• Description
  • Features
  • Benefits
  • Networking

The light weight, easy to install design allows the user to install the Intelli-DART™ at the wire drive motor inlet using industry standard quick disconnect conduit fittings or to a fixed surface with the optional mounting brackets.

The LED indicators provide the operator or maintenance personnel with a quick visual indication of sensor activity.

The unit is powered by a user supplied external 24 VDC power source via the sensor interface cable. This cable also provides the Analog and TTL Signal Outputs to an external system (data acquisition or PLC).

Total isolation of all sensors from the welding arc. Arc current is measured using a laser trimmed hall-effect transducer. Arc voltage sensor provides a 1 KV isolation using capacitive isolation technology.

The wire speed transducer is a precision optical encoder housed in a Delron body, for isolation and mechanical rigidity, with a heavy duty sealed bearing cartridge for increased durability. An integrated silicon differential pressure sensor provides torch shielding gas back pressure measurements.

Industry standard quick disconnect fittings for wire speed transducer and mounting
Hall effect current transducer with 25 mm opening for welding cable
A screw terminal block connections for positive and negative voltage sense leads
Gas pressure sensor to measure welding torch back pressure
Optional mounting brackets


Mount directly to wire drive motor inlet
Provides electrical isolation and reduces cable heating by eliminating additional mechanical connections
Provides easy installation of voltage sense leads and allows custom wire lengths
Provides indication of torch degradation due to leaks or clogged gas orifice or nozzle
Allows remote mounting of sensor using standard quick disconnect conduit assemblies for wire speed sensor



NetHub™ is an isolated RS-485 communications driver and power supply to connect up to six sensor units to the MODBUS™ RTU network.

A total of 247 sensors may be connected to the network using multiple NetHub™ units. Any Intelli-DART™, WireTrak™ or Micro ADM™ unit can be connected to the same NetHub™ unit.

The Intelli-DART™, WireTrak™ or Micro ADM™ units can be communicated with their appropriate software through the MODBUS™ RTU network.



Product Specifications




  • Current Sensor
  • Voltage Sensor
  • Wire Speed Sensor
  • Gas Pressure Sensor
  • Mechanical
  • Electrical
Current Range 0 - 600 amps (DC)
Relative Precision of Range ±1%
Max Linearity Error ±0.9 % of reading
Max Zero Offset Error ±3.0 mv
Sensitivity (V out / V in) 10mv / Amp
Band Width at ±1db 2.5 Khz
Voltage Range 0 - 100 volts (DC)
Relative Precision of Range ±1%
Max Linearity Error ±0.5 % of reading
Max Zero Offset Error ±1.0 mv
Sensitivity (V out / V in) ±1.0 mv
Band Width at ±1db 2.5 Khz
Wire Diameter (min / max) 0.30 – 0.62 (0.8 mm / 1.6 mm)
Speed Range 10 – 1000 ipm (4 – 420 mm / s)
Relative Precision of Range ±3%
Encoder Pulse Rate 102 pulse / inch (3.94 pulses / mm)
Output Frequency Range 17.0 – 1700.0 Hz
Pressure Range 2.5–14.5 Psi (15 – 100 Kpa)
Relative Precision of Range ±3%
Max Linearity Error ±1.8 % of reading
Max Zero Offset Error 1.00 Psi (6.9 Kpa )
Sensitivity (V out / V in) 0.07 Psi ( 0.44 Kpa)
Band Width at ±1db 250 Hz
Dimensions 5.24”L X 5.38”W X 3.41”H(133mm X 137mm X 87mm)
Weight 2.7 lbs (1.2 kg)
Temperature -10°F–140°F (-12°C - 60°C)
Sensor Power 24 vdc @ 0.1 amp ripple 200 mv
Analog Output 0 - 10 vdc @ 10ma current limited
Encoder Output TTL compatible levelssink / source 25 ma.
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