Controller Manual
Contents
1. Version 1 121 Controller Manual Ge IPM CM S LBS KG WIRE CENTRAL VERSION 1 0 2007 2008 ELCo Enterprises Inc Version 1 01 Rev A ELCo Enterprises Inc Wizard View 1 121 1 Introduction The Wizard View 1 0 controller 1s the base unit for an entire range of ELCo equipment dedicated to analyzing weld quality and wire usage The function of this controller is to measure and analyze the wire consumption in the welding process The controller can operate stand alone or it can be connected to a local PC to retrieve data The controller unit measures the welding wire speed and quantity of wire consumed in welding process through an easy to install Wire Speed Sensor Additionally the controller will send an alarm when the quantity of wire used from a drum exceeds a preset value For computing these values the controller has an internal table with 15 preset types of wire This table can be updated from a local PC with the Wizard View software All data is displayed locally on two lines with four digits on a bright red LED display On the first line the controller displays the wire speed in IPM inches per minute On the second line the controller shows the total quantity of consumed wire in lbs The controller is easy to install and works with all types of welding applications It requires a single power supply from automation equipment 24V or from a power adapter 110V 24V or 220V 24VDC 350 mA Th2. View 1 121 B Steel D 5 32 C Aluminum 0 030 D Aluminum 0 035 E Aluminum 0 045 F Aluminum 3 64 If controller does not function properly please call ELCo technical support at 517 782 8040 4 PC Operation For configuration or remote control of controller you will need the SITECH WVC CONNECTOR cable This cable is connected with the controller with a nine pin connector see Figure 17 and the other end is plugged into a PC USB port Refer to the software manual for further instructions Figure 17 Figure 18 5 Error Messages The only error intercepted by the controller s software 1s Quantity Counter Overflows This error appears when the quantity counter is greater than 9999 0 lbs In this case the quantity display line will Ek ee e present Figure 19 Figure 19 This error can be solved by restoring default parameters For this see Restore to Defaults Operation on page 10 If restoring to default parameters does not solve this problem please contact ELCo technical support page 11 ELCo Enterprises Inc 6 Troubleshooting Problem The controller does not start The power LED and display do not light The controller does not start The power LED is on but the display is not The controller does not start The power LED is on some display segments are lighting but the display messages are not understandable The controller starts The
3. relay an additional output Drum Warning Signal For accessing this signal you must connect two AWG 24 wires with the first MOLEX 2 poles adapter see Figure 1 This output is a passive relay output fully isolated by other connections The position of connector 1s presented in Figure 7 Figure 7 Pin specifications are presented in the table below Adapter PIN NO Drum Warning Signal Connector K102 1 K102 2 Let s Start If all connections are done you can switch on the power to the controller If all is OK the display must show the hello message and the orange power led will light up Figure 8 Possible Errors If the display is dark and the orange led does not light you must check the power cables If the display lights but the orange led does not light please check the Wire Speed Sensor connections a short circuit may have occurred Reset Counter for the First Time It 1s possible that the controller may have a value stored in its memory Before normal operation get a pin and press the COUNTER RESET button for first time From this point the controller is ready to begin counting the sensor s pulses This pin can be connected in common with 2 from Drum Warning Signal Connector This pin can be connected in common with 2 from Wire Moving Signal Connector page 5 ELCo Enterprises Inc Wizard View 1 121 3 Operation Normal Operation In a normal operation cycle user intervention is n
4. age 10 If problem is still not solved call ELCo technical support Restore controller to default parameters to do this please see Restore to Defaults Operation on page 10 If problem is still not solved call ELCo technical support Restore controller to default parameters to do this please see Restore to Defaults Operation on page 10 If problem is still not solved call ELCo technical support Restore controller to default parameters to do this please see Restore to Defaults Operation on page 10 If problem is still not solved call ELCo technical support 1 Before setting default parameters you can connect the controller to a PC and save the current settings after solving the problem you can restore them l Before setting default parameters you can connect the controller to a PC and save the current settings after solving the problem you can restore them page 12 ELCo Enterprises Inc Wizard View 1 Controller User Manual Publication Ver 1 01 Rev A 2008 Software Integration Technology Ltd ELCo Enterprises Inc August 28 2008 Wizard View 1 121 page 13
5. e connection with the Wire Speed Sensor is easily made through a pluggable MOLEX connector The controller unit also powers the Wire Speed Sensor The controller is able to produce two output relay signals One relay is designated to indicate the wire status the other relay will activate when the welding wire is moving An alert will indicate when the computed weight of wire used exceeds the preset limit For connecting with a PC the controller has a low voltage communication port which connects the controller and PC over a special communication cable For US Version IPM and for Metric Version the controller will display in cm s cm min or m min Ibs for US Version for the Metric Version the controller will display kg page 2 ELCo Enterprises Inc Wizard View 1 121 2 Installation Powering the Controller First bring the power from your power supply or power adapter near the controller location using two wires If you have 24 V voltages in your automation equipment you may bring this voltage directly to the controller otherwise you must use a power adapter from 110 V AC voltages to 12 V DC filtered d Figure 1 This voltage will be coupled using two AWG 24 wires and connect them to pluggable adapter shown in Figure 1 The voltage polarity is not important With the power off plug the MOLEX connector into the controller power board connector shown in Figure 2 Figure 2 Connect the Wire Speed Senso
6. igure 11 using the firstStep Wizard View application This LED can indicate one of the following parameters Figure 11 Controller Run in this mode the LED is blinking with 1 pulse 1 6 seconds Wire Movement Signal in this mode the LED lights when the controller detects wire movement Drum Warning Signal in this mode the LED lights when the controller detects the weight of the wire used is greater than the drum warning preset value This is the default LED indication Reset Controller Use this function only when a malfunction appears in normal operation mode To do this please press the RESET CPU button on the front of the controller Note If you disconnect the power supply the controller will not fully reset because the data is stored on the flash memory After a normal reset you can view the following messages on the controller display Hello Message The controller displays the name WV and version 1 121 On the controller you can read vv v in place of WV and the version in format 1 121 Figure 12 Copyright Information This information presents the developer and producer d mm ELCo Enterprises Inc LIEU Li JS D Figure 13 page 7 ELCo Enterprises Inc Wizard View 1 121 Measurement System First line is a country area message Cout and on the second line US is displayed for US measuring system or it will display EU 1 EU 2 o
7. n the controller Before plugging in this connector please ensure the controller is Figure 4 not powered The sensor should now be connected to the controller as shown in Figure 5 Figure 5 Use Enable Inhibit Counting Signal The controller has an optional counting function that can be enabled or disabled using an Inhibit Signal The Inhibit Signal is active in low and is positioned on the Sensor Connector see table below Adapter PIN NO Wire Speed Sensor Connector 1 5V DC Enable Signal Normal Speed Signal Connection The Wizard View version 1 121 controller features a normal speed wire moving signal The signal is obtained from pulse analysis and is compared with a preset level called normal speed level To access this information you must connect two AWG 24 wires with the third MOLEX 2 pole adapter see Figure 1 This output is a not an active relay output fully isolated by other connections To connect this signal to a PLC or other automation equipment you can use the MOLEX two poles pluggable adapter shown in Figure 1 in position of the Wire Signaling gt output see Figure 6 The output is a passive output isolated Figure6 by the controller s electronic components page 4 ELCo Enterprises Inc Wizard View 1 121 Pin specifications are presented in the table below Adapter PIN NO Moving Wire Signal Connector K101 1 K101 2 Drum Warning Signal Connection The controller is able to
8. ot required The user must only watch the wire speed and the weight of wire consumed see Figure 9 Figure 10 Figure 9 If you change the wire type we recommend resetting the counter see paragraph 3 3 and select a new type of wire from the wire selector see Figure 10 By default the wire types stored in the controller database are listed in the table below En Type a Ibs inch Steel 5 0 00011758 00011758 ER Al Stel 0 035 0000272279 o 6 Steel 0052 f 0000601013 SI Stel 564 0001356617 o 9 Stel 292 0001953529 B Steel 532 000542647 D Aluminum 0 035 9 42878E 05 If you want to change this wire type database we recommend using the firstStep Wizard View Software see firstStep Wizard View Operation Manual Is important to note that the 0 Figure 10 selection is used only for testing the equipment When using 0 on wire type selector on the first line the controller will display the input frequency in Hz and on the second line it will display the internal counter divider page 6 ELCo Enterprises Inc Wizard View 1 121 Possible Errors If the controller doest not count anything please reset the controller After you reset the controller if it is still not counting check electrical connections with the wire sensor and contact technical support Also on the controller display is a green LED indicator The indications of this LED can be programmed from a PC see F
9. power LED does not light up The controller starts The wire speed indicated is zero even when the wire is moving The controller starts The wire speed indicated is not zero When the wire is moving but the indication is not correct The controller starts The wire speed indicated is correct but the mass of wire does not change The controller starts The wire speed indicated is correct and the mass of wire is changed but the quantity displayed is not correct Wizard View 1 121 Solution Check the power connections power cable amp power source Try to reset controller s CPU If problem is not solved disconnect power supply wait a few minutes then reconnect power cable If problem is still not solved call ELCo technical support Try to reset controller s CPU If problem is not solved disconnect power supply wait a few minutes then reconnect power cable If problem is still not solved call ELCo technical support Disconnect the power supply cable then disconnect the wire feed sensor cable Then reconnect the power supply cable if system operation restores please check the connections on the wire feed speed sensor If problem is still not solved call ELCo technical support Check the connection with wire feed speed sensor Check the wire feed speed sensor If the problem is not solved restore controller to default parameters to do this please see Restore to Defaults Operation on p
10. r EU 3 for metric measuring systems The measuring system can be changed using the firstStep Wizard View application Figure 14 Measuring units selected in accordance with selected measuring system area are presented in the table below system area After initializing the controller enters normal operation mode NOTE After pressing the RESET CPU button the counter value will be loaded with the value saved at the last power failure shutdown Controller Reset Counter Reset VERSION 1 0 On the older versions until version 1 121 of Wizard View Controller is possible EU identification area to be displayed in place of EU 1 page ELCo Enterprises Inc Wizard View 1 121 Reset Counter Use this function when you change the wire type or you change the wire drum By using this function the counter is reset and the counter value stored in internal memory will also be reset For resetting the counter please press with a pin the RESET COUNTER button After pressing this button a reset message will appear on the display on both lines will appear message 00 Figure 15 Figure 15 When you release the button the counter will then enter normal operation mode page 9 ELCo Enterprises Inc Wizard View 1 121 Restore to Defaults Operation The controller stores all parameters in its flash memory It is possible that controller could have an abnormal run This abnormal run can be cau
11. r with Controller For this you will need the second MOLEX pluggable adapter from the Controller kit Figure 3 Also you must get the Wire Speed Sensor and bring all vvires to the controller Connect the sensor wires using a Screw Driver in the order described in table below Figure 3 Adapter PIN NO Wire Speed Sensor Wire O O 5V DC Power Supply B Signal A Signal gt 110 V for US version for European countries use 220 V We recommend doing all connections with power voltage disconnected If the Wire Speed Sensor has an INDEX signal this signal will not connect to controller On other versions of controllers this signal should be connected on PIN 2 Pin 1 is marked on Figure 3 page 3 ELCo Enterprises Inc Electrical Schematic CA 3131 15 Sa GND BLACK A SIG WHITE B SIG BROWN ON DC RED ve PP Ee SENSOR E r Wizard View 1 121 Re1 CA 06B 20B 010F PIG TAIL S RED 2 c4V DCILTERED RED WHITE 1 OV DC FILTERED RED BLUE 6 NORMAL SPEED SIG RED YELLOW 4 NORMAL SPEED SIG RED BLACK 5 DRUM WARNING SIG RED YELLOW JUMPER RED 24VDC REDAVHT ME cl RED BLU NORMAL SPEED SIG WELD CELL Ch RED YEL NORMAL SPEED SIG ENCLOSURE RED BLK DRUM WARNING SIG CONNECTIONS Rel AEG 00VY 060F B MALE BOX CONNECTOR 6 PIN RECEPTICAL ELCo Enterprises Inc Wizard View 1 121 After all connections are made you can plug the adapter in the corresponding connector o
12. sed by the loss of normal parameter values from the flash memory Since version 1 121 the controller is now able to restore parameters to factory defaults values To restore factory defaults you must do the following power off the controller by disconnecting the power cable disconnect the communication cable from the controller connector see Figure 17 wait a few minutes for discharging of all the capacitors on the board take a pin and press and hold it on the RESET COUNTER button L ci with RESET COUNTER button pressed power e the controller keep the RESET COUNTER button pressed until the message Load Default Ld Def is ci L pa displayed Figure 16 After this message is e displayed you may release the RESET Figure 16 COUNTER button After this operation is performed the controller will return to normal operation mode with factory default settings Factory default parameters are default name unnamed default country US default wire feed speed sensor ELCo HHSS Wire Speed Sensor default drum warning level 1000 default lower speed limit 5 0 default status LED DRUM WARNING default wire constants 0 TEST 1 0 1 Steel P 0 023 2 Steel P 0 030 3 Steel P 0 035 4 Steel D 0 040 5 Steel P 0 045 6 Steel 0 052 7 Steel P 0 062 8 Steel 6 5 64 9 Steel D 3 32 A Steel D 1 18 page 10 ELCo Enterprises Inc Wizard
Download Pdf Manuals
Related Search