CWT GFM A0A0161, Operation & Installation Manual

Page 1: ...nitor Operation Installation Manual Manual Part Number A8M5028 Revised 01 23 2017 Computer Weld Technology Inc 10702 Old Bammel N Houston Rd Houston TX 77086 Phone 713 462 2118 Fax 713 462 2503 Email cwt cweldtech com ...

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Page 3: ...ervers from arc radiation When handling gas cylinders consult the instructions issued by the manufacturers and the suppliers of the pressurized gas Work pieces that have been degreased using chlorinated solvents must be sprayed down with clean water before welding starts to avoid the risk of phosgene forming For the same reason no degreasing baths containing chlorine must be placed close to the we...

Page 4: ...ly off from the welding or cutting arc The flying sparks hot work piece and hot equipment can cause fires and burns Accidental contact of electrode to metal objects can cause sparks explosion overheating or fire Check and be sure the area is safe before doing any welding or cutting Remove all flammables within 35 ft 10 7 m of the welding or cutting arc If this is not possible tightly cover them wi...

Page 5: ...AW DC constant voltage wire welder 2 a DC manual stick welder or 3 an AC welder with reduced open circuit voltage In most situations use of a DC constant voltage wire welder is recommended And do not work alone Disconnect input power or stop engine before installing or servicing equipment Lockout tagout input power according to OSHA 29 CFR 1910 147 see Safety Standards Properly install ground and ...

Page 6: ... welding cutting or other electrical circuits Never drape a welding electrode or cutting torch over a gas cylinder Never allow a welding electrode or cutting torch to touch any cylinder Never weld on a pressurized cylinder explosion will result Use only the correct compressed gas cylinders regulators hoses and fittings designed for the specific application maintain them and associated parts in goo...

Page 7: ...ce doors and panels tightly shut keep spark gaps at correct setting and use grounding and shielding to minimize the possibility of interference California Proposition 65 Warnings Welding or cutting equipment produces fumes or gases that contain chemicals known to the State of California to cause birth defects and in some cases cancer California Health Safety Code Section 25249 5 et seq This produc...

Page 8: ...andards ANSI Standard Z49 1 SAFETY IN WELDING AND CUTTING American Welding Society 2501 N W 7 th St Miami FL 33125 Free download at http www aws org technical AWS_Z49 pdf ANSI Standard Z41 1 STANDARD FOR MEN S SAFETY TOE FOOTWEAR obtainable from the American National Standards Institute 1430 Broadway New York NY 10018 ANSI Standard Z49 2 FIRE PREVENTION IN THE USE OF CUTTING AND WELDING PROCESSES ...

Page 9: ...P 9 5 0 GAS FLOW SURGE PEAK MEASUREMENT 10 5 1 DESCRIPTION 10 5 2 SETUP 10 6 0 GAS FLOW USAGE LOG 11 6 1 DESCRIPTION 11 6 2 SETUP 11 6 3 RESET LOG MODE CLOCK 11 6 4 RESET LOG MODE VOLUME 12 7 0 GFM CONNECTOR PIN ASSIGNMENT 13 7 1 AUX CONNECTOR 13 8 0 POWER OPTIONS AND BATTERY SPECIFICATION CHANGING 14 8 1 POWER OPTIONS 14 8 2 BATTERY SPECIFICATIONS 16 8 3 CHANGING THE BATTERY 16 9 0 MODEL SPECIFIC...

Page 10: ...11 1 GFM AUX CABLE P N A3W0352 26 11 2 ADM III GFM SENSOR CABLE P N A3W0356 27 11 3 ADM IV GFM SENSOR CABLE P N A3W0350 28 11 4 WDL II GFM SENSOR CABLE P N A3W0351 29 12 0 MODBUS SCPECIFICATIONS 30 12 1 GFM MODBUS REGISTER DATA 30 12 2 MODBUS COILS CR 1 16 30 12 3 MODBUS REGISTER REG 1 10 31 12 4 MODBUS SERIAL PORT CONNECTIONS 31 ...

Page 11: ...the GFM can provide sure flow gas testing by setting upper and lower control limits for the user defined gas flow rates An internal fault relay can be used to warn or interrupt the welding process if an out of limits condition is detected 1 3 Features Some of the features contained in the unit are the capability to limit test provide an accumulated gas usage and peak flow rates as well as displayi...

Page 12: ...1 vdc 1 CFH 0 01 V 1 LPM Power Requirement 12 28 vdc 100 ma Operating Temperature 20 to 140 F 7 to 60 C Battery Charger 120 vac 60 hz 300 ma 220 VAC 50 hz 300 ma Battery Life Approximately 24 hours with full charge User configurable English Metric units of measurement Note Specifications subject to change without notification 1 6 Models The following models are covered in this document Part No Des...

Page 13: ...Section 3 Operations 2 2 Gas Line Hookup The GFM may also be installed into the gas line and used to permanently monitor the gas flow rate This model is supplied with barbed 3 8 ID hose fittings The sensor will accept any 3 8 NPT pipefitting The user may hard plumb the sensor if desired DO NOT USE PIPE DOPE OR TEFLON TAPE ON THE PIPE FITTINGS The sensor should be located between the welding gas so...

Page 14: ...UT 0 00 2 55 vdc 2 4 Gas Flow Limits The GFM can be used to test for High Low gas flow limits An internal fault relay will be set CLOSED when the gas flow is within the programmed limits The fault relay can be interfaced to an external weld fixture controller 2 5 Gas Flow Volume The GFM can also be used to monitor accumulated gas flow and to provide an indication when the volume in a gas cylinder ...

Page 15: ...tivate the gas solenoid for the welding torch The GFM will now display the gas flow rate in CFH Cubic Feet per Hour or LPM Liters per Minute 3 2 Program Limits To program the High Low limits and test parameters press both and switch simultaneously to enter the Select Para INC DEC mode The first programmable parameter will appear on the display To increment through the program menus press the butto...

Page 16: ... the High Low limit testing Setting this option to No will disable the alarm relay output Setting this option to Yes will enable the alarm relay output Status Yes or No Enable Peak Setting this parameter to yes will enable the Peak Flow display When enabled an additional Peak sec display will be active Where is the last peak flow rate measured and is the Total time at peak flow The time at peak is...

Page 17: ...Gas conversion factor Status Yes or No Note Disabling all Gas types set to NO will enable the Air conversion factor CO2 Gas Allows the user to enable or disable CO2 Gas conversion factor Setting this option to No will disable the CO2 Gas conversion factor Setting this option to Yes will enable the CO2 Gas conversion factor Status Yes or No Note Disabling All Gas types set to NO will enable the Air...

Page 18: ...rgon CO2 Gas Allows the user to enable or disable 90 10 Argon CO2 Gas conversion factor Setting this option to No will disable the 90 10 Argon CO2 Gas conversion factor Setting this option to Yes will enable the 90 10 Argon CO2 Gas conversion factor Status Yes or No Note Disabling All Gas types set to NO will enable the Air conversion factor ...

Page 19: ...flow is initiated The lower limit is always being checked during the gas flow period A high gas flow fault will only occur after this time period has expired 4 2 Setup To program the High Low limits and test parameters press both and switch simultaneously to enter the Select Para INC DEC mode The first programmable parameter will appear on the display To increment through the program menus press t...

Page 20: ... max limit When the flow starts again the values are cleared and new values are displayed 5 2 Setup To enable the Peak flow and set the High limits and test parameters press both and switch simultaneously to enter the Select Para INC DEC mode The first programmable parameter will appear on the display To increment through the program menus press the button To decrement through the menus press the ...

Page 21: ... DEC press both and switch simultaneously to exit and return to the normal display mode The Tot Volume and the Total Time HR MN SS will be displayed Where is the total accumulated volume and HR MN SS is the total time of gas flow since the last user reset Log mode option will be enabled NOTE THE GFM PROVIDES A REASONABLE ESTIMATE OF SHIELDING GAS USAGE HOWEVER THIS NUMBER CANNOT BE CONSIDERED TO B...

Page 22: ...e program menus press the button To decrement through the menus press the button Until the Reset Volume option is displayed To edit a menu option press both and switch simultaneously to enter the Edit Para INC DEC mode To toggle the option to Yes presses the button To end the Edit Para INC DEC press both and switch simultaneously to exit and return to the normal display mode The Tot Volume 0 0 wil...

Page 23: ...ort 2 BRN User supplied Power Input VIN 12 28 VDC 100 ma 3 GRN CR A Will be active when gas flow is within programmed limits 4 YEL CR B Will be active when gas flow is within programmed limits 5 GRY User supply power common VCOM 6 PNK Modbus RS485 and Vout analog common 7 BLU Modbus RS 485 D serial port 8 RED Gas Flow Analog output VOUT 0 00 2 55 vdc ...

Page 24: ...installed for Manual function This will enable the power switch whenever the battery is being used as the power source To enable the Auto Power Up function a jumper must be removed on Header JP1 This disables the power switch for whenever the external power is applied through the Power Connector or Aux Connector keeping the GFM always turned on Header JP1 Inside View of GFM Enclosure Power Board R...

Page 25: ... as the power source When the jumper is on Location B this sets the Auto function This disables the power switch for whenever the external power is applied through the Power Connector or Aux Connector keeping the GFM always turned on Header JP1 Inside View of GFM Enclosure Power Board Revision A GFM CPU Board GFM Power Board Battery Connector J3 Sensor Connector J7 Programming Port ...

Page 26: ...CHRG LED When the LED is on the GFM is charging the Battery or supplying power to the GFM When the charge is complete the LED is off The LED will be on until the charge current drops below a C 10 rate or when the float charge timer has expired 22 5 minutes 8 3 Changing the Battery 1 To open the unit remove the six screws on the back cover of the unit Carefully lift the cover off 2 How to remove th...

Page 27: ...ry on top of the two white cable tie mounts and secure in place with the two cable ties Trim back the two cable ties Connect the two circuit plug of the battery to J3 Battery Header on the Power Board 4 Reinstall the cover and the six screws CWT Replacement Part P N A3A0278 4 1V rechargeable battery Battery Cable Ties Cable Tie Mounts ...

Page 28: ...1 120 240 VAC Portable GFM System P N A0A0161 ITEM QTY PART NO DESCRIPTION 1 1 A3A0277 GFM Enclosure Assembly 2 1 A3A0278 Rechargeable Battery 3 1 A2M0170 Hose Cone Assembly 4 1 X3T5089 12VDC Universal Switching Power Supply 2 4 3 1 ...

Page 29: ... QTY PART NO DESCRIPTION 1 1 A3A0277 GFM Enclosure Assembly 2 1 A3E0104 GFM Mounting Bar 3 1 X3T5089 12VDC Universal Switching Power Supply 4 2 X6F5093 Adaptor Fitting 5 2 X6F5094 Barb Fitting 6 2 X6F5095 B Size Nut 7 2 10 32 x 1 2 Lg Socket Flat Hd Screw ...

Page 30: ...TEM QTY PART NO DESCRIPTION 1 1 A3A0277 GFM Enclosure Assembly 2 1 A3E0104 GFM Mounting Bar 3 1 A3W0356 ADM3 GFM Sensor Cable 4 2 X6F5093 Adaptor Fitting 5 2 X6F5094 Barb Fitting 6 2 X6F5095 B Size Nut 7 2 10 32 x 1 2 Lg Socket Flat Hd Screw ...

Page 31: ...EM QTY PART NO DESCRIPTION 1 1 A3A0277 GFM Enclosure Assembly 2 1 A3E0104 GFM Mounting Bar 3 1 A3W0350 ADM4 GFM Sensor Cable 4 2 X6F5093 Adaptor Fitting 5 2 X6F5094 Barb Fitting 6 2 X6F5095 B Size Nut 7 2 10 32 x 1 2 Lg Socket Flat Hd Screw ...

Page 32: ...EM QTY PART NO DESCRIPTION 1 1 A3A0277 GFM Enclosure Assembly 2 1 A3E0104 GFM Mounting Bar 3 1 A3W0351 WDL2 GFM Sensor Cable 4 2 X6F5093 Adaptor Fitting 5 2 X6F5094 Barb Fitting 6 2 X6F5095 B Size Nut 7 2 10 32 x 1 2 Lg Socket Flat Hd Screw ...

Page 33: ...osure Cover 3 1 A3E0192 GFM Enclosure Overlay 4 1 A3E0179 GFM Display Lens 5 1 A5A0165 GFM CPU PCB Assembly 6 1 A5A0166 GFM Power PCB Assembly 7 1 A5A0167 GFM Display PCB Assembly 8 1 A3W0366 GFM Sensor Harness 9 1 X3Q5032 Airflow Sensor 10 7 M3 0 5 X 6MM Phillips Pan Head Screw 11 6 6 32 x Pan Head Screw w Lock Washer 12 2 10 32 Small Pattern Nut ...

Page 34: ...24 10 2 GFM Mounting Dimensions Installation with Threaded Inserts or Free Hanging ...

Page 35: ...25 Installation with Mounting Bar ...

Page 36: ... Cable 2 1 Cable Label Sleeve 3 9 Wire Label Sleeve 4 1 Heat Shrink Tubing WIRE COLOR FROM DESCRIPTION White Pin 1 Net Brown Pin 2 Power In 12 28 VDC Green Pin 3 Relay CR A Yellow Pin 4 Relay CR B Grey Pin 5 Power Common Pink Pin 6 Sensor Vout common Blue Pin 7 Net Red Pin 8 Sensor Vout 0 2 55 VDC Shield Conn Ring Earth ...

Page 37: ...TION White Item 1 Pin 1 Not Connected Net Brown Item 1 Pin 2 Item 2 Pin 1 Power In 12 28 VDC Green Item 1 Pin 3 Not Connected Relay CR A Yellow Item 1 Pin 4 Not Connected Relay CR B Grey Item 1 Pin 5 Item 2 Pin 4 Power Common Pink Item 1 Pin 6 Item 2 Pin 3 Sensor Vout common Blue Item 1 Pin 7 Not Connected Net Red Item 1 Pin 8 Item 2 Pin 2 Sensor Vout 0 2 55 VDC Shield Conn Ring Item 2 Pin 5 Earth...

Page 38: ...E COLOR FROM TO DESCRIPTION White Item 1 Pin 1 Not Connected Net Brown Item 1 Pin 2 Item 2 Pin A Power In 12 28 VDC Green Item 1 Pin 3 Not Connected Relay CR A Yellow Item 1 Pin 4 Not Connected Relay CR B Grey Item 1 Pin 5 Item 2 Pin E Power Common Pink Item 1 Pin 6 Item 2 Pin C Sensor Vout common Blue Item 1 Pin 7 Not Connected Net Red Item 1 Pin 8 Item 2 Pin B Sensor Vout 0 2 55 VDC Shield Conn ...

Page 39: ... FROM TO DESCRIPTION White Item 1 Pin 1 Not Connected Net Brown Item 1 Pin 2 Item 2 Pin 1 Power In 12 28 VDC Green Item 1 Pin 3 Not Connected Relay CR A Yellow Item 1 Pin 4 Not Connected Relay CR B Grey Item 1 Pin 5 Item 2 Pin 5 Power Common Pink Item 1 Pin 6 Item 2 Pin 3 Sensor Vout common Blue Item 1 Pin 7 Not Connected Net Red Item 1 Pin 8 Item 2 Pin 2 Sensor Vout 0 2 55 VDC Shield Conn Ring It...

Page 40: ...CODE DESCRIPTION ADDRESS RANGE 01 Read Coil Status 1 49 03 Read Holding Registers 1 124 05 Force Single Coil 1 49 06 Preset Single Register 1 124 15 Force Multiple Coils 1 49 16 Preset Multiple Registers 1 124 17 Report Slave ID 5 bytes All Modbus Register values are word sized unsigned integer unless otherwise indicate 12 2 MODBUS COILS CR 1 16 INPMSK Simulated Relay Inputs CR 1 8 Bit 0 Enable Lo...

Page 41: ... to the GFM Auxiliary cable A3W0352 Connect the RS 485 driver output A TxD RxD to the BLUE Pin 7 wire Connect the RS 485 driver output B TxD RxD to the WHITE Pin 1 wire Connect the RS 485 driver output COM to the PINK Pin 6 wire The RS 485 driver COM should also be connected to the user supplied GFM Power Input common The following is the pin out for the GFM AUX Cable P N A3W0352 Pin No Wire Color...