD HISTORY STATUS MESSAGES STATUS MESSAGE 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 INPUT TOO SMALL PRESS RUN BEFORE WELDING NOT USED NOT USED NOT USED NOT USED ACCESS DENIED SYSTEM SECURITY ON ILLEGAL SECURITY CODE ENTERED NOT USED NOT USED NOT USED NOT USED NOT USED NOT USED ACCESS DENIED SCHEDULE LOCK ON NOT USED NOT USED NOT USED NOT USED NOT USED NOT USED NOT USED CURRENT gt UPPER LIMIT CURRENTI LOWER LIMIT VOLTAGE UPPER LIMIT VOLTAGE lt LOWER LIMIT POWERI UPPER LIMIT POWERI lt LOWER LIMIT RESISTANCE gt UPPER LIMIT NOT USED NOT USED SCHEDULES ARE RESET 61 63 64 65 DC25 UB25 WELD STAT ADVANCED SERIAL DATACOM COMMUNICATIONS INTERFACE A 4 990 661 APPENDIX WELD HISTORY STATUS MESSAGES SYSTEM PARAMETERS ARE RESET NOT USED NOT USED WELD TIME TOO SMALL NOT USED CURRENT2 gt UPPER LIMIT CURRENT2 lt LOWER LIMIT VOLTAGE2 UPPER LIMIT VOLTAGE2 LOWER LIMIT POWER2 UPPER LIMIT POWER2 LOWER LIMIT INHIBIT 2ND PULSE
27. by the Control s during welding Datacom also allows you to monitor a single Control at a time or to monitor all Controls at the same time When monitoring in real time you may view data as alphanumeric text a graph or as a histogram of these choices are determined by the Communication Role you choose The descriptions below will help you decide which communication role to choose Following the descriptions are the instructions on setting up the Control s and Datacom Communication Settings Communication Role There are two different communication roles MASTER SLAVE The Control s automatically send weld history data to the computer as each weld 15 made The only limit to how much weld data history can be collected and stored 1s the space available on the computer s hard drive The MASTER role is automatic faster and collects data from up to 30 Controls If multiple Controls are connected to the computer all data is collected into a single file This file can be exported to a spreadsheet such as Excel then sorted to list welds made by individual Controls NOTE In this mode only new data will be sent from the welder to the computer Previously stored data will not be sent to the computer Each Control stores weld history data in its own memory and does not send data until requested by the computer Each Control stores data for up to 1 500 welds In the SLAVE role you must manually collect data from each Co
28. compare four stored graphs although not all of the View functions are available Click on the Waveform Trace icon on the toolbar 2 Click on the Compare tab NOTES Example In the screen the right the Graph Display Buttons are blank because no graphs were previously loaded If old names appear on the buttons they will be replaced when new graphs are selected Weld Salt Windows View Window Heb 1 xj COMPARE TAB word DESUS F Com RAW 9 Graphs C Weld Stal Windows A BUDE 63a Inthe Compare mode only the Load button is active so you can not Update or Save selected graphs 3 Click on the Load button the Open popup window will appear 4 Click on the List files of type pull down menu select the GRF format Open Look jn WeldStat S A es m Fixcurr grf Fixpower arf tan Fixvolt ort Files of type Waveform Trace Cancel History dat araph dat Histogram dat Schedule sch Wavelom Trace GRAF Ae DC25 UB25 WELD STAT ADVANCED SERIAL DATACOM COMMUNICATIONS INTERFACE 36 990 661 OPERATING INSTRUCTIONS 5 From File name box select the graph s you want to open Use the standard Windows procedure of holding down the Shift or Control key while you click on each file name 5 e
29. the last weld made When Disconnected from the Control s you may view and print stored weld pulses View Graph of Last Weld Made 1 Press the Waveform icon on the Toolbar 2 see the latest graph from Control click on the View button The Current Voltage and Power waveforms will display as shown on the right 3 To view the Resistance graph click on the last button on the right Update D Marrum 117 NOTE You may click on the Current Am Voltage Power or Resistance buttons at Compan y any time in order to hide or view specific waveforms 4 If welds have been made since you went into the View mode click on Update to view the waveform of the most recent weld NOTES Update button will be inactive greyed out briefly while the software collects weld data The scale of the graph may change depending on the ranges of the data to be shown decimal point 1 not shown on the vertical axis of the graph DC25 UB25 WELD STAT ADVANCED SERIAL DATACOM COMMUNICATIONS INTERFACE 32 990 661 OPERATING INSTRUCTIONS 5 select parameters for the Update click on the LOAD button then click on the buttons in the pop up window for the parameter s you want 6 To a waveform ON or OFF press the corresponding button on the bottom Trace Freer Maximum 303A 323mV 122W Mean 303A 121 5mV 37 07W Time 9 12ms 9 12ms 9 12 5
30. would look like D REPORT NEW number crlf If The string must begin with a then the ZD or identification number of the Control you wish data from The REPORT NEW is one command from the command list in Section NOTES The letters cr 13 represent carriage return e The letters lt f gt 10 represent line feed For additional remote data collection commands see Section III Computer Originated Commands and Section IV Control Originated Commands The number is the quantity of welds you would like to acquire from the control This number can be greater or lesser than the number of welds made since the last data collection The carriage return line feed sequence lt crlf gt lt If gt terminates the command and is required The Control will then send the requested number of weld reports up to the amount stored into the control since the last data collection The control erases all the weld data sent from the weld data buffer Each weld report data is separated with a carriage return line feed sequence crif2 fields within report are separated with a comma This allows you to import this data into a spreadsheet program like Microsoft Excel The Host is requesting the Control with 1 to send the last 10 weld reports from the stored accumulated weld reports by sending the following command 1 REPORT OLD 10 lt crlf gt lt lf gt The weld data counter in the Control is decr
31. 80 ae m ee em Se cgo wo m eee eee See eee eee 1 a a 7 a E i kreere beseer onum a Lj a i L i 12 X o a a 4 eee e dam eee eee Pee ALTO Ero eR NEM Ma LE LS 1 xoxo RR R OA Xo ko m mox d a om 4 1 murum Maximum 303A 323mV 122W 303A 121 5mV 37 07W Schedule SCHEDULE 0 lek tahon to Library View Library Receive Mean anergy 0500 energy 0500 150 140 1 00 1 00 1 00 1 00 1 00 140 i weld item cool up wild dawn hold Upper 0 000 Lipper 0 000 Lowa ranis Liwer Action Copyright 2001 Unitek 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 Printed in the United States of America REVISION RECORD Revision EO Date Basis of Revision 18987 10 01 Original Release
32. Bar click on File DC25 UB25 WELD STAT ADVANCED SERIAL DATACOM COMMUNICATIONS INTERFACE 26 990 661 OPERATING INSTRUCTIONS From the File pull down menu click on Print Preview 4 Click on Close To Print the portion of the graph displayed in Print Preview e From Menu Bar click on File e From the File pull down menu click on Print select your print options then click on OK Weld History Histogram This allows you to view weld history in a histogram format If the computer is Connected you may press the Weld History Histogram icon on the Menu to see the collected Weld Histories as they are being received The graph is automatically updated each time a weld 15 received If the computer 15 Disconnected from the Control s this window can be used to view stored weld history files Press the Histogram icon on the Toolbar value entered into the Welds Used for Calculation box 2 Use selector buttons to choose the pulse and values to display Mean sum of LAST n weld values n Variance sum of LAST n weld values Mean squared n 3 To change the numbers for Welds Used sigma standard deviation square root variance for Calculation Upper Control Limit or Upper Control Limit Mean 3 sigma Lower Control Limit Lower Control Limit Mean 3 sigma A Highlight the number you want to Process Capability Index is Cpk change Cpk lesser of Mean Lower Control Limit 3 sigma B Typ
33. CATIONS INTERFACE 990 661 C 3 APPENDIX PROGRAMMING CODES Section Ill Computer Originated Commands These are the commands sent by the host computer via RS 485 or RS 232 to a Control Command Control State Description Command Control State Description Command Control State Description Command Control State Description Command Control State Description Command Control State Description Command Control State Description Command STATUS lt crlf gt lt lf gt Any Requests the Control to report the status of the weld data buffer Control returns STATUS with either OK or OVERRUN TYPE lt crlf gt lt lf gt Any Requests the Control to return the type of welder release number and revision letters NOTE UB25 software lower than version 1 22 will not display release number revision letter COUNT lt crlf gt lt lf gt Any Requests the Control to report the number of weld data accumulated since the last data collection Control returns the COUNT even if there is no weld data available ERASE lt crlf gt lt lf gt Any Requests the Control to erase all the weld reports SYNC lt crlf gt lt lf gt Any Provides synchronization of the commands The Control returns SYNC command back to the host computer CURRENT lt crlf gt lt lf gt Any Requests the Control to report the sampled Current data of the last weld Control shall return with CURRENT report See CURRENT command under
34. COM COMMUNICATIONS INTERFACE 990 661 C 11 APPENDIX PROGRAMMING CODES Command KEY key lt crlf gt lt lf gt Control State Some key codes only function in certain states Description Process the key code as if it was pressed from the front panel The followings are the key code KEY DEC HEX KEY DEC HEX UP 5 3B 6 s 36 wD 3C 7 5 3 DOWNI 6 3D 56 3 coL 9 5 3 4 DOWN 65 4 v 5 6 HOD 66 42 kw 6 06 0 48 30 ENERGY 10 f oa 3 SCHEDULE 8 08 DC25 UB25 WELD STAT ADVANCED SERIAL DATACOM COMMUNICATIONS INTERFACE C 12 990 661 APPENDIX C PROGRAMMING CODES Section IV Control Originated Commands These are the commands sent from a Control to a host computer Command Control State Description Command Control State Description Command Control State Description Command Control State Description STATUS lt crlf gt lt lf gt Any Identifies the current status of the weld data buffer May be in response with or OVERRUN OK means that the Control weld buffer did not over run since the last data collection and all the data are intact OVERRUN means that the Control weld buffer did over run since the last data collection and only the latest 1500 weld data are available to report TYPE type release n
35. CTIONS Control s and continue to collect incoming weld data Copy 2 can not connect to the serial port because it 1s being used Therefore it is safe to Open Graph or Save files in copy 2 without being corrupted by incoming data Tip To verify whether you working in copy 1 or copy 2 open the Communication View Window and check it regularly If you are using copy 1 you can see incoming weld data in the window as it is received Copy 2 will not display incoming data because it 1s not connected to the Control s Software Startup Datacom installation automatically puts a Datacom shortcut icon right on your 7 desktop 1 Ifthe Datacom icon is on your desktop double click on it to start the software WeldStat 2 If the Datacom icon 15 not on your desktop open the folder that contains the Datacom software either the default directory C programfiles unitek datacom25 or the custom folder you selected 3 Locate the datacom exe file then double click on it to start the software Connect Software to the Serial Port Press the CONNECT icon on the Menu Bar This connects the software to the serial port and automatically tests the status of the Control s connected to the computer to determine if a Control 15 connected properly Wek Slat Windews EU Test results appear in the Communication View Window If you do not see test results from gj Control you believe 15 connected to th
36. Communication com ICOM2 m COM4 Baud Rate Welders Role DC25 UB25 WELD STAT ADVANCED SERIAL DATACOM COMMUNICATIONS INTERFACE 12 990 661 OPERATING INSTRUCTIONS Toolbar Icons Electronically connects Datacom software to the serial communication port RS 232 or RS 485 so the computer can communicate with the Control s Connect Electronically disconnects Datacom software from the serial port so the computer cannot communicate with the Control s even though cables are still connected This allows other devices to use the serial port and allows display and graphic functions to be used without adding incoming data to existing files Communication View Displays incoming data from the Control s in real time This window Input Window automatically opens when the program is started and will display the status of each Control connected to the computer Displays weld histories listing the unit weld count number weld schedule pulse one and two energy values and status of each weld performed in chronological order Displays weld histories graphical form showing the average or peak data of either current voltage power or resistance for either pulse one or pulse two Two graph windows are provided allowing the data between different pulses or energy values to be compared Maximum and minimum visual control limits can be set for visual indication only Displays weld histories in
37. O REMOTE NONE lt crlf gt FIRESW AUTO 1 NONE lt crlf gt GRAPH OFF ON lt crlf gt WELDABORT OFF lt crlf gt DEBOUNCE NONE 10 20 30 lt crlf gt lt gt Control State Any Description Reports the current settings of the Control system parameters light value is a number to 99 for brightness of the LCD 015 dark and 100 15 the brightest loudness value 15 a number 0 to 99 for buzzer loudness 015 off and 100 1s the loudest Command ALARM error message crlf lf7 Control State Any Description Identifies the current error condition of operation of the Control 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 Control error message is a text string describing the error message which 15 the same error message that 1s displayed to the screen Command SYNC lt crlf gt lt lf gt Control State Any Description Control return SYNC command back to the host computer when the SYNC command 15 received from the host computer DC25 UB25 WELD STAT ADVANCED SERIAL DATACOM COMMUNICATIONS INTERFACE C 20 990 661
38. S INTERFACE C 14 990 661 APPENDIX C PROGRAMMING CODES Description average current 2 The average current of pulse 2 in A Continued average voltage 2 The average voltage of pulse 2 1 mV peak current 2 The peak current of pulse 2 in A peak voltage 2 The peak voltage of pulse 2 1n mV average power 2 The average power of pulse 2 in W peak power 2 The peak power of pulse 2 in W average resistance 2 The average resistance of pulse 2 in 1070 peak resistance 2 The peak resistance of pulse 2 in 10 2 waveform stability 2 The waveform stability result average devation energy capacity 2 The energy capacity result of devation Command STATE state_name lt crlf gt lt lf gt Control State Any Description Identifies the current state of operation of the Control 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 Control front panel state name may be RUN MENU or MONITOR Command COUNTER number lt crlf gt lt lf gt Control State Any Description Returns the requested current Control weld counter number Command CURRENT number_of_data lt crlf gt data lt crlf gt data lt crlf gt data lt crlf gt lt lf gt Control State Any Description Returns the Current 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 crlf and this
39. TING INSTRUCTIONS Section VII Operating I nstructions Before You Start It is important to know how the Datacom communication and memory system works so you can choose the best Datacom method for your documentation needs and to make sure you do not accidentally delete or corrupt your weld history data Control Software Each Control is operated by internal software which communicates with Datacom software Older versions of Control software may not be able to perform all of Datacom s functions The following instructions will note these software differences Before starting press the Info button right on the front panel of the Control to see which version of software 1s installed the Control Memory and Data Datacom s memory was designed to collect data from multiple Controls and combine them into a single file As a result Datacom will add new data to any open file CAUTION To avoid accidentally combining data files or deleting data you want to save follow the Operating Instructions carefully If you forget to Purge Data before you Open A New File old data memory will be combined with new data If you Purge Data before you Save data will be deleted and can not be recovered Example 1 You have chosen to keep daily weld history files If you start to weld on a Tuesday the new weld data will be added to Monday s file unless you first Save Monday s file then Purge Data to clear the Datacom memory then Open A New F
40. WELD STOP LIMIT REACHED NOT USED NOT USED NOT USED NOT USED NOT USED COOL TIME MINIMUM TEST WELD CAPACITY EXCEEDED P1 CAPACITY EXCEEDED P2 STABILITY LIMIT EXCEEDED PI 91 STABILITY LIMIT EXCEEDED P2 92 WELD FIRE LOCKOUT DC25 UB25 WELD STAT ADVANCED SERIAL DATACOM COMMUNICATIONS INTERFACE 990 661 A 5 APPENDIX 5 232 RS 485 CONNECTIONS RS 232 Connector PIN 1 NOT USED PIN 2 TX TRANSMIT DATA PIN 3 RECEIVE DATA PIN 44 NOT USED PIN 5 SIGNAL GROUND PIN 6 NOT USED PIN 7 NOT USED PIN 8 NOT USED PIN 49 NOT USED C wa 7 Signal Ground Analog Ground ISOGND1 wwa wowa NOTE Use the Serial Extension Cable supplied in the Datacom Kit DC25 UB25 ADVANCED SERIAL DATACOM COMMUNICATIONS INTERFACE 990 661 B 1 APPENDIX RS 232 AND RS 485 CONNECTIONS RS 485 IN and Out Connectors NOTE Pin connections and specifications for both RS 485 connectors are identical 1 SIGNAL GROUND PIN 42 NOT USED PIN 3 NOT USED PIN 4 TRANSMIT PIN 5 TRANSMIT PIN 6 NOT USED PIN 7 NOT USED PIN 48 RS 485 RECEIVE PIN 9 RS 485 RECEIVE wa DC25 UB25 ADVANCED SERIAL DATACOM COMMUNICATIONS INTERFACE B 2 990 661 APPENDIX 5 232 AND RS 485 CONNECTIONS RS 485 Connections The following illustrations sh
41. a weld history for a specific time period day week etc be sure to remove the previous weld history report from the printer before the next time period starts NOTE Laser printers automatically make a page break between lines of data If you are using fan fold paper on an impact printer there are no page breaks Therefore a line of weld history data may print on top of the perforated fold in the paper DC25 UB25 WELD STAT ADVANCED SERIAL DATACOM COMMUNICATIONS INTERFACE 990 661 3 OPERATING INSTRUCTIONS Section Ill RS 232 Control To Computer Operation Equipment Connection and Setup PRINTER Turn the Control OFF 2 Verify your computer s baud rate check the computer s settings 3 Connect the 9 pin to 9 pin cable to the RS 232 connector on the rear panel of the Control to the 5 232 connector on the computer Use a 9 pin to 25 pin adapter if necessary The cable and adapter are part of the Datacom kit Turn the Control ON You must match the Control to the computer following the instructions in Section VI Setup Operation When connected to a computer equipped with Datacom software you may use all of the Datacom functions Collect and store Weld History Data from the Control s e Print export and display Weld History Data in different graphic formats e Remotely select and modify Weld Schedules and System settings in the Control s connected to the host computer Follow the procedures in Sect
42. arameter name value lt crl gt lt gt Control State Any Relay 1 Active High or Active Low Relay 1 Active Conditions Relay 2 Active High or Active Low Relay 2 Active Conditions Relay 3 Active High or Active Low Relay 3 Active Conditions Relay 4 Active High or Active Low Relay 4 Active Conditions WELD END ALARM LIMITS P1HI PILOW P2HI P2LOW Description Provides control over the Control s system parameters When used with the Continued On READ keyword all system parameters are returned see SYSTEM under Next Page CONTROL ORIGINATED COMMANDS When used with the SET keyword the host may set change the value of one or more of the system parameters DC25 UB25 WELD STAT ADVANCED SERIAL DATACOM COMMUNICATIONS INTERFACE C 10 990 661 Description Continued Command Control State Description Command Control State Description APPENDIX C PROGRAMMING CODES The following 15 a list of valid literal substitutions for the parameter name and value variables LIGHT Light value LCD contrast LOUDNESS value Buzzer Loudness BUZZER OFF ON end of cycle buzzer DISPLAY PEAK AVG Display mode SWTYPE MECHANICAL OPTO I PLC Input Switch Type SWSTATE OPEN CLOSED Input Switch State CTTYPE MECHANICAL OPTO PLC Control Signals Type CTSTATE OPEN CLOSED Control Signals State FIRESW AUTO REMOTE NONE Firing Switch Type GRAPH OFF Upd
43. ate Graph WELDABORT OFF ON Footswitch weld abort DEBOUNCE NONE 101 20 30 Switch debounce time in msec These parameters pertain to the settings of the option menus available via the front panel user interface light value is a number to 100 for brightness of the LCD 0 is dark and 100 is the brightest loudness_value is a number to 100 for buzzer loudness 015 off and 100 is the loudest ALARM READ CLEAR SET error number DISPLAY alarm_message_string lt crlf gt lt lf gt Any Provides access to the Control 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 15 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 SECURITY OFF SCHEDULE SYSTEM CALIBRATION lt crlf gt lt lf gt Any Allows control of the system security mode OFF sets all security status Control to OFF SCHEDULE sets the schedule lock to ON SYSTEM sets the system lock to ON CALIBRATION sets the calibration lock to DC25 UB25 WELD STAT ADVANCED SERIAL DATA
44. aveform Trace icon on the toolbar Click on the View tab NOTES e Inthe View mode the Update Save and Load buttons are active e Inthe screen on the right the Graph Display Buttons are blank because no graphs were previously loaded If old names appear on the buttons they will be replaced when new graphs are selected Click on the Load button the Open popup window will appear Click on the List files of type pull down menu select the GRF format From the File name box select the graph you want to open e Double click on the file name OR e Type a name in the File name box then click on Open Weld Sial Windows Waveloem Trace Seu Window Heb VIEW TAB Help F1 Vs san weld Stat Windows A acre x TE EE Fixcurr grf 2 Fixpower arf tan Fixvolt ort File name Files of type Waveform inputi dat History dat araph dat Histogram dat Schedule sch Wavetorm Trace GRE DC25 UB25 WELD STAT ADVANCED SERIAL DATACOM COMMUNICATIONS INTERFACE 990 661 OPERATING INSTRUCTIONS 6 Click on the Current Voltage Power or Resistance button to assign the loaded graph to a Graph Display Button under the display area The Current Voltage Power or Resistance buttons correspond to the Graph Display Buttons as shown below
45. ce First Available Tray Landscape button 3 Verify that the Paper Size and Source are correct If not use the pull down menus to select what you want VieW View The View button on the Menu Bar gives you the pull down menu on the right that offers the same Input Data History Window History Graph e ICOM Histogram Schedule Waveform Trace Menu and Library options as the History Graph Toolbar icons Histogram Schedule In addition clicking on Toolbar and Status Bar turns them ON or OFF Waveform Trace Menu Library Input Data Toolbar v Status Bar DC25 UB25 WELD STAT ADVANCED SERIAL DATACOM COMMUNICATIONS INTERFACE 990 661 11 OPERATING INSTRUCTIONS Window Window The Window button on the Menu Bar allows you to select and bring to Arrange the front any of the windows you have open 1 View Input The pull down menu on the right shows that six windows are open and 2 History that 6 Waveform Trace has been selected which brings that window to the 3 Graph front for viewing 4 Histogram 5 Schedule Pull Down Menus Many of the Datacom selections are offered on pull down menus To make a selection Click on the menu button 2 When pull down menu appears click on your selection then click on OK 6 Waveform Trace MENU BUTTON Communication Settings Communication Port Baud Rate 3600 Welders Role MASTER Cancel Communication Settings
46. command ends with lt crlf gt lt lf gt number of da a This is the number of data that shall be included in this command The Control samples current every 40 us For a weld less than 80 ms weld time the number of data will be approximately total weld time 40 us This number will be always less than 2000 an integer number in unit of A DC25 UB25 WELD STAT ADVANCED SERIAL DATACOM COMMUNICATIONS INTERFACE 990 661 C 15 APPENDIX PROGRAMMING CODES Command Control State Description Command Control State Description VOLTAGE number of data crlt data lt crlf gt data lt crlf gt data lt crlf gt lt lf gt Any Returns the Voltage reading of the last weld First field 1s 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 Control samples Voltage every 40 us For a weld less than 80 ms weld time the number of data will be approximately total weld time 40 us This number will be always less than 2000 da a Aninteger number in unit of mV POWER number of data lt crlf gt data lt crlf gt data lt crlf gt data lt crlf gt lt lf gt Any Returns the Power reading of the last weld First field 1s the number of data to be sent Then follows the packets of data Each data is separated by crlf
47. d readings If the reading was within the range of the imit 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 If the monitor type is V the value is in unit of ImV If the monitor type 15 kW the imit value is in unit of IW The valid number for limit value is through 9999 and 0 is for none The delay value is the parameter that defines the time for the given period in 0 1ms Valid range 15 from 0 to 99 Lower delay value 15 only valid during WELD time Upper delay value 15 valid during UP time WELD time and DOWN time Command CHECK READ SET lt crlf gt parameter name value crlf lt Control State except while welding Description Requests the Control to return the waveform check values When used with the READ keyword all parameters pertaining to the waveform check values are returned see CHECK under CONTROL ORIGINATED COMMANDS When the SET keyword is used the host may set change the value of one or more of the waveform check parameters The following 15 a list of valid literal substitutions for the parameter name and value variables ENABLE OFF ON Enable waveform check STABILITY stability_value Stability check limit DELAY delay_value Stability check delay in ms CAPACITY capacity_value Energy capacity limit stability_value is the limit of the allowable average deviation f
48. d value up to the point that an idle line 15 detected Thus at least one character time of idle line 1s required between packets to wake up all Control Weld Controls on the communication line in order to recognize any subsequent packet that may be addressed to them DC25 UB25 WELD STAT ADVANCED SERIAL DATACOM COMMUNICATIONS INTERFACE C 2 990 661 APPENDIX C PROGRAMMING CODES Section 1 Command Format ID KEYWORD parameters crlf2 lf2 UNIT IDENTIFICATION D ID is any number from 00 to 30 must be a two digit number COMMAND KEYWORDS BOLD VARIABLE italics REQUIRED PARAMETERS enclosed in braces one required and only one parameter allowed CHOICE OF PARAMETERS separated by vertical bar I indicates OR another of choices presented REQUIRED OPTIONAL PARAMETERS enclosed in brackets one or more allowed used in the SET parameter zero allowed in the READ parameter RANGE OF PARAMETERS ow end high end separated by hyphen END OF PARAMETER TERMINATOR lt crlf gt carriage return followed by linefeed TERMINATION OF COMMAND lf linefeed must be preceded by the end of line terminator lt gt Each unit identifier command keyword and parameters must be separated by more spaces except the termination of command lf must follow the end of parameter terminator lt crlf gt immediately I E lt erli gt lt lf gt DC25 UB25 WELD STAT ADVANCED SERIAL DATACOM COMMUNI
49. described on the next page DC25 UB25 WELD STAT ADVANCED SERIAL DATACOM COMMUNICATIONS INTERFACE 990 661 A 1 APPENDIX WELD HISTORY STATUS MESSAGES Weld History Data Text TXT Format m amp UNIT NUMBER m SCHEDULE NUMBER lt STATUS ul 1 4 AVERAGE CURRENT S O i lt AVERAGE VOLTAGE mV lt PEAK CURRENT lt PEAK VOLTAGE lt lt AVERAGE POWER W PEAK POWER W 9 aU AVERAGE RESISTANCE x 10 Q 88 8 807 6 6 6 RESISTANCE x 1070 lt WAVEFORM STABILITY RESULT AVERAGE DEVIATION ENERGY CAPACITY RESULT OF DEVIATION amp AVERAGE CURRENT 4 AVERAGE VOLTAGE lt CURRENT lt PEAK VOLTAGE mV a amp AVERAGE POWER W gt PEAK POWER W AVERAGE RESISTANCE x 1070 VCl LCVZC SLVT ITV6T OSCI 9vZCI T Pi a PEAK RESISTANCE x 1070 WAVEFORM STABILITY RESULT AVERAGE DEVIATION ENERGY CAPACITY RESULT OF DEVIATION WELD PULSE 1 WELD PULSE 2 DC25 UB25 WELD STAT ADVANCED SERIAL DATACOM COMMUNICATIONS INTERFACE A 2 990 661 APPENDIX WELD HISTORY STATUS MESSAGES Status Message Codes As shown on the previous page the Status of the weld is the third entry in a line of text data represented by a one or two digit number Status Messages
50. e Control e Verify that the Control is turned ON e Verify that the Control is correctly connected to the computer The Test icon will poll the serial port to identify any controls connected to the system Verify that the Control and computer settings have been matched following the instructions in Section VI Setup For Help press IREPORT 2 Basten wets 5 windows Pee DC25 UB25 WELD STAT ADVANCED SERIAL DATACOM COMMUNICATIONS INTERFACE 20 990 661 OPERATING INSTRUCTIONS Disconnect Software from the Serial Port Press the Disconnect icon on the Menu Bar to electronically disconnect the Datacom software from the serial port display and graphing functions of the Datacom software are still functional but the computer 15 not able to communicate with the Control s even though cables are connected to the computer and the Control s To resume normal communication between the computer and the Control s or to set new communication settings press the Connect icon on the Menu Bar The Status bar at the bottom of the screen provides information concerning the data that the software asks the control for to permit proper operation View Input Press the View Input icon on the Menu Bar any 10674 2mV 2 04 Om GOOD time you want to see Incoming data from the DAI E A Control s The View Input Window displays 02 11 1068A 2mV 2 04 OmV 04 Omv
51. e in the new number or Upper Control Limit Mean 3 sigma NOTES The default upper and lower control limits are calculated from the mean using plus and minus 3 sigma Entering new values will change the CPK value e see the calculations used in generating the default values click on the Equations button DC25 UB25 WELD STAT ADVANCED SERIAL DATACOM COMMUNICATIONS INTERFACE 990 661 27 OPERATING INSTRUCTIONS To Print the weld history histogram 1 From the Menu Bar click on File 2 From the File pull down menu click on Print select your print options then click on OK NOTE To preview what the histogram m Histogram Series 25 Station Number 1 Standard Deviation 258 2 Total Number of Welds 182 Upper Contral 1239 0288 3 sigma Welds Used for Calculation 182 Equations 4644 Lower Contral 31 0 2596 3 sigma 6 Pubel Puke2 C Average Peak Cok 1 6 Vokage Power Resistance X Step Size 23 will look like before printing Click on File e From the File pull down menu click on Print Preview 208 40 Click on Close 101 0 267 359 451 543 635 727 819 911 1003 Remotely Program Weld Schedules This provides the same weld schedule programming features available on the front panel of the Control For more information on weld schedule programming see the DC25 Operator Manual or UB25 Operator Manual NOTE To use this function
52. eld energy e Current Feedback mode weld energy range for the UB25 is from 5 to 1 000A 5 1000 For the DC25 the range 1s from 100 4 000A 100 4000 e Voltage Feedback mode weld energy for the UB25 is in units of 0 01 V and the range 15 from 0 1 to 4 9V 100 to 4900 For the DC25 the range 15 from 0 1 to 9 9V 100 to 9900 for the DC25 e Power Feedback mode weld energy for the UB25 is in units of 10W and the range for the UB25 1s from 10 to 4900W 10 4900 For the DC25 the range 1s from 100W to 9900W 100 9900 pid gain is the PID gain of the last weld RELAY lt crlf gt ACTIVEI HIGH LOW lt crlf gt CONDITIONI WELD END ALARM LIMITS PIHI PILOW P2HI IP2LOW lt crif gt ACTIVE2 HIGH LOW lt crif gt CONDITION2 WELD END ALARM I LIMITS PIHI PILOW P2HI IP2LOW lt crif gt ACTIVE3 HIGH LOW lt crlf gt CONDITION3 WELD END ALARM LIMITS PIHI PILOW P2HI IP2LOW lt crif gt ACTIVE4 HIGH LOW lt crif gt CONDITION4 WELD END ALARM LIMITS PIHI PILOW P2HI IP2LOW lt crif gt lt gt DC25 UB25 WELD STAT ADVANCED SERIAL COMMUNICATIONS INTERFACE C 18 990 661 Control State Any APPENDIX C Description Reports the relay settings Command MONITOR MONTYPEI UPPERI LOWERI ACTIONI MONTYPE2 UPPER2 LOWER2 ACTION2 schedule number crlt KA KW crlf2 value lt crlf gt value lt
53. emented by 10 The corresponding Control the Control with ID 1 responses with 1 REPORT 10 lt crlf gt 1 1 0 551 552 908 920 410 835 89 123 0 0 931 1246 1250 1941 1476 2427 122 15 9 0 0 crif 1 1 0 551 550 908 920 409 835 89 123 0 0 932 1248 1250 1941 1478 2427 122 15 9 0 0 crif 1 1 0 551 550 912 914 410 829 89 121 0 0 932 1249 1250 1941 1479 2427 124 16 5 0 0 lt crlf gt 1 1 0 550 550 912 914 409 833 89 119 0 0 931 1246 1250 1941 1476 2427 122 16 1 0 0 crif 1 1 0 551 552 912 914 410 833 89 121 0 0 932 1249 1250 1945 1480 2431 123 15 8 0 0 lt cr f gt 1 1 0 551 554 912 933 411 842 89 122 0 0 931 1248 1250 1948 1478 2435 123 15 6 0 0 crif 1 1 0 551 554 908 927 412 839 89 120 0 0 932 1249 1250 1941 1480 2427 123 15 6 0 0 crif If DC25 UB25 WELD STAT ADVANCED SERIAL DATACOM COMMUNICATIONS INTERFACE 990 661 C 1 APPENDIX PROGRAMMING CODES When no information 15 being passed the host passes an empty token which 15 a packet consisting of the token followed by the end of packet sequence lt crlf gt lt lf gt If the Control has a message to return it sends the message along with the token to the host Otherwise if the Control 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 Control ignores any packet beginning with a unit ID that does not match it s programme
54. ent 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 STATE READ RUN MENU MONITOR lt crlf gt lt lf gt Any Commands the Control to identify its current state READ keyword see STATE under CONTROL ORIGINATED COMMANDS section or go to either RUN state or PROGRAM state LOAD schedule_number lt crlf gt lt lf gt RUN state Selects the schedule_number as the currently loaded schedule schedule_number may be any number from 0 to 99 There must be a space between LOAD and schedule_number DC25 UB25 WELD STAT ADVANCED SERIAL DATACOM COMMUNICATIONS INTERFACE 990 661 C 5 APPENDIX PROGRAMMING CODES Command Control State Description Command Control State Description Command Control State Description Continued On Next Page COPY from schedule number to schedule number crlf2 lf Any Allows one schedule to be copied to another schedule number From schedule number and to schedule number may be any number from 0 to 99 Copying a schedule to itself has no effect other than to invoke a schedule printout when PRINT SCHEDULES PROGRAMS is enabled SCHEDULE ccrlf2 lf Any state except while welding Requests the Control to return the currently selected schedule number SCHEDULE READ SET lt crlf gt parameter name value lt crl gt lt RUN state Provides control ove
55. er the Control erases the weld data sent to the host from the weld data buffer report unit number schedule number weld status average current average voltage 1 peak current peak voltage 1 average power 1 peak power 1 average resistance 1 peak resistance 1 waveform stability 1 energy capacity 1 average current 2 average voltage 2 peak current 2 peak voltage 2 average power 2 peak power 2 average resistance 2 peak resistance 2 waveform stability 2 energy capacity 2 The fields in the report packet are separated with a comma and all fields are in integer format There are always 23 fields a report packet unit number The unit number assigned to the unit schedule number The schedule number of the weld weld status The status of the weld average current The average current of pulse 1 in A average voltage The average voltage of pulse 1Gn mV peak current 1 The peak current of pulse 1 in A voltage 1 The peak voltage of pulse 1 in mV average power The average power of pulse 1 1n W peak power 1 The peak power of pulse 1 in W average resistance l The average resistance of pulse 1 in 10 2 peak resistance 1 The peak resistance of pulse 1 in 10 Q waveform stability 1 The waveform stability result average devation energy capacity 1 The energy capacity result of devation DC25 UB25 WELD STAT ADVANCED SERIAL DATACOM COMMUNICATION
56. erence only it changes as numerical values change 7 Click on the Receive button to read the existing schedule in the Control Use the AV Up Down scroll buttons next to the Schedule window to select the schedule you want to program 9 Change the Weld Pulse and Monitor values Use the mouse to highlight a time or energy value number e Type in the new time or energy value number e Use the pull down menus to select the Upper and Lower energy units and Monitor Action Press the Send button to send the new schedules to the Control 11 Repeat Steps 7 through 10 for each schedule you want to program DC25 UB25 WELD STAT ADVANCED SERIAL DATACOM COMMUNICATIONS INTERFACE 990 661 29 OPERATING INSTRUCTIONS How to Use Schedule Name and Schedule Library Functions Name a Weld Schedule Click the Name field to give a weld schedule a name Using the Schedule Library Click the To Library button to transfer a weld schedule to the weld library A Save Comments box appears where you can enter Enter Comments comments about the particular weld schedule Enter your Comments Here NOTE The weld library is a database Each field in the Weld Schedule will be given it s Date own column in the database Restore a Weld Schedule from the Library view the Datacom database click on View Library NOTE To view the schedule database outside the Datacom software use a database program like Microsoft Access
57. folder then click on Next complete installation click on Finish DC25 UB25 WELD STAT ADVANCED SERIAL DATACOM COMMUNICATIONS INTERFACE 990 661 7 OPERATING INSTRUCTIONS InstallShield Wizard Completed on InstallShield Wizard h nstalled Un WeldStat ck Fini o UNITEK MIYACHI CORPORATION 6 When the InstallShield Wizard Completed screen appears click on Finish 9 EN Weld Stat Windows Application 10 When the correct Release Key is entered the 11 screen above appears Click on OK Thin soltera ur not 7 Da the val exin UNITEX MACHI 3035576 When installation 15 complete the registration screen appears displaying the software Serial Number and a request for the Release Key which is a code number available from the E Mail address shown on this window Your trial penod has expwed Paul Brackell or Marty Mewbome E Mail weldwizard unitekequpment com UNITEK Corporation 626 303 5676 If you did not register within 7 days the screen above will appear showing the E Mail address where you can get the information you need to complete installation DC25 UB25 WELD STAT ADVANCED SERIAL DATACOM COMMUNICATIONS INTERFACE 990 661 8 OPERATING INSTRUCTIONS Description Datacom software uses standard Windows features al
58. gured for a standard RS 232 serial port connection which is common on most printers and computers RS 485 Operation Your computer must be equipped and configured for RS 485 operation using e An internal RS 485 circuit card installed in your computer OR Anexternal RS 232 3 RS 485 Converter such as the Telebyte Model 285 Superverter or equivalent With the exception of RS 232 Control To Printer Operation Datacom software must be installed in the host computer in order to match the Control s to the computer and to perform Datacom functions Before operation see Section V Using Datacom Software to familiarize yourself with the software features and Section VI Setup for the procedures to match the Control s to the computer Remote Programming Most users will find the Datacom software functions sufficient for collecting and using weld history information and remote schedule programming However advanced users may wish to perform additional programming for custom welding applications The codes needed to perform remote programming are listed Appendix C Datacom Program Codes Using these codes users can write customized software for controlling all functions of the welding control and interfacing the unit to automation control systems DC25 UB25 WELD STAT ADVANCED SERIAL DATACOM COMMUNICATIONS INTERFACE 2 990 661 OPERATING INSTRUCTIONS Section 1 RS 232 Control To Printer Operation Equipment Connection and Setup T
59. he currently loaded schedule The following 15 a list of valid literal substitutions for the parameter name and value variables 1 1 value value ACTIONI STOP INHIBIT MONTYPE2 LUKATIVIKW UPPER2 value LOWER2 value ACTION2 STOP Monitor Type for pulse 1 Upper Limit for pulse 1 Lower Limit for pulse 1 Out of Limit Action for pulse 1 Monitor Type for pulse 2 Upper Limit for pulse 2 Lower Limit for pulse 2 Out of Limit Action for pulse 2 NOTE If your UB25 Control has a software version lower than 1 22 you will not the parameters below PILDLY1 delay value PILDLY2 delay value PIUDLYI delay value PIUDLY2 delay value P2LDLY1 delay value P2LDLY2 delay value P2UDLYI delay value P2UDLY2 delay value Pulse 1 Lower Delay Start Time For Lower Limit Pulse 1 Lower Delay End Time For Lower Limit Pulse 1 Upper Delay Start Time For Upper Limit Pulse 1 Upper Delay End Time For Upper Limit Pulse 2 Lower Delay Start Time For Lower Limit Pulse 2 Lower Delay End Time For Lower Limit Pulse 2 Upper Delay Start Time For Upper Limit Pulse 2 Upper Delay End Time For Upper Limit DC25 UB25 WELD STAT ADVANCED SERIAL DATACOM COMMUNICATIONS INTERFACE C 8 990 661 APPENDIX C PROGRAMMING CODES limit value is the parameter that specifies the range of the vali
60. his connection allows you to print weld history data directly from the Control to a serial printer without using a computer or Datacom software You can use an inexpensive impact printer such as a Panasonic 1124 2124 with serial option or equivalent or a laser printer such as a Hewlett Packard LaserJet or equivalent CONTROL SERIAL PRINTER Turn the Control OFF 2 Verify that your printer is set for serial port operation and note the baud rate see the operator manual that came with the printer 3 Connect the 9 pin to 9 pin cable to the RS 232 connector on the rear panel of the Control to the 5 232 connector on the printer Use a 9 pin to 25 pin adapter if necessary The cable and adapter are part of the Datacom kit 4 Turn the Control ON 5 Match the Baud Rate of the computer and the printer following the instructions in Section VI Setup Operation When ready turn the printer ON making sure you have enough paper and toner ink to last for the number of welds you expect to make In the MASTER mode the Control sends a line of weld history data for each weld made The data looks like this 1 1 0 550 549 913 914 408 833 88 121 0 0 931 1246 1250 1941 1475 2427 124 17 0 0 This contains weld energy and other information which is defined Appendix Weld History Data The printer will print continuously as long as it is connected to the Control and the Control remains in the MASTER mode To print
61. histogram form Allows you to choose which Weld Histogram values to display Mean plus and minus 3 sigma control limits and CPK values can be seen Allows you to remotely program weld schedules in the Control s attached to the computer Weld schedule and all monitoring functions are accessible Displays the waveform traces for current voltage power and resistance Waveforms can be saved Compare function allows up to four waveforms to be displayed and compared Waveform Trace System Relay Allows you to remotely program System settings Waveform Check Waveform Check and Relay settings the Control s connected to the computer This Setup button is inactive greyed out if the computer is not Connected Issues a Status command to all Controls connected to the computer Test from zero to 30 Incoming status reports from each Control will be Communications displayed in the Communication View Window Test is not active if the software 1s disconnected 5 About Datacom nro Information Displays Datacom software version and release date information 2 Help Opens Datacom software instructions and information DC25 UB25 WELD STAT ADVANCED SERIAL DATACOM COMMUNICATIONS INTERFACE 990 661 13 5 OPERATING INSTRUCTIONS Section VI Setup Overview Datacom allows you to monitor welding in real time as each weld 15 made or to collect weld history data at the end of a work period that was recorded
62. ile for Tuesday Tuesday s file will be empty and will store incoming weld data from this point forward Example 2 You are welding on a Wednesday but need to look at a file you saved on Monday If you are communicating with operating Controls in the MASTER role then Open Monday s file incoming weld data will no longer be added to the file you opened for Wednesday Instead it will be added to the file you just opened Monday This will corrupt Monday s file and prevent Wednesday s file from being complete Communication Connect Disconnect To collect weld data you must connect the software to the computer s serial communication port As noted above if you are collecting data in the MASTER role then Open an existing file new data will be added to the old file If you Disconnect the software from the serial port you may open and view files without being corrupted by the addition of new data However if the Controls continue to weld the computer will not receive incoming data and the current weld record will be incomplete due to the missing data A solution to this conflict comes from the fact that a serial port can only be used by one program at atime To continue to collecting weld data and to view existing files you can open a second copy of the Datacom software using normal startup procedures Copy 1 will still be connected to the DC25 UB25 WELD STAT ADVANCED SERIAL DATACOM COMMUNICATIONS INTERFACE 990 661 19 OPERATING INSTRU
63. ion Operating Instructions DC25 UB25 WELD STAT ADVANCED SERIAL DATACOM COMMUNICATIONS INTERFACE 4 990 661 OPERATING INSTRUCTIONS Section IV RS 485 Operation Equipment Connection and Setup RS 485 NOT REQUIRED IF THE HOST COMPUTER TERMINATOR IS EQUIPPED FOR RS 485 OPERATION RS 485 RS 232 CONVERTER PRINTER To connect a computer to multiple Controls up to 30 the computer must be equipped for RS 485 operation using e An internal RS 485 circuit card installed in your computer OR e An external RS 232 3 RS 485 Converter such as the Telebyte Model 285 Superverter equivalent If the host computer does have an operating RS 485 communication port you do not need to use an RS 232 To RS 485 converter If you do need to use a converter there is no standard cable for RS 485 connection therefore special cabling 15 required See Appendix B Connectors and Wiring Diagrams for the Control s RS 232 and RS 485 connector pin assignments and RS 485 wiring diagrams 1 Turn all Controls OFF Without Converter A Connect one end of the 9 pin to 9 pin custom cable to the RS 485 connector on the back of the computer Use a 9 pin to 25 pin adapter 1f necessary B Connect the other end of the cable to the RS 485 IN connector on the first Control C Connect additional Controls in a Daisy Chain by connecting the RS 485 OUT connector on the first Control to the RS 485 IN connector on the next Control and so on unti
64. l all the desired Controls are connected Use custom 9 pin male to 9 pin male serial cables With Converter A Connect a cable between the RS 232 connector on the back of the computer to the Input connector on the RS 232 to RS 485 converter as described in Appendix B Connectors and Wiring Diagrams DC25 UB25 WELD STAT ADVANCED SERIAL DATACOM COMMUNICATIONS INTERFACE 990 661 5 OPERATING INSTRUCTIONS Connect the RS 485 IN connector on the rear panel of the first Control to the RS 485 connector on the RS 485 to RS 232 converter as described Appendix Connectors and Wiring Diagrams C Connect additional Controls up to 30 in a Daisy Chain by connecting the RS 485 OUT connector on the first Control to the RS 485 IN connector on the next Control and so on until all the desired Controls are connected Use standard 9 pin male to 9 pin male serial cables 2 After the last Control of the chain 15 connected plug the RS 485 Terminator plug supplied in the Datacom kit into the RS 485 OUT connector of the last Control RS 485 communication will not work correctly unless the line is terminated 3 Turn each Control ON 4 Youmust match the baud rate for each Control in the Daisy Chain to the computer and set the Communication Role to SLAVE following the instructions in Section VI Setup NOTE The default setting for the Control 15 Baud rate 9600 Data bits 8 Parity none and Stops Bits 1 Operation When connected to
65. les of type window and then click on a new file type 4 Ifyou want to change the folder for the file click on the Menu Button next to the Look In window then select a new folder Dad asc oum 1 hi Court omia gomon 0000003 0000005 0000008 0000004 0000010 0000011 0000012 01 E For press Ft REPORT we 5 When you have made your choices click on the Open button this performs the Export function 6 Close the Export window by clicking on the X on the top right of the window 7 If you want to clear the open file click on the File pull down menu then click on Purge Data DC25 UB25 WELD STAT ADVANCED SERIAL DATACOM COMMUNICATIONS INTERFACE 990 661 25 OPERATING INSTRUCTIONS o ANI Weld History Graph This allows you to view weld histories in a graph format If the computer is Connected you may press the Graph icon on the Menu to see the collected Weld Histories as they are being received The graph is automatically updated each time a weld is received The History Graph serves as a Run chart for the process If the computer is Disconnected from the Control s this window can be used to view stored weld history files Press the Weld History Graph icon on the Toolbar 2 the selector buttons to choose the pulse and value to display SELECTOR BUTTONS C Pulse 6 Pulse2 6 Average
66. lowing you to display single or multiple windows at the same time Specific windows can be accessed using either pull down menus or by clicking on Toolbar icons The Toolbar at the top of the screen and the Status bar at the bottom of the screen can be turned ON or OFF using the VIEW pull down menu Toolbar Icons ore FILE Pulldown Menu dal E III Wido Help press betae Windows Create a new document Status Bar a one REA Datacom Windows re DC25 UB25 WELD STAT ADVANCED SERIAL DATACOM COMMUNICATIONS INTERFACE 990 661 OPERATING INSTRUCTIONS Menu Bar Buttons File File The File button on the Menu Bar gives you the pull down menu on the right that offers the New Open Save and Save As options as described in Section VII Operating Instructions Print Print Preview and Print Setup are the standard Windows menus Print Preview allows you to see how a graph will print out before you actually print Procedures for Import and Export are described in Section VII Operating Instructions File Purge Data CAUTION This feature deletes all data from any file that is open Save or Save As all files with data you want to keep before using this feature Before you purge make sure the only file that is open 15 the file with data you want to purge delete
67. m windows will show Displaying ALL The AV up down buttons are inactive Communication Settings Communication Port Baud Rae 880 Welders Role MASTER Cancel Series 25 TYPE 25 Series 25 D Refresh Rate Seconds He BUTTONS INACTIVE DISPLAYING ALL 1 H Displaying ALL Pulsel C 2 6 Average Peak Series 25 Station Number NOTE You may change the communication role any time you like but the Datacom and all Controls must be set to the same communication role either MASTER or SLAVE Control Setup Before operation the following settings on the Control and the computer must be matched Use the front panel controls and LCD menus to change the settings below If you are using multiple Controls this must be done for each Control From the MAIN MENU press the 5 key to go to the COMMUNICATION menu shown with default settings 2 From the COMMUNICATION menu toggle the 1 key to select MASTER or SLAVE The COMMUNICATION ROLE line will now reflect your role selection 1 0 Number COMMUNICATION 1 COMMUNICATION ROLE SLAVE 2 1 0 NUMBER 01 3 BAUD RATE 9600 NUMBER Select MENU Previous menu If multiple Controls are connected to the computer using an RS 485 communication line each Control must have a different ID number the default I D setting for each Control is 1 The I D Number can be any number from 0 to 99
68. ntrol after welds have been made Each file will be a separate weld history for that specific Control NOTE Memory on the Control is limited to 1 500 weld records If fewer than 1 500 welds were made all weld records will be sent to the computer Ir more than 1 500 welds were made only the last 1 500 weld records will be sent to the computer NOTE All Controls must be set to the same communication role either MASTER or SLAVE DC25 UB25 WELD STAT ADVANCED SERIAL DATACOM COMMUNICATIONS INTERFACE 14 990 661 SLAVE Mode SLAVE mode only allows you to communicate with one Control at a time Therefore when SLAVE 15 selected the Datacom Communication Settings window the Display Units feature 1s inactive greyed out When monitoring welding in the Weld History Weld Graph or Weld Histogram mode the top left corner of each window will display the communication role you have selected The word SLAVE appears and the up down buttons are inactive MASTER Mode Monitor a Single Control When MASTER is selected in the Datacom Communication Settings window the Display All Units feature is active To monitor a single Control do not click on the Display All Units feature If there isa 4 in the box click on Display All Units to remove the V Now the top left corner of the Weld History Weld Graph or Weld Histogram will not display the word SLAVE and the up down buttons are active You can u
69. ntrols this must be done for each Control After matching one Control to the computer select the next Control in the Daisy Chain and repeat the following procedures 1 From the SETUP pull down menu click on COMMUNICATION Communication Port x With the Disconnect button enabled click on the Communication Port pull Baud Rate 350 down menu to select which port Welders Role COMI COM2 etc the computer 15 Cancel Series 25 using for the serial connection check your computer s settings Select the Series 25 LD 1 _ Display All Units Refresh Rate 8 Seconds port then click on OK Click on the Series 25 1 0 window then enter the 1 0 Number of the Control Click on the Baud Rate pull down menu click on the baud rate set on the Control Click on the Welder s Role Communication Role pull down menu click on MASTER or SLAVE Click on the Series 25 Type pull down menu select the DC25 or UB25 If the Refresh Rate window 1 active you may enter a new time value now do it later Refresh rate determines how often the computer will request data from the control when they are matched in slave mode When you have made all your selections click on OK to save the new settings Repeat Steps 1 through 8 for each Control until Controls are matched to the computer DC25 UB25 WELD STAT ADVANCED SERIAL DATACOM COMMUNICATIONS INTERFACE 18 990 661 OPERA
70. ontrol has a software version lower than 1 23 you will not see either PIDG1 or PIDG2 squeeze time and hold time 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 Valid ranges are shown below HOST CONTROL inerements Range Weld Time for UB25 0 99 ms Weld Time for DC25 0 9 9 ms weld energy is the parameter that specifies the amount of weld energy In the current feedback mode weld energy is in unit of 0 001 KA In the voltage feedback mode weld energy is in units of 0 001 V In the power feedback mode weld energy is units of 0 001 kW pid gain 15 the PID gain Setting this value to will force the next weld to be a test weld DC25 UB25 WELD STAT ADVANCED SERIAL DATACOM COMMUNICATIONS INTERFACE 990 661 C 7 APPENDIX PROGRAMMING CODES Command MONITOR READ SET lt crlf gt parameter name value lt crl gt lt gt Control State except while welding Description Provides control over the basic weld monitor settings of the Control schedule When used with the READ keyword the basic weld monitor settings of the currently loaded schedule are returned see MONITOR under Control ORIGINATED COMMANDS When the SET keyword 15 used the host may set change the value of one or more of the parameters of the basic weld monitor settings pertaining to t
71. ow these RS 485 Datacom connections RS 232 To RS 485 Converter Connection RS 485 Full Duplex Connection DC25 UB25 1 Signal Ground 4 RS485 Transmit Data HOST COMPUTER CONVERTER Signal Ground RS485 Receive Data RS485 Receive Data RS485 Transmit Data RS485 Transmit Data OFF ON Switch 1 Switch 2 SERIAL CABLE Switch Switch4 Switch 5 L ESI 5 RS485 Transmit Data 8 RS485 Receive Data 9 RS485 Receive Data RS 232 To RS 485 Converter Connection DC25 UB25 HOST COMPUTER signal Ground 1 Signal Ground RS485 Receive Data RS485 Receive Data RS485 Transmit Data RS485 Transmit Data RS485 Transmit Data 4 RS485 Transmit Data 5 R5485 Receive Data 8 RS485 Receive Data RS 485 Full Duplex Connection DC25 UB25 ADVANCED SERIAL DATACOM COMMUNICATIONS INTERFACE 990 661 B 3 APPENDIX DATACOM PROGRAMMING CODES Section l Remote Data Collection and Programming The Control data communication protocol includes the capability of collecting basic weld information for each individual weld The Control stores weld information for the last 1 500 welds In order to do the simple data collection the Control must be in the SLAVE mode The host only needs to send an ASCII character string to the control This allows ease of comprehension and debugging remote data collection development An example string
72. r the Control schedule parameters When used with the READ keyword all parameters pertaining to the currently loaded schedule are returned see SCHEDULE under Control ORIGINATED COMMANDS When the SET keyword 15 used the host may set change the value of one or more of the parameters pertaining to the currently loaded schedule The following 15 a list of valid literal substitutions for the parameter name and value variables DC25 UB25 WELD STAT ADVANCED SERIAL DATACOM COMMUNICATIONS INTERFACE C 6 990 661 APPENDIX C PROGRAMMING CODES Description ENGI weld energy energy amount for pulse 1 Continued 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 UP1 weld time up slope time of pulse 1 WELDI weld time weld time of pulse 1 DOWNI weld time down slope time of pulse 1 COOL weld time cool time UP2 weld time up 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 PIDGI pid gain PID Gain for Pulse 1 Change in value is seen after a weld is made PIDG2 pid gain PID Gain for Pulse 2 You will not be able to see this change NOTES e If your UB25 Control has a software version lower than 1 22 you will see VMULT This parameter is not used ignore If your UB25 C
73. rom the set point for the weld pulse after the delay period NOTE The valid number for the delay value is through 99 representing 0 0 through 9 9ms delay time delay_value is the delay period in milliseconds This delay period at the start of the pulse will not be used when the average deviation 15 calculated capicity_value is the capacity limit This limit is the below the set point the energy is allowed to be at the end of the weld pulse DC25 UB25 WELD STAT ADVANCED SERIAL DATACOM COMMUNICATIONS INTERFACE 990 661 9 APPENDIX PROGRAMMING CODES Command RELAY READ SET lt crlf gt parameter name value lt crl gt lt gt Control State Any except while welding Description Provides control over the Control schedule parameters for relay settings When used with the READ keyword the relay settings of the currently loaded schedule are returned see RELAY under Control 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 CONDITIONI ACTIVE2 CONDITION2 CONDITION3 ACTIVEA CONDITIONA HIGH LOW condition_value HIGH LOW condition_value HIGH LOW condition_value HIGH LOW condition_value condition_value is Command SYSTEM READ SET lt crlf gt p
74. se the AV up down buttons to select any Control to monitor without having to return to the Communications Setting window OPERATING INSTRUCTIONS Communication Settings Communication Port 1 Baud Rae 3600 ss Welders Role Cancel Senes 25 TYPE 25 Series 25 D Refresh Rate 3 Seconds BUTTONS INACTIVE SLAVE 1 H Slave Average Peak Series 25 Station Number Pulse C Pulse2 Communication Settings Communication Port COMI ox Baud Rae 900 so Cancel 25 1 0 f Refresh Rate Seconds Display All Units MASTER Not Displayed T Pukel Puke2 Average C Peak BUTTONS ACTIVE 25 Station Number DC25 UB25 WELD STAT ADVANCED SERIAL DATACOM COMMUNICATIONS INTERFACE 990 661 15 OPERATING INSTRUCTIONS MASTER Mode Monitor Controls To monitor all Controls click on the Display Units feature to puta 4 in the box Now incoming data will be received from all Controls NOTE In this mode the only window that displays which Control is reporting is the Weld History window If you see an anomaly and want to check a specific Control go the Communications Settings window click to remove the the Display All Units box and select the Control you want to monitor Now the top left corner of the Weld History Weld Graph or Weld Histogra
75. the Control s must be set in the RUN mode From the Menu Bar click on Setup Communication Settings 2 Fromthe Setup pull down menu click on Communication 3 Highlight the number in the Series 25 1 0 window 4 Enter I D number of the Control you want to program then click the OK button 5 Click on Schedule icon to get the Schedule window After 1 second delay the values will display from the schedule currently being used by the Control Communication Port Baud Rate 3600 sn Welders Role RE Series 25 TYPE Series 25 D 1 Refresh Rate 9 Seconds Cancel Display All Units DC25 UB25 WELD STAT ADVANCED SERIAL DATACOM COMMUNICATIONS INTERFACE 28 990 661 OPERATING INSTRUCTIONS Schedule SCHEDULE 0 series 25 Station 1 energy 000 A energy 0 500 150 1 00 1 00 1 00 1 00 1 00 1 00 1 00 100 ms _ TIME squeeze up weld down cool up weld down hold Upper 0 000 EN Upper 0 000 KA Lower 0 000 Apion none Lower 0 000 Action _ MONITOR 4 hone ENERGY SELECTION MONITOR ACTION PULL DOWN MENU PULL DOWN MENUS Datacom Schedule Window 6 Verify that the I D Number of the Control you want to program is displayed in the Unit ID window If not repeat Steps 1 through 4 until it does NOTE The waveform graph is for ref
76. umbers revision letters lt crl gt lt lf gt NOTE UB25 software lower than version 1 22 will not display release number or revision letter Any Returns UB25 1 22E for UB25 and DC25 1 22E for DC25 COUNT number lt crif gt lt lf gt Any Returns the number of weld data available in Control The total number of weld data that the Control holds in the buffer is 1 500 SCHEDULE schedule number lt crlf gt lt lf gt Any Returns the current schedule number to the host schedule number may be any number from 0 to 99 DC25 UB25 WELD STAT ADVANCED SERIAL DATACOM COMMUNICATIONS INTERFACE 990 661 C 13 APPENDIX PROGRAMMING CODES Command REPORT number of reports lt crlf gt report crlf report lt crlf gt report crlt2 lf Control State Any Returns the requested number of weld reports First field 1s the number of reports to be 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 crlt lf Description 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 15 available the weld data buffer the Control sends only the weld reports the weld buffer and the number of reports 15 the number of weld reports available in the weld data buffer After the report 1 sent to the host comput
77. want to change type click on the Menu Button next to the Files of type window then click on a new file type When you have made your choices click on the Open button The screen will prompt you Create the file Click on Yes DC25 UB25 WELD STAT ADVANCED SERIAL DATACOM COMMUNICATIONS INTERFACE 990 661 23 OPERATING INSTRUCTIONS File Open An Existing Data File This allows you to open a saved file and view the data using the graph functions CAUTION If you open a file while the Datacom software is connected to Controls and is receiving data the new data will be added to the file you just opened From the Menu Bar click on File 2 From the File pull down menu click on Open The default file type is DAT If you want another type of file click on the Look in Gy WeldStat List files of type menu button to display 5 MARTY the pull down menu 5 Seties25 dat 4 Click on the type of file you want 5 open a file e Double click a displayed name OR Type a name in the File name box then o click on Open Files of type input dan Cancel e To look for files in other folders click on the icon in the Folders column then click on the folder you want e Select a file and click on the Open button Import A File This allows you to take a previously saved weld history file and import it add it to the file that is currently open

DC25 UB25 Datacom Technical Manual

Contents

Download Pdf Manuals

Related Search

Related Contents