OPERATION MANUAL for Cyclomatic Series Seam Tracker Systems

OPERATION MANUAL
for Cyclomatic Series
Seam Tracker Systems
Revised September 2006
IMPORTANT
Read this manual carefully before installing,
commissioning or operating this product.
Jetline Engineering, 15 Goodyear Street, Irvine CA 92618
Telephone: 949-951-1515 · Fax: 949-951-9237
Web site: www.jetline.com · www.cyclomatic.com
E-mail: sales@jetline.com
LIMITED WARRANTY
Jetline Engineering, of Irvine, California, U.S.A., warrants all new equipment to be free from defects in
material and workmanship for the period of one (1) year, provided that the equipment is installed and operated according to instructions.
Jetline Engineering’s obligation under this warranty is expressly limited to replacing or repairing and defective part or correcting any manufacturing defect without charge during the warranty period, if Jetline’s inspection confirms the existence of such defects. Jetline’s option of repair or replacement will be F.O.B.
Factory at Irvine, California, and therefore no compensation for transportation costs of any kind will be allowed.
The warranty period begins on the date of sale to the original-purchase user of the equipment.
Jetline Engineering will not be liable for any loss or consequential damage or expense accruing directly
or indirectly from the use of equipment covered by this warranty.
This warranty supersedes all previous Jetline Warranties and is exclusive with no other guarantees or
warranties expressed or implied.
NOTICE
The installation, operation and maintenance guidelines set out in this manual will
enable you to maintain the equipment in peak condition and achieve maximum efficiency with your welding operation. Please read these instructions carefully to become
aware of every advantage.
CAUTION
Only experienced personnel familiar with the
operation and safe practice of welding equipment
should install and/or use this equipment.
9660 SERIES SEAM TRACKER CONTROLLER
OVERVIEW
Overview
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . vi
Table of Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . vii
Table of Tables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . x
Table of Figures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xii
Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xv
A. Arc Welding. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xv
B. Electric Shock. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xv
C. Arc Rays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xv
D. Fumes and Gases. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xvi
E. Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xvi
F. Welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xvi
G. Moving Parts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xvii
H. EMF Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xvii
I. Principal Safety Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xvii
TST Control System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Description Of Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Drawings and Parts Lists. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Circuit Descriptions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
Schematics and Block Diagrams. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
Optional Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
PTST Control System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
PTST Seam Tracking System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
PTST Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
PTST Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
PTST Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
PTST Drawings and Parts Lists. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
PTST Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
PTST Schematics and Block Diagrams. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
vi
TABLE OF CONTENTS
9660 SERIES SEAM TRACKER CONTROLLER
Table of Contents
Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xv
A. Arc Welding. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xv
B. Electric Shock. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xv
C. Arc Rays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xv
D. Fumes and Gases. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xvi
E. Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xvi
F. Welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xvi
G. Moving Parts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xvii
H. EMF Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xvii
I. Principal Safety Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xvii
TST Control System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Description Of Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Control Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Operation. . . . . . . . . . . . . . . . . .
Drive Cable . . . . . . . .
Cross-Slide Assembly . . . . .
Omni-Guide Sensor and Accessories .
Principle of Operation . . . .
5-Axis Mount . . . . . . . .
Control Pendant and Cable Assembly
Special Length Cable Assemblies . .
Standard Options . . . . . . .
Tip Selection Guide . . . . . .
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17
17
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18
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Installation . . . . . . . . . . . . . . . . . . . . . . . . . .
Cross-Slide Assembly Mounting . . . . . . .
Omni-Guide Sensor Mounting . . . . . . . .
Omni-Guide Sensor Tips . . . . . . . . .
Omni-Guide Sensor Vertical Spring Force Adjustment
Omni-Guide Sensors and 5-Axis Mount Assembly .
Control Pendant Installation . . . . . . . .
Control Unit Installation . . . . . . . . .
Weld Head Installation . . . . . . . . . .
System Interconnection . . . . . . . . . .
During Operation . . . . . . . . . . . .
NOTE . . . . . . . . . . . . . .
During Mechanical Adjustments . . . . . . .
During Electrical Adjustments . . . . . . . .
Initial Set-up Instructions . . . . . . . . .
Operating Sequence . . . . . . . . .
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19
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22
vii
9660 SERIES SEAM TRACKER CONTROLLER
Work Engagement Sequence
Manual Operations . . .
Automatic Operations . .
Sidetrack Force Adjustment
TABLE OF CONTENTS
. . . . . . . . . . . . . . . . . . . . . . 22
. . . . . . . . . . . . . . . . . . . . . . 22
. . . . . . . . . . . . . . . . . . . . . . 22
. . . . . . . . . . . . . . . . . . . . . . 22
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . .
Maintenance Requirements . . . . . . . . .
Control Unit Assembly . . . . . . . . . .
Control Pendant and Cable Assembly . . . . .
Cross-Slide Assembly . . . . . . . . . .
Omni-Guide Sensor Assembly . . . . . . . .
Mounting Brackets . . . . . . . . . . .
Preventive Maintenance Schedule . . . . . . .
Monthly Maintenance . . . . . . . . .
Omni-Guide Sensor Assembly . . . . . .
Probe Bracket Assembly . . . . . . . .
Quarterly Maintenance. . . . . . . . .
Torch Bracket Assembly . . . . . . . .
Cables . . . . . . . . . . . . . .
Pendant Assembly . . . . . . . . . .
Cross Slides . . . . . . . . . . . .
Semi Annual Maintenance . . . . . . . .
Control Unit Assembly . . . . . . . . .
Omni-Guide Sensor Calibration Procedure . . . .
Tools Required . . . . . . . . . . .
Omni-Guide Sensor Interface Circuitry. . . .
Calibration Of The Omni-Guide Sensor Assembly
Servo Amplifier Circuitry Calibration . . . . .
Tolls Required . . . . . . . . . . .
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25
25
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26
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27
27
27
27
27
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27
28
29
29
Drawings and Parts Lists. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Recommended Spares for Troubleshooting . . . . . . . . . . . . . . . . . . . 59
Helpful Hints . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Hint # 1 - Lap Joint Welding Applications . . . . . . . . . . . . . . . . . . 62
Hint # 2 - Circumferential Welding Applications . . . . . . . . . . . . . . . . 62
Hint # 3 - Cross Slide to Sensor Relationship . . . . . . . . . . . . . . . . . 62
Hint # 4 - Sensor Rotated 180° Degrees . . . . . . . . . . . . . . . . . . 63
Circuit Descriptions . . . . . . . . . . . . . . . . . . .
System Wiring Diagram . . . . . . . . .
Main Board Assembly . . . . . . . . .
Voltage Regulation . . . . . . . . .
Control Circuitry Description. . . . . .
Omni-Guide Sensor Interface . . . . . .
Pendant Control . . . . . . . . . .
Servo Amplifier . . . . . . . . . .
Advance Programming Option Components .
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65
65
65
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66
66
67
67
68
Schematics and Block Diagrams. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
Optional Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
Rotary Table Bracket . . . . . . . . . . . . . . . . . . . . . . . . . . 74
PTST Control System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
PTST Seam Tracking System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
viii
TABLE OF CONTENTS
Features Applications . . . . .
Timed Cycle Function . . . .
Auto Cutoff Function . . . .
Switched Auto-Disable Function .
Tack Cutoff Function . . . .
Features . . . . . . . . . .
Z Search Feature. . . . . .
Lockout Feature . . . . . .
Crater Fill Delay . . . . .
Horizontal Retract Delay . . .
Vertical Search Delay . . . .
Sidetrack Disable at Null . . .
9660 SERIES SEAM TRACKER CONTROLLER
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75
75
75
76
76
77
77
78
78
80
80
81
PTST Operation . . . . . . . . . . . . . . . . . .
User Interface . . . . . . . . . .
J3 Output Relay Connector . . . .
J4 Input Connector . . . . . . .
multi-system operation . . . . . . .
Start. . . . . . . . . . . .
Emergency Stop . . . . . . . .
Synchronized Timing (Null Input) . .
Cutoff . . . . . . . . . . .
Vertical Disable and Horizontal Disable
Operational Precautions . . . . . .
Z Search Feature. . . . . . . .
Vertical and Horizontal Disable . . .
Tack Function . . . . . . . .
Remote Interface Connections . . .
Field Installation . . . . . . . . .
Control Pendant . . . . . . . . .
Control Box . . . . . . . . . .
PTST Seam Tracking System . . . .
Remote Interface Connector Assembly .
Program Switch Settings . . . . . .
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83
83
83
83
84
84
84
84
84
84
84
84
84
85
85
85
85
85
86
86
86
PTST Installation . . . . . . . . . . . . . . .
PTST Programming . . . . . . .
PTST Programming of the Features . .
PTST Preliminary Checkout Procedure .
PTST Checkout Procedure . . . . .
Sequence of Operation . . . . . .
Example One . . . . . . . .
Example Two . . . . . . . .
Seam Tracker Grounding and Cabling .
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88
88
88
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92
92
92
94
96
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PTST Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
PTST Drawings and Parts Lists. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
PTST Troubleshooting . . . . . . . . . . . . . . . . .
Interfacing the Seam Tracker to Other Equipment
Subassembly Interface . . . . . . .
General. . . . . . . . . . . . . .
Recommended Troubleshooting Equipment. .
Setup and General Information . . . . .
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107
107
107
107
107
107
PTST Schematics and Block Diagrams. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
ix
9660 SERIES SEAM TRACKER CONTROLLER
TABLE OF TABLES
Table of Tables
Description Of Equipment
Table 1 - TST40 System Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Table 2 - TST250 System Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Table 3 - Omni-Guide Sensor Tips Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Table 4 - Fillets and V-Grooves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Table 5 - Butt Type Joints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Table 6 - Adjacent or Parallel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Table 7 - Tack Weld Grooves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Table 8 - Tack Weld Fillet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Table 9 - Tack Weld Over-Ride . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Table 10 - Tube Mills . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Table 11 - MSP40 Load Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Table 12 - MSP250 Load Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Operation
Installation
Maintenance
Drawings and Parts Lists
Table 13 - Omni-Guide Sensor Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Table 14 - MSP40 cross-slide Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Table 15 - MSP250 Cross-Slide Parts List. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Table 16 - MSP250 Cross-Slide Parts List. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Table 17 - 9660S Seam Tracker Control Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Table 18 - 9660S-100 Control Pendant Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Table 19 - Power Switch Assembly Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Table 20 - Transformer Assembly Parts List. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Table 21 - Motor Driver Heatsink Assembly Parts Lists . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Table 22 - Motor Driver Heatsink Assembly Parts Lists (Cont.) . . . . . . . . . . . . . . . . . . . . . . . 49
Table 23 - Voltage Selector Switch Assembly Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Table 24 - Drive Connector Harness Assembly Parts List. . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Table 25 - Pendant Connector Harness Assembly Parts List . . . . . . . . . . . . . . . . . . . . . . . . . 52
Table 26 - Std. Torch Clamp Bracket Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Table 27 - Optional Universal Bracket Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Table 28 - U-Bracket (TST40) Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
x
TABLE OF TABLES
9660 SERIES SEAM TRACKER CONTROLLER
Table 29 - 5-Axis Mount Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Table 30 - 5-Axis Mount Parts List (Cont.) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Troubleshooting
Table 31 - Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Table 32 - Voltage Test Points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Table 33 - Drive Signal Test Points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Table 34 - Omni-Guide Sensor Test Points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Table 35 - Recommended Spare Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Circuit Descriptions
Schematics and Block Diagrams
Optional Equipment
PTST Seam Tracking System
PTST Operation
Table 37 - PTST Programming Option Dip Switch Descriptions . . . . . . . . . . . . . . . . . . . . . . . 85
Table 38 - PTST Programming Option Programs, Factory Default . . . . . . . . . . . . . . . . . . . . . . 87
PTST Installation
Table 39 - Program Values, Example 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
Table 40 - Program Values, Example 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
Table 41 - 9660P Control Program Worksheet. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
PTST Maintenance
PTST Drawings and Parts Lists
Table 42 - 9660P Control Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
Table 43 - 9660P-100 Pendant Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
Table 44 - Remote Input/Output Connector Harness Parts List . . . . . . . . . . . . . . . . . . . . . . . 106
PTST Troubleshooting
PTST Schematics and Block Diagrams
xi
9660 SERIES SEAM TRACKER CONTROLLER
TABLE OF FIGURES
Table of Figures
Description Of Equipment
Figure 1 - TST40 System Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Figure 2 - TST250 System Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Figure 3 - Omni-Guide Sensor Tips . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Figure 4 - Tip Selection, Fillet and V-Groove. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Figure 5 - Tip Selection, Butt Type Joints. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Figure 6 - Tip Selection, Adjacent or Parallel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Figure 7 - Tip Selection, Tack Weld Groove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Figure 8 - Tip Selection, Tack Weld Fillet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Figure 9 - Tip Selection, Tack Weld Over-Ride . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Figure 10 - Tip Selection, Tube Mills . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Figure 11 - Interconnection Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Figure 12 - MSP40 Cross-Slide Mounting Dimensions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Figure 13 - MSP250 Cross-Slide Mounting Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Figure 14 - 9660S and 9660P Control Mounting Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . 10
Figure 15 - 9660S-100 and 9660P-100 Pendant Mounting Dimensions. . . . . . . . . . . . . . . . . . . . 11
Figure 16 - Omni-Guide Sensor Mounting (Std. Bracket). . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Figure 17 - Omni-Guide Sensor Mounting (Univ. Bracket) . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Figure 18 - Vertical Force Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Figure 19 - Torch Clamp Mounting Bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Figure 20 - Universal Mounting Bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Figure 21 - Opt. U-Bracket Mounting Bracket (TST40) . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Figure 22 - Side View, MSP40. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Figure 23 - Side View, MSP250 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Figure 24 - Load Specifications Envelope Top View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Operation
Installation
Figure 25 - Tracking Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Figure 26 - Sidetrack Force Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Maintenance
Drawings and Parts Lists
Figure 27 - Seam Tracker Main Board Layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Figure 28 - Omni-Guide Sensor Exploded View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
xii
TABLE OF FIGURES
9660 SERIES SEAM TRACKER CONTROLLER
Figure 29 - MSP40 cross-slide Exploded View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Figure 30 - MSP250 Cross-Slide Exploded View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Figure 31 - 9660S Seam Tracker Control Exploded View. . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Figure 32 - 9660S-100 Control Pendant Exploded View . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Figure 33 - Power Switch Assembly Exploded View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Figure 34 - Transformer Assembly Exploded View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Figure 35 - Motor Driver Heatsink Assembly Exploded View . . . . . . . . . . . . . . . . . . . . . . . . 48
Figure 36 - Voltage Selector Switch assembly Exploded View . . . . . . . . . . . . . . . . . . . . . . . . 50
Figure 37 - Drive Connector Harness Exploded View. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Figure 38 - Pendant Connector Harness Exploded View . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Figure 39 - Std. Torch Clamp Bracket, 1103-0017 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Figure 40 - Optional Universal Bracket, 1103-0009 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Figure 41 - U-Bracket (TST40), 1103-0025 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Figure 42 - 5-Axis Mount . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Troubleshooting
Figure 43 - 9660S Control Signal Flow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Figure 44 - Sensor Angle on Lap Joints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Figure 45 - Sensor Orientation on Tanks, Pressure Vessels and Pipes. . . . . . . . . . . . . . . . . . . . . 62
Figure 46 - Cross Slide to Sensor Relationship, Correct. . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Figure 47 - Cross Slide to Sensor Relationship, Incorrect . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Figure 48 - Sensor Rotated 180° Degrees . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
Circuit Descriptions
Figure 49 - 9660S-100 Pendant Schematic, Standard Seam Tracker . . . . . . . . . . . . . . . . . . . . . 69
Schematics and Block Diagrams
Figure 50 - 9660S Seam Tracker Block Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
Figure 51 - 9660S Seam Tracker Block Diagram (Cont.) . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
Figure 52 - Motor Driver Heatsink Schematic Diagram. . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
Optional Equipment
Figure 53 - Rotary Table Bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
PTST Seam Tracking System
Figure 54 - Z Search Feature. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
Figure 55 - Timed Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
Figure 56 - Auto Cutoff, Down Cutoff. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
Figure 57 - Auto Cutoff, Up Cutoff . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
Figure 58 - Tack Cutoff Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
PTST Operation
xiii
9660 SERIES SEAM TRACKER CONTROLLER
TABLE OF FIGURES
PTST Installation
Figure 59 - PTST Programming Option Timed Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
Figure 60 - PTST Programming Option Auto Down Cutoff. . . . . . . . . . . . . . . . . . . . . . . . . . 90
Figure 61 - PTST Programming Option Auto Up Cutoff . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
Figure 62 - PTST Programming Option Tack Cutoff . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
Figure 63 - PTST Programming Option Z Search Feature . . . . . . . . . . . . . . . . . . . . . . . . . . 91
Figure 64 - PTST Time Line, Example One . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
Figure 65 - PTST Programming Option Time Line, Example Two . . . . . . . . . . . . . . . . . . . . . . 95
PTST Maintenance
PTST Drawings and Parts Lists
Figure 66 - PTST Control Board Layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
Figure 67 - 9660P Control Exploded View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
Figure 68 - 9660P-100 Pendant Exploded View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
Figure 69 - Remote Connector Harness Exploded View . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
PTST Troubleshooting
Figure 70 - 9660P Control Signal Flow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
PTST Schematics and Block Diagrams
Figure 71 - 9660P-100 Pendant Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
Figure 72 - 9660P Control Block Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
Figure 73 - 9660P Control Block Diagram (Cont.) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
Figure 74 - Remote Input Interface Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
Figure 75 - Remote Output Interface Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
Figure 76 - 9660P Multi-System Operation and Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
Figure 77 - 9660P Auto-Disable Operation and Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
Figure 78 - 9660P Control to Miller Auto M Interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
xiv
SAFETY PRECAUTIONS
9660 SERIES SEAM TRACKER CONTROLLER
6
When making input connections, attach proper
grounding conductor first - double-check connections.
7
Frequently inspect input power cord for damage
or bare wiring. Replace cord immediately if
damaged - bare wiring can kill.
8
Turn off all equipment when not in use.
9
If earth grounding of the workpiece is required,
ground it directly with a separate cable - do not
use work clamp or work cable.
10
Do not touch electrode if you are in contact with
the work, ground, or another electrode from a
different machine.
11
Use only well-maintained equipment. Repair or
replace damaged parts at once. Maintain unit according to manual.
12
Wear a safety harness if working above floor
level.
13
Keep all panels and covers securely in place.
14
Clamp work cable with good metal-to-metal
contact to workpiece or worktable as near the
weld as practical.
Safety Precautions
WARNING
A. ARC WELDING
Arc Welding can be hazardous. Protect yourself and
others from possible serious injury or death. Keep
children away. Pacemaker wearers keep away until
consulting your doctor.
In welding, as in most jobs, exposure to certain hazards occurs. Welding is safe when precautions are
taken. The safety information given below is only a
summary of the more complete safety information
that will be found in the Safety Standards listed at the
end of this section. Read and follow all Safety Standards.
Have all installation, operation, maintenance and repair work performed only by qualified people.
B. ELECTRIC SHOCK
Touching live electrical parts can cause fatal shocks or
severe burns. The electrode and work circuit is electrically live whenever the output is on. The input power
circuit and machine internal circuits are also live
when power is on. When using mechanized wire feed,
the wire, wire reel, drive roll housing and all metal
parts touching the welding wire are electrically live.
Incorrectly installed or improperly grounded equipment is a hazard.
1
Do not touch live electrical parts.
2
Wear dry, hole-free insulating gloves and appropriate body protection.
3
Disconnect input power before installing or servicing this equipment. Lockout/Tagout input
power according to OSHA 29 CFR 1910.147
(see Safety Standards).
4
5
C. ARC RAYS
Arc rays can burn eyes and skin; noise can damage
hearing; flying slag or sparks can injure eyes.
Arc rays from the welding process produce intense
visible and invisible (ultraviolet and infrared) rays
that can burn eyes and skin. Noise from some processes can damage hearing. Chipping, grinding and
weld cooling throw off pieces of metal or slag.
Properly install and ground this equipment according to the operation manual and national,
state and local codes.
Always verify the supply ground-check and be
sure that input power cord ground wire is properly connected to ground terminal in disconnect
box or that cord plug is connected to a properly
grounded receptacle outlet.
xv
1
Use approved ear plugs or ear muffs if noise
level is high.
2
Use a welding helmet fitted with a proper shade
of filter to protect your face and eyes when
welding or watching.
3
Wear approved safety glasses with side shields.
4
Use protective screens or barriers to protect others from flash and glare; warn others not to
watch the arc.
5
Wear protective clothing made from durable,
flame-resistant material (wool and leather) and
foot protection where necessary.
9660 SERIES SEAM TRACKER CONTROLLER
SAFETY PRECAUTIONS
D. FUMES AND GASES
5.
Use only correct shielding gas cylinders, regulators, hoses and fittings designed for the specific
application; maintain them and associated parts
in good condition.
6.
Turn face away from valve outlet when opening
cylinder valve.
7.
Keep protective cap in place over valve except
when cylinder is in use or connected for use.
8.
Read and follow instructions on compressed gas
cylinders, associated equipment, and CGA publication P-1 listed in Safety Standards.
Fumes and gases can be hazardous to your health.
Welding produces fumes and gases. Breathing these
fumes and gases can be hazardous to your health.
1
Keep your head out of the fumes. Do not
breathe the fumes.
2
If inside, ventilate the area and/or use exhaust at
the arc to remove welding fumes and gases.
3
If ventilation is poor, use an approved
air-supplied respirator.
4
Read the Material Safety Data Sheets (MSDS)
and the manufacturer's instruction for metals,
consumables, coatings, cleaners, and degreasers.
5
Work in a confined space only if it is well ventilated, or while wearing an air-supplied respirator. Always have a trained watch person nearby.
6
Do not weld in locations near degreasing, cleaning, or spraying operations. The heat and rays of
the arc can react with vapors to form highly
toxic and irritating gases.
7
Do not weld on coated metals, such as galvanized, lead or cadmium plated steel, unless the
coating is removed from the weld area, the area
is well ventilated, and if necessary, while wearing an air-supplied respirator. The coatings and
any metals containing these elements can give
off toxic fumes if welded.
F. WELDING
Welding can cause fire or explosion.
Welding on closed containers, such as tanks, drums,
or pipes, can cause them to blow up. Sparks can fly
off from the welding arc. The flying sparks, hot
workpiece, 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.
1.
Protect yourself and others from flying sparks
and hot metal.
2.
Do not weld where flying sparks can strike
flammable material.
3.
Remove all flammables within 35 ft (10.7 m) of
the welding arc. If this is not possible, tightly
cover them with approved covers.
Cylinders can explode if damaged.
4.
Shielding gas cylinders contain gas under high pressure. If damaged, a cylinder can explode. Since gas
cylinders are normally part of the welding process, be
sure to treat them carefully.
Be alert that welding sparks and hot materials
from welding can easily go through small cracks
and openings to adjacent areas.
5.
Watch for fire, and keep a fire extinguisher
nearby.
1.
Protect compressed gas cylinders from excessive heat, mechanical shocks, slag, open flames,
sparks, and arcs.
6.
Do not weld on closed containers such as tanks,
drums, or pipes, unless they are properly prepared according to AWSF4.1 (see safety Standards).
2.
Install cylinders in an upright position by securing to a stationary support or cylinder rack to
prevent falling or tipping.
7.
Connect work cable to the work as close to the
welding area as practical to prevent welding
current traveling long, possibly unknown paths
and causing electric shock and fire hazards.
8.
Wear oil-free protective garments such as
leather gloves, heavy shirt, cuffless trousers,
high shoes, and a cap.
E. CYLINDERS
3.
Keep cylinders away from any welding or other
electrical circuits.
4.
Never weld on a pressurized cylinder - explosion will result.
xvi
SAFETY PRECAUTIONS
9660 SERIES SEAM TRACKER CONTROLLER
G. MOVING PARTS
4.
Moving parts, such as fans, rotors, and belts can cut
fingers and hands and catch loose clothing.
5.
1.
Keep all doors, panels, covers, and guards
closed and securely in place.
2.
Have only qualified people remove guards or
covers for maintenance and troubleshooting as
necessary.
Connect work clamp to workpiece as close to
the weld as possible.
About Pacemakers:
The above procedures are among those also normally
recommended for pacemaker wearers. Consult your
doctor for complete information.
I. PRINCIPAL SAFETY STANDARDS
H. EMF INFORMATION
Reference as applicable
Considerations About Welding and the Effects of
Low Frequency Electric and Magnetic Fields.
Safety in Welding and Cutting, ANSI Standard Z49.1,
from American Welding Society, 550 N.W. LeJeune
Rd, Miami, FL 33126
Safety and Health Standards, OSHA 29 CFR 1910,
from Superintendent of Documents, U.S. Government
Printing Office, Washington, D.C. 20402
National Electric Code, NFPA Standard 70 from National Fire Protection Association, Batterymarch Park,
Quincy, MA 02269
Recommended Safe Practices for the Preparation for
Welding and Cutting of Containers That Have Held
Hazardous Substances, American Welding Society
Standard AWS F4.1, from American Welding Society,
550 N.W. LeJeune Rd, Miami, FL 33126
Safe Handling of Compressed Gases in Cylinders,
CGA Pamphlet P-1, from Compressed Gas Association, 1235 Jefferson Davis Highway, Suite 501,
Arlington, VA 22202
Code for Safety in Welding and Cutting, CSA Standard W117.2, from Canadian Standards Association,
Standards Sales, 178 Rexdale Boulevard, Rexdale,
Ontario, Canada M9W 1R3
Sales Practices for Occupation and Educational Eye
and Face Protection, ANSI Standard Z87.1, from
American National Standards Institute, 1430 Broadway, New York, NY 10018
Cutting and Welding Processes, NFPA Standard 51B,
from National Fire Protection Association,
Batterymarch Park, Quincy, MA 02269
The following is a quotation from the General Conclusions Section of the U.S. Congress, Office of Technology Assessment, Biological Effects of Power
Frequency Electric & Magnetic Fields - Background
Paper, OTA-BP-E-53 (Washington, DC: U.S. Government Printing Office, May 1989):
".... there is now a very large volume of scientific
findings based on experiments at the cellular level and
from studies with animals and people which clearly
establish that low frequency magnetic fields can interact with, and produce changes in, biological systems.
While most of this work is of very high quality, the
results are complex. Current scientific understanding
does not yet allow us to interpret the evidence in a
single coherent framework. Even more frustrating, it
does not yet allow us to draw definite conclusions
abut questions of possible risk or to offer clear science-based advice on strategies to minimize or avoid
potential risks."
To reduce magnetic fields in the work place, use the
following procedures:
1.
Keep cables close together by twisting or taping
them.
2.
Arrange cables to one side and away from the
operator.
3.
Do not coil or drape cables around the body.
Keep welding power source and cables as far
away as practical.
xvii
9660 SERIES SEAM TRACKER CONTROLLER
SAFETY PRECAUTIONS
xviii
DESCRIPTION OF EQUIPMENT
9660 SERIES SEAM TRACKER CONTROLLER
TST Control System
DESCRIPTION OF EQUIPMENT
Jetline Engineering Seam Tracker Systems are used
for torch positioning in automated welding processes
requiring a constant torch position with respect to the
joint to be welded. The system can be configured for
various combinations of manual and automatic positioning maneuvers.
be mounted to another control console without
re-wiring the pendant assembly.
A typical standard Jetline Engineering Seam Tracker
System (see Figure 1 - TST40 System Components
and Figure 2 - TST250 System Components, beginning on page 2) consists of a Control Unit Assembly,
Drive Cable Assembly, Cross-Slide Assembly,
Omni-Guide Sensor Assembly (with standard 1/8"
ball tip and extension rod) 5 Axis Mount, Torch
Clamp Bracket, and Control Pendant Assembly. An
optional Universal Bracket is also available in addition to the Torch Clamp Bracket. The user's welding
torch or weld head is normally mounted to the adapter
plate which is a part of the cross-slide assembly providing two-axis positioning control of the torch.
CONTROL UNIT
The 9660 Series Seam Tracking Controller is a heavy
gauge steel enclosure containing the electronic circuitry used in the system. Solid state circuits are used
to provide long, trouble-free operation. The standard
unit operates on 115/230VAC, 50/60 Hz commercial
power, capable of supplying approximately 5 amps
peak current. The unit has a lighted power switch and
fuse holder mounted on the exterior of the unit.
Included with the pendant assembly are mounting
brackets to mount it to a fixture and an attachable
hook to allow convenient location changes as required
by the operator or application.
The system is operated from the controls located on
the control pendant assembly which connects to the
control unit. A sealed heatsink mounted on the side of
the control unit allows for convection cooling of heat
dissipating devices, while preventing dust and dirt
from entering the enclosure.
The Omni-Guide Sensor Assembly is normally
mounted to the welding torch via the torch clamp
bracket, but can optionally be mounted to the universal bracket. The sensor tip on the Omni-Guide Sensor
contacts the joint to be welded and senses any horizontal or vertical movement of the weld joint with respect to the welding torch.
The 9660 Series Control unit is sold in two models,
i.e., 9660S Standard Seam Tracking Controller and
the 9660P Programmable Seam Tracking Controller.
The systems these controllers are configured into are
the Tactile Seam Tracking (TST) and the Programmable Tactile Seam Tracking (PTST) systems, respectively, and this convention is used throughout this
manual.
The control unit contains the solid state electronic
controls that apply the proper voltage to the motors on
the cross-slide assembly to correct the positioning error detected by the Omni-Guide Sensor. Jetline Engineering Seam Tracker Systems will correct
positioning errors within .005 inches and provide various proportional correction speeds.
Two blank panels, located on the front cover and the
bottom right of the enclosure, allow provision for factory and field installation of the PTST Programmable
Seam Tracking Option (see PTST Programmable
Seam Tracking Option beginning on page 75).
The control pendant assembly, connected to the control unit via a cable (attached), provides the controls
used to initially position the cross-slides and start the
tracking operation. The pendant assembly is made so
that the faceplate and cable can be removed from the
pendant enclosure allowing the pendant faceplate to
The two connectors located on the bottom of the unit
provide for connection of the control pendant cable
and the drive cable to the cross-slide assembly.
1
9660 SERIES SEAM TRACKER CONTROLLER
DESCRIPTION OF EQUIPMENT
FIGURE 1 - TST40 SYSTEM COMPONENTS
TABLE 1 - TST40 SYSTEM SPECIFICATIONS
DESCRIPTION
SPECIFICATIONS
RATING
Load Capacity
6” (152 mm) from Faceplate
40 lbs. (18 Kg)
Standard Stroke Length
Vertical x Horizontal
3” (76 mm) x 3” (76 mm)
Non-Standard Stroke Length
Vertical x Horizontal
6” (152 mm) x 6” (152 mm)
Minimum Envelope
Standard Stroke 3” (76 mm) x 3” (76 mm)
12” (305 mm) Diameter
Tracking Accuracy
Maximum Correction Rate 24 ipm (610 mm/min.)
Within .005” (1.27 mm)
Tracking Controls
Manual
Up/Down and Left/Right
Automatic
Left/Right Sidetrack and Off
Precision Ball Screw with Mechanical Override
Clutch
Drive System
Control Unit
Enclosure
Standard NEMA Style Sealed enclosure with provisions for plug-in options
Remote Control Pendant
Enclosure
Handheld or mounted steel enclosure containing
manual and automatic tracking controls with provisions for plug-in options
Cross Slide Cable
Standard Length
10’ (3 M)
Omni-Guide Sensor Cable
Standard Length
4’ (1.2 M)
Power Cable
Standard Length
6’ (1.8 M)
Pendant Cable
Standard Length
10’ (3 M)
Weights
Cross-slide Assembly (cable incl.)
10 lbs. (4.1 Kg)
Omni-Guide Sensor
1 lb. (.45 Kg)
Control Unit (power cable incl.)
33 lbs. (15 Kg)
Remote Control Pendant (cable incl.)
4 lbs. (1.8 Kg)
Torch Bracket, TIG
1 lb. (.45 Kg)
Torch Clamp Bracket
2 lb. (.9 Kg)
5-Axis Mount
3 lbs. (1.4 Kg)
Plug-in Option
PTST Programming Option
2
Advanced Programming Control
DESCRIPTION OF EQUIPMENT
9660 SERIES SEAM TRACKER CONTROLLER
FIGURE 2 - TST250 SYSTEM COMPONENTS
TABLE 2 - TST250 SYSTEM SPECIFICATIONS
DESCRIPTION
SPECIFICATIONS
RATING
Load Capacity
12” (305 mm) from Faceplate
200 lbs. (91 Kg) Derated 15 lbs./inch (6.8 Kg/25.4
mm) beyond 12” (305 mm)
Standard Stroke Length
Vertical x Horizontal
Non-Standard Stroke Length
Vertical x Horizontal
Minimum Envelope
Standard Stroke 5” (127 mm) x 5” (127 mm)
17” (431 mm) Diameter
Tracking Accuracy
Maximum Correction Rate 0 -32 ipm (813
mm/min.)
Within .005” (1.27 mm)
Tracking Controls
Manual
Up/Down and Left/Right
Automatic
Left/Right Sidetrack and Off
5” (127 mm) x 5” (127 mm) or
10“ (254 mm) X 10“ (254 mm)
10” (254 mm) x 10” (254 mm) Inboard Drive Assy
24” (610 mm) x 24” (610 mm) Outboard Drive Assy
Drive System
Precision Ball Screw
Control Unit
Enclosure
Standard NEMA Style Sealed enclosure with provisions for plug-in options
Remote Control Pendant
Enclosure
Handheld or mounted steel enclosure containing
manual and automatic tracking controls with provisions for plug-in options
Cross-Slide Cable
Standard Length
10’ (3 M)
Omni-Guide Sensor Cable
Standard Length
4’ (1.2 M)
Power Cable
Standard Length
6’ (1.8 M)
Pendant Cable
Standard Length
10’ (3 M)
Weights
Cross-slide Assembly (5” x 5”)
38 lbs. (16 Kg)
Omni-Guide Sensor
1 lb. (.45 Kg)
Control Unit (power cable incl.)
33 lbs. (15 Kg)
Remote Control Pendant (cable incl.)
4 lbs. (1.8 Kg)
Torch Bracket, TIG
1 lb. (.45 Kg)
Torch Clamp Bracket
2 lb. (.9 Kg)
5-Axis Mount
3 lbs. (1.4 Kg)
Plug-in Option
PTST Programming Option
3
Advanced Programming Control
9660 SERIES SEAM TRACKER CONTROLLER
DESCRIPTION OF EQUIPMENT
FIGURE 3 - OMNI-GUIDE SENSOR TIPS
TABLE 3 - OMNI-GUIDE SENSOR TIPS PARTS LIST
Model #
Description
Part #
Alternate Part #
TX03
3” Extension Tip
179746
1110-2107
PT006
1/16” Diameter Round
179747
1106-1974
PT012
1/8” Diameter Round
179748
1106-1923
PT025
1/4” Diameter Ball
179749
1106-2032
PT038
3/8” Diameter Ball
179750
1106-2024
PT050
½” Diameter Ball
179751
1106-2016
PT063
5/8” Diameter Ball
179752
1106-2008
PT075
3/4” Diameter Ball
179753
1106-1991
PT100
1” Diameter Ball
179754
1106-1982
ST01
Blade & Roller
179755
1103-0262
ST03
Straight Side Extension
179756
1103-0271
ST04
Curved Extension
179758
1103-0301
ST07
Tack Weld Groove
179759
1103-0289
ST08
Tack Weld Fillet
179760
1103-0327
ST09
Tack Weld Over-ride
179761
1103-0297
ST11
Curved Tip
179763
1103-0505
ST12
Single Wheel Tip
179765
1103-0319
ST13
Twin Tip Assembly
N/A
1103-1209
4
DESCRIPTION OF EQUIPMENT
9660 SERIES SEAM TRACKER CONTROLLER
TABLE 4 - FILLETS AND V-GROOVES
Model
Description
PT006
1/16” Dia. Round
PT012
1/8” Dia. Round
PT025
1/4” Dia. Ball
PT038
3/8” Dia. Ball
PT050
½” Dia. Ball
PT063
5/8” Dia. Ball
PT075
3/4” Dia. Ball
PT100
1” Dia. Ball
FIGURE 4 - TIP SELECTION, FILLET AND V-GROOVE
TABLE 5 - BUTT TYPE JOINTS
Model
Description
ST01
Blade and Roller
FIGURE 7 - TIP SELECTION, TACK WELD GROOVE
TABLE 6 - ADJACENT OR PARALLEL
Model
Description
ST04
Curved Side Extension
FIGURE 5 - TIP SELECTION, BUTT TYPE JOINTS
TABLE 7 - TACK WELD GROOVES
Model
Description
ST07
Tack Weld Groove
FIGURE 6 - TIP SELECTION, ADJACENT OR PARALLEL
5
9660 SERIES SEAM TRACKER CONTROLLER
DESCRIPTION OF EQUIPMENT
TABLE 8 - TACK WELD FILLET
Model
Description
ST03
Tack Weld Fillet
ST08
Straight Side Extension
FIGURE 8 - TIP SELECTION, TACK WELD FILLET
TABLE 9 - TACK WELD OVER-RIDE
Model
Description
ST09
Tack Weld Over-ride
FIGURE 9 - TIP SELECTION, TACK WELD OVER-RIDE
TABLE 10 - TUBE MILLS
Model
Description
ST11
Single Wheel
FIGURE 10 - TIP SELECTION, TUBE MILLS
6
DESCRIPTION OF EQUIPMENT
9660 SERIES SEAM TRACKER CONTROLLER
FIGURE 11 - INTERCONNECTION DIAGRAM
7
9660 SERIES SEAM TRACKER CONTROLLER
DESCRIPTION OF EQUIPMENT
FIGURE 12 - MSP40 CROSS-SLIDE MOUNTING DIMENSIONS
8
DESCRIPTION OF EQUIPMENT
9660 SERIES SEAM TRACKER CONTROLLER
FIGURE 13 - MSP250 CROSS-SLIDE MOUNTING DIMENSIONS
9
9660 SERIES SEAM TRACKER CONTROLLER
DESCRIPTION OF EQUIPMENT
FIGURE 14 - 9660S AND 9660P CONTROL MOUNTING DIMENSIONS
10
DESCRIPTION OF EQUIPMENT
9660 SERIES SEAM TRACKER CONTROLLER
FIGURE 15 - 9660S-100 AND 9660P-100 PENDANT MOUNTING DIMENSIONS
11
9660 SERIES SEAM TRACKER CONTROLLER
DESCRIPTION OF EQUIPMENT
FIGURE 16 - OMNI-GUIDE SENSOR MOUNTING (STD. BRACKET)
FIGURE 17 - OMNI-GUIDE SENSOR MOUNTING (UNIV. BRACKET)
12
DESCRIPTION OF EQUIPMENT
9660 SERIES SEAM TRACKER CONTROLLER
FIGURE 18 - VERTICAL FORCE ADJUSTMENTS
13
9660 SERIES SEAM TRACKER CONTROLLER
DESCRIPTION OF EQUIPMENT
FIGURE 19 - TORCH CLAMP MOUNTING BRACKET
14
DESCRIPTION OF EQUIPMENT
9660 SERIES SEAM TRACKER CONTROLLER
FIGURE 20 - UNIVERSAL MOUNTING BRACKET
FIGURE 21 - OPT. U-BRACKET MOUNTING BRACKET (TST40)
15
9660 SERIES SEAM TRACKER CONTROLLER
DESCRIPTION OF EQUIPMENT
TABLE 11 - MSP40 LOAD SPECIFICATIONS
“A” Inches
6
7
8
9
“W” lbs.
40
30
20
10
“B” Inches
6
7
8
9
“C” Inches
3
3.5
4
4.5
“D” Inches
2
2
2
2
FIGURE 22 - SIDE VIEW, MSP40
TABLE 12 - MSP250 LOAD SPECIFICATIONS
“A” Inches
12
16
20
24
“W” lbs.
250
190
130
70
“B” Inches
12
16
20
24
“C” Inches
4
4
4
4
“D” Inches
3
3
3
3
FIGURE 23 - SIDE VIEW, MSP250
NOTE
1>
Center of Gravity (CG) of load (W) to be within envelope.
2> ST600B Load Ratings determined with the lower axis positioned
horizontally and upper axis positioned vertically.
FIGURE 24 - LOAD SPECIFICATIONS ENVELOPE TOP VIEW
16
OPERATION
9660 SERIES SEAM TRACKER CONTROLLER
OPERATION
OMNI-GUIDE SENSOR AND ACCESSORIES
The Jetline Engineering Omni-Guide Sensor Assembly is a two-axis sensing device. When connected to
the appropriate control electronics, deflection of the
pivoted rod end results in an electrical signal proportional to the amount of deflection from a set null position. By causing the end of the rod to ride in a groove
or along the edge of a work piece, the position of the
material to be welded can be indicated. Signals from
the Omni-Guide Sensor are translated by the control
unit which in turn provides drive signals to the motors
on the slides, thus keeping the weld head positioned
properly relative to the seam.
DRIVE CABLE
The drive cable connects the cross-slide assembly to
the control unit. It is used to transmit signals and
power between the units. The standard drive cable is
10 feet long (for longer lengths, consult our factory).
CROSS-SLIDE ASSEMBLY
The seam tracker cross-slide assemblies are light
weight compact designs consisting of two motorized
linear slides mounted at right angles to provide X-Y
axis positioning. Guidance along each axis is accomplished through the use of ball bearing vee wheels riding on hardened steel tracks which are in turn
mounted to thick wall aluminum channel sections
forming the basic structure.
A standard 1/8" diameter round end tip and tip extension are provided with each unit. Other standard tips
are available for applications on most weld joint configurations. Some of these tips are shown in Figure 3 Omni-Guide Sensor Tips on page 4, along with a selection table for standard tips in Table 3 - Omni-Guide
Sensor Tips Parts List on page 4.
Wheels and tracks are factory adjusted to remove play
and provide smooth uniform motion along the full
stroke. A DC gear motor coupled to a drive screw provides linear motion along each axis. The drive screws
are ball bearing mounted, and are specially constructed to free wheel at the end of travel in each direction. This prevents damage should the unit reach
the end of stroke and eliminates the need for limit
switches.
The ball style tips have a cobalt steel ball at the tip
end. A shielded Omni-Guide Sensor cable, 4' length is
provided for system interconnection.
Principle of Operation
The Omni-Guide Sensor rod end is spring loaded to
provide centering about a null position in the horizontal direction and at the same time force the rod down
toward the work piece in the vertical direction.
Seam tracker model numbers indicate the acceptable
load rating of the cross-slide assembly, e.g., MSP40 is
rated at 40 lbs. Load (see Table 1 - TST40 System
Specifications and Table 12 - MSP250 Load
Specifications, beginning on page 2).
A flat groove lengthwise along the cylindrical outer
case of the Omni-Guide Sensor provides orientation
and is to be positioned away from the work piece.
Two additional grooves are provided for special applications (see Figure 16 - Omni-Guide Sensor Mounting (Std. Bracket) on page 12).
The MSP250B cross slide has a brake mounted on
vertical axis motor shaft at the top of the slide assembly. With power removed either by switching power
off or disconnecting the control cable, the brake is engaged and prevents creep in the slides when heavy
loads are applied.
The sensing device used in the Jetline Engineering
Omni-Guide Sensor is designed for ruggedness and
simplicity of operation. It consists of a two-axis variable reluctance sensor which is fully encapsulated in
the end housing of the sensor. Movements of a magnetic coupling block on the end of the sensor rod
causes an electrical imbalance in the sensor coils, resulting in an indication of rod deflection from the null
position. This unique approach requires no mechanical contact between the sensor rod and the control circuitry, thus the unit is rugged and resistant to wear or
damage from normal use.
Electrical connections are made at the junction box or
the motor cover mounted to the lower slide depending
on the model. Connectors are provided for attaching
the control and Omni-Guide Sensor cables to the slide
assembly.
An adapter plate is furnished which mounts to the
face plate of the cross-slides. Insulation is provided
between the face plate and adapter plate as well as on
the Omni-Guide Sensor mount to permit mounting of
electrically "hot" torches or weld heads without danger of electrical currents shorting to the drive unit or
work piece. Holes can be added to the adapter plate
for mounting wire feeder, weld head, torch, wire
spool, etc. Torch clamp brackets are furnished to
mount the Omni-Guide Sensor in the proper position
relative to the torch and seam. Optional mounting
bracketry is also available on certain models.
5-AXIS MOUNT
The 5-axis mount supports and positions the
Omni-Guide Sensor relative to the weld torch. It includes a manual cross-slide assembly and an insulated
arm assembly. The manual cross-slides allow fine positioning over a 1.5 inch range in the vertical and horizontal axes. The insulated arm assembly clamps the
Omni-Guide Sensor and permits adjustment of its an-
17
9660 SERIES SEAM TRACKER CONTROLLER
OPERATION
gular orientation to the weld torch in three different
planes.
NOTE
Special non-standard 5-axis mounts of up to 6
inches in stroke length are also available.
CONTROL PENDANT AND CABLE ASSEMBLY
The standard control pendant has two sealed rocker
switches and one sealed joystick switch mounted in
an aluminum housing suitable for handheld or
mounted operation. The switches are:
Rocker Switches
• MODE (Manual/Automatic)
• SIDETRACK (Left/Off/Right)
Joystick Switch
• MANUAL (Up/Down) and (Left/Right)
The control pendant connects to the control unit with
a 10 foot standard cable attached.
SPECIAL LENGTH CABLE ASSEMBLIES
Special length cables and extension cables can be
made to order for the control pendant to the control
unit in lengths to 60 feet and for the cross-slide assembly to the control unit up to 95 feet.
NOTE
Long length, non-standard cables normally require heavier gauge conductors to reduce voltage drop. Consult factory before making cable
length changes from standard as system performance may be affected.
STANDARD OPTIONS
Several standard options are available for use with
standard seam tracker systems. These options include
electronic features for special welding operation controls and other mechanical options (e.g., Rotary Table
Bracket illustrated in Figure 53 - Rotary Table
Bracket on page 74) to enhance the system performance and adaptability. These options are described
in the Optional Equipment section.
TIP SELECTION GUIDE
These tips are used for most conventional fillet and
V-Groove joints. Small diameter balls are generally
utilized on thin machine cut parts without tacks or
spatter. Larger diameters are generally utilized on
rougher cut parts to allow smoother movement over
grooves, multi pass welds, tacks, splatter, etc. Examples of these tips and applications are illustrated in
Figures 3, 4, 5, 6, 7, 8, 9 and 10 beginning on page 4.
18
INSTALLATION
9660 SERIES SEAM TRACKER CONTROLLER
INSTALLATION
OMNI-GUIDE SENSOR MOUNTING
INFORMATION
ALL INSTALLATIONS TO BE MADE WITH
AC POWER OFF.
WARNING
The vertical axis of the Omni-Guide Sensor
must be in line with the vertical axis of the
weld torch and cross-slide assembly for
proper operation.
A typical Jetline Engineering Seam Tracker
interconnection diagram is shown in Figure 11 - Interconnection Diagram on page 7. The major system
components are listed below. When unpacking, check
all items for damage and make certain nothing is
missing.
The Omni-Guide Sensor is installed in the insulated
arm assembly mounting clamp hole by aligning the
Omni-Guide Sensor orientation key with the proper
key-way on the Omni-Guide Sensor, and inserting the
Omni-Guide Sensor into the clamp. The proper
key-way for normal use is the center key-way without
screws installed (See NOTE below). The Omni-Guide
Sensor is clamped securely to the insulated arm assembly by tightening the cap screw on the arm assembly clamp.
• Seam Tracker Cross-Slide Assembly
• Adapter Plate
• Drive Cable
• Omni-Guide Sensor Assembly with Tip and Cable
• 5-axis Omni-Guide Sensor Mount Assembly
Left or right angular adjustment of the Omni-Guide
Sensor relative to the work is made by loosening the
stud nuts on the arm assembly base, rotating the base
to the desired angle and re-tightening the stud nuts.
• Mounting Bracketry; TST40 -"U" Bracket, TST250 -
Torch Clamp Bracket (STD.) or Universal Bracket
(OPT)
• Control Pendant
• Control Unit
• Options (as ordered)
All required lubrication has been performed at the
factory and needs no further attention at this time. The
interconnecting cables are standard length; however,
other lengths may be ordered, if needed.
NOTE
Some installations may require extreme
left or right angular adjustments. These
situations may require additional compensation to keep the Omni-Guide Sensor
axis properly oriented. Two additional key-ways
in the casing are provided for this purpose with
two small screws installed to prevent unintentional use. If it is necessary to utilize one of
these key-ways remove the screws first.
CROSS-SLIDE ASSEMBLY MOUNTING
Cyclomatic models ST40 (Figure 12 - MSP40
Cross-Slide Mounting Dimensions on page 8),
MSP250 (Figure 13 - MSP250 Cross-Slide Mounting
Dimensions on page 9) outline drawings show the
size and location of the holes for mounting the unit in
any required position. The mounting surface must be
nearly flat to assure that no twist will be applied to the
base of the slide assembly when it is bolted down,
causing a bind in operation.
Vertical angular positioning is acquired by loosening
the cap screw on the arm assembly and rotating one
side of the serrated arm until the Omni-Guide Sensor
is positioned to provide vertical sensing in close
proximity to the welding torch. It may also be necessary to loosen the cap screw on the insulated arm assembly mounting clamp at this time and in
combination with angular positioning, described
above, to obtain the optimum position and orientation
for vertical sensing relative to the weld joint and
torch.
Also, the mounting surface must be rigid to prevent
movement or vibration of the unit during operation.
For proper operation, the slide assembly must be oriented correctly with respect to the weld. The lower
(horizontal) axis is mounted parallel to the plane of
the weld, and the upper (vertical) axis is mounted perpendicular to the plane of the weld (see Figure 11 - Interconnection Diagram on page 7).
For best results, an angle of less than 45 degrees
should be maintained between the Omni-Guide Sensor and the work piece (Figure 16 - Omni-Guide Sensor Mounting (Std. Bracket) and Figure 17 Omni-Guide Sensor Mounting (Univ. Bracket) beginning on page 12). Steeper angles may be used, however, performance is degraded as the angle is
increased and proper operation should be verified in
each application. The Omni-Guide Sensor tip should
be located as close to the welding torch as possible.
(½" to 1" ahead of torch is acceptable for most applications).
Once the cross-slide assembly has been mounted,
make certain that adequate clearance is maintained
between the moving slides and any protrusion that
could restrict the full travel of the slides or interfere
with the movement of the electrical cable.
19
9660 SERIES SEAM TRACKER CONTROLLER
INSTALLATION
Omni-Guide Sensor Mounting (Univ. Bracket) on
page 12 illustrates typical mounting.
The standard ST40 model is furnished with a "U"
shaped metal bracket for mounting the Omni-Guide
Sensor manual slide assembly. A set of “V” clamps is
provided for clamping a torch barrel. Several hole patterns are provided for alternate mounting. The adapter
plate on the ST40 may be inverted to provide an additional configuration. The mounting bracketry used on
the TST250 can also be used on model TST40, if required.
OMNI-GUIDE SENSOR TIPS
Omni-Guide Sensor tips are installed and removed by
tightening or loosening the set screws in the tips. The
Omni-Guide Sensor rod or extension rod should be
fully inserted into the tip for proper installation.
OMNI-GUIDE SENSOR VERTICAL SPRING
FORCE ADJUSTMENT
Cyclomatic Omni-Guide Sensor's are equipped with a
feature to allow mechanical adjustment of vertical
spring force. This feature is useful for optimizing operation in various welding applications.
CONTROL PENDANT INSTALLATION
The seam tracker control pendant is constructed from
a rugged steel housing with mounting brackets (see
Figure 15 - 9660S-100 and 9660P-100 Pendant
Mounting Dimensions on page 11). The control
pendant has a standard cable length of 10 feet. Special
cable lengths are available upon request.
On the side of the Omni-Guide Sensor case opposite
the key-way groove is a slot approximately one inch
long. In this slot is a panhead screw, which when
loosened ½ turn can be moved to various positions in
the slot. The location of this screw determines the
amount of vertical force that the Omni-Guide Sensor
exerts on the work-piece during tracking. Move the
screw away from the rod end and toward the connector to achieve maximum spring force (Figure 18 - Vertical Force Adjustments on page 13). Move the screw
toward the rod end to achieve minimum spring force.
Varying degrees of force occur at intermediate positions between the two extremes.
Complete control of the seam tracker system is
achieved through the sealed rocker switches which are
in the cover of the control pendant. Manual operation
of the vertical and horizontal axes, sidetrack to the
right or left and automatic control, as well as the
PTST Programming Option plug-in for the Seam
Tracker, are handled with the control pendant
assembly.
IMPORTANT
Re-tighten the screw once the proper adjustment has been made.
CONTROL UNIT INSTALLATION
On page 10, Figure 14 - 9660S and 9660P Control
Mounting Dimensions shows the size and location of
holes for mounting the control unit in the proper position. It should be located for ready access to the
power switch and allow clearance for opening the
hinged door. This allows for inspection, replacement
of parts or installation of the Advanced Programming
Control components, when necessary.
Minimum force is recommended when sidetracking across a work-piece surface occurs. The drag
on the tip is minimized and the Omni-Guide Sensor
will move at a more uniform speed and is not likely to
stop prematurely due to roughness or friction of the
work surface.
Maximum force is suggested when tracking “V”
grooves at high rates of speed or when the groove is
shallow and not well defined. The increased pressure
provides more tracking force in the downward direction.
Another important consideration is to make certain
that the control unit has unrestricted air flow over the
cooling fins to assure adequate cooling during operation.
A chassis ground lug is located near the power
cord/RFI Filter connection. Care must be taken that
this be connected to a solid earth ground (Protective
Earth or PE) in a high noise environment. All system
components except the Omni-Guide Sensor and control pendant are connected to chassis ground through
cable shields.
OMNI-GUIDE SENSORS AND 5-AXIS MOUNT
ASSEMBLY
The standard TST250 model is furnished with a torch
clamp mounting bracket designed to fit most weld
torches and give proper mounting for the Omni-Guide
Sensor 5-axis mount. Figure 19 - Torch Clamp
Mounting Bracket on page 14 illustrates a typical
mounting with the torch clamp bracket attached to the
barrel of the torch.
WELD HEAD INSTALLATION
Weld head installation is made by bolting the weld
head to the cross-slide assembly adapter plate. This
plate can have additional holes drilled to accommodate the users weld head, as required. The user must
ensure that any added holes or hole patterns permit
proper orientation of the weld head and torch axis to
the drive axis. Review Figure 11 - Interconnection
An optional universal bracket is also available for the
TST250. Designed for a multitude of configurations
to fit most weld heads, these brackets can be extended
to several positions as well as reversed, Figure 17 -
20
INSTALLATION
9660 SERIES SEAM TRACKER CONTROLLER
Insure that all are properly installed prior to applying
power to the control unit.
Insure all cables are of adequate length and clear of
moving parts to prevent possible damage during operation.
Diagram on page 7 and Figure 17 - Omni-Guide Sensor Mounting (Univ. Bracket) on page 12 prior to assembly of the weld head to the adapter plate, and
before drilling any additional holes.
SYSTEM INTERCONNECTION
Once the cross-slide assembly and control unit are
properly mounted, the cables can be connected for operation. On page 10, Figure 14 - 9660S and 9660P
Control Mounting Dimensions shows connector arrangement on the control unit. Connect the control
pendant to J1 on the control unit. The drive cable connects to J2.
DURING OPERATION
Keep fingers, hands, etc. away from the cross-slides
during operation of the seam tracker.
NOTE
When unit is on and in manual mode,
downward drift may occur under heavy
load conditions. Directions for correcting
this condition can be found in the TROUBLESHOOTING section.
NOTE
Model ST40 drive cable is permanently
attached to the slide assembly. On all
other models it is a separate cable assembly which also has a connector at the
DURING MECHANICAL ADJUSTMENTS
slide.
Ensure that the AC power is disconnected
from the control unit to prevent possible
shock when adjusting the control unit,
and accidental operation of moving parts
being adjusted.
Additional connectors may be used in conjunction
with various options to provide relay switching for remote initiation of welding power, carriage, travel, etc.
These connectors mount in the provided blank panel
when used (see Advanced Programming Control).
DURING ELECTRICAL ADJUSTMENTS
The Omni-Guide Sensor cable assembly connects the
Omni-Guide Sensor to the junction box or connector
on the cross-slide assembly. Refer to Figure 11 - Interconnection Diagram on page 7, which illustrates
typical system interconnection.
Do not disconnect connectors or remove
circuit boards when the power is connected at the control unit.
WARNING
For your own safety and to ensure proper
operation of this equipment, read this manual and all operating precautions before operating the equipment.
a) Read this entire Operator's Manual
prior to operation of the Jetline Engineering Seam Tracker System.
b) Be sure that adequate eye protection and ventilation is provided in the vicinity of the welding
area.
Be sure that all insulators and protective covers
on the torch and torch lead connections are in
place.
With the power off, check the following connections
on the seam tracker system:
• Control Unit to Cross-Slides
• Cross-Slides to Omni-Guide Sensor
• Control Pendant
21
9660 SERIES SEAM TRACKER CONTROLLER
INSTALLATION
• Fine adjustments can now be made using the manual
INITIAL SET-UP INSTRUCTIONS
To take full advantage of seam tracker stroke capability, the cross-slide assembly should be positioned at
the center of both horizontal and vertical strokes.
Weld torch mounting should be such that it is approximately in its nominal welding position relative to the
weld joint. This then allows for error compensation in
all directions during welding. There are exceptions to
this, however.
Omni-Guide Sensor cross-slides to attain final
cross-seam and arc gap positions.
• The unit is now ready for operation under weld conditions.
The user must now consider the weld to be made, then
select the system to operate in one of two modes,
manual or automatic.
Manual Operations
Manual operations are controlled by the user at the
control pendant. The user selects this mode by pushing the “MAN” side of the MODE switch. This action
allows the user to be able to move the cross-slide
assembly to a desired position by use of the joystick
switch on the pendant assembly.
For example, you may want the majority of the vertical stroke to be available for manually driving the
slides upward and clear of the part after welding for
inspection, part removal and insertion of a new part.
When mounting the Omni-Guide Sensor and its
bracketry , adjust the brackets and mounting hardware
to position the Omni-Guide Sensor in the proper relationship to the torch (see Figure 16 - Omni-Guide
Sensor Mounting (Std. Bracket) and Figure 17 Omni-Guide Sensor Mounting (Univ. Bracket) beginning on page 12). Keep the manual Omni-Guide Sensor cross-slides at approximately their center position
to permit fine adjustment later.
These switches are momentary switches and will
cause the indicated movement to occur only when depressed and held. Release of the switch causes the
movement to stop.
The Sidetrack switch is not active during manual operations.
Certain weld joint configurations will require use of
the Sidetrack feature of the seam tracker system. The
sidetracking force required should be set up at this
time. Follow the instructions under Operating
Sequence, page 22, to place the Omni-Guide Sensor
in position.
Automatic Operations
Automatic operations are also selected by the user at
the control pendant. This mode is engaged by depressing the “AUTO” side of the MODE switch. Automatic tracking operations are directed by the control
unit as it responds to signals from the Omni-Guide
Sensor and the type of joint being tracked.
Operating Sequence
Work Engagement Sequence
The user insures that the Seam Tracker System has
been properly installed and the initial set-up has been
made. Next, AC power is connected to the control
unit. The control unit power switch is turned CW to
the ON position. The Switch Lamp should turn “On”,
indicating that the system is ready for operation (if the
light is not on, refer to the Troubleshooting Section
later in this manual).
The Sidetrack switch selects the tracking mode. These
modes are LEFT, OFF, and RIGHT Sidetrack modes.
LEFT and RIGHT modes cause a constant tracking
pressure to be exerted in the direction selected. The
OFF mode is used where neutral or equal side forces
are required.
Sidetrack Force Adjustment
Adjustment of Sidetrack Force is possible through the
use of the adjustment potentiometer on the Seam
Tracker Main Board (see Figure 26 - Sidetrack Force
Adjustment on page 23) in the control box. This
adjustment varies the pressure to the left or right, depending upon the Sidetrack switch position. A CCW
rotation of the knob reduces this pressure and a CW
rotation increases the pressure (see Figure 26 - Sidetrack Force Adjustment on page 23).
The user can now operate the Seam Tracker System
manually according to the instructions in this manual.
Review these instructions before allowing the seam
tracker/sensor to touch the work and/or begin tracking
the seam. Then proceed as follows:
• Manually drive the vertical axis down until the
Omni-Guide Sensor contacts the work and its rod is
approximately parallel to the case (vertical null).
• Adjust the manual Omni-Guide Sensor cross-slides so
that the torch arc gap is in its approximate desired position.
• Insure the Sidetrack switch is in the desired position, if
necessary.
• Switch from MAN to AUTO at the control pendant,
the Omni-Guide Sensor will now seek its true null automatically.
22
INSTALLATION
9660 SERIES SEAM TRACKER CONTROLLER
FIGURE 25 - TRACKING DIAGRAM
FIGURE 26 - SIDETRACK FORCE ADJUSTMENT
23
9660 SERIES SEAM TRACKER CONTROLLER
INSTALLATION
24
MAINTENANCE
9660 SERIES SEAM TRACKER CONTROLLER
and replacing the blown fuse with a new fuse. Then
restore power and turn ON system to perform a test
run.
MAINTENANCE
MAINTENANCE REQUIREMENTS
Replacement of the printed circuit board, the Main
board, involves disconnecting the connectors to the
board, removing the mounting screws, and replacing
the Main board with another.
Cyclomatic Seam Tracker Systems are designed for
trouble-free operation and normally require only minimal preventive care and cleaning. This section of the
users manual provides instructions for maintaining
user serviceable items. The suggested repair procedure for all user serviceable items is to remove and replace defective assemblies or parts. Service personnel
employed by the user should be familiar with electrical and electronic equipment or else service problems
should be corrected by factory authorized representatives.
The service person should exercise care in removing
the Main board to ensure that excessive force is not
placed on the connectors or components on the board
and that the mounting screws are not over tightened.
The Main board is held by eight screws to stand-offs
mounted in the enclosure. Disconnect all necessary
cabling at the connection plugs provided. Remove the
mounting screws and the Main board. Install another
Main board and tighten the mounting screws until
snug; do not over tighten as damage to the board and
enclosure standoffs may result.
CONTROL UNIT ASSEMBLY
The control unit assembly (Figure 31 - 9660S Seam
Tracker Control Exploded View on page 42) consists
of an enclosure housing the major electronic assemblies of the seam tracker system. Maintenance is generally limited to periodic dusting of the enclosure. The
user should ensure that the unit is not operated with
the access door open and/or option plates and cable
connector mounting holes open. The user should exercise caution in operating the unit if it has been inadvertently exposed to excessive dust or liquid
contamination, since such conditions may cause electrical shorting and/or malfunctioning of the electrical/electronics assemblies. The user should consult
with the factory if such conditions have occurred. Repair of the control unit assembly is generally limited
to a remove and replace operation.
Replacement of Heatsink assembly is accomplished
by the removal of six screws and the disconnection of
the appropriate connectors. Replace with a working
assembly. Individual transistors may be replaced by
removing two screws and the defective part (easiest if
the heatsink is out of the control unit.) The replacement part may then be installed in the existing socket
provided, using heatsink compound (Thermal Compound) on the transistors to ensure good heat transfer.
Secure the replaced transistors with the two screws).
Replacement of other user serviceable items is to be
performed according to normal maintenance and repair standards, usually involving the removal of
mounting hardware, unplugging the old unit, mounting the replacement part and reconnecting the connectors.
NOTE
If the user should decide to repair unauthorized items, then the user should exercise caution when repairing the control
unit subassemblies and printed circuit
boards, since these repairs can void the warranty.
CONTROL PENDANT AND CABLE ASSEMBLY
Maintenance of the control pendant and cable assembly is to periodically remove dust, soot, metal particles, slag, etc., from the face plate.
WARNING
When repairing the control unit assembly,
disconnect A.C. power from the unit before opening the access door and turn the
power switch to OFF.
Repair of the control pendant and cable assembly is
limited to replacement of defective units (see Figure
32 - 9660S-100 Control Pendant Exploded View on
page 44). A wiring diagram includes control pendant
schematics for troubleshooting purposes (see Figure
49 - 9660S-100 Pendant Schematic, Standard Seam
Tracker on page 69).
Assemblies and parts which are authorized for user
replacement are listed in Table 17 - 9660S Seam
Tracker Control Parts List on page 43. Replacement
should be performed after the user has determined
that the part or assembly to be replaced is the cause of
a system problem (see Troubleshooting on page 59).
CROSS-SLIDE ASSEMBLY
The cross-slide assembly should be maintained by periodic inspections for worn moving parts (e.g. ball
screws, couplings, magnetic brakes). Further maintenance includes removing excess dust, weld slag, soot,
etc., from the assemblies. If any connectors or parts
Replacement of the fuse does not require access to the
housing interior; however, the blowing of the fuse
may indicate other system problems. The fuse is replaced by unscrewing the fuse holder lid, removing
25
9660 SERIES SEAM TRACKER CONTROLLER
MAINTENANCE
are damaged during operation, the defective parts
should be replaced as soon as practical.
PREVENTIVE MAINTENANCE SCHEDULE
The following schedule is provided to assist in preforming timely maintenance to the system to maintain
optimum performance from the system.
Repair of the cross-slide is limited to the replacement
of defective parts and adjustment of the Dual-Vee
Guide Rails to remove play between wheels and rails.
Exploded views of the cross-slides in Figures 29 and
30 and their parts lists in Tables 14 and 15 are provided to aid in parts ordering and replacement beginning on page 36. The Dual-Vee Guides are adjusted
by loosening their retaining screw, adjusting, and
re-tightening the screws.
Monthly Maintenance
Omni-Guide Sensor Assembly
Proper Function
There should be spring tension on the Sensor Rod
throughout the entire horizontal travel.
Test
Clean slag and splatter from Omni-Guide Sensor’s rod & tip. Notice that the sensor rod is
sprung downward. With the index finger and
thumb, grasp the sensor rod and move it upward
slightly while keeping slight upward pressure on
the sensor rod, move it left and right very
slightly and very slowly. If there is any play
horizontally (un-sprung movement), the
Omni-Guide Sensor Assembly should be repaired or replaced.
OMNI-GUIDE SENSOR ASSEMBLY
The Omni-Guide Sensor Assembly may require adjustment as noted in the Installation section under Figure 18 - Vertical Force Adjustments on page 13 and in
the Operation section under Initial Setup Instructions.
Otherwise keep the unit free of dust and slag. The
Omni-Guide Sensor Assembly is to be removed and
replaced only. The Omni-Guide Sensor Assembly is
shown in an exploded view Figure 28 - Omni-Guide
Sensor Exploded View with the parts lists in Table 13
- Omni-Guide Sensor Parts List beginning on page 35
for reference.
NOTE
MOUNTING BRACKETS
Each drive unit is provided with an adapter plate for
mounting to the face plate. This plate is furnished for
drilling to suit the requirements of the intended application.
There will always be spring tension pressing
downward on the Omni-Guide Sensor’s rod.
Probe Bracket Assembly
(Bracket that holds Omni-Guide Sensor)
IMPORTANT
Proper Function
Allows the operator to position the torch over
the weld seam. It should be snug, enough to allow the operator to position the torch across the
weld seam but without play in the bracket itself.
No play should exist in the bracket.
The face plate should not be removed,
drilled or tapped, as the guide wheels and
drive screw unit are factory adjusted, and
thus, alignment may be affected. Use the
adapter plate only for mounting purposes.
A bracket assembly is furnished for mounting the
manual slides and includes a torch clamp bracket for
mounting to the barrel of the welding torch. The
two-axis manual slides and Omni-Guide Sensor adjustment bracket, as well as the Omni-Guide Sensor
Assembly, mount to this bracket. The MSP250 cross
slide assembly can also be provided with an optional
Universal Mounting Bracket designed to accommodate a wide variety of weld-heads and torches.
Test
Clean the bracket to remove weld splatter and
dust. Grasp the Omni-Guide Sensor Assembly’s
outer case and try to move it left, up, right and
down. If you feel play in the bracket, try to pinpoint which axis it is in. There are 3 set screws
on each axis base, simply tighten them until
there isn’t any play.
The TST40 is supplied with a U-Shaped Bracket Kit.
Provisions are also made for using this kit on an
TST250, if desired.
Quarterly Maintenance
Torch Bracket Assembly
The Drawings and Parts Lists are provided to aid in
parts ordering information and for parts replacement
for each of these Mounting Brackets beginning on
page 53.
Proper Function
Holds the torch firmly to the cross-slide assembly at the desired angle.
26
MAINTENANCE
9660 SERIES SEAM TRACKER CONTROLLER
Test
Clean dirt from bracket and torch. Check the
torch to be sure it is held tight. If not, tighten
bolts that hold the torch to the bracket.
still play in the lower axis, the drive screw is
showing wear and may need to be replaced.
Step # 3 - Check for Play, Vertical
Check the vertical (upper) axis, using the same
procedure starting with Step # 1.
Cables
Check for proper installation.
Semi Annual Maintenance
All cables should be connected tightly to the respective receptacles. Be sure that the cables do
not have sharp bends in them and that the insulation of the cable is not frayed or cracked.
Control Unit Assembly
Be sure the control unit is turned off and unplug.
Using clean, dry air blowout dust from the inside of
the control unit.
Pendant Assembly
Be sure all other connections in the control unit are
seated firmly in their receptacles and reconnect the
power cord to an electrical outlet. Turn power on and
check for proper operation.
Check for proper function
The pendant assembly should be clean.
Maintenance for the pendant assembly simply
involves cleaning dust, slag, etc. from the face
plate. Verify the switch function normally and
that the Joystick switch returns to its center
postion.
OMNI-GUIDE SENSOR CALIBRATION PROCEDURE
This procedure will describe the calibration to be performed on all Omni-Guide Sensors for maintenance
purposes.
Tools Required
Digital Volt-Meter (D.V.M.) capable of reading 3
places to the right of the decimal point.
Cross Slides
Proper Function
Verify that the cross-slide assembly travels the
full length of its stroke on each axis.
To determine whether calibration of the Omni-Guide
Sensor is required can be done using the steps explained earlier in Monthly Maintenance section of the
Preventive Maintenance Schedule on page 26.
Test
Check for axial play on each axis.
In addition, calibration can be required, if during operation, the cross slides drift left or right while driving
downward in search of the seam when Sidetrack is in
the off position.
Step # 1 - Center the Slides
Position slides in the center of their strokes. Put
one hand on the motor assembly (on the left
hand slide of the horizontal (lower) axis on most
cross slides). Using your other hand, push the
cross-slides face plate/adaptor plate toward the
motor and then pull it back away from the motor
assembly. If no play is felt, go on to step # 2.
Omni-Guide Sensor Interface Circuitry
Step # 1 - Power on the Control
Turn the POWER SWITCH to the ON position.
Let
the Seam Tracker warm up for 15 minutes.
Step # 2 - Connect the Calibration Tool
Connect the Calibration Tool to the Omni-Guide
cable, if available.
If you feel any play on the lower axis; notice the
drive screw; if it moves back and forth (not spinning), the assembly needs shimmed.
Step # 3 - Connect the D.V.M.
Connect the ground lead of the digital volt-meter
to the ground test point TP11 (GND) on the
main board of the seam tracker control. (See
Figure 27 - Seam Tracker Main Board Layout on
page 31.) Connect the positive lead of the digi-
Step # 2 - Check for Play, Horizontal
If the drive screw does not move back and forth,
try to spin the dual-vee wheels without the slide
moving. If they do not spin, go to step # 3.
If both the wheels do not spin and the drive
screw does not move back and forth and there is
27
9660 SERIES SEAM TRACKER CONTROLLER
MAINTENANCE
tal volt-meter to the Horizontal Probe test point
TP10 (HP) on the main board.
volt-meter should read +4 VDC minimum in this
direction.
Step # 4 - Adjust Horizontal
Adjust the trimpot labeled HA on main board
until the digital volt-meter reads .000VDC
± .005VDC.
Step # 8 - Left Horizontal Deflection Reading
Do the same thing as in Step # 7, but deflect the
lower rod in the full, left horizontal direction.
The digital volt-meter should read a -4 VDC
minimum in this direction.
Omni-Guide Sensor Interface circuit is now calibrated.
Step # 9 - Verify Mechanical and Electrical Null
Push (deflect) and release the lower rod in a
slightly upward and full horizontal right direction and let the lower rod of the Omni-Guide
Sensor settle. The reading on the digital
volt-meter should be between 0 VDC and + .050
VDC with the rod at rest. Preform the same
lower rod deflection as above, but in the opposite horizontal direction--left. The reading on
the digital volt-meter should be between 0 VDC
and - .050 VDC with the rod at rest.
Step # 5 - Remove the Calibration Tool
Disconnect the Calibration Tool from the
Omni-Guide cable.
Calibration Of The Omni-Guide Sensor Assembly
Step # 1 - Connect the Sensor
Connect the Omni-Guide Sensor Assembly to be
tested to the sensor cable. Hold the Omni-Guide
Sensor so that the grooves are facing the upward
direction (12 o'clock) during testing.
Step # 10 - Adjusting the Sensor’s Mechanical Null
If the volt-meter reading is more than .050V
from 0 in either direction, then the Omni-Guide
Sensor must be centered in the horizontal axis.
This is accomplished by turning the adjusting
screw inside the Omni-Guide Sensor Assembly
(See Item # 31 in Figure 28 - Omni-Guide Sensor Exploded View). The adjusting screw is accessible through a hole in the case and can be
turned with 3/32" hex key. A setscrew is inserted into the access hole and can be removed
with a 1/8" hex key; setscrew prevents dust and
dirt from getting into the internal parts of the
Omni-Guide Sensor Assembly.
Step # 2 - Connect the D.V.M. to VP
Move the positive lead of the Digital Voltmeter
from Horizontal Probe (HP) test point to the
Vertical Probe (VP) test point on the main board.
Step # 3 - Verify Reading
Verify that the digital volt-meter reads + 4 VDC
minimum in the rest position.
Step # 4 - Vertical Deflection Reading
Push the lower rod toward the upward (vertical
direction) and verify that the digital volt-meter
reads - 4 VDC ± 1 VDC minimum in the vertical
direction.
Step # 11 - Adjust the Sensor’s Horizontal Null
To center the horizontal axis, perform the following:
Step # 5 - Vertical Check Complete
There is no vertical adjustment of the
Omni-Guide Sensor Assembly. This test checks
for correct vertical operation of the Omni-Guide
Sensor Assembly.
• Push the lower rod vertically until the adjusting screw
can be reached with the hex key.
• Turn the adjusting screw slightly and remove the hex
key.
• Push and release rod, as in Step # 9, in both directions.
Observe the digital volt-meter reading when the rod
returns to its rest position. The voltage reading cannot
exceed ± .050VDC in either direction (+ or -).
• Repeat the above steps until the readings are achieved.
Replace setscrew using a thread locking compound to
prevent the setscrew from becoming loose.
End of Calibration.
Step # 6 - Connect the D.V.M. to HP
Now, move the positive lead of the digital
volt-meter back to the Horizontal Probe (HP)
test point main board.
Step # 7 - Right Horizontal Deflection Reading
Push (deflect) the Omni-Guide Sensor’s lower
rod by hand in a slightly upward and horizontal
right direction and hold it. The digital
28
MAINTENANCE
9660 SERIES SEAM TRACKER CONTROLLER
SERVO AMPLIFIER CIRCUITRY CALIBRATION
This procedure describes the calibration techniques
needed to for regular maintenance. This is useful and
may become necessary to perform when a motor or
heatsink transistor is replaced. When these components are replaced during troubleshooting or regular
maintenance, the feedback to this circuitry also
changes, making this calibration necessary.
Step # 8 - Repeat Step 7
Perform the same function as in Step # 7,
but only in the down position on the joystick. Observe the vertical slide moves
down and observe on the oscilloscope,
approximately - 15 VDC.
Tolls Required
Digital Volt-Meter (D.V.M.) capable of reading 3
places to the right of the decimal point.
NOTE
Oscilloscope
Step # 9 - Verify Reading and No Movement
Release the joystick on the pendant and observe
approximately 0 VDC on the oscilloscope and
observe on the cross-slides, no drive movement.
Some ripple may be seen, this is typical.
Step # 1 - Adjust HI and VI Full Clock-Wise
Adjust the Servo Amplifier Circuitry trim-pots
Horizontal Current (HI) and Vertical Current
(VI) full Clock-Wise.
Step # 10 - Connect the Oscilloscope to TP1
Connect an oscilloscope to the Horizontal Error
(HE) test point on the main board, TP1 and observe approximately 0 VDC.
Step # 2 - Monitor TP4 and TP8
Monitor the + 15 VDC (TP4) and - 15VDC
(TP8) test points on main board with a digital
volt-meter to verify voltage in and out of Servo
Amplifier Circuitry on the main board. Use test
point TP11 (GND) as reference for the
volt-meter.
Step # 11 - Adjust HI trimpot Counter Clock-Wise
Adjust the Horizontal Current (HI) Trim-pot
Counter Clock-Wise (CAW) until signal on the
oscilloscope begins to oscillate.
Step # 3 - Connect the Oscilloscope to TP2
Connect an oscilloscope to the Vertical Error
(VE) test point main board, TP2.
Step # 12 - Adjust HI Trimpot Clock-Wise
Slowly adjust the Horizontal Current (HI)
Trim-pot Clock-Wise (CW) until the oscillation
just stops, then adjust the trim-pot CW an additional four (4) turns.
Step # 4 - Verify Reading
Observe on oscilloscope approximate 0 VDC.
Step # 13 - Verify Reading
On the pendant, move the joystick switch
right and observe the horizontal slide
move right and observe on the oscilloscope observe approximately + 15 VDC.
Step # 5 - Adjust VI Trimpot Counter Clock-Wise
Adjust the Vertical Current (VI) Trim-pot Counter Clock-Wise (CCW) until signal on the oscilloscope begins to oscillate.
Step # 6 - Adjust VI Trimpot Clock-Wise
Slowly adjust the Vertical Current (VI) Trim-pot
Clock-Wise (CW) until the oscillation just stops,
then adjust the trim-pot CW an additional four
(4) turns.
NOTE
Some ripple may be seen, this is typical.
Step # 14 - Repeat Step 13
Perform the same function as in Step #
13, but only in the left position on the joystick.
Observe on the oscilloscope approximately - 15
VDC and observe the horizontal slide moving to
the left.
Step # 7 - Verify Reading
On the pendant, move the joystick switch up and
observe the vertical slide moving up and observe
on oscilloscope approximately + 15 VDC.
NOTE
NOTE
Some ripple may be seen, this is typical
Some ripple may be seen, this is typical.
29
9660 SERIES SEAM TRACKER CONTROLLER
MAINTENANCE
Step # 15 - Verify Reading and No Movement
Release the joystick on the pendant and observe
approximately 0 VDC on the oscilloscope and
observe on the cross-slides, no drive movement.
This completes the Servo Amplifier Circuitry on the
main board.
30
DRAWINGS AND PARTS LISTS
9660 SERIES SEAM TRACKER CONTROLLER
DRAWINGS AND PARTS LISTS
FIGURE 27 - SEAM TRACKER MAIN BOARD LAYOUT
31
9660 SERIES SEAM TRACKER CONTROLLER
DRAWINGS AND PARTS LISTS
32
DRAWINGS AND PARTS LISTS
9660 SERIES SEAM TRACKER CONTROLLER
33
9660 SERIES SEAM TRACKER CONTROLLER
DRAWINGS AND PARTS LISTS
FIGURE 28 - OMNI-GUIDE SENSOR EXPLODED VIEW
34
DRAWINGS AND PARTS LISTS
9660 SERIES SEAM TRACKER CONTROLLER
TABLE 13 - OMNI-GUIDE SENSOR PARTS LIST
Item
No.
1
QPA
UM
2.000
EA
Part
No.
970010-100
Description
SCREW, 2-56 X .12 CR1F SBZ
2
1.000
EA
1110-1119
OUTER CASE
3
1.000
EA
2360-1109
PIN ROLL .0938 DIA X .750 LG
4
1.000
EA
1106-0811
SHORTING BAR ASSY
5
2.000
EA
970004-101
SCR 2-56 X .19 CR1P SSP
6
1.000
EA
1110-1194
COLLAR
7
1.000
EA
970043-001
SCREW, SET, 1/4-28 X .19 HHC SBZ
8
4.000
EA
1116-0484
SETSCREW PIVOT
8
AR
EA
3070-0082
TORQUE SEAL
9
1.000
EA
1110-1062
SHIELD, Omni-Guide Sensor
10
1.000
EA
979006-375
RING RTNG EXTERNAL SHAFT .375
12
1.000
EA
1110-2093
INSULATOR, OMNI GUIDE
14
1.000
EA
1110-1054
LOWER ROD
16
2.000
EA
2360-0404
SPRING EXT.(HORIZ AXIS)
17
1.000
EA
1110-1208
SUPPORT, LEVER ARM
18
4.000
EA
970000-201
SCREW, 4-40 X .19 CR1P SBZ
19
3.000
EA
970000-102
SCREW, 4-40 X .25 CR1P SBZ
20
1.000
EA
1106-0838
SENSOR MODULE
21
2.000
EA
970000-202
SCREW, 4-40 X .25 CR1P SBZ
22
1.000
EA
1110-1046
SHIELD CONNECTOR
23
1.000
EA
1110-1216
ARM LEVER
24
1.000
EA
1110-1224
ARM LEVER
25
1.000
EA
1110-2387
POST SPRING
26
1.000
EA
1110-2441
ROD UPPER
26
1.000
EA
1110-2417
SLEEVE SHORTING BAR
27
1.000
EA
1110-1232
SLIDE ADJUSTING
28
1.000
EA
1110-1241
PIN ELLIPTICAL ADJUST
29
1.000
EA
1110-1071
BEARING SLIDE
30
4.000
EA
2360-0030
SPHERE 1/8IN CHROME STEEL G25
31
1.000
EA
1116-0514
SCR 4-40 X .75 HSC SBZ N
32
2.000
EA
2360-1117
PIN DOWEL HRD .125 X .500 LG
33
1.000
EA
972014-001
NUT 4-40 H SS NL
34
1.000
EA
2360-0331
SPRING
35
1.000
EA
1106-3205
SPRING SLIDE ASSY
36
2.000
EA
1110-1101
CLAMP ROD
37
1.000
EA
1110-1089
SLEEVE
38
2.000
EA
974000-002
WSR F #4 .312 X .125 X .032 SBZ
35
9660 SERIES SEAM TRACKER CONTROLLER
DRAWINGS AND PARTS LISTS
FIGURE 29 - MSP40 CROSS-SLIDE EXPLODED VIEW
36
DRAWINGS AND PARTS LISTS
9660 SERIES SEAM TRACKER CONTROLLER
TABLE 14 - MSP40 CROSS-SLIDE PARTS LIST
Item
No
1
QPA
UM
1.000
EA
Part
Part
No 3” X 3”
No 6” X 6”
1110-0007
1110-0066
Description
BASE UPP-ST40
2
1.000
EA
1110-0015
1110-0074
BASE LWR ST40
3
2.000
EA
1110-2310
1110-2310
PLATE END - ST40
4
4.000
EA
1116-0000
1116-0034
SEAM TRACKER RAIL - ST40
6
2.000
EA
1110-0121
1110-0155
BAR RAIL ADJ
8
2.000
EA
1116-0042
1116-0077
ASSY SCR ACTR ST40
10
2.000
EA
1110-0180
1110-0091
COVER RETAINER - ST40
12
2.000
EA
1112-0008
1112-0016
COVER RETAINER
14
2.000
EA
1110-0198
1110-0198
BEARING HOUSING ST40A
15
2.000
EA
1110-0210
1110-0210
NUT HOUSING-ST40A
16
1.000
EA
1110-0171
1110-0171
FACEPLATE - ST40
17
1.000
EA
1110-0236
1110-0236
ADAPTER PLATE ST40
18
2.000
EA
1117-0587
1117-0587
MOTOR-ST40
19
4.000
EA
1116-0115
1116-0115
SET SCR HALF DOG - MOD
20
2.000
EA
1116-0107
1116-0107
COVER GEAR - ST40
21
1.000
EA
1106-0048
1106-0048
JUNCTION BOX ASSY - ST40
22
4.000
EA
2000-0015
2000-0058
COVER TELESCOPING .50 X 1.0 X 3.5 STRK
24
8.000
EA
2360-0552
2360-0552
WHEEL GUIDE DUAL VEE #2
25
8.000
EA
2360-0226
2360-0226
BUSHING ADPTR STNRY ¼ X 9/16 L
26
2.000
EA
2416-0157
2416-0157
RING RTNG-BOWED “E” RING .025 THK
27
2.000
EA
2320-0139
2320-0139
GEAR SPUR 36T 32P
28
2.000
EA
2320-0147
2320-0147
GEAR SPUR 60T 32P SS
29
4.000
EA
2040-0544
2040-0544
GEAR CLAMP SPLIT HUB
30
4.000
EA
2320-0112
2320-0112
BEARING BALL
31
1.000
EA
989009-004
989009-004
CLAMP CABLE 1/8 ID
32
4.000
EA
981007-003
981007-003
STDOFF M/F 6-32 X .250 X .562 LG A
33
AR
EA
933001-105
933001-105
SHRINK TUBING 3/16 PVC BLK
34
AR
EA
974031-103
974031-103
WSR F .505 X .317 X .005 SBZ
36
8.000
EA
974005-006
974005-006
WSR, F ¼ .468 X .255 X .032 SBZ
37
8.000
EA
972014-008
972014-008
NUT, 1/4-20 H SS NL
38
6.000
EA
970043-300
970043-300
SCR SET 6-32 X .12 HHC SBZ
39
4.000
EA
970000-302
970000-302
SCR 6-32 X .25 CR1P SBZ
40
5.000
EA
970000-402
970000-402
SCR 8-32 X .25 CR1P SBZ
41
6.000
EA
970015-306
970015-306
SCR 6-32 X .50 HSC SBZ
42
10.000
EA
970015-404
970015-404
SCR 8-32 X .38 HSC SBZ
43
16.000
EA
970015-406
970015-406
SCR 8-32 X .50 HSC SBZ
44
8.000
EA
970015-410
970015-410
SCR 8-32 X .75 HSC SBZ
45
4.000
EA
970015-502
970015-502
SCR 10-32 X .25 HSC SBZ
46
4.000
EA
970015-604
970015-604
SCREW 1/4-20 X .38, HSC SBZ
47
4.000
EA
970015-608
970015-608
SCR 1/4-20 X .62 HSC SBZ
48
8.000
EA
970039-616
970039-616
SCR 1/4-20 X 1.25H SBZ G8
37
9660 SERIES SEAM TRACKER CONTROLLER
DRAWINGS AND PARTS LISTS
FIGURE 30 - MSP250 CROSS-SLIDE EXPLODED VIEW
38
DRAWINGS AND PARTS LISTS
9660 SERIES SEAM TRACKER CONTROLLER
TABLE 15 - MSP250 CROSS-SLIDE PARTS LIST
Item
No
1
QPA
UM
2.000
EA
Part
Part
No 5” x 5”
No 10” x 10”
0600-0034
0600-0036
Description
UNIVERSAL BASE,ST250
2
4.000
EA
0600-0366
0600-0366
BEARING BLOCK O-RING
3
3.000
EA
0600-0302
0600-0302
UNIVERSAL BRG BLK ST250
4
1.000
EA
0600-0372
0600-0372
4 BOLT ST250 BRG BLOCK
5
3.000
EA
2320-0244
2320-0244
BEARING BALL, ANLR CONT
6
1.000
EA
0600-0123
0600-0123
BALL BEARING ST250
7
2.000
EA
2380-0128
2380-0128
SEAL OIL .375X1.125X.312
9
2.000
EA
0600-0346
0600-0346
NUT HOUSING INSERT ST250
10
2.000
EA
0600-0339
0600-0339
NUT HOUSING PLATE ST250
11
2.000
EA
0600-0336
0600-0336
NUT HOUSING ST250
12
2.000
EA
0600-0380
0600-0374
ST250 SCREW ACTUATOR ASSY
13
2.000
EA
0600-0064
0600-0068
TRACK COVER, LOWER LEFT
14
2.000
EA
0600-0065
0600-0069
TRACK COVER, LOWER RIGHT
15
4.000
EA
0600-0159
0600-0098
SCREW COVER ASSY ST250
16
1.000
EA
0600-0058
0600-0058
FACEPLATE
17
1.000
EA
0600-0048
0600-0048
END PLATE, LOWER
18
2.000
EA
1112-0211
1112-0211
COVER SEAL, BEARING
19
2.000
EA
0600-0373
0600-0373
2" STAND-OFF
20
4.000
EA
0600-0279
0600-0282
RAIL ST250
21
8.000
EA
2360-0561
2360-0561
WHEEL, GUIDE, DUAL VEE
22
4.000
EA
0600-0054
0600-0054
ADAPTOR BUSHING, ADJUSTABLE
23
2.000
EA
2320-1151
2320-1151
INSERT COUPLING
24
4.000
EA
2320-1160
2320-1160
COUPLING HALF, 3/8 IN
25
1.000
EA
0600-0111
0600-0111
MOTOR ASSY ST250 UPPER
26
4.000
EA
2360-0234
2360-0234
BUSHING ADAPTER
27
8.000
EA
970039-718
970039-718
SCR 5/16-18X1.50 H SBZ G8
28
1.000
EA
1116-0123
1116-0123
GEAR MOTOR, 25:1
29
2.000
EA
981002-004
981002-004
STDOFF HX M/F 8-32X.25X1.12 SS
30
1.000
EA
0600-0377
0600-0377
UPPER MTR CVR ST250 3.5"
32
1.000
EA
1110-0392
1110-0392
ADAPTER PLATE
34
1.000
EA
0600-0094
0600-0094
BRAKE ASSY
35
36.00
EA
970000-402
970000-402
SCREW, 8-32X.25 CR1P SBZ
36
4.000
EA
1110-0406
1110-0406
COLLAR, INSULATING
37
1.000
EA
1112-0237
1112-0237
PLATE, INSULATING
38
1.000
EA
1115-0705
1115-0705
NAMEPLATE SEAM TRACKER
40
4.000
EA
970039-710
970039-710
SCR 5/16-18X.75 H SBZ G8
41
2.000
EA
970039-725
970039-725
DOWEL PIN 1/4 X 1
42
28.00
EA
970039-610
970039-610
SCREW, 1/4-20X.75 H SBZ G8
43
8.000
EA
970039-606
970039-606
SCREW, 1/4-20X.50 H SBZ G8
44
1.000
EA
930014-013
930014-013
CONN CIRC BOX RCPT 20-27P
45
1.000
EA
930014-010
930014-010
CONN CIRC BOX RCPT 14S-6S
46
1.000
EA
976000-005
976000-005
GROMMET RUBBER 5/16ID X 5/8 OD
39
9660 SERIES SEAM TRACKER CONTROLLER
DRAWINGS AND PARTS LISTS
TABLE 16 - MSP250 CROSS-SLIDE PARTS LIST
Item
Part
Part
No 5” x 5”
No 10” x 10”
EA
0600-0060
0600-0060
MOTOR COVER, LOWER
12.00
EA
970010-608
970010-608
SCR 1/4-20X.62 CR1F SBZ
2.000
EA
2414-0201
2414-0201
SCR RND HD U-DRV #2X1/4
51
2.000
EA
2360-0863
2360-0863
3/32 X .375 SQ. KEY
52
2.000
EA
970043-401
970043-401
SET SCREW, 8-32x.19 HHC SBZ
53
8.000
EA
970000-003
970000-003
WASHER 5/16
55
6.000
EA
970015-610
970015-610
SCREW, 1/4-20X.75 HSC SBZ
56
10.00
EA
970015-618
970015-618
SCREW, 1/4-20X1.50 HSC SBZ
57
1.000
EA
0600-0052
0600-0052
END PLATE, UPPER UNIVERSAL
58
8.000
EA
970015-402
970015-402
SCREW, 8-32X.25 HSC SBZ
59
1.000
EA
0600-0099
0600-0099
MTR CVR ASSY LWR ST250
QPA
UM
47
1.000
49
50
No
40
Description
DRAWINGS AND PARTS LISTS
9660 SERIES SEAM TRACKER CONTROLLER
41
9660 SERIES SEAM TRACKER CONTROLLER
DRAWINGS AND PARTS LISTS
FIGURE 31 - 9660S SEAM TRACKER CONTROL EXPLODED VIEW
42
DRAWINGS AND PARTS LISTS
9660 SERIES SEAM TRACKER CONTROLLER
TABLE 17 - 9660S SEAM TRACKER CONTROL PARTS LIST
Item
Part
QPA
UM
1
1.000
EA
9660-1
ST CONTROL ENCLOSURE, 9660
1
1.000
EA
9660-1-DOOR
ST CONTROL ENCLOSURE, DOOR, 9660
1
1.000
EA
9660-2
ST CONTROL ENCLOSURE OVERLAY, 9660
2
1.000
EA
1101-2002-2
CONTROL TRANSFORMER ASSY
3
1.000
EA
1101-2002-3
MAIN BOARD ASSY
4
1.000
EA
1101-2002-4
MOTOR DRIVER ASSY
5
1.000
EA
1101-2002-5
CONTROL DRIVE CABLE ASSY
6
1.000
EA
1101-2002-6
VOLTAGE SELECTOR SWITCH ASSY
7
1.000
EA
1101-2002-7
CONTROL PENDANT CABLE ASSY
8
1.000
EA
1101-2002-8
POWER SWITCH ASSY
9
1.000
EA
9660S-2
OPTION PLATE COVER - CONNECTOR, 9660
10
1.000
EA
9660S-1
OPTION PLATE COVER, FRONT PANEL, 9660
12
1.000
EA
1175-0079
LABEL CAUTION 110/220VAC (NOT SHOWN)
13
0.625
EA
999005-005
TAPE NEO FOAM ADH 1/8INX1/4THK
14
5.000
EA
979001-001
CABLE TIE .75 BUNDLE DIA (NOT SHOWN)
15
1.000
EA
989003-001
CBL TIE MNT ADH BACK .75IN SQ (NOT SHOWN)
16
0.417
FT
2040-0536
GROMMET CATERPILLAR
17
1.000
EA
929000-001
3 CONDCTR PWR SPLY CORD (NOT SHOWN)
18
4.000
EA
2414-0201
SCR RND HD U-DRV #2X1/4
19
4.000
EA
970000-204
SCR 4-40X.38 CR1P SBZ
21
15.000
EA
970000-406
SCR 8-32X.50 CR1P SBZ
23
8.000
EA
974010-002
WSR SL #4.209X.121X.025 SBZ
24
7.000
EA
974010-004
WSR SL #8.293X.175X.040 SBZ
28
8.000
EA
972000-002
NUT 4-40 H SBZ
30
4.000
EA
972000-005
NUT 10-32 H SBZ
31
4.000
EA
974010-005
WSR SL #10 .334X.202X.047 SBZ
32
4.000
EA
974006-005
WSR F #10 .374X.195X.032 B
33
8.000
EA
970000-404
SCR 8-32X.38 CR1P SBZ
34
8.000
EA
974010-004
WSR SL #8.293X.175X.040 SBZ
35
6.000
EA
972000-003
NUT 6-32 H SBZ
37
6.000
EA
974000-004
WSR F #8 .438X.188X.049 SBZ
No
No
Description
43
9660 SERIES SEAM TRACKER CONTROLLER
DRAWINGS AND PARTS LISTS
FIGURE 32 - 9660S-100 CONTROL PENDANT EXPLODED VIEW
44
DRAWINGS AND PARTS LISTS
9660 SERIES SEAM TRACKER CONTROLLER
TABLE 18 - 9660S-100 CONTROL PENDANT PARTS LIST
Item
Part
QPA
UM
1
1.000
EA
9660-100-1
SEAM TRACKER PENDANT ENCLOSURE 9660
2
1.000
EA
9660-100-2
SEAM TRACKER PENDANT FACEPLATE 9660
3
1.000
EA
1116-0352
SWITCH SIDETRACK
4
1.000
EA
2066-0112
SW JOY STICK 9 POS SNGL POLE
5
1.000
EA
1116-0387
SWITCH AUTO/MAN
6
1.000
EA
1114-1332
ST PENDANT ASSY, 10 FT. (NOT SHOWN)
7
1.000
EA
2040-0579
CBL FTTNG W/NUT&BSH .375-.500
8
1.000
EA
2208-0105
CONN RECT PLUG (9CKT) (NOT SHOWN)
9
2.000
EA
2212-0107
TERM PIN CRIMP 24-30 GA (NOT SHOWN)
10
1.000
EA
2208-0059
CONN RECT RCPT (9CKT) (NOT SHOWN)
11
9.000
EA
2212-0093
TERM SOCKET CRIMP 18-24 GA (NOT SHOWN)
12
1.000
EA
900007-003
CAP CER .1UF 500V +80 -20% (NOT SHOWN)
13
16.00
EA
970021-404
SCR 8-32X.38 HSBC SBZ
14
4.000
EA
0600-0026
FEET, RUBBER
15
1.000
EA
9660S-100-1
TST PENDANT BLANK OPTION PANEL
No
No
Description
45
9660 SERIES SEAM TRACKER CONTROLLER
DRAWINGS AND PARTS LISTS
FIGURE 33 - POWER SWITCH ASSEMBLY EXPLODED VIEW
TABLE 19 - POWER SWITCH ASSEMBLY PARTS LIST
Item
Part
QPA
UM
1
1.000
EA
2066-0171
SWITCH, SELECT 1-3/16 RED
2
1.000
EA
2100-0086
INCANDESCENT LAMP, 1/2 28V
3
2.000
EA
2068-0172
BLOCK CONTACT N.O.
4
1.000
EA
2208-0181
CONN RECT PLUG (8CKT)
5
6.000
EA
2212-0018
TERMINAL CRIMP PIN 18-24 GA
No
No
Description
46
DRAWINGS AND PARTS LISTS
9660 SERIES SEAM TRACKER CONTROLLER
FIGURE 34 - TRANSFORMER ASSEMBLY EXPLODED VIEW
TABLE 20 - TRANSFORMER ASSEMBLY PARTS LIST
Item
Part
QPA
UM
1
1.000
EA
1117-1118
XFRMR 115/230VAC,30VCT/10.5VAC
2
1.000
EA
2208-0199
CONN RECT PLUG (10CKT)
3
9.000
EA
2212-0018
TERMINAL CRIMP PIN 18-24 GA
4
2.000
EA
970000-426
SCR 8-32X2.50 CR1P SBZ
5
2.000
EA
972001-004
NUT 8-32 FH SBZ SL GB
6
2.000
EA
974010-004
WSR, SL #8.293X.175X.040 SBZ
No
No
Description
47
9660 SERIES SEAM TRACKER CONTROLLER
DRAWINGS AND PARTS LISTS
FIGURE 35 - MOTOR DRIVER HEATSINK ASSEMBLY EXPLODED VIEW
TABLE 21 - MOTOR DRIVER HEATSINK ASSEMBLY PARTS LISTS
Item
No
1
QPA
UM
2.000
EA
Part
No
1103-0491
Description
TRANSISTOR REPLACEMENT KIT
CONSISTING OF:
2
2.000
EA
2708-0081
XSTR 2N6282 PWR 60V NPN (ALT: 2N6283 OR 2N6284)
3
2.000
EA
2708-0103
XSTR 2N6285 PWR 80V PNP (ALT: 2N6286 OR 2N6287)
4
4.000
EA
2716-0000
INSULATOR MICA TO-3
5
2.000
EA
902004-019
RES WW .1 OHM +/- 3% 5W
6
1.000
EA
2702-0186
RECITIFIER BRIDGE CBR35-01P
7
1.000
EA
2610-1093
RES WW 250 OHM +/- 3% 10W
8
1.000
EA
2702-0178
RECTIFIER BRIDGE 2AMP 200V
9
1.000
EA
2208-0202
CONN RECT PLUG (12 CKT)
10
1.000
EA
2208-0148
CONN RECT PLUG (5 CKT)
11
18.00
EA
2212-0019
TERMINAL CRIMP MOLEX 18-20 .156
12
2.000
EA
2500-0692
CAP CER 680PF (NOT SHOWN)
13
8.000
EA
970015-412
SCREW 8-32 X .88 HSC SBZ
48
DRAWINGS AND PARTS LISTS
9660 SERIES SEAM TRACKER CONTROLLER
TABLE 22 - MOTOR DRIVER HEATSINK ASSEMBLY PARTS LISTS (CONT.)
Item
Part
QPA
UM
14
0.000
AR
3070-0058
THERMAL COMPOUND
15
4.000
EA
2716-0034
TRANSISTOR SOCKET TO-3
16
6.000
EA
970000-103
SCREW 2-56 X .31 CR1P SBZ
17
6.000
EA
974010-001
WASHER SPLIT LOCK # 2
20
2.000
EA
970000-308
SCREW 6-32 X .62 CR1P SBZ
21
10.000
EA
974010-003
WASHER SPLIT LOCK # 6
27
1.000
EA
970000-502
SCREW 10-32 X .25 CR1P SBZ
30
1.000
EA
974010-005
WASHER SPLIT LOCK # 10
38
1.000
EA
989009-005
CABLE CLAMP 3/16” PVC BLACK
No
No
Description
49
9660 SERIES SEAM TRACKER CONTROLLER
DRAWINGS AND PARTS LISTS
FIGURE 36 - VOLTAGE SELECTOR SWITCH ASSEMBLY EXPLODED VIEW
TABLE 23 - VOLTAGE SELECTOR SWITCH ASSEMBLY PARTS LIST
Item
Part
QPA
UM
1
1.000
EA
920035-001
SLIDE SW 2 POS LINE VOLT SEL
2
1.000
EA
2120-0123
FILTER RFI-PWR LINE 3 AMP
3
1.000
EA
2208-0551
CONN RECT PLUG (6 PIN) .200"P
4
5.000
EA
???
TERMINAL CRIMP PIN 18-24 GA
5
1.000
EA
2120-0000
FUSE CARRIER 1/4 X 1 1/4 FEK
6
1.000
EA
2120-0263
FUSE 7-1/2A 250V
7
1.000
EA
2340-0618
TERM RING 1/4 22/16 RED
No
No
Description
50
DRAWINGS AND PARTS LISTS
9660 SERIES SEAM TRACKER CONTROLLER
FIGURE 37 - DRIVE CONNECTOR HARNESS EXPLODED VIEW
TABLE 24 - DRIVE CONNECTOR HARNESS ASSEMBLY PARTS LIST
Item
Part
QPA
UM
1
1.000
EA
930014-001
CONN CIRC BOX RCPT 20-27S
2
1.000
EA
2208-0211
CONN RECT PLUG (14CKT)
3
1.000
EA
2212-0018
TERMINAL CRIMP PIN 18-24 GA
4
1.000
EA
2340-0588
TERM RING INSUL #6 X .92 LG
No
No
Description
51
9660 SERIES SEAM TRACKER CONTROLLER
DRAWINGS AND PARTS LISTS
FIGURE 38 - PENDANT CONNECTOR HARNESS EXPLODED VIEW
TABLE 25 - PENDANT CONNECTOR HARNESS ASSEMBLY PARTS LIST
Item
Part
QPA
UM
1
1.000
EA
930014-015
CONN CIRC BOX RCPT 22-14S
2
1.000
EA
???
CONN RECT PLUG (18 CKT)
3
17.000
EA
2212-0018
TERMINAL CRIMP PIN 18-24 GA
4
1.000
EA
2340-0588
TERM RING INSUL #6 X .92 LG
No
No
Description
52
DRAWINGS AND PARTS LISTS
9660 SERIES SEAM TRACKER CONTROLLER
FIGURE 39 - STD. TORCH CLAMP BRACKET, 1103-0017
TABLE 26 - STD. TORCH CLAMP BRACKET PARTS LIST
Item
Part
QPA
UM
2.000
EA
974010-005
WSR SL #10 .334 X .202 X .047 SBZ (NOT SHOWN)
2.000
EA
972000-005
NUT, 10-32 H SBZ (NOT SHOWN)
2.000
EA
970010-510
SCREW, 10-32 x .75 CR1F SBZ (NOT SHOWN)
29A
2.000
EA
970015-616
SCR 1/4-20 X 1.25 HSC SBZ
29B
2.000
EA
970015-623
SCR 1/4-20 X 2.25 HSC SBZ
30
2.000
EA
974010-006
WSR SL ¼ .489 X .263 X .062 SBZ
31
1.000
EA
1110-1445
CLAMP - GTA TORCH
32
1.000
EA
1110-1461
CLAMP BASE - TORCH MTG BRKT
33
1.000
EA
1110-1470
BASE PLATE - TORCH MTG BRKT
No
No
Description
53
9660 SERIES SEAM TRACKER CONTROLLER
DRAWINGS AND PARTS LISTS
FIGURE 40 - OPTIONAL UNIVERSAL BRACKET, 1103-0009
TABLE 27 - OPTIONAL UNIVERSAL BRACKET PARTS LIST
Item
Part
QPA
UM
16
12.000
EA
972000-006
NUT, 1/4-20 H SBZ
17
12.000
EA
974010-006
WSR SL 1/4.489X.263X.062 SBZ
19
2.000
EA
1113-0020
BRACKET UNIV - STAMPING
21
4.000
EA
970039-614
SCR 1/4-20X1.00 H SBZ G8
22
2.000
EA
1113-0038
BRACKET UNIV - STAMPING
23
8.000
EA
970039-606
SCR 1/4-20X.50 H SBZ G8
24
2.000
EA
972000-005
NUT, 10-32 H SBZ
25
2.000
EA
974010-005
WSR SL #10 .334X.202X.047 SBZ
26
1.000
EA
1112-0059
BRACKET PROBE
27B
2.000
EA
970010-510
SCREW, 10-32 x .75 CR1F SBZ
27A
2.000
EA
970010-506
SCR 10-32X.50 CR1F SBZ
No
No
Description
54
DRAWINGS AND PARTS LISTS
9660 SERIES SEAM TRACKER CONTROLLER
FIGURE 41 - U-BRACKET (TST40), 1103-0025
TABLE 28 - U-BRACKET (TST40) PARTS LIST
Item
Part
QPA
UM
3
1.000
EA
1110-1453
CLAMP BASE - GTA TORCH
5
1.000
EA
1110-1445
CLAMP - GTA TORCH
6
2.000
EA
974004-006
WSR, F 1/4 .734X.312X.065 SBZ
7
2.000
EA
970015-622
SCREW, 1/4-20 X 2.00, HSC SBZ
8
2.000
EA
972000-005
NUT, 10-32 H SBZ
9
2.000
EA
974010-005
WSR SL #10 .334X.202X.047 SBZ
10
1.000
EA
1112-0113
BRACKET SLIDE - GTA TORCH
11
2.000
EA
970010-506
SCR 10-32X.50 CR1F SBZ
12
4.000
EA
970039-606
SCR 1/4-20X.50 H SBZ G8
No
No
Description
55
9660 SERIES SEAM TRACKER CONTROLLER
DRAWINGS AND PARTS LISTS
FIGURE 42 - 5-AXIS MOUNT
TABLE 29 - 5-AXIS MOUNT PARTS LIST
Item
No
36
QPA
UM
1.000
EA
Part
No
1106-0692P
Description
SLIDE ASSEMBLY PROBE H.D.
Consisting of:
1
2.000
EA
1110-0830
BASE SLIDE - 1 1/2IN STR
3
1.000
EA
1110-1402
CROSS SLIDE LOWER
4
1.000
EA
1110-2298
CROSS SLIDE UPPER
5
2.000
EA
1112-0156
GIB SLIDE - 1 1/2IN STR
7
2.000
EA
1110-0856
HOUSING BUSHING
8
2.000
EA
1112-0164
END PLATE STOP
9
2.000
EA
1110-3880
SCR ADJUSTING-1 1/2IN STR
11
1.000
EA
1110-3898
NUT DRIVE-LOWER AXIS
12
1.000
EA
1110-3901
NUT DRIVE-UPPER AXIS
13
2.000
EA
2320-0180
BUSHING FLG .38 X .63 X .625LG BRZ
14
2.000
EA
1116-0450
KNOB - MODIFIED
20
2.000
EA
974031-105
WSR F .630 X .380 X .010 SBZ
21
4.000
EA
970000-404
SCR 8-32 X .38 CR1P SBZ
56
DRAWINGS AND PARTS LISTS
9660 SERIES SEAM TRACKER CONTROLLER
TABLE 30 - 5-AXIS MOUNT PARTS LIST (CONT.)
Item
Part
QPA
UM
22
4.000
EA
970015-406
SCR 8-32 X .50” HSC SBZ
23
2.000
EA
970010-001
SCR 10-24 X 1.25” CR1F SBZ
24
2.000
EA
2408-1036
STUD PRESS 1/4-20 X 1.00” LG S
25
6.000
EA
970043-401
SET SCREW, 8-32 X 1/4” SHCP
26
2.000
EA
2416-0203
EXT RET RING .035” THK
28
2.000
EA
2360-1109
PIN ROLL .0938” DIA X .750” LG
29
2.000
EA
974031-002
WSR F .750” X .401” X .075” SSP
1.000
EA
1106-0668
BRKT ASSY PROBE ADJUST
No
No
Description
Consisting of:
37
2.000
EA
970015-614
SCR 1/4-20 X 1.00” HSC SBZ
38
1.000
EA
974004-006
WSR, F 1/4 .734” X .312” X .065” SBZ
39
1.000
EA
1106-0684
ARM ASSY - PROBE ADJUST
40
1.000
EA
1110-0805
PIVOT - MACHINED
41
2.000
EA
974005-006
WASHER FLAT ¼ .468” X ..255” X .032”
42
2.000
EA
972014-008
NUT 1/4-20 NL
43
1.000
EA
1100-0258
5-AXIS PROBE BRACKET ASSEMBLY
44
1.000
EA
45
1.000
EA
1100-1017
SENSOR ASSEMBLY (SEE PAGE 34)
46
1.000
EA
1114-0378
SENSOR CABLE ASSEMBLY
SEE SENSOR TIPS BEGINNING ON PAGE 4
57
9660 SERIES SEAM TRACKER CONTROLLER
DRAWINGS AND PARTS LISTS
58
TROUBLESHOOTING
9660 SERIES SEAM TRACKER CONTROLLER
Many of the Integrated Circuits (IC’s) on the Main
board are CMOS logic, and require standard CMOS
precautions against damage by static electricity discharge.
TROUBLESHOOTING
The following list describes typical problems and suggested corrective procedures.
The CIRCUIT DESCRIPTIONS section, which includes block diagrams and schematics, will also be a
helpful reference for troubleshooting.
RECOMMENDED SPARES FOR TROUBLESHOOTING
This manual was written in a manner to provide
enough detail to identify individual components and
parts for maintenance purposes. A recommended
spare parts lists is given in Table 35 - Recommended
Spare Parts on page 60. For troubleshooting, the following items are recommended to isolate most problems.
Full line voltage is exposed inside the control unit.
Do not turn power “On” when the Main board is removed, partially removed or disconnected.
TABLE 31 - TROUBLESHOOTING
Problem #
Problem 1 Lamp Off
description
Lamp is not lit
Cause
• Unit unplugged
• Blown Fuse
• Lamp is bad
Solution
• Plug unit into an appropriate AC
Source
• Replace Fuse
• Replace Lamp
• Cables disconnected from the control • Check cables from the control to other
to other components of the system
Problem 2 - No
Operation
Power Switch and Indicator Lamp are
ON, but nothing works
• Connectors are disconnected inside
the control
• Main board voltages are not present
components of the system
• Check connectors inside the control
unit
• Check Main board voltages, ± 20VDC,
±15VDC, and ±6VDC
Problem 3 Horizontal Drift
• Sidetrack is enabled
• Main board is out of calibration
Cross-slide drifts horizontally in Auto- • Omni-Guide Sensor is out of adjustmatic Mode only
ment
• Check the Sidetrack switch to verify it
is in the desire position
• Adjust the Horizontal Null Adjustment
Potentiometer on the Main board
• Replace the Omni-Guide Sensor with
a known good sensor or send the
sensor in for repair
• Main board Vertical Offset may need
Problem 4 - Vertical Drift
Cross-slide drifts vertically in Manual
Mode only
adjustment
• Main board may be faulty
• Adjust Vertical Offset on the Main
board
• Replace the Main board with a known
good board
Problem 5 System
Oscillation
System oscillates while tracking in
Automatic Mode
• Omni-Guide Sensor is not in the cor-
• Check the Omni-Guide Sensor to ver-
rect orientation with the drive assemblies axes
ify its X and Z axes are in the same
orientation as the cross-slides X and Z
axes. Make adjustments as necessary
• The system is mounted on a fixture
that is not stable
• The cross-slides have mechanical
play in the horizontal and/or vertical
axes
• Check the fixture for rigidity and eliminate the instability
• Check the cross-slides for mechanical
play or looseness and eliminate it
59
9660 SERIES SEAM TRACKER CONTROLLER
Problem #
description
TROUBLESHOOTING
Cause
Solution
• Possibly Main board may be faulty
• Possibly heatsink assembly may be
Problem 6 Doesn’t Drive
Downward
System doesn’t drive down and contact the work when the Mode Switch
on the pendant assembly is switched
to Automatic Mode (no PTST Seam
Tracking Option is installed)
faulty
• Possibly Omni-Guide Sensor may be
• Check vertical drive signals on the
Main board to verify the proper voltages
• Check the output test points on the
Main board for verify the heatsink
voltages are correct
faulty
• Check the Omni-Guide Sensor’s
lower rod is pointing in the downward
position, check voltages on the Main
board for the Omni-Guide Sensor’s
output
• Switches on the pendant assembly
• Switch commands from the pendant
are faulty
Problem 7 Slides will not
Drive
Cross-slides will not drive in one or
more directions using manual commands on Manual Mode
• Main board is faulty
• Heatsink assembly is faulty
Description
Values
TP7
-20 VDC
-20 VDC ±1.0 VDC
TP3
+20 VDC
+20 VDC ±1.0 VDC
TP8
-15 VDC
-15 VDC ±0.5 VDC
TP4
+15 VDC
+15 VDC ±0.5 VDC
TP9
-6 VDC
-6 VDC ±0.5 VDC
TP5
+6 VDC
+6 VDC ±0.5 VDC
• Check Test Points on the Main board
to verify the signals are being received and sent to the motors on the
cross-slides (see the following tables)
TABLE 34 - OMNI-GUIDE SENSOR TEST
POINTS
TABLE 32 - VOLTAGE TEST POINTS
TP #
assembly are not getting to the main
board
TP #
Description
TP6
Vertical Probe (VP)
TP10
Horizontal Probe (HP)
TP12
2KHz Clock/Probe
Drive
Values
UP » -4 VDC
DN » +4 VDC
RIGHT » -4 VDC
LEFT» +4 VDC
2KHz +/- 300Hz
TABLE 35 - RECOMMENDED SPARE PARTS
TABLE 33 - DRIVE SIGNAL TEST POINTS
TP #
TP1
TP2
Description
Horizontal Error (VE)
Vertical Error (HE)
Values
RIGHT » +12.5 VDC
Item #
Qty
Part #
Description
1
2
2120-0263
Fuse
2
1
2100-0086
Power Lamp
3
1
1101-2002-3
Main Board
4
2
1110-2093
Insulator
5
2
1110-1101
Rod Clamp
6
1
2702-0186
Rectifier
7
1
1103-0491
Transistor Kit
LEFT» -12.5 VDC
UP » +12.5 VDC
DN » -12.5 VDC
60
TROUBLESHOOTING
9660 SERIES SEAM TRACKER CONTROLLER
FIGURE 43 - 9660S CONTROL SIGNAL FLOW
61
9660 SERIES SEAM TRACKER CONTROLLER
TROUBLESHOOTING
The Figure 45 - Sensor Orientation on Tanks, Pressure
Vessels and Pipes on page 62 shows a typical angle
for welding on a tank or pipe. The acceptable angles
are from 10° to 45° degrees. The system performs
better and will require less maintenance, when the angle is set less than 45° degrees. As a initial angle setting for the sensor, efforts should be made to position
the sensor at or around a 30° degree angle.
HELPFUL HINTS
The sensor position and angle are crucial for proper
tracking and sidetrack performance. Below are a few
tips to assist in proper sensor adjustment to maintain
optimum performance.
Hint # 1 - Lap Joint Welding Applications
The angle of the sensor is extremely important when
tracking a lap joint. If the sensor’s tip is at a 90° degree angle from the Lower Member, the sensor could
be pulled out of the joint by the Upper Member of the
lap joint. This is especially true if the Upper Member
of the joint has a sharp edge at the top of the joint,
which can capture the sensor’s tip and pull it onto the
Upper Member. Once on top of the Upper Member of
the lap joint the seam tracking system has lost the
weld joint with no hope of recovery.
Notice also in Figure 45 - Sensor Orientation on
Tanks, Pressure Vessels and Pipes that the angle measurement is not made from our horizon, but from the
location of the tip to work contact point. This is important to note, because often the sensor is located on
the leading side of the tank (as illustrated), which requires the sensor angle to appear to be pointing upward when measuring the angle from our horizon.
In circumferential applications welding smaller tanks,
vessels or pipes, the sensor angle must change considerably to maintain the 10° to 45° degree angle requirement.
By adjusting the sensor’s angle, this problem can be
reduced or eliminated. By pointing the tip into the lap
joint, as in Figure 44 - Sensor Angle on Lap Joints on
page 62, we no longer track the top edge of the Upper
Member and minimize the chances of the tip from being captured by a burr or sharp edge.
Hint # 3 - Cross Slide to Sensor Relationship
The cross slide to sensor relationship must be maintained to within ± 5° degrees. The cross slide is made
up of two axes--vertical and horizontal. The sensor
also has these two axes. To properly track the joint,
the two must be in the same axis. For example, an
upward movement on the sensor’s tip, must direct the
slide to move upward as well. If these relationships
aren’t maintained, an upward movement of the sensor’s tip could cause the slides to move up and to the
right. This could cause the system to climb out of the
joint or worse. Figure 46 - Cross Slide to Sensor Relationship, Correct on page 63 illustrates the proper
configuration of the sensor and the cross slide. Figure 47 - Cross Slide to Sensor Relationship, Incorrect
Hint # 2 - Circumferential Welding Applications
Like with lap joint welding applications, Circumferential welding applications also require proper angle
settings for the system to track properly, both while
welding and when trying to locate the seam.
If the sensor angle is too steep, the sensor’s tip will
tend to gouge or scribe the material. In doing so, the
sensor often gets caught by the material being welded,
preventing the system from finding the joint properly
or from properly tracking the joint when using sidetrack to bias one side of the joint.
FIGURE 45 - SENSOR ORIENTATION ON TANKS,
PRESSURE VESSELS AND PIPES
FIGURE 44 - SENSOR ANGLE ON LAP JOINTS
62
TROUBLESHOOTING
9660 SERIES SEAM TRACKER CONTROLLER
shows a configuration to avoid when setting up the
seam tracking system. Please note in the figure the
grooves on the outer case of the sensor. The groove
on the sensor traveling the entire length of the sensor
body indicates the vertical up direction and should be
oriented with the vertical axis of the cross slide.
To correct these problems, it is necessary to change to
sets of wires. Inside the Horizontal Motor Cover assembly, item # 59 in Figure 30 - MSP250 Cross-Slide
Exploded View on page 38, is a motor with two leads.
Simply reverse these two leads. This corrects the
cross slide problem.
Hint # 4 - Sensor Rotated 180° Degrees
Certain Applications and fixtures require the sensor to
be rotated 180° degrees from the design intent. Figure 11 - Interconnection Diagram on page 7 and Figure 19 - Torch Clamp Mounting Bracket on page 14
and others in the Description of Equipment section of
this manual illustrate proper installation of the sensor
to the cross slides. The sensor is mounted to the front
and tracks the seam in front of the cross slide’s face
plate. This plate mounted to the cross slides vertical
slider is used to mount a wire feed head assembly,
torch, etc., and to mount the 5-axis mount assembly
and the sensor.
To correct the pendant problem, swap pins 6 & 7 on
the wiring harness at the P1 connector of the main
board inside the control unit. See Figure 27 - Seam
Tracker Main Board Layout on page 31 for the location of the P1 connector.
Occasionally, the sensor must be mounted to the back
side of the cross slides (180° degrees out of original
design configuration) to accommodate fixtures or
other needs of the system as shown in Figure 48 Sensor Rotated 180° Degrees on page 64.
This configuration causes two problems: the horizontal slide will want to travel in the wrong direction as
commanded from the sensor and the Joystick switch
on the pendant will when commanding the sides to
move left will move the horizontal slide to the right.
FIGURE 46 - CROSS SLIDE TO SENSOR RELATIONSHIP, CORRECT
FIGURE 47 - CROSS SLIDE TO SENSOR RELATIONSHIP, INCORRECT
63
9660 SERIES SEAM TRACKER CONTROLLER
TROUBLESHOOTING
FIGURE 48 - SENSOR ROTATED 180° DEGREES
64
CIRCUIT DESCRIPTIONS
9660 SERIES SEAM TRACKER CONTROLLER
mode selected by placing the MODE switch on the
control pendant in the AUTO position.
CIRCUIT DESCRIPTIONS
WARNING
When the MODE switch is in the MAN (Manual) position, it disables the Sidetrack switch and the Sidetrack feature and enables the MANUAL switches, allowing the cross-slides to be positioned manually by
pressing the momentary contact switches for
UP/DOWN and LEFT/RIGHT, as desired.
For use by Qualified Service Technicians
The Jetline Engineering Seam Tracker electronic circuitry consists primarily of two nearly identical servo systems, one for the horizontal axis and one
for the vertical axis; and is known as a closed loop
feedback system. These servo systems position the
cross-slides to maintain the Omni-Guide Sensor rod in
a null (centered) position.
Switching to the manual mode also disables sensing
of the Omni-Guide Sensor signals in the down direction, so that the servo will not drive down due to the
spring loaded down deflection that occurs when the
sensor rod is moved away from the work piece. A
modified form of signals from the Omni-Guide Sensor are enabled during MANUAL mode, allowing UP,
LEFT and RIGHT movement of the cross-slides.
This is done so that sensor rod deflection signals will
override the manual signals if the sensor rod is accidently driven against an obstruction, thus preventing
damage. This is referred to as the "Anti-Jam" feature.
When no external forces are applied to the sensor rod,
mechanical spring loading inside the Omni-Guide
Sensor keeps the rod Nulled in the horizontal axis and
full down in the vertical axis. Due to the spring
loaded in the down deflection, the vertical servo
drives down until the sensor rod contacts the work
piece just hard enough to push the rod up to the null
position.
SYSTEM WIRING DIAGRAM
The and beginning on page and Figure 49 9660S-100 Pendant Schematic, Standard Seam
Tracker on page 69 is a circuit diagram of the entire
seam tracker system. These diagrams include detailed
schematics of all portions of the system except the
Main board. Schematics of the MSP40 and MSP250
drives are shown in Figure , as well. Substituting one
drive for the other is the only electrical difference between ST40 and either the MSP250 Seam Trackers.
In normal operation, the tip of the sensor rod rides in
the weld joint just ahead of a welding torch mounted
on the cross-slides. During welding, as the work piece
moves under the seam tracker slides, the Omni-Guide
Sensor and torch are moved over the work piece. The
horizontal movement of the weld joint relative to the
slides causes a left or right deflection of the
Omni-Guide Sensor rod. The servo system then immediately moves the cross-slide just enough to put the
sensor rod back in the null position. Likewise, the vertical servo follows any relative vertical movement of
the work piece. Thus the welding torch is always kept
in the proper position over the weld joint.
The Figures 49 and show all wires and connector pins
in the interfaces between the various assemblies in the
control unit. on page and Figure 32 - 9660S-100
Control Pendant Exploded View on page 44 identifies
the major assemblies covered in Figure 49 and . The
physical location of sub-assemblies packaged inside
the control unit assembly are shown in . Parts lists for
each assembly are also included in the DRAWINGS
AND PARTS LISTS section beginning on page .
The operation just described requires that the weld
joint captures the sensor rod tip like a needle in a phonograph record, by applying left or right and vertical
(upward) forces to it. As illustrated in Figure 25 Tracking Diagram on page 23, some types of weld
joints can exert only left or right pressure on the sensor rod. The seam tracker handles this situation by applying an electrical bias to the horizontal servo, so
that it pushes the sensor tip (to the left or right as required) against the weld joint to be tracked. This
mode of operation is referred to as "Sidetracking."
MAIN BOARD ASSEMBLY
This section will describe generally the circuitry, signal flows and test points on the Main board to assist in
a better understanding and more effective and accurate troubleshooting of the system. The on page is a
drawing of the board to assist in placement of the Test
Points for better understanding and troubleshooting.
In addition to the board layout drawing, Figure 43 9660S Control Signal Flow on page 61illustrates very
simply the flow of signals in the standard seam
tracker system.
As with all of the seam tracker control switches, except the power switch, the Sidetrack control switch is
located on the control pendant. This switch has
LEFT, OFF, and RIGHT positions. The amount of
sidetracking force can be adjusted by the "Sidetrack
Adjust" knob located inside the control unit on the
Main board as shown in Figure 26 - Sidetrack Force
Adjustment on page 23.
Voltage Regulation
The Main board contains control circuitry for the system and also performs primary input voltage and control voltage regulation. Input voltage to the control
All of the previously described operations are performed with the standard seam tracker (PTST Seam
Tracking Option is not installed) in the automatic
65
9660 SERIES SEAM TRACKER CONTROLLER
CIRCUIT DESCRIPTIONS
unit is supplied to the Main board through a fuse and
Radio Frequency Interference and Electro-Magnetic
Interference (RFI/EMI) filter and voltage selector
switch mounted on the bottom of the enclosure. The
system will operate from 110/220 VAC, 50/60 Hz at
less than 3 amps input power.
accomplished by rectifier circuits U1 for vertical deflection and U2 for horizontal deflection.
The Omni-Guide Sensor can be considered a transformer with a primary and four secondary coils oriented 90 degrees from each other. Attached to the
sensor tip is a magnetic coupling bar that couples a
portion of the primary signal to the secondary coils.
The closer the coupling bar is to a particular secondary coil, the larger the signal will be in that particular
winding. Also, the farther away the bar is from particular winding the smaller the signal will be on that
coil. The secondary coils are designated horizontal (+)
horizontal (-) for horizontal deflection, and vertical
(+) and vertical (-) for vertical deflection.
The voltage into the control unit is brought to the
Main board and is then routed through the power
On/Off switch located on the door of the enclosure.
Once the switch is in the On position, voltage is
passed through the transformer to step down the primary input voltage to approximately 30VAC with a
Center Tap (two secondaries at 15 VAC), and a third
secondary of approximately 10 VAC (used for the
PTST Seam Tracking Option discussed later beginning on page ). A fourth 115VAC secondary winding
is routed directly to the heatsink assembly and is rectified to @ 130VDC for used with a cross-slide assembly with brakes installed on the motors or screw
shafts. No filtration is provided on this voltage, due
to the brake coil acting as a current filter to smooth
the power.
The primary voltage for the Omni-Guide Sensor is
generated by an oscillator circuitry. The Omni-Guide
Sensor drive signal is a nominal 2KHz square wave of
approximately 12V p-p. This drive signal or “Clock”
can be adjusted by R90 while monitoring the signal
on the TP12.
Because of mechanical springs and component variations, the DC error voltage will not be exactly equal at
null. So Horizontal Adjustment (R84) is required to
account for these variations. To properly adjust R84,
the system should be in the MANUAL mode of operation with the sensor tip off of the work piece in free
air.
The 30 VAC is rectified on the heatsink assembly and
sent back to the Main board where the ±20 VDC (TP3
+20 VDC and TP7 -20 VDC) is filtered through 8
electrolytic capacitors. The ±20 VDC is used as the
source voltage for the motor driver circuit and is also
regulated down to ±15 VDC (TP4 +15 VDC and TP8
-15 VDC (for servo amplification--Pre-amplifier)).
The ±15 VDC is also regulated down to ±6 VDC
(TP5 +6 VDC and TP9 -6 VDC (for Omni-Guide
Sensor applications and control circuitry)). All voltages are referenced to power ground on TP11 GND.
Monitor the horizontal sensor output TP10 HP (Horizontal Probe Adjustment) with a D.V.M. or oscilloscope. Deflect the sensor tip right and left and allow
the internal probe tip springs to return the tip to its
normal mechanical null position. Adjust R84 either
CW or CCW until the voltage on the monitoring
equipment is 0 VDC ±0.1 VDC. Repeat sensor deflection and again monitor horizontal output to insure
it returns to 0 VDC ±0.1 VDC.
Control Circuitry Description
The following will describe in basic terms how the
seam tracker system functions, beginning from the
Omni-Guide Sensor’s operation, remote pendant assembly, and Motor Drivers (heatsink assembly).
NOTE
Omni-Guide Sensor Interface
The Omni-Guide Sensor is used to track the seam and
produces horizontal and vertical error signals proportional to the mechanical movement of the sensor’s rod
while tracking the seam. For clarity, this circuitry will
be referenced as Omni-Guide Sensor Interface.
During the time the sensor is being deflected the horizontal and/or vertical
slides may move due to the Anti-jam circuitry being activated. The horizontal adjustment R84 is adjusted properly at the factory and
need not be readjusted even when a new
Omni-Guide Sensor is installed.
The Omni-Guide Sensor Interface (SSI) has two primary functions; control of servo drive signals commanded from the remote pendant assembly (pendant)
and conversion of the signals from the Omni-Guide
Sensor to DC signals of appropriate magnitude and
direction.
The vertical channel circuitry functions the same as
the horizontal with a few exceptions. There is no vertical adjustment required on the vertical channel, because the vertical slide will force the Omni-Guide
Sensor downward to compensate for component variations and stays down against the part due to the
spring in the Omni-Guide Sensor. In addition, while
monitoring voltage at TP6 VP (Vertical Probe) with
the Omni-Guide Sensor is in free air, you will notice
voltage will read 4 VDC ±0.5 VDC.
The signal conversion function of the SSI is to convert the 2KHZ square wave signals coming from the
Omni-Guide Sensor into a DC voltage appropriate for
driving the servo amplifier board. This conversion is
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CIRCUIT DESCRIPTIONS
9660 SERIES SEAM TRACKER CONTROLLER
These error signals generated on TP6 VP and TP10
HP are converted to motor drive signals depending
upon what mode of operation the system is in, determined by the Pendant switches.
Motor Speed is made up of two parts, Voltage and
Current. The resistance from one motor to another
will vary. The motor resistance can be accommodated
by adjusting R18 Vertical IR Comp and R20 Horizontal IR Comp. An EMF Sense Resistor (0.1 W ) for
each axis is used as a shunt to accurately measure and
limit the motor current.
Pendant Control
Manual Mode
Selecting Manual mode on the pendant allows Left,
Right, Up and Down control of the cross-slides. As
the operator selects either the Left, Right, Up or
Down manual controls, the generated signals can be
monitored at TP1 VE (Vertical Error) and TP2 HE
(Horizontal Error). The voltages when these manual
controls are selected will generate a +12 VDC ±1.0
VDC for Up or Right and -12 VDC ±1.0 VDC for
Down and Left.
The adjustment procedure is to turn R18 and R20
counter-clockwise until the horizontal slide oscillates
or vibrates. Then turn them clockwise to the point
where oscillations stop, which should be checked by
alternately driving the slides in the Manual mode with
normal operating weight on the cross-slides. When
this point has been established, turn them clockwise
an additional two and one-half turns to allow a margin
for circuit variations due to temperature, etc.
NOTE
While the operator selects one of the manual controls,
i.e., Vertical and Horizontal, and the Omni-Guide
Sensor’s rod comes in contact with an obstruction a
protection circuit is activated. This protection circuit,
called Anti-jam, overrides the pendant manual controls, protecting the sensor, the bracketry, the torch
and other related components at the torch area.
If R18 and R20 is backed off too far
(Clockwise), the servo will have sluggish
response.
The signal through R13 is derived from motor current,
which can be sensed directly. The Motor’s DC resistance enters in as a constant factor, the exact value of
which is accounted for by trimpot adjustment, R11 ,
as described later. Motor current is sensed as a voltage
across the 0.1 ohm "horizontal EMF sense" resistor.
The resistor’s voltage drop is fed to the differential inputs, pins 5 & 6, of amplifier U2. The signal is further
amplified when it reaches the output of U2 pin 8,
where it is connected through trimpot R11 to drive
R13. R11 adjusts the amount of motor current proportional voltage fed back for correct compensation.
Automatic Mode
Selecting Auto mode of operation on the pendant activate seam tracking of the system. The system begins
by driving downward in search of the seam. Once in
contact with the workpiece, signals proportional to the
Omni-Guide Sensors vertical and horizontal error deflection drive the horizontal and vertical slides in the
appropriate direction. These signals can be monitored
at the Test points for the Probe Signals, i.e., TP6 VP
and TP10 HP and at the Error Signals, i.e., TP1 VE
and TP2 HE.
The vertical and horizontal channels are identical, except for the R7 trimpot on the vertical channel. R7 is
normally adjusted completely clockwise, which
makes the circuit completely the same as the horizontal channel. With heavy loads, the vertical slide may
creep down while in the manual mode. In this case,
R7 is adjusted counter-clockwise just enough to offset
the creep.
Two other horizontal control signals may occur in the
Auto mode of operation. These signals are either
Right Sidetrack or Left Sidetrack. When one of the
sidetrack controls is selected on the pendant, this signal drives the horizontal slide to the Right (or Left)
until the Omni-Guide Sensor finds the weld joint, and
continues until an opposing voltage generated by the
Sidetrack Force Adjustment is 0 VDC at TP6 HP.
Servo Amplifier
The primary purpose of the Servo Amplifier Circuitry
is to amplify the signals generated by the SSI circuit
to the appropriate levels required by the complementary Darlington Push-Pull Transistors located on the
heatsink assembly used to drive the motors and to regulate the motor current.
One remaining point should be covered with regard to
the Servo Amplifier. Occasionally, users want to
mount the Omni-Guide Sensor rotated 180 degrees in
order to track in the reverse direction. Rotating the
Omni-Guide Sensor to track in the opposite direction,
causes the system to interpret the Right and Left Signals as Left and Right signals instead. This requires
that the horizontal drive motor leads be reversed.
What is actually required of the Servo Amplifier is
that it produces a motor speed proportional to the error signal voltage from the SSI. Motor speed is regulated by measuring back EMF from the motor. The
technique used to regulate motor speed is known as
IR Compensation.
The reversal is best accomplished in the Motor Cover
Assembly or in the Junction Box Assembly in the
case of the ST40 drive (see Figure 29 - MSP40
cross-slide Exploded View on page 36). The cord
from the horizontal motor has two leads, white and
black, whose connections can be reversed in the junc-
67
9660 SERIES SEAM TRACKER CONTROLLER
CIRCUIT DESCRIPTIONS
tion area mentioned above. Reversing the white and
black leads reverses the direction that the motor
drives and takes only a moment to complete.
Advance Programming Option Components
Additional components required for the PTST Seam
Tracking Option (PTST) is also located on the Main
board. These components allow the PTST Programming Option to interface with external equipment, such as carriages, power sources and wire
feeders, PLC’s and others.
The relays, K1, K2, and K3 are among some of the
components required. Other components are used to
convert the Standard Seam Tracker System to an Advanced Tracking system when the PTST Programming Option is installed and plugged into the
Main board via the ribbon cable at the J5 connector.
68
SCHEMATICS AND BLOCK DIAGRAMS
9660 SERIES SEAM TRACKER CONTROLLER
SCHEMATICS AND BLOCK DIAGRAMS
FIGURE 49 - 9660S-100 PENDANT SCHEMATIC, STANDARD SEAM TRACKER
69
9660 SERIES SEAM TRACKER CONTROLLER
SCHEMATICS AND BLOCK DIAGRAMS
FIGURE 50 - 9660S SEAM TRACKER BLOCK DIAGRAM
70
SCHEMATICS AND BLOCK DIAGRAMS
9660 SERIES SEAM TRACKER CONTROLLER
FIGURE 51 - 9660S SEAM TRACKER BLOCK DIAGRAM (CONT.)
71
9660 SERIES SEAM TRACKER CONTROLLER
SCHEMATICS AND BLOCK DIAGRAMS
FIGURE 52 - MOTOR DRIVER HEATSINK SCHEMATIC DIAGRAM
72
SCHEMATICS AND BLOCK DIAGRAMS
9660 SERIES SEAM TRACKER CONTROLLER
73
9660 SERIES SEAM TRACKER CONTROLLER
OPTIONAL EQUIPMENT
ball bearing carrying the rotating faceplate on which
the welding equipment is mounted.
OPTIONAL EQUIPMENT
ROTARY TABLE BRACKET
Engineered and designed for use with MSP250 Cross
Slides, the Rotary Table Bracket allows the user to position equipment at any point through 360 degrees and
lock it into place. Used primarily for fillet weld applications where angling of the torch is necessary or for
operations requiring the removal of welding equipment away from the immediate work area to provide
ample access for inspection, part removal, etc.
Convenient indexing detents are provided every 90
degrees and positive positioning of table is achieved
by means of a short, single stroke of the locking handle. Two adjustable stops are also included, providing
the user the facility to accurately re-position
equipment after it has been rotated away from the operating position. Sturdily constructed from solid aluminum the mounting plate houses a large diameter
FIGURE 53 - ROTARY TABLE BRACKET
74
PTST SEAM TRACKING SYSTEM
9660 SERIES SEAM TRACKER CONTROLLER
PTST Control System
PTST SEAM TRACKING SYSTEM
The PTST Seam Tracking Option performs various
automatic seam tracking functions. Such functions
are required for highly mechanized weld processes
which need automatic starting and stopping of the
weld cycle. These functions are listed below and are
described in the following section.
The Weld and Retract presetable timers are provided
on the seam tracker control for the selection of Weld
and Retract times (see Figure 55 - Timed Mode on
page 78).
The operator simply depresses the Start Cycle push
button on the control pendant and the following
automatic sequence takes place:
• Omni-Guide Sensor locates the weld joint.
• Timed Cycle
• The arc is initiated.
• Auto Cutoff Cycle
• Weld travel commences and the seam is accurately
• Switched Auto Disable
• Tack Cutoff
•
The PTST Seam Tracking System may be programmed to perform either the Timed Cycle or Auto
Cutoff weld cycle control functions. These features
can be performed either by themselves or in combination with Horizontal/Vertical Disable or with the Tack
Cutoff features.
•
•
•
tracked.
The Weld Time duration completes.
Travel stops.
Arc is extinguished.
Torch is raised up and out of the work area to the start
position.
Auto Cutoff Function
This function is used for I beams, T sections, plate-toplate and circumferential welds, where the length of
the automatic cycle may vary due to variable speed or
length from one weld or part to the next.
In addition to these basic functions, special features
which enhance the automation or provide user flexibility in various welding applications are programmable. These special features are:
• Z Search Feature
This option is similar to the Timed Cycle function except the end of the weld is not determined by the weld
timer, but instead by the Omni-Guide Sensor sensing
the end-of-weld. This feature is also programmed and
stored into memory using the S5 DIP switch position
# 2 (in the On or Down position). The Weld Timer is
used to disable the end-of-weld sensing function for
most of the weld duration to allow the Omni-Guide
Sensor to track over tacks or rough seams without
ending the weld prematurely (see Figure 56 - Auto
Cutoff, Down Cutoff and Figure 57 - Auto Cutoff, Up
Cutoff beginning on page 79).
• Lockout Time
• Crater Fill Time
• Horizontal Retract Delay
• Multi System Synchronization
• Remote Input/Output Control
• Automatic Sidetrack Disable at Null
• Vertical Search Delay
These features are described in the following section.
The operator simply depresses the Start Cycle push
button on pendant assembly and the following automatic sequence takes place:
FEATURES APPLICATIONS
Timed Cycle Function
This function is used for circumferential and fixed
length longitudinal welds when it is appropriate to
time the weld cycle. It is used for high production applications where the operator must be free to perform
other tasks, such as loading and unloading a second
fixture.
• Omni-Guide Sensor locates the weld joint.
• Arc is initiated.
• Weld travel commences and seam is accurately
tracked.
• Weld/Enable Timer times out before sensor reaches
the end-of-weld cutoff point.
This feature needs to be programmed and stored into
memory on the PTST Programming Option using S5
DIP switch position # 2 (in the Off or Up position).
75
9660 SERIES SEAM TRACKER CONTROLLER
PTST SEAM TRACKING SYSTEM
• When sensor reaches the cutoff point, the seam tracker
The Auto Down Cutoff also has an adjustable Threshold. This Threshold potentiometer is located on the
inside of the PTST Board, near the lower right of the
board. Auto Down Cutoff Threshold adjustment is
normally not adjusted in typical applications.
is locked out to prevent the torch from moving out of
position and continues welding for the duration of the
Overlap and Final Timer setting.
• When the torch reaches the end of the weld, the travel
is automatically stopped and the torch is raised up out
of the work area and back to the start position.
As stated above, there are two methods of Auto Cutoff--Up or Down. The following describes these
methods.
Its main use is to eliminate nuisance end-of-weld cutoffs from occuring due to tracking a rough part, or
from bounce created from an older carriage. To minimize the false triggers, the Down Cutoff Threshold
can be adjusted to a counter-clockwise position to
make the system less sensitive to these errors, while
still sensing the true end-of-weld position. The Auto
Down Threshold potentiometer is factory set at a full
clock-wise position, giving maximum sensitivity to
sense the end-of-weld position.
Auto Up Cutoff
Auto Up Cutoff mode uses the Omni Guide Sensor to
determine the end-of-weld. While welding in a circumferential application, the Omni Guide senses the
beginning of the weld by the upward movement of the
sensor’s tip as it begins riding up onto the weld bead.
This upward movement is typically a rapid movement
the Omni Guide Sensor / controller can’t compensate
for fast enough, which triggers the Auto Up Cutoff.
This trigger level can be adjusted by the Threshold
Adjustment potentiometer on the PTST front panel,
labeled Threshold. The Threshold adjustment potentiometer can be adjusted to account for large or small
beads.
Switched Auto-Disable Function
The Switched Auto-Disable feature is typically used
in conjunction with AVC or in multi-pass applications when after the root pass has been performed, the
a seam is not able to be reliably tracked (typically in
the horizontal axis) on subsequent passes.
Used for manual override, this function requires a
switch on the remote inputs cable (see Figure 74 - Remote Input Interface Connections on page 114 and
Figure 77 - 9660P Auto-Disable Operation and
Wiring on page 117), which allows the operator to
"Disable" the automatic function of either the horizontal or the vertical axes.
A large bead can be sensed as an end-of-weld cutoff
rather easily. The Threshold adjustment could be set
to a minimum Threshold position, or counter-clockwise.
A small bead is a bit more difficult to sense the
end-of-weld position, because the sensor will only
rise up a small amount. Sensing small beads, it will
be necessary to increase the Threshold adjustment
level by turning the Threshold potentiometer toward
the clockwise position. The lowers the trigger level
so that even small upward movements will trigger the
system into Overlap.
For example, when the system is in Automatic Mode,
and the horizontal axis is disabled, the vertical axis is
controlled normally by the Omni-Guide Sensor, but
the horizontal axis is controlled by the joystick’s Left
and Right directions on the pendant assembly (manually).
An example of when this situation is used would be
on a cap pass where there is no horizontal joint edge
to track.
The Auto Up Cutoff method is also used in Tack Cutoff operations with one expection. When the Auto Up
Cutoff Threshold is triggered, the system goes into
Overlap Mode.
This function may be incorporated with either the
Timed Cycle or the Auto Cutoff function.
NOTE
Tack Cutoff Function
An "Arm" push button is provided on the PTST Programming Option assembly on the pendant for manually arming or disarming of the Tack Circuitry.
Care should be used to select an Auto Up
Cutoff / Tack Cutoff Threshold setting that
will accommodate the needs of both functions.
When selected by the S5 DIP switch position # 1 (in
the On or Down position) and stored into memory on
the Advanced Programming Control (PTST) board,
the tack circuit is automatically armed when the weld
seam is located.
Auto Down Cutoff
Auto Down Cutoff works in the same manner as the
Auto Up Cutoff function, but in the opposite direction. Like the name implies, Auto Down Cutoff
senses the downward movement of the Omni Guide
Sensor to determine the end-of-weld position. This
method of end-of-weld cutoff is typically much easier
to sense than the Auto Up Cutoff method, because the
sensor normally falls off the end of the plate, indicating the end-of-weld position.
This function automatically disables the seam
tracker’s cross-slide’s movement when the
Omni-Guide Sensor contacts a tack; this prevents the
torch from moving out of position and causing cold
laps, or leaving the weld joint. When the sensor has
76
PTST SEAM TRACKING SYSTEM
9660 SERIES SEAM TRACKER CONTROLLER
passed over the tack, the seam tracker is re-enabled
and continues tracking normally (see Figure 58 - Tack
Cutoff Mode on page 80).
The horizontal slide will move at the factory set
(non-adjustable) manual speed in the direction of the
selected Sidetrack for a preset time of two seconds (if
the Vertical Delay feature is selected and stored into
memory see Figure 54 - Z Search Feature on page 77
and Figure 63 - PTST Programming Option Z Search
Feature on page 91). This allows the sensor to clear
any fixture interference before moving downward in
search of the weld seam. After the two-second delay,
the vertical slide is allowed to move downward, causing the sensor to move at a 45° angle, overshooting
the weld seam.
Sensitivity of the Tack Cutoff circuitry is adjustable
for different tack sizes. The circuitry’s sensitivity can
be adjusted using the Threshold potentiometer located
on the PTST Programming Option assembly and is
accessible on the front panel of the control unit and is
labeled “Threshold.”
This function may be used with either the Timed Cycle or the Auto Cutoff function.
When the sensor touches the work piece and vertical
null is achieved, the horizontal slide will move in the
opposite direction of the selected sidetrack until the
sensor drops into the weld seam. Sidetrack reverts
back to the selected sidetrack direction. When null is
achieved, the sidetrack pressure is then controlled by
the Sidetrack Force Adjustment potentiometer (see
Figure 26 - Sidetrack Force Adjustment on page 23)
on the Main board. If Sidetrack Disabled at Null is
selected and programmed using the S5 DIP switch position # 4 (in the On or Down position), sidetrack is
disabled at this time. Thus, the slides search for the
weld seam at manual speed and once the seam is located, reduces the sidetrack pressure or removes it
completely, ensuring the sensor tip does not climb out
of the seam.
FEATURES
Z Search Feature
Z Search is used to locate an end cap weld seam, such
as, gas propane tanks, or to find a seam where there
may be holding fixture interference.
When selected by the S5 DIP switch position # 3 (in
the On or Down position) and stored into memory on
the Advanced Programming Control (PTST) board,
the Z Search feature is automatically enabled when
the Start Cycle push button on the pendant or a Start
input is commanded from the remote input cable (see
Figure 74 - Remote Input Interface Connections on
page 114).
FIGURE 54 - Z SEARCH FEATURE
77
9660 SERIES SEAM TRACKER CONTROLLER
PTST SEAM TRACKING SYSTEM
The Omni-Guide Sensor locates the weld seam and
energizes the user relay, K1. (The relay may be used
to turn on the wire feeder, power source, etc.) For one
second after the relay is turned on, the slides are in the
manual mode of operation preventing any horizontal
or vertical movement from the Omni-Guide Sensor.
During this time, movement is allowed of the slides
from the joystick switch on the pendant. After this
one second delay, the slides are in automatic mode,
tracking the seam, and the Weld/Enable timer begins.
NOTE
Automatic removal of sidetrack pressure
is typically used when welding "V"
grooves.
Lockout Feature
This feature is applicable when a constant current
power supply drops out at initial arc due to heavy
wire feed displacing the work piece. It is also useful
for allowing arc adjustment during the time the torch
is on a run-on tab.
Crater Fill Delay
This feature is useful at the end of a weld seam allowing the power supply to down-slope, additional wire
to be fed into the joint (crater) and wire to burn back.
When selected by the S5 DIP switch position # 7 (in
the On or Down position) and stored into memory on
the Advanced Programming Control (PTST) board,
the Lockout circuitry is automatically enabled when
the weld seam is located.
When selected by the S5 DIP switch position # 8 (in
the On or Down position) and stored into memory on
the PTST Programming Option board, the Crater Fill
FIGURE 55 - TIMED MODE
78
PTST SEAM TRACKING SYSTEM
9660 SERIES SEAM TRACKER CONTROLLER
FIGURE 56 - AUTO CUTOFF, DOWN CUTOFF
FIGURE 57 - AUTO CUTOFF, UP CUTOFF
79
9660 SERIES SEAM TRACKER CONTROLLER
PTST SEAM TRACKING SYSTEM
FIGURE 58 - TACK CUTOFF MODE
Delay circuitry is automatically enabled when the
weld seam is located.
Retract Delay circuitry is automatically enabled when
the weld seam is located.
If the user relay, K1, controls the carriage, the torch
will be located at the end of the weld seam when the
Weld/Enable and Overlap times have completed.
When K1 relay contacts open, many TIG welding
power sources initiate a down-slope function. In addition, many MIG power sources and wire feed controllers initiate a crater fill and wire burn-back
function.
This combination enables the Omni-Guide Sensor to
find a weld seam close to a fixture obstruction. The
horizontal slide is inhibited for 2 seconds allowing the
vertical slides to retract approximately one inch (12
ipm) before the horizontal slide starts to retract. The
Horizontal Retract time is the Retract Time stored into
the selected program minus 2 seconds, if this feature
is selected.
The Crater Fill Delay maintains the slides in the manual mode of operation for 2 seconds at their last position prior to the K1 relay contacts opening, not
allowing the cross-slides to move during this 2 second
delay. After the Crater Fill Delay has completed, the
slides will retract for the duration of the Retract Timer
setting.
Vertical Search Delay
Normally, this feature is used in conjunction with
Horizontal Retract Delay (above) and Z Search features (see Figure 54 - Z Search Feature on page 77
and Figure 63 - PTST Programming Option Z Search
Feature on page 91).
When selected by the S5 DIP switch position # 5 (in
the On or Down position) and stored into memory on
the PTST Programming Option board, the Vertical
Search Delay circuitry is automatically enabled when
the weld seam is located.
Horizontal Retract Delay
Normally, this feature is used in conjunction with
Vertical Search Delay (below) and Z Search features
(see Figure 54 - Z Search Feature on page 77 and Figure 63 - PTST Programming Option Z Search Feature
on page 91).
The combination enables the Omni-Guide Sensor to
find a weld seam close to a fixture obstruction. The
vertical slide is inhibited for 2 seconds allowing the
horizontal slide to move approximately one inch (12
ipm) before the vertical slide starts to drive downward
in search of the seam.
When selected by the S5 DIP switch position # 6 (in
the On or Down position) and stored into memory on
the PTST Programming Option board, the Horizontal
80
PTST SEAM TRACKING SYSTEM
9660 SERIES SEAM TRACKER CONTROLLER
when the weld cycle starts (or the seam has been
found).
Sidetrack Disable at Null
Normally, this feature is used in conjunction with primarily the Z Search feature (see Figure 54 - Z Search
Feature on page 77 and Figure 63 - PTST Programming Option Z Search Feature on page 91), but
can be used with other features to enhance the performance of the system.
Sidetrack Disable at Null is useful when tracking a
V-groove seam and when Z Search is used to locate
the seam. Since Z Search requires a Sidetrack direction to be enabled on the pendant (either Left or
Right) for proper operation, it is required then to have
a means to disable it after the seam has been located.
If a V-groove is to be tracked when a Sidetrack direction is enabled, the Omni-Guide Sensor may climb
out of the joint. Enabling Sidetrack Disable at Null
reduces the likelihood of this occurring.
When selected by the S5 DIP switch position # 4 (in
the On or Down position) and stored into memory on
the PTST Programming Option board, the Sidetrack
Disable at Null circuitry is automatically enabled
81
9660 SERIES SEAM TRACKER CONTROLLER
PTST SEAM TRACKING SYSTEM
82
PTST OPERATION
9660 SERIES SEAM TRACKER CONTROLLER
PTST OPERATION
These control lines are:
USER INTERFACE
Two interface connectors are available to the user to
connect and control other equipment. Two cables are
supplied with the system to assist in interfacing the
seam tracker system with other equipment such as
welding power sources, wire feeder controllers, carriages, Programmable Logic Controllers (PLC’s), etc.
• Start
J3 Output Relay Connector
This connector makes available to the user, three relays, K1, K2, and K3. When reviewing these outputs
or performing system wiring, please see Figure 75 Remote Output Interface Connections on page 115, as
well as Figure 76 - 9660P Multi-System Operation
and Wiring on page 116 and Figure 77 - 9660P
Auto-Disable Operation and Wiring on page 117 for
additional information.
Below are definitions of each of these Remote Inputs.
When reviewing these inputs or preforming system
wiring, please see Figure 74 - Remote Input Interface
Connections on page 114, as well as Figure 76 9660P Multi-System Operation and Wiring on page
116 and Figure 77 - 9660P Auto-Disable Operation
and Wiring on page 117 for additional information.
• Emergency Stop
• Horizontal Disable
• Vertical Disable
• Null Input
• Cutoff
Start
A momentary contact closure between P4-A and P4-J
will start the cycle when the Auto Mode of Operation
is selected on the control pendant. If the closure is
maintained, the cycle will repeat immediately after
the retract cycle has finished. This input may be
paralleled with other seam tracker systems for use in
Multi-System Operations.
K1 Relay
The K1 relay has three normally open relay contact
closures capable of carrying 10A @ 12OVAC (form
“C”). These three sets of contacts from the K1 relay
are protected by 130V varistors. A closure of the
three contacts indicates the seam tracker has found the
seam and the weld cycle can now commence. The
contact closures are normally used to turn on the carriage, wire feeders, power supplies, etc.
Emergency Stop
A maintained or momentary contact closure between
P4-B and P4-J will interrupt the cycle turning OFF the
interface relays, K1, K2, and K3 and placing the seam
tracker in the manual mode of operation. This input
may be paralleled with other seam tracker systems
for use in Multi-System Operations. Contact closure
must be released before another cycle can be initiated.
The K1 relay is energized at the moment the weld
seam is found to the end of the Final Timer.
In addition to the K1 relay, there are two relays that
are capable of carrying 5A @ 120VAC. These relay
contacts from relays K2 and K3 are provided to allow
extended interfacing options to the customer and are
also protected by 130V varistors.
Horizontal Disable
A maintained contact closure P4-F and P4-J will disable horizontal tracking while the closure is maintained. While a closure is made on these two lines,
the sidetrack selection is overridden.
K2 Relay
The K2 relay energizes at the start of Final Time (if
not set to zero seconds) and remains On for the
duration of Final time. At the completion of the Final
time, the K2 relay de-energizes, opening the relay
contact.
Null Input
A maintained contact closure between P4-G and P4-I
will inhibit the system from initiating the Weld/Enable Time and will prevent the interface relay K1
from turning On until this closure is released. This input may be paralleled with other seam tracker systems
in a multi-system operation. The last seam tracker
achieving a null (locating the seam) will turn On (or
release) all other seam tracker relays.
K3 Relay
The K3 relay acts in a similar manner, but is energized at the start of Retract time and remains On for
the duration of the Retract time. At the completion of
the Retract time, the K3 relay de-energizes, opening
the relay contact. The Weld Cycle is complete at this
time.
A switch may also be used on the Null Input line to
prevent the relay K1 from energizing (and the welding
arc from continuing after the seam tracker has found
the seam) until the operator has verified the
Omni-Guide Sensor(s) are in the seam and all is okay
to release the K1 relay(s) (and the Arcs).
J4 Input Connector
Six input control lines used in conjunction with the
seam tracker control pendant allow the operator to
control the seam tracker from a remote control panel
or from other equipment, e.g., PLC’s.
83
9660 SERIES SEAM TRACKER CONTROLLER
PTST OPERATION
Cutoff
A momentary contact closure between P4-C and P4-I
will interrupt the cycle, placing the system in the
Overlap Mode of Operation. This input may be paralleled with other seam tracker systems in a
multi-system operation.
tor to stop one or more seam tracker systems anywhere in their cycle by placing all systems in the
Manual Mode of Operation and de-energizing the K1,
K2, and K3 relays.
Synchronized Timing (Null Input)
Paralleling P4-G and P4-I from seam tracker system
to another seam tracker system (and so on) will inhibit
each seam tracker system from turning On their respective K1 relay and starting the Weld/Enable
Timers until the last seam tracker system has achieved
a null (located the seam).
This momentary contact closure could also be from a
encoder or PLC, to force the system into the Overlap
Mode of Operation, eliminating the Omni-Guide Sensor from sensing the end-of-weld. This is useful if the
weld bead is not uniform and the Omni-Guide Sensor
has difficulty reliably and repeatably sensing the
end-of-weld.
These same lines may also be paralleled with a normally closed switch. Each system will find its respective weld seam and remain in the tracking mode. The
operator may then check each system making any
alignment or adjustments, as required. Opening the
switch will immediately initiate the weld cycle by
turning On each seam tracker's K1 relay.
No matter where in the Weld/Enable time cycle, if an
remote Cutoff input signal is received by the seam
tracker, the system is forced to go into the Overlap
mode of operation.
Vertical Disable
A maintained contact closure between P4-E and P4-J
will disable vertical tracking as long as the closure is
maintained. (Similar to Horizontal Disable.)
Cutoff
Used in applications where the operation may be interrupted, such that the Weld/Enable timer need not be
used.
MULTI-SYSTEM OPERATION
Each seam tracker is a self contained tracking system.
Figure 76 - 9660P Multi-System Operation and
Wiring on page 116 shows a typical system interface
in a multi-system setup. Properly paralleling common
input control lines, one or more seam trackers systems
may be:
The operator may elect to place a micro-switch at the
end of the weld seam or fixture or an encoder and
counter combination counting pulses/degrees of
rotation. The micro-switch closure or the counter’s
relay output are placed between P4-C and P4-I. This
will interrupt the cycle, placing the system in the
Overlap Mode of Operation.
Vertical Disable and Horizontal Disable
These remote control inputs are usually associated
with single system operation. The Horizontal and Vertical Disable inputs are usable at any time. A closure
between P4-F and P4-J disables the vertical slide and
a closure between P4-E and P4-J disables the
horizontal slide.
• Started
• Stopped (Emergency)
• Disable Vertical Tracking
• Disable Horizontal Tracking
• Initiate Remote Cutoff
The seam tracker systems can also turn On user related equipment:
CAUTION
For optimum performance of the seam
tracker system, certain precautions and
limitations should be adhered to.
• Welding power supplies
• Wire feeder, Carriage, etc.
• Synchronize more than one seam tracking system
• and other equipment
OPERATIONAL PRECAUTIONS
Start
Paralleling P4-A and P4-J with Double Pole (DP) momentary pushbutton enables the operator to start one
or more seam tracker systems simultaneously. The
switch should have one pole for each seam tracker
system being started simultaneously.
Z Search Feature
Proper application of the Z Search feature requires
that the Omni-Guide Sensor tip drops down into a
weld seam.
Vertical and Horizontal Disable
Vertical and Horizontal Disable may be initiated after
the seam tracker has achieved a null (Cycle Lamp On
and K1 relay energized). Disabling these axes prior to
this will not allow the Omni-Guide Sensor to contact
the work piece. Vertical or Horizontal Disable will
Emergency Stop
Paralleling P4-B and P4-J with a normally open
switch, such as a mushroom switch enables the opera-
84
PTST OPERATION
9660 SERIES SEAM TRACKER CONTROLLER
inhibit the anti-jam feature of the seam tracker. Care
must be taken not to exceed the mechanical deflection
capability of the Omni-Guide Sensor’s lower rod and
tip.
tracker system. Seam tracker signal grounds (P4-I)
are isolated from chassis ground. The +6 VDC output
(P4-J) for remote use should also be isolated from
other power sources.
TABLE 37 - PTST PROGRAMMING OPTION DIP SWITCH DESCRIPTIONS
Position #
Off Position (Up)
On Position (Down)
1
Tack Cutoff Feature Disabled
Tack Cutoff Feature Enabled
2
Timer Weld Mode of Operation
Auto Cutoff Mode of Operation
3
Z Search Disabled
Z Search Enabled
4
Sidetrack Enabled at Null
Sidetrack Disabled at Null
5
Vertical Search Delay Disabled
Vertical Search Delay Enabled
6
Horizontal Retract Delay Disabled
Horizontal Retract Delay Enabled
7
Lockout Disabled
Lockout Enabled
8
Crater Fill Delay Disabled
Crater Fill Delay Enabled
Tack Function
The number of tacks and height of the tack relative to
the weld seam are important considerations for proper
operation. Tacks should not be above the weld seam
when sidetrack is required for tracking. Sidetrack
preloads the horizontal spring located in the
Omni-Guide Sensor. When a tack is sensed, the vertical and horizontal slides are switched into the manual
mode of operation. If the tack is above the weld
seam, the Omni-Guide Sensor tip is not constrained
by the weld seam and the horizontal springs in the
Omni-Guide Sensor will position the tip in a mechanical zero position, which may be outside of the weld
seam.
P-4 cable must be removed when remote control inputs are not used. This prevents accidental shorting
and false triggering of remote inputs.
P-4 and P-3 cable shields are tied to the seam
tracker’s control box chassis ground at their connectors and so they should be taped back at the cable end
to prevent shorting and possible grounding/noise
interference.
FIELD INSTALLATION
Refer to on page , Figure 32 - 9660S-100 Control
Pendant Exploded View on page 44, on page and on
page to aid in identifying the location of areas where
changes will be made to your equipment needed to install the PTST Seam Tracking Systems in your existing system as a field installation.
NOTE
This tack problem may be corrected to
some extent by reducing the number of
tacks to a minimum and biasing the tack
in such a way as to force the Omni-Guide Sensor tip around the tack in a direction where the
horizontal springs will return the tip to the weld
seam.
CONTROL PENDANT
On the control pendant remove top blank plate (save
the screws). Install the PTST Programming Option
Pendant Option assembly, P/N 1101-2002-4 in the
pendant opening by connecting assembly’s P1 connector to the prewired pendant J1 connector. Secure
the assembly with the screws.
Remote Interface Connections
P-4 cabling shall be routed away from heavy current-carrying cables to prevent erroneous triggering of
remote control inputs.
CONTROL BOX
Be sure the power is disconnected from the control
unit prior to servicing the unit for field installation of
the PTST Programming Option.
P-4 pins I and J must not be connected to chassis
ground, earth ground (PE) or any power source. They
can be connected between other seam tracker systems
for multi-system operation, but should use discrete
contacts to maintain isolation between each seam
85
9660 SERIES SEAM TRACKER CONTROLLER
PTST OPERATION
may still be used to Arm or Disarm the Tack Cutoff
circuitry.
PTST Seam Tracking System
In the control box remove the standard option plate in
the door of the enclosure and install the PTST Programming Option assembly in the opening using the
same hardware, i.e., washers, star washers, and nuts
(just removed).
Timed Weld/Auto Cut-Off Mode
With this switch in the Off position when the program
button on the PTST Programming Option board has
been pressed and confirmed, the seam tracker is in the
Timed Cycle Mode of Operation, and the cycle times
are controlled by the values stored in memory for the
Weld/Enable Timer.
Install the ribbon cable from J1 of the PTST Programming Option board to the Main board ribbon cable connector J5.
If this switch is in the On position when the program
button on the PTST Programming Option board has
been pressed and confirmed, the seam tracker is in
the Auto Cut-Off Mode of Operation. This mode is
most useful for ending the weld cycle when welds of
varying lengths must be accomplished.
Remote Interface Connector Assembly
Install the Remote Interface Connector Assembly by
removing the washers, star washers, and nuts attaching the blank plate and install the connector assembly
plate utilizing the same hardware just removed. Connect the J3 amphenol connector (the larger of the two
connectors) harness to the J3 connector on the Main
board, located between the K1 relay and the K2 and
K3 relays. Also connect the J4 amphenol connector
harness to the J4 connector on the Main board, located near the center of the board.
It is important when operating in this mode to ensure
that the value stored in the Weld/Enable Timer is
shorter than the actual time required to finish the
weld. After the weld timer has timed out, the next Up
or Down signal from the Omni-Guide Sensor will automatically place the seam tracker in the Overlap
Mode.
PROGRAM SWITCH SETTINGS
The Program DIP switch, S5, is used to select the various functions provided by the PTST Programming
Option (see on page ). Changes of the function desired may occur as a result of changing weld requirements. These changes in functions are easily
implemented by the customer simply by changing a
switch setting, storing the settings into memory and
selecting the desired program for welding.
Z Search
With this switch in the Off position when the program
button on the PTST Programming Option board has
been pressed and confirmed, the Z Search feature is
disabled.
If this switch is in the On position when the program
button on the PTST Programming Option board has
been pressed and confirmed, the Z Search feature is
Enabled.
Table 37 - PTST Programming Option Dip Switch
Descriptions on page 85 describes the function of
each DIP switch.
Sidetrack Disable at Null
Sidetrack will not automatically be disabled at Null
when this switch is in the Off position when the program button on the PTST Programming Option board
has been pressed and confirmed.
NOTE
The following describes the results of the
different DIP switch settings after storing
them into memory.
If this switch is in the On position when the program
button on the PTST Programming Option board has
been pressed and confirmed, Sidetrack will automatically be disabled at Null.
Tack Cutoff
If this switch is in the On position when the
cycle has been initiated and the Omni-Guide Sensor
has found the seam and settled into a "Null" condition, the Tack Cutoff circuitry will arm itself automatically. This function allows sensing of tacks by the
Omni-Guide Sensor as it travels across them. The result is automatic lockout of the slides to prevent displacement of the torch. When the Omni-Guide
Sensor has crossed over the tack, normal tracking is
resumed.
This is helpful in V-grooves when sidetrack pressure
may tend to cause the Omni-Guide Sensor to “climb
the walls” of the groove.
Vertical Search and Horizontal Retract Delay
These two switches are used mostly in conjunction
with the Z Search feature, however, they can be used
independently to provide "delays" in slide motion if
necessary to clear fixture obstructions (see Figure 63 PTST Programming Option Z Search Feature on page
91).
If this switch is in the Off position when the program
button on the PTST Programming Option board has
been pressed and confirmed, the system will prevent
the tack circuitry from becoming active at null. However, the Tack Arm switch, located on the pendant,
86
PTST OPERATION
9660 SERIES SEAM TRACKER CONTROLLER
TABLE 38 - PTST PROGRAMMING OPTION PROGRAMS, FACTORY DEFAULT
Timer Values
Features Selected
TIMED /
AUTO
CUTOFF
SIDETRACK
DISABLED
AT NULL
WELD /
ENABLE
OVERLAP
FINAL
RETRACT
TACK
CUTOFF
1
60
0.0
1.0
0.5
ü
T
2
60
0.0
2.0
1.0
ü
T
ü
3
60
0.0
3.0
2.0
T
ü
4
60
5.0
4.0
3.0
T
5
60
0.0
5.0
4.0
T
6
60
2.0
5.0
5.0
T
7
60
0.0
5.0
10.0
T
ü
8
60
0.0
5.0
5.0
T
ü
ü
9
60
0.5
5.0
5.0
ü
T
ü
ü
10
60
0.0
5.0
5.0
ü
T
ü
ü
11
60
0.0
5.0
5.0
ü
A
ü
12
60
0.0
5.0
5.0
A
ü
13
60
0.0
5.0
5.0
A
ü
14
60
0.0
5.0
5.0
A
ü
15
60
0.0
5.0
5.0
A
ü
16
60
3.0
5.0
5.0
A
17
60
0.0
5.0
5.0
ü
A
18
60
0.0
5.0
5.0
ü
A
19
60
1.0
5.0
5.0
ü
A
#
Note:
ü = Feature is Enabled
T = Timed Mode
Z SEARCH
VERTICAL
DELAY
HORIZONTAL
DELAY
LOCKOUT
CRATER
FILL
DELAY
ü
ü
ü
ü
ü
ü
ü
ü
ü
ü
ü
ü
ü
ü
ü
ü
ü
ü
ü
ü
ü
ü
ü
ü
ü
ü
ü
ü
ü
ü
ü
ü
ü
ü
ü
ü
ü
ü
ü
ü
ü
ü
ü
ü
A = Auto Cutoff Mode
Blank = Feature is Disabled
With these switches in the Off position when the program button on the PTST Programming Option board
has been pressed and confirmed, these Delay features
are disabled.
With this switch in the Off position when the program
button on the PTST Programming Option board has
been pressed and confirmed, the Lockout feature is
disabled.
If these switches are in the On position when the program button on the PTST Programming Option board
has been pressed and confirmed, these Delay features
are enabled.
If this switch is in the On position when the program
button on the PTST Programming Option board has
been pressed and confirmed, the Lockout feature is
enabled.
Lockout
This feature is to allow settling of the Omni-Guide
Sensor after null, following the start of a MIG arc
when the wire feed may push against the work, causing jitter.
Crater Fill Delay
The feature provides a two second delay to be inserted
between the end of Final time and the beginning of
Retract.
87
9660 SERIES SEAM TRACKER CONTROLLER
PTST INSTALLATION
With this switch in the Off position when the program
button on the PTST Programming Option board has
been pressed and confirmed, the Crater Fill Delay feature is disabled.
timer setting. On the inside of the control unit located
on the back side of the PTST Programming Option
Board, press the Program Button (see on page ). This
stores the timer value into the Weld/Enable timer setting. You’ll notice the display will go blank for a moment and then the display and the LED’s will flash in
succession as it stores the values from each timer and
for the features.
If this switch is in the On position when the program
button on the PTST Programming Option board has
been pressed and confirmed, the Crater Fill Delay feature is enabled.
Press the Select button on the front panel once to
move from the Weld/Enable LED to the Overlap
LED. Perform the same actions to modify the Overlap Time as done with the Weld/Enable Timer. Once
completed, press the Program Button on the inside of
the control unit on the back side of the PTST Programming Option board.
PTST INSTALLATION
A seven segment digital display has been provided for
use during programming of the PTST’s 19 weld programs. This digital display allows the operator to select and store timer values for each of the timers, i.e.,
Weld/Enable, Overlap, Final, and Retract. LED indicators are also an indication of which timer value the
operator is storing into memory. These LEDs are labeled Weld/Enable, Overlap, Final, and Retract and
are visible on the front panel of the PTST Programming Option.
Continue these steps for each of the remaining timers,
i.e., Final and Retract. Remembering to press the Program button on the back side of the PTST Programming Option board each time after the desired
time has been entered on the panel.
As the seam tracker is in the welding cycle and the
Weld/Enable Timer has become active, the digital display will count backwards to indicate the remaining
time left for each of the timer values. The LED will
also light to indicate which one of the timers is active.
PTST PROGRAMMING OF THE FEATURES
The PTST Programming Option features are programmed and stored into memory using the S5 DIP
Switches, located on the inside of the PTST Programming Option board (see on page ).
A Program LED is also visible on the front panel of
the PTST Programming Option and indicates that the
program value is being displayed on the digital display.
Select the Features you want for a particular program
(the features can be unique for each program stored in
memory).
Refer to Table 37 - PTST Programming Option Dip
Switch Descriptions on page 85 for a complete list of
these features and how to enable or disable them.
PTST PROGRAMMING
The PTST Programming Option is stored with default
values from the factory for your immediate use.
These default values are listed in Table 38 - PTST
Programming Option Programs, Factory Default on
page 87. Any one of these values or settings can be
changed to meet your specific welding needs.
To program the features, select which features you
want enabled and disabled using the S5 DIP Switch
and then Press the Program button on the back side of
the PTST Programming Option Board. The PTST
Programming Option will indicate which Features are
different from those currently stored in memory on
the front panel of the PTST Programming Option
board by lighting the Features LED.
Programming the PTST Programming Option is a five
step process. The first is to select which program you
wish to change. Press the Select button to select between the LED’s and the timers they represent ordered in this manner; Weld/Enable, Overlap, Final,
Retract and Program. Once the Program LED is lit,
use the 2 keys on the right (there are 4 keys total) located below the 7 segment display to change the numbers to indicate the Program # (1 through 19) you
wish to program/change.
If you are satisfied with the Features Selection, press
the Program button once more for confirmation. The
Features are now stored in memory.
If you are not satisfied with the selection after you
press the Program button the first time, you may
change the Features you want enabled/disabled now
by changing the DIP switches. The PTST Programming Option indicates the Features that are different and allows you to change them prior to storing
them into memory.
After you have chosen the program to modify, press
the Select button again. The Weld/Enable LED will
light indicating the Weld/Enable Timer value. The 7
segment display (from now on, referred to as display)
will show the current stored value.
To change this timer value, press the 4 buttons below
the display to increment the numbers to the desired
88
PTST INSTALLATION
9660 SERIES SEAM TRACKER CONTROLLER
NOTE
PTST PRELIMINARY CHECKOUT PROCEDURE
Once the Program button has been pressed once
and the PTST Programming Option indicates the
Features on the front panel that are different than
those stored into memory, the next time Program
button is pressed, those Features will be stored
into memory (along with the Timer value displayed on the PTST Programming Option for
any of the timers).
NOTE
Please review the Standard Seam Tracker
Section to become familiar with the operation of the Seam Tracker.
Before starting the checkout procedure, ensure the
following checklist has been accomplished:
] The power switch on the control unit is in the Off
position and the power cord is disconnected from the
wall outlet.
] The pendant is in the Manual Mode and Sidetrack
is in the Off position.
] Recheck all cables ensuring enough slack to prevent cable stretching, binding or pinching when slides
are operated to their maximum stroke lengths.
] Verify the Omni-Guide Sensor tip is facing toward
the torch and in the opposite direction of the weld
travel.
] Ensure the Omni-Guide Sensor-to-torch relationship is properly adjusted.
This second confirmation is useful in that it
gives a Features verification to the operator.
Providing this verification will reduce/eliminate
unwanted Features stored into memory when the
operator simply wants to change the time stored
into the Weld/Enable Timer for example. Prior
to pressing the Program button, the operator
should verify the positions of the DIP switches
to ensure the proper Features are stored for all
programs.
FIGURE 59 - PTST PROGRAMMING OPTION TIMED MODE
89
9660 SERIES SEAM TRACKER CONTROLLER
PTST INSTALLATION
FIGURE 60 - PTST PROGRAMMING OPTION AUTO DOWN CUTOFF
FIGURE 61 - PTST PROGRAMMING OPTION AUTO UP CUTOFF
90
PTST INSTALLATION
9660 SERIES SEAM TRACKER CONTROLLER
FIGURE 62 - PTST PROGRAMMING OPTION TACK CUTOFF
FIGURE 63 - PTST PROGRAMMING OPTION Z SEARCH FEATURE
91
9660 SERIES SEAM TRACKER CONTROLLER
PTST INSTALLATION
Each step is indicated by a letter to reference from
these descriptions to the actual Time Line. Below is a
table of the Timer Values stored and the Features enabled in the PTST Programming Option for this example.
CAUTION
The relationship of the Omni-Guide Sensor to the torch is a critical adjustment.
Care must be taken in positioning the
torch and the Omni-Guide Sensor prior to
selecting the Automatic Mode in order to prevent damage to any of the equipment.
TABLE 39 - PROGRAM VALUES, EXAMPLE 1
Reconnect power cord and turn the control unit On.
Operate the vertical and horizontal slides by moving
the joystick switch on the pendant in the desired direction and verify the cross-slides move in the same
direction.
Move the Omni-Guide Sensor’s lower rod and tip upward, and verify the vertical slide also moves upward.
Move the Omni-Guide Sensor’s lower rod and tip to
the Left and Right directions and again verify the
slides move in the same directions.
Manually drive the vertical axis down until the
Omni-Guide Sensor contacts the work and its rod is
approximately parallel to the case (Vertical Null). Set
the torch arc gap is in its approximate desired position
(see Figure 16 - Omni-Guide Sensor Mounting (Std.
Bracket) and Figure 17 - Omni-Guide Sensor Mounting (Univ. Bracket) beginning on page 12). If so,
manually drive the vertical slide up and switch from
Manual to Automatic Mode at the pendant, first ensuring that the appropriate sidetrack switch is in its
desired position (see the many figures and tables beginning on page 4 and Figure 25 - Tracking Diagram
on page 23 to assist in the proper position and tip selection). The Omni-Guide Sensor will seek its true
null automatically. Using the fine adjustments of the
manual slides of the 5-axis mount, adjustments can
be attained for the final arc gap positions and the
cross-seam alignment.
Description
Values
Weld/Enable Timer
60 seconds
Overlap Timer
5 seconds
Final Timer
4 seconds
Retract Timer
4 seconds
Tack Cutoff
Enabled
Timed / Auto Cutoff Mode
Timed Mode
Z-Search
Enabled
Sidetrack Disable at Null
Disabled
Vertical Search Delay
Enabled
Horizontal Retract Delay
Enabled
Lockout
Enabled
Crater Fill Delay
Enabled
Sidetrack Selected
Left
Start
Set the pendant controls to Auto and select the desired
sidetrack direction. Start may be initiated by either
the Start Cycle pushbutton on the pendant or via the
Remote Interface (see Figure 74 - Remote Input Interface Connections on page 114). Indicated by the “A”.
PTST CHECKOUT PROCEDURE
After the pre-check procedure, the PTST Programming Option may be checked for proper operation. Provided below are two examples of Sequence
of Operations, that will help in understanding the process, each processes role in the system and assist in
troubleshooting the system, if needed.
Cycle
The Cycle has started. Cycle allows sequential circuitry to be activated for the search mode of operation.
Search
The horizontal slide will move at maximum speed in
the direction of the selected sidetrack for a preset time
of two seconds (vertical search delay). Indicated by
the “B”. This allows the sensor to clear any fixture
interference before moving downward in search of the
weld seam. After the two-second delay the vertical
slide is allowed to move downward, causing the sensor to move at a 45 degree angle, overshooting the
weld seam. When the sensor touches the workpiece
and vertical null is achieved, indicated by the “C”, the
horizontal slide will move in the opposite direction of
the selected sidetrack until the sensor drops into the
SEQUENCE OF OPERATION
Example One
This sequence of operation describes the cyclic events
for a seam tracker system configured with Timed
Weld Mode, Tack Cutoff, Z Search, Vertical Search
Delay, Lockout, Crater Fill Delay and Horizontal Retract Delay, along with the timer values stored into
the memory of the PTST. Figure 64 - PTST Time
Line, Example One on page 93 is a diagram provided
to help in understanding the seam tracker’s process
and typical automated welding sequence of events.
92
PTST INSTALLATION
9660 SERIES SEAM TRACKER CONTROLLER
weld seam, indicated by the “D”. Sidetrack reverts
back to the select sidetrack direction. When null is
achieved, the sidetrack pressure is then controlled by
the side track adjust potentiometer and once the seam
is located, reduces the side track pressure ensuring the
sensor tip does not walk out of the seam.
Lockout
Energizing the relay will lock the slides in the manual
mode of operation for a preset time of two seconds,
allowing each system to strike an arc. This is the area
between “E” and “F”.
System Null
When in system null the seam tracker is in the tracking mode of operation waiting for other tracking systems to find their respective seams and null. After all
systems have nulled, each systems relay is turned On.
This is indicated by the “E”.
Tracking
At the end of the two-second lockout delay, indicated
by the “F”, the system is in the tracking mode of operation. (Tracking mode of the slides is indicated by a
grayed area along the horizontal and vertical slides
axis on the time line.) The tack circuitry is armed
(pendant Arm lamp is lit) and the weld time is displayed on the display and begins counting down.
Relay
Each tracking system has a relay which, when activated, turns on the start lamp of their respective control pendants. The contact closures from this relay
may be used to start carriages, wire feeders, etc. Three
sets of contact closures are present at the J3 customer
interface connector of each control box.
Weld Time
During weld time if a tack is encountered, indicated
by the “G”, the slides will stay in a manual mode of
operation until the tack is passed, indicated by the
“H”. (Only one tack is shown here for clarity.) During weld time the tack circuitry may be disabled from
the pendant. Activating the remote cut-off will terminate the weld time. After the weld timer times out, in-
FIGURE 64 - PTST TIME LINE, EXAMPLE ONE
93
9660 SERIES SEAM TRACKER CONTROLLER
PTST INSTALLATION
dicated by the “I”, the system will be in the overlap
mode of operation.
PTST Programming Option Time Line, Example Two
on page 95 is a diagram provided to help in understanding the seam tracker’s process and typical automated welding sequence of events. Each step is
indicated by a letter to reference from these descriptions to the actual Time Line. Below is a table of the
Timer Values stored and the Features enabled in the
PTST Programming Option for this example.
Overlap Time
In the Overlap Mode of operation, the slides are in the
Manual Mode and the K1 relay remains On. This
timer useful to allow the torch position to “Catch up”
to the position at which the Cutoff signal was received
(if used, not shown in this example) or where the weld
timer timed out, indicated by the “J”. This timer acts
as a delay to the Final time.
TABLE 40 - PROGRAM VALUES, EXAMPLE 2
Final Time
After the Overlap timer times out, “J”, the system is
forced to the Final Timer. During the Final time, the
K2 relay is energized and remains energized for the
duration of the timer setting. Final time is useful to
allow other equipment indication of what portion of
the sequence the cycle it in. By providing the K2 relay output, the seam tracker can signal the power
source or other weld controller’s to change from one
weld schedule to another. Extremely useful in circumferential welding applications when a hotter weld
is needed to flatten out the overlap pass at the end of
the weld.
When the timer is completed the system is forced into
Crater Fill Delay Mode, indicated by the “K”, and the
K1 and K2 relays are de-energized.
Crater Fill Delay
At the start of Crater Fill Delay (a two-second delay),
the K1 and K2 relays are turned off indicating Crater
Fill Delay Mode of operation, the area between “K”
and “L”. The slides still remain in manual mode of
operation, locked in their last position. After two seconds, the system is forced into the Retract Mode of
operation, indicated by the “L”.
Description
Values
Weld/Enable Timer
60 seconds
Overlap Timer
5 seconds
Final Timer
4 seconds
Retract Timer
4 seconds
Tack Cutoff
Enabled
Timed / Auto Cutoff Mode
Auto Cutoff Mode
Z-Search
Enabled
Sidetrack Disable at Null
Disabled
Vertical Search Delay
Enabled
Horizontal Retract Delay
Enabled
Lockout
Enabled
Crater Fill Delay
Enabled
Sidetrack Selected
Left
Start
Set the pendant controls to Auto and select the desired
sidetrack direction. Start may be initiated by either
the Start Cycle pushbutton on the pendant or via the
Remote Interface (see Figure 74 - Remote Input Interface Connections on page 114). Indicated by the “A”.
Retract Time
Immediately after Crater Fill Delay, the vertical slide
will move upward, indicated by the “L”. The horizontal slide will not retract until after a two-second delay,
Horizontal Retract Delay, indicated by the “M”.
Thus, the horizontal retract time will be the Retract
Timer setting minus two seconds, .i.e., the Horizontal
Retract Delay. After the delay is completed, the sensor is clear of the workpiece and the horizontal slide
is allowed to move to the right. After the Retract
Timer times out, the sensor is positioned back to the
start position and the cycle is complete, indicated by
the “N”. The system is ready for the next welding
operation.
Cycle
The Cycle has started. Cycle allows sequential circuitry to be activated for the search mode of operation.
Search
The horizontal slide will move at maximum speed in
the direction of the selected side track for a preset
time of two seconds (vertical search delay). Indicated
by the “B”. This allows the sensor to clear any fixture interference before moving downward in search
of the weld seam. After the two-second delay the vertical slide is allowed to move downward, causing the
sensor to move at a 45 degree angle, overshooting the
weld seam. When the sensor touches the workpiece
Example Two
This sequence of operation describes the cyclic events
for a seam tracker system configured with Auto
Cutoff Weld Mode, Tack Cutoff, Z Search, Vertical
Search Delay, Lockout, Crater Fill Delay and Horizontal Retract Delay, along with the timer values
stored into the memory of the PTST. Figure 65 -
94
PTST INSTALLATION
9660 SERIES SEAM TRACKER CONTROLLER
and vertical null is achieved, indicated by the “C”, the
horizontal slide will move in the opposite direction of
the selected sidetrack until the sensor drops into the
weld seam, indicated by the “D”. Side track reverts
back to the select side track direction. When null is
achieved, the side track pressure is then controlled by
the side track adjust potentiometer and once the seam
is located, reduces the side track pressure ensuring the
sensor tip does not walk out of the seam.
sets of contact closures are present at the J3 customer
interface connector of each control box.
Lockout
Energizing the relay will lock the slides in the manual
mode of operation for a preset time of two seconds,
allowing each system to strike an arc. This is the area
between “E” and “F”.
Tracking
At the end of the two-second lockout delay, indicated
by the “F”, the system is in the tracking mode of operation. (Tracking mode of the slides is indicated by a
grayed area along the horizontal and vertical slides axis on the time line.) The tack
circuitry is armed (pendant Arm lamp is lit)
and the weld time is displayed on the display and begins counting down.
System Null
When in system null the seam tracker is in the tracking mode of operation waiting for other tracking systems to find their respective seams and null. After all
systems have Nulled, each systems relay is turned On.
This is indicated by the “E”.
Relay
Each tracking system has a relay which, when activated, turns on the start lamp of their respective control pendants. The contact closures from this relay
may be used to start carriages, wire feeders, etc. Three
Weld Time
During weld time if a tack is encountered, indicated
by the “G”, the slides will stay in a manual mode of
FIGURE 65 - PTST PROGRAMMING OPTION TIME LINE, EXAMPLE TWO
95
9660 SERIES SEAM TRACKER CONTROLLER
PTST INSTALLATION
operation until the tack is passed, indicated by the
“H”. (Only one tack is shown here for clarity.) During weld time the tack circuitry may be disabled by
remote. Activating the remote cut-off will terminate
the weld time. After the weld timer times out, indicated by the “I”, the system will continue tracking
the joint until the next tack is sensed, indicated by the
“J”. The tack sensed could be simply another tack or
it could be the beginning of the weld bead, as those
sensed on a circumferential welding application, such
as, a fuel tank, pressure vessel, etc. Once the weld
bead is sensed, the system is forced into the Overlap
Mode of operation.
start position and the cycle is complete, indicated by
the “O”. The system is ready for the next welding
operation.
SEAM TRACKER GROUNDING AND CABLING
It is necessary to have the Seam Tracker grounded
properly to protect the unit from electrical noise. This
is of particular importance during GTAW (TIG) applications which employ high frequency or high voltage
spikes for arc starting.
The seam tracker is provided with a 1/4-20 ground
stud on the bottom of the unit. USE IT! The seam
tracker should be tied to a good earth ground (PE).
The seam tracker ground should not be hooked up to
the fixture, unless the fixture is using a known good
earth ground (PE).
Overlap Time
In the Overlap Mode of operation, the slides are in the
Manual Mode and the K1 relay remains on. This
timer useful to allow the torch position to “Catch up”
to the position at which the Cutoff signal was received
(if used, not shown in this example) or where the weld
timer timed out, indicated by the “K”. This timer acts
as a delay to the Final time.
NOTE
All cabling provided with this system is
shielded. If you extend cables, in particular cables for remote interfacing, they must be in
shielded cables. The outer shield should be continuous back to the seam tracker. Do not hook up
the shield to the equipment which the remote cable is going to. Tape the shield back, this forms
a drain system taking noise off the cables back
to the seam tracker and ground.
Final Time
After the Overlap timer times out, “K”, the system is
forced to the Final Timer. During the Final time, the
K2 relay is energized and remains energized for the
duration of the timer setting. Final time is useful to
allow other equipment indication of what portion of
the sequence the cycle it in. By providing the K2 relay output, the seam tracker can signal the power
source or other weld controller’s to change from one
weld schedule to another. Extremely useful in circumferential welding applications when a hotter weld
is needed to flatten out the overlap pass at the end of
the weld.
When the timer is completed the system is forced into
Crater Fill Delay Mode, indicated by the “L”, and the
K1 and K2 relays are de-energized.
Crater Fill Delay
At the start of Crater Fill Delay (a two-second delay),
the K1 and K2 relays are turned off indicating Crater
Fill Delay Mode of operation, the area between “L”
and “M”. The slides still remain in manual mode of
operation, locked in their last position. After two seconds, the system is forced into the Retract Mode of
operation, indicated by the “M”.
Retract Time
Immediately after Crater Fill Delay, the vertical slide
will move upward, indicated by the “M”. The horizontal slide will not retract until after a two-second
delay, Horizontal Retract Delay, indicated by the “N”.
Thus, the horizontal retract time will be the Retract
Timer setting minus two seconds, .i.e., the Horizontal
Retract Delay. After the delay is completed, the sensor is clear of the workpiece and the horizontal slide
is allowed to move to the right. After the Retract
Timer times out, the sensor is positioned back to the
96
PTST INSTALLATION
9660 SERIES SEAM TRACKER CONTROLLER
97
9660 SERIES SEAM TRACKER CONTROLLER
PTST INSTALLATION
TABLE 41 - 9660P CONTROL PROGRAM WORKSHEET
98
PTST MAINTENANCE
9660 SERIES SEAM TRACKER CONTROLLER
Additional maintenance to be preformed on the PTST
Programming Option is periodic cleaning of the front
panel overlay and the pendant face plate.
PTST MAINTENANCE
Maintenance required by the PTST Programming Option is minimal. The best preventive maintenance to
be preformed on the PTST Programming Option or on
the seam tracker is to be sure the door of the enclosure
is closed tightly. This prevents dust, dirt and other
contaminants from entering and fouling the circuit
boards inside.
There is periodic mechanical maintenance necessary
to keep the system in optimum working condition. A
Preventive Maintenance Schedule is provided in the
Maintenance section earlier in this manual. The Preventive Maintenance Schedule and other mechanical
maintenance functions and procedures can be found in
the Maintenance Section beginning on page 25.
99
9660 SERIES SEAM TRACKER CONTROLLER
PTST MAINTENANCE
100
PTST DRAWINGS AND PARTS LISTS
9660 SERIES SEAM TRACKER CONTROLLER
PTST DRAWINGS AND PARTS LISTS
FIGURE 66 - PTST CONTROL BOARD LAYOUT
101
9660 SERIES SEAM TRACKER CONTROLLER
PTST DRAWINGS AND PARTS LISTS
FIGURE 67 - 9660P CONTROL EXPLODED VIEW
102
PTST DRAWINGS AND PARTS LISTS
9660 SERIES SEAM TRACKER CONTROLLER
TABLE 42 - 9660P CONTROL PARTS LIST
Item
Part
QPA
UM
1
1.000
EA
9660-1
CONTROL ENCLOSURE 9660
1
1.000
EA
9660-1-DOOR
CONTROL ENCLOSURE DOOR 9660
1
1.000
EA
9660-2
CONTROL ENCLOSURE OVERLAY 9660
2
1.000
EA
1101-2002-2
CONTROL TRANSFORMER ASSY
3
1.000
EA
1101-2002-3
MAIN BOARD ASSY
4
1.000
EA
1101-2002-4
MOTOR DRIVER ASSY
5
1.000
EA
1101-2002-5
CONTROL DRIVE CABLE ASSY
6
1.000
EA
1101-2002-6
VOLTAGE SELECTOR SWITCH ASSY
7
1.000
EA
1101-2002-7
CONTROL PENDANT CABLE ASSY
8
1.000
EA
1101-2002-8
POWER SWITCH ASSY
9
1.000
EA
9660P-3
REMOTE PANEL/HARNESS ASSY-PTST
10
1.000
EA
1103-2002-1
PTST CONTROL BOARD ASSY
11
1.000
EA
9660P-1
PTST OVERLAY & PLATE ASSY 9660P
13
0.625
EA
999005-005
TAPE NEO FOAM ADH 1/8INX1/4THK
14
5.000
EA
979001-001
CABLE TIE .75 BUNDLE DIA (NOT SHOWN)
15
1.000
EA
989003-001
CBL TIE MNT ADH BACK .75IN SQ (NOT SHOWN)
16
0.417
FT
2040-0536
GROMMET CATERPILLAR
17
1.000
EA
929000-001
3 CONDCTR PWR SPLY CORD (NOT SHOWN)
18
4.000
EA
2414-0201
SCR RND HD U-DRV #2X1/4
19
4.000
EA
970000-204
SCR 4-40X.38 CR1P SBZ
21
15.000
EA
970000-406
SCR 8-32X.50 CR1P SBZ
23
8.000
EA
974010-002
WSR SL #4.209X.121X.025 SBZ
24
7.000
EA
974010-004
WSR SL #8.293X.175X.040 SBZ
28
8.000
EA
972000-002
NUT 4-40 H SBZ
30
4.000
EA
972000-005
NUT 10-32 H SBZ
31
4.000
EA
974010-005
WSR SL #10 .334X.202X.047 SBZ
32
4.000
EA
974006-005
WSR F #10 .374X.195X.032 B
33
8.000
EA
970000-404
SCR 8-32X.38 CR1P SBZ
34
8.000
EA
974010-004
WSR SL #8.293X.175X.040 SBZ
35
6.000
EA
972000-003
NUT 6-32 H SBZ
37
6.000
EA
974000-004
WSR F #8 .438X.188X.049 SBZ
38
1.000
EA
1103-2002-5
PTST RIBBON CABLE (NOT SHOWN)
No
No
Description
103
9660 SERIES SEAM TRACKER CONTROLLER
PTST DRAWINGS AND PARTS LISTS
FIGURE 68 - 9660P-100 PENDANT EXPLODED VIEW
104
PTST DRAWINGS AND PARTS LISTS
9660 SERIES SEAM TRACKER CONTROLLER
TABLE 43 - 9660P-100 PENDANT PARTS LIST
Item
Part
QPA
UM
1
1.000
EA
9660-100-1
SEAM TRACKER PENDANT ENCLOSURE 9660
2
1.000
EA
9660-100-2
SEAM TRACKER PENDANT FACEPLATE 9660
3
1.000
EA
1116-0352
SWITCH SIDETRACK
4
1.000
EA
2066-0112
SW JOY STICK 9 POS SNGL POLE
5
1.000
EA
1116-0387
SWITCH AUTO/MAN
6
1.000
EA
1114-1332
ST PENDANT ASSY, 10 FT. (NOT SHOWN)
7
1.000
EA
2040-0579
CBL FTTNG W/NUT&BSH .375-.500
10
1.000
EA
2208-0059
CONN RECT RCPT (9CKT) (NOT SHOWN)
11
9.000
EA
2212-0093
TERM SOCKET CRIMP 18-24 GA (NOT SHOWN)
12
1.000
EA
900007-003
CAP CER .1UF 500V +80 -20% (NOT SHOWN)
13
16.00
EA
970021-404
SCR 8-32X.38 HSBC SBZ
14
4.000
EA
0600-0026
FEET, RUBBER
15
1.000
EA
9660P-100-1
PTST PENDANT PROG MODULE OPTION
No
No
Description
Consisting of:
16
1.000
EA
9660P-100-2
PTST PENDANT PROG MODULE OPTION PLATE
17
2.000
EA
2062-0081
SWITCH PB 10 AMP BLACK
18
1.000
EA
1116-0400
SW MUSHROOM STOP ST PENDANT
19
2.000
EA
941000-103
LAMP LENS TRANSLUCENT YELL SM
20
1.000
EA
941000-101
LAMP LENS TRANSLUCENT RED SM
21
3.000
EA
941000-200
LAMP HOLDER LH73/1
22
1.000
EA
2208-0105
CONN RECT PLUG (9CKT) (NOT SHOWN)
23
9.000
EA
2212-0107
TERM PIN CRIMP 24-30 GA (NOT SHOWN)
24
3.000
EA
941000-011
LAMP 387
105
9660 SERIES SEAM TRACKER CONTROLLER
PTST DRAWINGS AND PARTS LISTS
FIGURE 69 - REMOTE CONNECTOR HARNESS EXPLODED VIEW
TABLE 44 - REMOTE INPUT/OUTPUT CONNECTOR HARNESS PARTS LIST
Item
Part
QPA
UM
1
1.000
EA
930014-016
CONN CIRC BOX RCPT 24-19S
2
1.000
EA
930014-011
CONN CIRC BOX RCPT 18-1S
3
1.000
EA
9660P-4
PTST REMOTE OPTION AMPHENOL PLATE
4
1.000
EA
???
CONN RECT PLUG (8 CKT)
5
1.000
EA
???
CONN RECT PLUG (12 CKT)
6
18.000
EA
???
TERMINAL CRIMP PIN 18-24 GA
7
2.000
EA
2340-0588
TERM RING INSULATED #6
8
8.000
EA
974000-002
WSR SL #6
9
8.000
EA
972000-002
NUT #6
No
No
Description
106
PTST TROUBLESHOOTING
9660 SERIES SEAM TRACKER CONTROLLER
Setup and General Information
It is assumed that switches, connectors and power
supply voltages are proper. The reference for the
digital multi-meter may be obtained on the Main
board. All analog signals are referenced to signal
(logic) ground (GND). This troubleshooting guide is
limited to the substitution of assemblies only. No
schematic of boards or assistance are provided for
troubleshooting to the component level of the boards.
PTST TROUBLESHOOTING
INTERFACING THE SEAM TRACKER TO OTHER
EQUIPMENT
The interconnect diagrams in on page and Figure 71
- 9660P-100 Pendant Schematic on page 111, shows
the functional relationship of the PTST Programming
Option with subassemblies in the seam tracker system.
Many problems appear to be electrical in nature, when
in fact, they are mechanical problems in the
cross-slides, Omni-Guide Sensor, bracketry, cables,
etc. Inspection of the mechanical components the
Seam Tracker System and of the complete system
should be performed periodically and prior to continuing electrical troubleshooting (see the Maintenance
section earlier in this manual for detailed information
on troubleshooting mechanical system issues beginning on page 25. Also within this section review the
Preventive Maintenance Schedule beginning on page
26 for periodic maintenance requirements).
In addition to the board layout drawings, Figure 70 9660P Control Signal Flow on page 109 illustrates
very simply the flow of signals in the seam tracker
system with the Advanced Programming Control
installed.
Subassembly Interface
The interface between the PTST Programming Option
and the other subassemblies in the control unit are
modular. The subassemblies make discrete connections to primarily the Main board via molex connectors and wiring harnesses (see on page and on page
).
Vertical Delay
Vertical delay is evidenced by watching the torch
slides. The horizontal slide will move in the direction
of the selected sidetrack for approximately 2 seconds
before the vertical slide will move downward. If this
doesn’t occur, verify the Feature is selected by the
Vertical Delay LED being lit.
A basic signal flow diagram is provided in Figure 70 9660P Control Signal Flow on page 109 to provide effective troubleshooting should the need arise.
GENERAL
NOTE
Lockout
Lockout is initiated for 2 seconds after the start lamp
on the pendant illuminates. This is verified by displacing the Omni-Guide Sensor tip resulting in no slide
movement, or the tack lamp illuminating 2 seconds
after start lamp illuminates. If this doesn’t occur, verify the Feature is selected by the Lockout LED being
lit.
For use by qualified service technicians
The following list describes typical problems and suspect assemblies for the system. The schematics and circuit descriptions
will be a helpful reference for troubleshooting.
Tack Cutoff
Tack operation is evident when the tack lamp on the
control pendant illuminates when the Omni-Guide
Sensor is displaced upward. This function is only operative when the arm lamp is illuminated. If this
doesn’t occur, verify the Feature is selected by the
Tack Cutoff LED being lit.
CAUTIONS
• Full line voltage is exposed inside the control unit.
• Do not turn the power On when any of the connectors
are removed from their position.
• Use discretion when substituting components. It is
possible for the unit to have defects that could damage
replaced components.
• The main and PTST Programming Option boards contain CMOS logic components, which require standard
CMOS precautions against damage by Electro-Static
Discharge (ESD).
Crater Fill Delay
Crater delay will occur immediately after the start
lamp on the control pendant extinguishes. The vertical
and horizontal slides will remain stationary for 2 seconds before retracting. If this doesn’t occur, verify
the Feature is selected by the Crater Fill Delay LED
being lit.
Recommended Troubleshooting Equipment.
• Digital multi-meter (with frequency counter and diode
and capacitor checker)
• Miscellaneous screw drivers, nut drivers, and
wrenches
Horizontal Delay
Horizontal delay occurs during retract. The vertical
slides will retract upward for 2 seconds and then the
horizontal slides will retract the opposite direction of
the selected sidetrack. If this doesn’t occur, verify the
107
9660 SERIES SEAM TRACKER CONTROLLER
PTST TROUBLESHOOTING
Feature is selected by the Horizontal Delay LED being lit.
Relay K1 does not operate
Verify the seam tracker has found the seam and that
the Omni-Guide Sensor is not binding or gouging the
workpiece. Try jogging the Omni-Guide Sensor’s
lower rod and tip back and forth to ensure the tip is
free to move (if binding or gouging is at fault, this
may allow the K1 relay to energize).
Verify the relay is seated correctly in the relay socket.
Z Search
Verify the Omni-Guide Sensor is not binding or gouging the workpiece as it tries to traverse the
work-piece, adjusting the angle to allow proper tip
movement along the work-piece. Try jogging the
Omni-Guide Sensor’s lower rod and tip back and
forth to ensure the tip is free to move (if binding or
gouging is at fault, this may allow the Z-Search feature operate properly).
Verify the Feature is selected by the Z-Search LED
being lit.
Seam tracker continues to cycle when start is not
activated.
Verify the remote Start input is not being held on or
closed. This will cause the system to immediately
start another cycle after a cycle has been completed.
Try to isolate the remote cables to determine if noise
is being picked up by the control unit and is false
starting a cycle.
108
PTST TROUBLESHOOTING
9660 SERIES SEAM TRACKER CONTROLLER
FIGURE 70 - 9660P CONTROL SIGNAL FLOW
109
9660 SERIES SEAM TRACKER CONTROLLER
PTST TROUBLESHOOTING
110
PTST SCHEMATICS AND BLOCK DIAGRAMS
9660 SERIES SEAM TRACKER CONTROLLER
PTST SCHEMATICS AND BLOCK DIAGRAMS
FIGURE 71 - 9660P-100 PENDANT SCHEMATIC
111
9660 SERIES SEAM TRACKER CONTROLLER
PTST SCHEMATICS AND BLOCK DIAGRAMS
FIGURE 72 - 9660P CONTROL BLOCK DIAGRAM
112
PTST SCHEMATICS AND BLOCK DIAGRAMS
9660 SERIES SEAM TRACKER CONTROLLER
FIGURE 73 - 9660P CONTROL BLOCK DIAGRAM (CONT.)
113
9660 SERIES SEAM TRACKER CONTROLLER
PTST SCHEMATICS AND BLOCK DIAGRAMS
FIGURE 74 - REMOTE INPUT INTERFACE CONNECTIONS
114
PTST SCHEMATICS AND BLOCK DIAGRAMS
9660 SERIES SEAM TRACKER CONTROLLER
FIGURE 75 - REMOTE OUTPUT INTERFACE CONNECTIONS
115
9660 SERIES SEAM TRACKER CONTROLLER
PTST SCHEMATICS AND BLOCK DIAGRAMS
FIGURE 76 - 9660P MULTI-SYSTEM OPERATION AND WIRING
116
PTST SCHEMATICS AND BLOCK DIAGRAMS
9660 SERIES SEAM TRACKER CONTROLLER
FIGURE 77 - 9660P AUTO-DISABLE OPERATION AND WIRING
117
9660 SERIES SEAM TRACKER CONTROLLER
PTST SCHEMATICS AND BLOCK DIAGRAMS
FIGURE 78 - 9660P CONTROL TO MILLER AUTO M INTERFACE
118
9660 SERIES SEAM TRACKER CONTROLLER
INDEX
!
"U" · · · · · · · · · · 19- 20
+15 VDC · · · · · · · · 60,66
+20 VDC · · · · · · · · · 66
+6 VDC · · · · · · · · 60,66,85
±15VDC · · · · · · · · · · 59
±20VDC · · · · · · · · · · 59
±6VDC · · · · · · · · · · 59
12V p-p · · · · · · · · · · 66
-15 VDC· · · · · · · · · 60,66
180 · · · · · · · · · 37,56,67
-20 VDC· · · · · · · · · · 66
2KHz· · · · · · · · · · · 66
45 · · · 2- 3,19,37,53,55- 57,77,92,94
5 Axis Mount· · · · · · · · 1,17
-6 VDC · · · · · · · · · 60,66
9660 Series
See PTST Programmable Tactile
Seam Tracking
See TST Tactile Seam Tracking
A
accidental · · · · · · · · 21,85
Accuracy · · · · · · · · · 2- 3
adapter · · · · · · 1,17,20- 21,26
adequate · · · · · · · · 19- 21
adjustment · · 17,19- 20,22,26,59,6667,78,84,92
Advanced Programming Control Option6566,68,111
amphenol · · · · · · · · · 86
angular · · · · · · · · · 18- 19
Anti-jam · · · · · · · · 66- 67
arm · · · · · 17,19,76,86,93,95,107
Arm · · · · · · · · 76,86,93,95
AUTO · · · · · · · 22,45,65,105
Auto Cutoff · · 75- 77,79,85,87,92,94
automatic · · 1- 3,20,22,65,75- 78,8081,86,92
B
backwards
barrel ·
brake ·
Button ·
·
·
·
·
·
·
·
·
·
·
·
·
·
·
·
·
·
·
·
·
·
·
·
·
·
·
·
·
· · 88
· 20,26
17,25,66
· · 88
C
Cable · · · · 1- 3,17- 19,21,25,27,59
calibration · · · · · · · · · 59
carriage · · · 21,68,80,83- 84,93,95
case · · · · · · 17,20,22,26,67,92
CCW · · · · · · · · · · 22,66
center · · · · · 17,19,22,27,65,86
chassis · · · · · · · · · 20,85
Checkout · · · · · · · · 89,92
circumferential · · · · · · 75,94,96
Clamp · · · · · 1- 3,14,17,19,53,60
clearance · · · · · · · · 19- 20
climb · · · · · · · · · 77,81,86
closed loop feedback· · · · · · 65
CMOS · · · · · · · · · 59,107
compensation · · · · · · 19,22,67
confirmation · · · · · · · 88- 89
contamination · · · · · · · · 25
Control · · · 1- 3,17- 22,25,66- 67,85
Correction· · · · · · · · · 2- 3
counter · · · · · 67,84,93,95,107
counter-clockwise · · · · · · · 67
coupling · · · · · · · · 17,25,66
Crater · 75,78,80,85,87- 88,92,94,96,107
Crater Fill75,78,80,85,87- 88,92,94,96,107
creep · · · · · · · · · 17,67
critical · · · · · · · · · · 92
Cross 1- 3,8,17,19- 22,25,27,38- 40,59- 60
cross-seam · · · · · · · · 22,92
cross-slide · 1,17- 22,25- 27,36- 37,5960,65- 67,76,80,92,107
current · · · · 1,17,66- 67,78,85,88
Cutoff · · · 75- 77,79- 80,83- 87,9092,94,96,107
CW · · · · · · · · · · 22,66
cylindrical · · · · · · · · · 17
D
de-energizes · · · · · · · · 83
deflection · · · · · · 17,65- 67,85
degrees · · · · 19- 20,66- 67,74,84
Delay 75,77- 78,80,85- 88,92,94,96,107108
depress · · · · · · · · · 22,75
depressed · · · · · · · · · 22
diagram · · · 19,25,59,65,92,94,107
diagrams · · · · · · · · · 59
Diameter · · · · · · · · · 2- 4
DIP · · · · 75- 78,80- 81,86,88- 89
Disarm · · · · · · · · · 76,86
Down· · · 2- 3,18,67,75- 81,85- 86,90
downward· · · · · 20- 21,26,60,6667,77,80,92,94,107
drag · · · · · · · · · · · 20
DRAWINGS · · · · · · · · 65
drifts · · · · · · · · · · · 59
Drive · · · · · 1- 3,17,19,21,60,66
duration · · · · 75- 76,80,83,94,96
dust · · · · · · · · 1,25- 27,99
DVM · · · · · · · · · · · 66
E
earth · · · · · · · · · 20,85,96
electrolytic · · · · · · · · · 66
Electro-Magnetic Interference · · · 66
Emergency Stop · · · · · · 83- 84
EMF · · · · · · · · · · · 67
EMI · · · · · · · · · · · 66
enclosure · · · · · 1- 3,25,66,86,99
encoder · · · · · · · · · · 84
encountered · · · · · · · 93,95
end-of-weld· · · · · · · · 75,84
Engagement · · · · · · · · 22
environment · · · · · · · · 20
EQUIPMENT · · · · · · 1- 16,18
erroneous · · · · · · · · · 85
error · · · · · · · · 1,22,66- 67
ESD · · · · · · · · · · 107
Exploded · 26,34,36,38,42,44,102,104
extension · · · · · · 1,17- 18,20
extinguished · · · · · · · · 75
extreme · · · · · · · · 19- 20
F
faceplate · · · · · · · · · 1,74
factory · · · 1,17- 19,25- 26,66,77,88
faulty · · · · · · · · · 59- 60
Field · · · · · · · · · · · 85
fillet · · · · · · · · · · 18,74
119
Filter · · · · · · · · · · · 20
Final · · · · 76,83,87- 88,92,94,96
Force · · · · · 13,20,22- 23,67,77
friction · · · · · · · · · · 20
fuse holder · · · · · · · · 1,25
G
gap · · · · · · · · · · 22,92
GND
See ground
groove · · · · · 17- 18,20,78,81,86
ground · · · · · · 20,66,85,96,107
GTAW · · · · · · · · · · 96
guide · · · · · · · · · 26,107
H
Handheld · · · · · · · · · 2- 3
HE · · · · · · · 35,37,57,60,67
Heatsink · · · · · · 25,60,66- 67
held · · · · · 2- 3,18,22,25,27,108
horizontal · 1,17,19- 20,22,26- 27,59,6567,76- 78,80,83- 85,92- 96,107
Horizontal Disable · · · · · 83- 84
Horizontal Retract 75,80,85- 86,92,94,96
HP · · · · · · · · · 60,66- 67
I
IC · · · · · · · 2- 3,35,45,59,105
independent · · · · · · · · 86
initiated · · · 75,83- 84,86,92,94,107
input · · · · 65- 67,76- 77,83- 85,108
Input Connector · · · · · · · 83
instability · · · · · · · · · 59
Installation · · · · · · · 20,26,85
INSTALLATION · · · · · 19,88- 98
insulated · · · · · · · · 17,19
Integrated Circuits
See IC
inter-connection · · · · · · · 19
interface · · · 65,68,83- 84,93,95,107
interior · · · · · · · · · · 25
interrupted · · · · · · · · · 84
IR · · · · · · · · 25,59,65- 68
J
J1 · · · · · · · · · 21,85- 86
J2· · · · · · · · · · · · 21
J3· · · · · · · · · 83,86,93,95
J4· · · · · · · · · · · 83,86
J5· · · · · · · · · · · 68,86
jitter · · · · · · · · · · · 87
junction · · · 17,21,68,76,80- 81,83,86
K
K1 · · · 68,78,80,83- 84,86,94,96,108
K2 · · · · · · 68,83- 84,86,94,96
K3 · · · · · · · · 68,83- 84,86
keyway · · · · · · · · · 19- 20
L
Lamp · · · · · · · 22,59- 60,84
Left · · · 2- 3,18- 19,67,76,81,92,94
linear· · · · · · · · · · · 17
liquid · · · · · · · · · · · 25
Load Capacity · · · · · · · 2- 3
Lockout · · · 75,78,85,87,93,95,107
longitudinal
· · · · · · · · 75
lug · · · · · 2- 3,20,25,27,59,67- 68
9660 SERIES SEAM TRACKER CONTROLLER
M
magnetic · · · · · · · 17,25,66
magnitude · · · · · · · · · 66
Main board 25,59- 60,65- 66,68,77,86,107
maintained· · · · · · 19,25,83- 84
Maintenance · · · 25- 27,99- 100,107
MAN · · · · · 18,22,45,65- 66,105
manual · · · 1- 3,17,20- 22,25- 26,5960,65,67,76- 78,80,83- 85,92- 96,99,107
Manual · · · 1- 3,17- 18,20- 22,25,5960,65,67,92
Mechanical · · · · · · · · 2,21
Mechanical Override Clutch · · · · 2
mechanical play · · · · · · · 59
mechanized · · · · · · · · 75
memory · 75- 78,80- 81,86,88- 89,92,94
micro-switch · · · · · · · · 84
MIG · · · · · · · · · · 80,87
Minimum Envelope · · · · · · 2- 3
MODE · · · · · · · · 18,22,65
See Automatic and Manual
momentary · · · · · 22,65,83- 84
motor · · · · · · 1,17,27,60,66- 68
motorized · · · · · · · · · 17
multi-pass · · · · · · · · · 76
Precautions · · · · · · · · 84
Precision Ball Screw · · · · · 2- 3
Preliminary · · · · · · · · · 89
preload · · · · · · · · · · 85
prematurely · · · · · · · 20,75
presetable · · · · · · · · · 75
pressure 20,22,26,65,77- 78,86,93,95- 96
preventive · · · · · · · · 25,99
primary · · · · · · · · · 65- 67
Probe · · · · · · · 26,60,66- 67
Problem · · · · · · · · 59- 60
program · · · · · 75,77,80,86- 89
Programmable Logic Controllers · · 83
proportional · · · · · · 1,17,66- 67
Protective Earth · · · · · · · 20
protrusion · · · · · · · · · 19
proximity · · · · · · · · · 19
PTST · · 1- 3,20,60,65- 66,68,75- 118
pulses · · · · · · · · · · 84
Q
Qualified
·
·
·
·
·
·
·
·
·
65
R
offset· · · · · · · · · · 59,67
Omni-Guide 1- 4,12,17,19- 22,26- 28,3435,59- 60,65- 67,75- 76,78,80- 81,8387,89,92,107- 108
ON· 2- 3,19,22,25,35,37,43,45,57,59,6568,78,83- 84,103,105
oriented · · · · · · · · · 19,66
oscillates · · · · · · · · 59,67
oscilloscope · · · · · · · · 66
Outboard · · · · · · · · · · 3
output · · · · 60,66- 67,83- 85,94,96
Output Relay · · · · · · · · 83
Override Clutch · · · · · · · · 2
overshoot · · · · · · · 77,92,94
R7 · · · · · · · · · · · 67
Radio Frequency Interference · · · 66
raised · · · · · · · · · 75- 76
Rating · · · · · · · · · · 2- 3
RATING · · · · · · · · · 2- 3
rectified · · · · · · · · · · 66
rectifier · · · · · · · · · · 66
Regulation · · · · · · · · · 65
relationship · · · · · 22,89,92,107
relay · 21,68,78,80,83- 84,86,93- 96,108
Remote Input · · · · · · 75,83,114
Remote Output · · · · · · · 115
resistor · · · · · · · · · · 67
reversed · · · · · · · · 20,67
RFI · · · · · · · · · · 20,66
See Radio Frequency Interference
ribbon · · · · · · · · · 68,86
Right · · · · · 2- 3,18,67,76,81,92
rigid · · · · · · · · · · 19,59
rigidity · · · · · · · · · · 59
rocker · · · · · · · · · 18,20
rod 1,17,20,22,26,60,65- 67,75,85,92,108
root · · · · · · · · · · · 76
rotated · · · · · · · · · 67,74
rotation · · · · · · · · · 22,84
roughness · · · · · · · · · 20
P
S
P3 · · · · · · · · · · 60,66
P4 · · · · · · · · 60,66,83- 85
panels · · · · · · · · · · · 1
parallel · · · · · · 19,22,83- 84,92
paralleled · · · · · · · · 83- 84
parts list · · · · · · · · · 26,59
Parts Lists · · · · · · · · · 65
patterns · · · · · · · · · · 20
PE 2- 3,20,35,43,45,56,84- 85,96,103,105
See Protective Earth
Pendant· 1- 3,11,18- 22,25,44- 45,60,6667,69,75- 76,85,104- 105
periodic · · · · · · · 25,99,107
perpendicular · · · · · · · · 19
plane · · · · · · · · · 18- 19
PLC · · · · · · · · · 68,83- 84
power switch· · · · 1,20,22,25,65,89
Pre-amplifier · · · · · · · · 66
S5 · · · · · · 75- 78,80- 81,86,88
Schedule · · · · · · · 26,99,107
schematics · · · · · 25,59,65,107
sealed · · · · · · · · · 1,18,20
seam · 17- 18,20- 22,25- 26,65- 67,7578,80- 81,83- 86,88,92- 96,99,107- 108
Seam · · · · 1,17- 22,25,65- 66,6869,85,92,96,107- 108
secondary · · · · · · · · · 66
Select · · · · · 5- 6,67,87- 88,92,94
selector · · · · · · · · · · 66
Sensitivity · · · · · · · · · 77
sensor 1,17,22,26,59,65- 67,75- 77,92- 96
sensor-to-torch · · · · · · · 89
sequence · · · · · · 75,92,94,96
Sequence · · · · · · · · 22,92
serrated · · · · · · · · · · 19
N
noise · · · · · · · 20,85,96,108
Non-Standard · · · · · · · 2- 3
normally open· · · · · · · 83- 84
null · 17,22,65- 66,77,83- 84,86- 87,9293,95
Null Input · · · · · · · · 83- 84
O
120
service · · · · · · · · · 25,107
Service · · · · · · · · · 25,65
See Also Troubleshooting
serviceable · · · · · · · · · 25
servo · · · · · · · · · 65- 67
seven segment · · · · · · · 88
shield · · · · · · · 17,20,85,96
shields · · · · · · · · · 20,85
Sidetrack · · · · · · · · 2- 3,2223,59,65,67,75,77,81,85- 87,89,92- 94
Sidetrack Disable 75,77,81,85- 87,92,94
Signals · · · · · · · · 17,60,67
Slide · · 1- 3,8,17,19,21- 22,25,27,3840,60,80
sluggish · · · · · · · · · · 67
solid state · · · · · · · · · 1
source · · · 66,68,78,80,83,85,94,96
SPECIFICATIONS · · · · · · 2- 3
speed · · · · · 1,20,67,75,77,92,94
square wave · · · · · · · · 66
SSI · · · · · · · · · · 66- 67
ST250 · · · · · · 19- 20,26,38- 40
ST40 · · · · · · · · 2,20,36- 37
stable · · · · · · · · 59,74,77
Start · · · · 75,77,83- 84,92,94,108
static electricity discharge · · · 59,107
stop · · · · · · 20,22,67,74- 76,84
Stroke Length · · · · · · · 2- 3
succession · · · · · · · · · 88
Switched Auto Disable · · · · · 75
switches · 17- 18,20,22,65,67,86- 89,107
Synchronization · · · · · · · 75
T
Tack Cutoff 75- 77,80,85- 87,91- 92,94,107
tapped · · · · · · · · · · 26
Technicians · · · · · · · · 65
test points · · · · · · · · 60,65
Threshold · · · · · · · · 76- 77
TIG · · · · · · · · · 2- 3,80,96
Timed · · · · 75- 78,86- 87,89,92,94
Timed Cycle · · · · · · 75- 77,86
torch · · · · · · · · 1,17- 22,2627,65,67,74,76,78,80,86,89,92,94,96,107
TP4 · · · · · · · · · · 60,66
TP5 · · · · · · · · · · 60,66
TP9 · · · · · · · · · · 60,66
Tracking · · · 2- 3,22- 23,68,84,93,95
transistors · · · · · · · · · 25
See Also Heat Sink Assembly
travel · · 17,19,21,26- 27,75- 76,86,89
triggering · · · · · · · · · 85
trimpot · · · · · · · · · · 67
TROUBLESHOOTING · · · 21,59- 64
TST · · · · · · · · · · 1,45
U
Universal · · · · · · 1,15,19,26,54
Up · · · · 2- 3,18,67,75,79,85- 86,90
User Interface · · · · · · · · 83
V
varistors · · · · · · · · · · 83
VE · · · · 35,37,43,56,60,67,84,103
vee · · · · · · · · · · 17,27
vertical · · 1,17,19- 20,22,27,59- 60,6567,76- 78,80,84- 85,92- 96,107
Vertical Disable · · · · · 75,83- 84
Vertical Search · · 75,80,85- 86,92,94
9660 SERIES SEAM TRACKER CONTROLLER
V-Groove · · · · · · · · · 5,18
vibrates · · · · · · · · · · 67
vibration · · · · · · · · · · 19
vicinity · · · · · · · · · · 21
view · · · · · 20,22,26,83,89,107
voltage· · · 1,18,59- 60,65- 67,96,107
Voltage · · · · · · · · 59,65,67
VP · · · · · · · · · 60,66- 67
W
X
Weights · · · · · · · · · 2- 3
Weld/Enable · · 75,78,80,83- 84,86,8889,92,94
wheel · · · · · · · · 17,26- 27
wire feeders · · · · · 68,83,93,95
wiring · · · · · · · 1,25,83,107
X and Z axes ·
X-Y axis · · ·
121
·
·
·
·
·
·
·
·
·
·
·
·
·
·
59
17
Z
Z Search ·
92,94,108
·
·
75,77,80- 81,84- 86,91-
9660 SERIES SEAM TRACKER CONTROLLER
122
Jetline Engineering, 15 Goodyear Street, Irvine, California 92618
Telephone: 949-951-1515 Fax: 949-951-9237 Fax
9660 Series Manual, Rev. D Septmeber 2006
Web site: www.jetline.com
www.cyclomatic.com
E-Mail: sales@jetline.com
service@jetline.com