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- JETLINE 9700T MICROPROCESSOR CONTROL
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OM-9700T-02-2015 8-5-2016 V OPERATION MANUAL For 9700T Microprocessor Travel Control August 2016 IMPORTANT Read this manual carefully before installing, Commissioning, or operating this product. Miller Welding Automation, 281 E. Lies Rd., Carol Stream, Il 60188 Telephone: (949) 951-1515 • Fax: (949) 951-9237 Web site: www.jetline.com • E-mail: [email protected] Blank page LIMITED WARRANTY Components or parts manufactured directly by Miller Electric Mfg. Co. are subject to Miller’s True Blue® Warranty set forth at www.millerwelds.com/support/warranty. Seller does not make any warranties for components or parts not manufactured directly by Jetline Engineering, Miller Welding Automation, and Panasonic Welding Systems Company; such components or parts are subject to the warranty terms of the respective manufacturer. Components and parts manufactured by Jetline Engineering, Miller Welding Automation, and Panasonic Welding Systems Company are subject to the following warranty terms. Terms and Conditions of Sale Seller warrants to Purchaser that the components or parts manufactured by Seller or Panasonic Welding Systems Company shall be free from defects in material and workmanship, and shall conform to the Seller’s specifications for the following periods: a. 12 months from the date of shipment of the Products for components and equipment manufactured by Panasonic Welding Systems Company including robot manipulator, controller and connecting cables; external axis components (external axis base unit, servo amplifiers, motors, connecting cables and pre-engineered positioners); peripheral devices (high voltage touch sensors, thru arc seam trackers); welding power sources (internally built into the robot controller cabinet); wire feeders (separated design or integrated design, i.e. Active Wire Torch/Feeder); or b. 12 months from date of shipment of the Products for equipment manufactured by Jetline Engineering or Miller Welding Automation. In the event of a breach of the warranties set forth above, Seller will, at Seller’s option and as Seller’s sole liability and Purchaser’s sole remedy, repair, replace or credit Purchaser’s account for, any Product that fails to conform to the above warranty, provided that (i) during the applicable warranty period Seller is promptly notified in writing upon discovery of such failure with a detailed explanation of any alleged deficiencies; (ii) Seller is given a reasonable opportunity to investigate all claims; and (iii) Seller’s examination of such Product confirms the alleged deficiencies and that the deficiencies were not caused by accident, misuse, neglect, improper installment, unauthorized alteration or repair or improper testing. No Products may be returned to Seller until inspection and approval by Seller. All warranty work performed shall be FOB Seller’s facility (Incoterms 2010) and freight for returned Products shall be paid for by Purchaser. The above warranty against defects does not apply to: (1) consumable components or ordinary wear items including but not limited to torches; or (2) defects due to (i) failure to install and perform maintenance set forth in Product documentation, (ii) the use of components, parts, peripherals, attachments, accessories, or perishable tooling not approved by Seller, (iii) accident, misuse, neglect, abuse, mishandling, misapplication, modification, alteration, acts of God, or (iv) improper installation, service or maintenance. Purchaser and/or the operator of the Products are in full control of the weld process. Seller makes no warranty regarding the quality or the success of the welds on the Products due to factors under Purchaser’s and/or operator’s control including but not limited to welding procedures, material types, material coatings, joint/part fit, part geometry, metallurgy, welding gases, proper machine/process maintenance, and operator skill. EXCEPT AS SET FORTH ABOVE, SELLER MAKES NO WARRANTY OR REPRESENTATION OF ANY KIND, EXPRESS OR IMPLIED (INCLUDING NO WARRANTY OF MERCHANTABILITY OR FITNESS FOR ANY PARTICULAR PURPOSE). - See more at: https://www.millerwelds.com/automation-terms-of-sale#sthash.l5oRebWB.dpuf 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. Table of Contents CONTENTS Section I........................................................................................................................................ 1 SAFETY PRECAUTIONS – READ BEFORE USING (som 2013-09)................................................. 1 1.1 Symbol Usage ............................................................................................................................................ 1 1.2 Arc Welding Hazards ................................................................................................................................. 1 1.3 Additional Symbols for Installation, Operation, And Maintenance .......................................................... 4 1.4 California Proposition 65 Warnings .......................................................................................................... 6 1.5 Principal Safety Standards ........................................................................................................................ 6 1.6 EMF Information ....................................................................................................................................... 6 Section II....................................................................................................................................... 7 Introduction ................................................................................................................................... 7 A. Description .............................................................................................................................................. 8 B. Specifications .......................................................................................................................................... 9 Section III.................................................................................................................................... 12 Operation Mode .......................................................................................................................... 12 1. RUN SCREENS ........................................................................................................................................ 13 2. PROGRAM SCREENS .............................................................................................................................. 13 3. MOVE SCREENS ..................................................................................................................................... 18 4. PTL SCREENS .......................................................................................................................................... 18 5. AUX1/2 SCREENS ................................................................................................................................... 19 6. SKIP SCREENS ........................................................................................................................................ 19 Section IV ................................................................................................................................... 21 Weld Screen ............................................................................................................................... 21 Section V .................................................................................................................................... 22 Error/ESTOP Screens................................................................................................................. 22 Section VI ................................................................................................................................... 23 Mechanical Installation ................................................................................................................ 23 Section VII .................................................................................................................................. 25 Electrical Installation ................................................................................................................... 25 A. Input Power ........................................................................................................................................... 25 B. Output Connections .............................................................................................................................. 25 C. Interconnections ................................................................................................................................... 33 Wire Feeder Addition.................................................................................................................................... 33 Arc Length Control Addition ......................................................................................................................... 34 ALC & Wire Feeder Addition ......................................................................................................................... 35 Section VIII ................................................................................................................................. 37 Maintenance ............................................................................................................................... 37 A. Calibration ............................................................................................................................................. 37 Initial Calibration ...................................................................................................................................... 37 Touch-up Calibration ................................................................................................................................ 37 B. Regular Maintenance ............................................................................................................................ 38 Section IX ................................................................................................................................... 39 Parts Lists ................................................................................................................................... 39 Section X .................................................................................................................................... 44 PCB Descriptions ........................................................................................................................ 44 Section XI ................................................................................................................................... 48 Electrical Diagrams ..................................................................................................................... 48 Appendix A Calibration Sub Menu Mode ..................................................................................... 51 Appendix B Configuration Sub Menu Mode ................................................................................ 57 Appendix C Auto Calibration ....................................................................................................... 63 SECTION I SAFETY PRECAUTIONS – READ BEFORE USING (som 2013-09) Protect yourself and others from injury – read, follow and save these important safety precautions and operating instructions. 1.1 Symbol Usage DANGER! − Indicates a hazardous situation which, if not avoided, will result in death or serious injury. The possible hazards are shown in the adjoining symbols or explained in the text. Indicates a hazardous situation which, if not avoided, could result in death or serious injury. The possible hazards are shown in the adjoining symbols or explained in the text. NOTICE − Indicates statements not related to personal injury. Indicates special instructions. This group of symbols means: Warning! Watch Out! ELECTRIC SHOCK, MOVING PARTS, and HOT PARTS hazards. Consult symbols and related instructions below for necessary actions to avoid the hazards. 1.2 Arc Welding Hazards The symbols shown below are used throughout this manual to call attention to and identify possible hazards. When you see the symbol, watch out, and follow the related instructions to avoid the hazard. The safety information given below is only a summary of the more complete safety information found in the Safety Standards listed in Section 1-5. Read and follow all Safety Standards. Only qualified persons should install, operate, maintain, and repair this unit. During operation, keep everybody, especially children, away. ELECTRIC SHOCK can kill. 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. In semiautomatic or automatic wire welding, 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. Do not touch live electrical parts. Wear dry, hole-free insulating gloves and body protection. Insulate yourself from work and ground using dry insulating mats or covers big enough to prevent any physical contact with the work or ground. Do not use AC output in damp areas, if movement is confined, or if there is a danger of falling. Use AC output ONLY if required for the welding process. If AC output is required, use remote output control if present on unit. Additional safety precautions are required when any of the following electrically hazardous conditions are present: in damp locations or while wearing wet clothing; on metal structures such as floors, gratings, or scaffolds; when in cramped positions such as sitting, kneeling, or lying; or when there is a high risk of unavoidable or accidental contact with the work piece or ground. For these conditions, use the following equipment in order presented: 1) a semiautomatic DC constant voltage (wire) welder, 2) a DC manual (stick) welder, or 3) an AC welder with reduced open-circuit voltage. In most situations, use of a DC, constant voltage wire welder is recommended. And, do not work alone! Disconnect input power or stop engine before installing or servicing this equipment. Lockout/tagout input power according to OSHA 29 CFR 1910.147 (see Safety Standards). Properly install, ground, and operate this equipment according to its Owner’s 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. When making input connections, attach proper grounding conductor first − double-check connections. Keep cords dry, free of oil and grease, and protected from hot metal and sparks. Frequently inspect input power cord and ground conductor for damage or bare wiring – replace immediately if damaged – bare wiring can kill. 1 Turn off all equipment when not in use. Do not use worn, damaged, undersized, or repaired cables. Do not drape cables over your body. If earth grounding of the workpiece is required, ground it directly with a separate cable. Do not touch electrode if you are in contact with the work, ground, or another electrode from a different machine. Do not touch electrode holders connected to two welding machines at the same time since double open-circuit voltage will be present. Use only well-maintained equipment. Repair or replace damaged parts at once. Maintain unit according to manual. Wear a safety harness if working above floor level. Keep all panels and covers securely in place. Clamp work cable with good metal-to-metal contact to workpiece or worktable as near the weld as practical. Insulate work clamp when not connected to workpiece to prevent contact with any metal object. Do not connect more than one electrode or work cable to any single weld output terminal. Disconnect cable for process not in use. Use GFCI protection when operating auxiliary equipment in damp or wet locations. SIGNIFICANT DC VOLTAGE exists in inverter welding power sources AFTER removal of input power. Turn Off inverter, disconnect input power, and discharge input capacitors according to instructions in Maintenance Section before touching any parts. HOT PARTS can burn. Do not touch hot parts bare handed. Allow cooling period before working on equipment. To handle hot parts, use proper tools and/or wear heavy, insulated welding gloves and clothing to prevent burns. FUMES AND GASES can be hazardous. Welding produces fumes and gases. Breathing these fumes and gases can be hazardous to your health. Keep your head out of the fumes. Do not breathe the fumes. If inside, ventilate the area and/or use local forced ventilation at the arc to remove welding fumes and gases. The recommended way to determine adequate ventilation is to sample for the composition and quantity of fumes and gases to which personnel are exposed. If ventilation is poor, wear an approved air-supplied respirator. Read and understand the Safety Data Sheets (SDSs) and the manufacturer’s instructions for adhesives, coatings, cleaners, consumables, coolants, degreasers, fluxes, and metals. 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. Welding fumes and gases can displace air and lower the oxygen level causing injury or death. Be sure the breathing air is safe. 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. 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 while wearing an air-supplied respirator. The coatings and any metals containing these elements can give off toxic fumes if welded. ARC RAYS can burn eyes and skin. Arc rays from the welding process produce intense visible and invisible (ultraviolet and infrared) rays that can burn eyes and skin. Sparks fly off from the weld. Wear an approved welding helmet fitted with a proper shade of filter lenses to protect your face and eyes from arc rays and sparks when welding or watching (see ANSI Z49.1 and Z87.1 listed in Safety Standards). Wear approved safety glasses with side shields under your helmet. Use protective screens or barriers to protect others from flash,glare and sparks; warn others not to watch the arc. Wear body protection made from durable, flame−resistant material (leather, heavy cotton, wool). Body protection includes oil-free clothing such as leather gloves, heavy shirt, cuffless trousers, high shoes, and a cap. 2 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. Remove all flammables within 35 ft (10.7 m) of the welding arc. If this is not possible, tightly cover them with approved covers. Do not weld where flying sparks can strike flammable material. Protect yourself and others from flying sparks and hot metal. Be alert that welding sparks and hot materials from welding can easily go through small cracks and openings to adjacent areas. Watch for fire, and keep a fire extinguisher nearby. Be aware that welding on a ceiling, floor, bulkhead, or partition can cause fire on the hidden side. Do not weld on containers that have held combustibles, or on closed containers such as tanks, drums, or pipes unless they are properly prepared according to AWS F4.1 and AWS A6.0 (see Safety Standards). Do not weld where the atmosphere may contain flammable dust, gas, or liquid vapors (such as gasoline). Connect work cable to the work as close to the welding area as practical to prevent welding current from traveling long, possibly unknown paths and causing electric shock, sparks, and fire hazards. Do not use welder to thaw frozen pipes. Remove stick electrode from holder or cut off welding wire at contact tip when not in use. Wear body protection made from durable, flame−resistant material (leather, heavy cotton, wool). Body protection includes oil-free clothing such as leather gloves, heavy shirt, cuffless trousers, high shoes, and a cap. Remove any combustibles, such as a butane lighter or matches, from your person before doing any welding. After completion of work, inspect area to ensure it is free of sparks, glowing embers, and flames. Use only correct fuses or circuit breakers. Do not oversize or bypass them. Follow requirements in OSHA 1910.252 (a) (2) (iv) and NFPA 51B for hot work and have a fire watcher and extinguisher nearby. FLYING METAL or DIRT can injure eyes. Read and understand the Safety Data Sheets (SDSs) and the manufacturer’s instructions for adhesives, coatings, cleaners, consumables, coolants, degreasers, fluxes, and metals. Welding, chipping, wire brushing, and grinding cause sparks and flying metal. As welds cool, they can throw off slag. Wear approved safety glasses with side shields even under your welding helmet. BUILDUP OF GAS can injure or kill. Shut off compressed gas supply when not in use. Always ventilate confined spaces or use approved air-supplied respirator. ELECTRIC AND MAGNETIC FIELDS (EMF) can affect Implanted Medical Devices. Wearers of Pacemakers and other Implanted Medical Devices should keep away. Implanted Medical Device wearers should consult their doctor and the device manufacturer before going near arc welding, spot welding, gouging, plasma arc cutting, or induction heating operations. NOISE can damage hearing. Noise from some processes or equipment can damage hearing. Wear approved ear protection if noise level is high. 3 CYLINDERS can explode if damaged. Compressed 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. Protect compressed gas cylinders from excessive heat, mechanical shocks, physical damage, slag, open flames, sparks, and arcs. Install cylinders in an upright position by securing to a stationary support or cylinder rack to prevent falling or tipping. Keep cylinders away from any welding or other electrical circuits. Never drape a welding torch over a gas cylinder. Never allow a welding electrode to touch any cylinder. Never weld on a pressurized cylinder − explosion will result. Use only correct compressed gas cylinders, regulators, hoses, and fittings designed for the specific application; maintain them and associated parts in good condition. Turn face away from valve outlet when opening cylinder valve. Do not stand in front of or behind the regulator when opening the valve. Keep protective cap in place over valve except when cylinder is in use or connected for use. Use the right equipment, correct procedures, and sufficient number of persons to lift and move cylinders. Read and follow instructions on compressed gas cylinders, associated equipment, and Compressed Gas Association (CGA) publication P-1 listed in Safety Standards. 1.3 Additional Symbols for Installation, Operation, And Maintenance FIRE OR EXPLOSION hazard. Do not install or place unit on, over, or near combustible surfaces. Do not install unit near flammables. Do not overload building wiring − be sure power supply system is properly sized, rated, and protected to handle this unit. FALLING EQUIPMENT can injure. Use lifting eye to lift unit only, NOT running gear, gas cylinders, or any other accessories. Use equipment of adequate capacity to lift and support unit. If using lift forks to move unit, be sure forks are long enough to extend beyond opposite side of unit. Keep equipment (cables and cords) away from moving vehicles when working from an aerial location. Follow the guidelines in the Applications Manual for the Revised NIOSH Lifting Equation (Publication No. 94−110) when manually lifting heavy parts or equipment. OVERUSE can cause OVERHEATING Allow cooling period; follow rated duty cycle. Reduce current or reduce duty cycle before starting to weld again. Do not block or filter airflow to unit. FLYING SPARKS can injure. Wear a face shield to protect eyes and face. Shape tungsten electrode only on grinder with proper guards in a safe location wearing proper face, hand, and body protection. Sparks can cause fires — keep flammables away. STATIC (ESD) can damage PC boards. Put on grounded wrist strap BEFORE handling boards or parts. Use proper static-proof bags and boxes to store, move, or ship PC boards. 4 MOVING PARTS can injure. Keep away from moving parts. Keep away from pinch points such as drive rolls. WELDING WIRE can injure. Do not press gun trigger until instructed to do so. Do not point gun toward any part of the body, other people, or any metal when threading welding wire. BATTERY EXPLOSION can injure. Do not use welder to charge batteries or jump start vehicles unless it has a battery charging feature designed for this purpose. MOVING PARTS can injure. Keep away from moving parts such as fans. Keep all doors, panels, covers, and guards closed and securely in place. Have only qualified persons remove doors, panels, covers, or guards for maintenance and troubleshooting as necessary. Reinstall doors, panels, covers, or guards when maintenance is finished and before reconnecting input power. READ INSTRUCTIONS. Read and follow all labels and the Owner’s Manual carefully before installing, operating, or servicing unit. Read the safety information at the beginning of the manual and in each section. Use only genuine replacement parts from the manufacturer. Perform maintenance and service according to the Owner’s Manuals, industry standards, and national, state, and local codes. H.F. RADIATION can cause interference. High-frequency (H.F.) can interfere with radio navigation, safety services, computers, and communications equipment. Have only qualified persons familiar with electronic equipment perform this installation. The user is responsible for having a qualified electrician promptly correct any interference problem resulting from the installation. If notified by the FCC about interference, stop using the equipment at once. Have the installation regularly checked and maintained. Keep high-frequency source doors and panels tightly shut, keep spark gaps at correct setting, and use grounding and shielding to minimize the possibility of interference. ARC WELDING can cause interference. Electromagnetic energy can interfere with sensitive electronic equipment such as computers and computer-driven equipment such as robots. Be sure all equipment in the welding area is electromagnetically compatible. To reduce possible interference, keep weld cables as short as possible, close together, and down low, such as on the floor. Locate welding operation 100 meters from any sensitive electronic equipment. Be sure this welding machine is installed and grounded according to this manual. If interference still occurs, the user must take extra measures such as moving the welding machine, using shielded cables, using line filters, or shielding the work area. 5 1.4 California Proposition 65 Warnings Welding or cutting equipment produces fumes or gases which contain chemicals known to the State of California to cause birth defects and, in some cases, cancer. (California Health & Safety Code Section 25249.5 et seq.) This product contains chemicals, including lead, known to the state of California to cause cancer, birth defects, or other reproductive harm. Wash hands after use. 1.5 Principal Safety Standards Safety in Welding, Cutting, and Allied Processes, ANSI Standard Z49.1, is available as a free download from the American Welding Society at http://www.aws.org or purchased from Global Engineering Documents (phone: 1-877-413-5184, website: www.global.ihs.com). Safe Practices for the Preparation of Containers and Piping for Welding and Cutting, American Welding Society Standard AWS F4.1, from Global Engineering Documents (phone: 1-877-413-5184, website: www.global.ihs.com). Safe Practices for Welding and Cutting Containers that have Held Combustibles, American Welding Society Standard AWS A6.0, from Global EngineeringDocuments (phone: 1-877-413-5184, website: www.global.ihs.com). National Electrical Code, NFPA Standard 70, from National Fire Protection Association, Quincy, MA 02269 (phone: 1-800-344-3555, website: www.nfpa.org and www. sparky.org). Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-1, from Compressed Gas Association, 14501 George Carter Way, Suite 103, Chantilly, VA 20151 (phone: 703-788-2700, website:www.cganet.com). Safety in Welding, Cutting, and Allied Processes, CSA Standard W117.2, from Canadian Standards Association, Standards Sales, 5060 Spectrum Way, Suite 100, Ontario, Canada L4W 5NS (phone: 800-463-6727, website: www.csa-international.org). Safe Practice For Occupational And Educational Eye And Face Protection, ANSI Standard Z87.1, from American National Standards Institute, 25 West 43rd Street, New York, NY 10036 (phone: 212-642-4900, web-site: www.ansi.org). Standard for Fire Prevention During Welding, Cutting, and Other Hot Work, NFPA Standard 51B, from National Fire Protection Association, Quincy, MA 02269 (phone: 1-800-344-3555, website: www.nfpa.org. OSHA, Occupational Safety and Health Standards for General Industry, Title 29, Code of Federal Regulations (CFR), Part 1910, Subpart Q, and Part 1926, Subpart J, from U.S. Government Printing Office, Superintendent of Documents, P.O. Box 371954, Pittsburgh, PA 15250-7954 (phone: 1-866512-1800) (there are 10 OSHA Regional Offices— phone for Region 5, Chicago, is 312-353-2220, website: www.osha.gov). Applications Manual for the Revised NIOSH Lifting Equation, The National Institute for Occupational Safety and Health (NIOSH), 1600 Clifton Rd, Atlanta, GA 30333 (phone: 1-800-232-4636, website: www.cdc.gov/NIOSH). 1.6 EMF Information Electric current flowing through any conductor causes localized electric and magnetic fields (EMF). The current from arc welding (and allied processes including spot welding, gouging, plasma arc cutting, and induction heating operations) creates an EMF field around the welding circuit. EMF fields may interfere with some medical implants, e.g. pacemakers. Protective measures for persons wearing medical implants have to be taken. For example, restrict access for passers−by or conduct individual risk assessment for welders. All welders should use the following procedures in order to minimize exposure to EMF fields from the welding circuit: 1. Keep cables close together by twisting or taping them, or using a cable cover. 2. Do not place your body between welding cables. Arrange cables to one side and away from the operator. 3. Do not coil or drape cables around your body. 4. Keep head and trunk as far away from the equipment in the welding circuit as possible. 5. Connect work clamp to workpiece as close to the weld as possible. 6. Do not work next to, sit or lean on the welding power source. 7. Do not weld whilst carrying the welding power source or wire feeder. About Implanted Medical Devices: Implanted Medical Device wearers should consult their doctor and the device manufacturer before performing or going near arc welding, spot welding, gouging, plasma arc cutting, or induction heating operations. If cleared by your doctor, then following the above procedures is recommended. 6 SECTION II INTRODUCTION This technical manual provides details of the set up and calibration procedures for the control as well as providing information about the interfacing of the system with other 9700 series controls and ancillary controls. It also provides troubleshooting and maintenance information. The 9700T microprocessor controller has been developed to provide high quality, precision travel control of all Miller Welding Automation longitudinal and circumferential welding fixtures. The quality design and workmanship of this control will provide many years of dependable service. The 9700T control includes a motor controller and can therefore be connected directly to the carriage drive motor. It is used for motors up to ½ HP of the type used on Miller Welding Automation standard travel carriages. It provides travel speed accuracy levels suitable for most conventional applications. Modes of operation are: Operator Mode: This is the mode used by the welding operator to run the unit. It permits travel speed, start and stop delays and weld time to be adjusted. Configuration Mode: This mode is used during the setting up of the unit. It permits the setting of the jog speeds, arc wait, weld direction, other control boxes and features are used in this system. Calibration Mode: In this mode, the closed loop can be turned on and off, the unit can be set for inch or metric units and the calibration can be checked and set. 7 A. Description The 9700 control is a microprocessor-based control designed for the control of welding travel speed linearly or circumferentially. The 9700T is one of a series of controls designed for ease-of-use and for accurate control of various drive motors for different weld applications. The control is packaged in a conveniently-sized enclosure with Amphenol connectors. The enclosure has four mounting holes to permit it to be fastened to the face of a travel carriage or to a control podium. The front panel is a membrane overlay with a graphic backlit LCD display and switches to control the setup and operation of the unit. The 9700T control has been designed to be easy to use. Its operation is made easier by the use of the display which guides you through the setup process, and during the welding sequence, tells you what is happening. Figure 1: Front view of 9700T control and mounting dimensions. 8 B. Specifications Processor: Microprocessor Display: Graphic Backlit LCD Panel: Polycarbonate overlay Input: 120 VAC, 1 ph, 50/60 Hz, 10 amps 240 VAC, 1 ph, 50/60 Hz, 5 amps Power cord: Standard 120 VAC 6 ft. (1.8 m) long Dimensions: Weight: 14 lbs. (6 kg) Height: 8” (200 mm) Width: 10” (250 mm) Depth: 6” (150 mm) Connections: Welding Power Supply Outputs: 1 Analog, 8 Digital Inputs: 2 Analog, 8 Digital Second 9700 Control S2 to S2 connection Output: Pulse Lockout Input: Remote Run, Pulse Lockout 9 Motor (90VDC Permanent Magnet) Output: Motor voltage, Pneumatic Torch Lift Input: Tach-generator voltage, Limit Switches 10 Figure 2: 9700T Front Panel Showing Operator Interface and functions of dials, switches 4 Line Screen display Knob, Dial adjust for screen- CW more and CCW less 3 Remote Receptacles S3 top, S2 middle, S1 at bottom Red Head push button Emergency Stop 4 touch arrows/buttons for screen navigation On/off Circuit Breaker 120 VAC input Weld – start and stop Mounting holes-4 places Ground Stud 11 SECTION III OPERATION MODE This mode is used by the operator to run the travel. The travel mode is typically set up at the factory for either longitudinal or rotational / circumferential travel. To set the conditions for operation, the operator can scroll through the various screens and make the appropriate changes using the up/down and left/right arrows on the face of the control. When changing a numeric value each click of the dial will increase or decrease the value by one. If the up button is pressed then each click of the dial increases or decreases the value by 10. Pressing the up button again allows the dial to change values by 100 per click. Using the down button will move the values back to 10 and pressing down again will move the values back to 1. The number location to be changed will be inversed until the dial is moved. The number 10 will appear on the top line while the up and down buttons will change the number location. Operator Mode consists of three main sections- Run, Program, and Move. All three sections linked together to form one list. Some entries in the program section also have sub menus. The three sub menus are –PTL, Aux1, and Skip. Use the right arrow to enter them and then you navigate as you would before. Use the left arrow to return to the Operator mode main section. Please note that not all the screens in this manual appear on your 9700T. Your system or control might not have the function. During programming if you disable a function it will not appear in run screens. WELCOME SCREEN This screen appears automatically when the unit is switched on and remains on the screen for approximately 3 seconds. The next screen will appear automatically. 12 1. RUN SCREENS The operator must be in either of the run screens in order to begin a weld. If the right or left buttons are pressed in the run screens, it will cause the travel to engage. A single press will give jog speed. A double press will give rapid speed. If the up button is pressed with moving, that speed will be maintained without the buttons pressed until it hits a limit switch or the stop button is pressed. When in the program portion of the menu, a left arrow will save all the program parameters to the program menu. TRAVEL SPEED RUN PTL POSITION TRAVEL IPM ADJUST The travel screen sets the travel speed during the weld. OUT 12.1 UNLOCKED Linear travel is shown in IPM (inches per minute) or CPM (centimeters per minute). The IPM or CPM setting is found in Calibration Mode / Units where it can be changed if required. If travel is rotational, and you want to set the speed in RPM (rotations per minute), change the diameter to 0. The number of decimal places is set in Configuration Mode / Set DP- where it can be changed if required. The 9700T limits the programmed speed to be between the high and low speeds set up in the Calibration Mode. UNLOCKED OR LOCKED RUN TRAVEL IPM 12.1 ADJUST UNLOCKED DIAMETER 1.000 The unlocked setting allows the user to change the speed during welding by adjusting the dial. Locked does not allow the user to change the speed during welding. 2. PROGRAM SCREENS Pressing the left arrow in any of the program screens will save the entire program to the permanent memory of the 9700T. DIAMETER PROGRAM ADJUST UNLOCKED DIAMETER 1.000 TOUCH RETRACT Diameter shows the diameter of the part in units as set in Calibration Mode / Units. The minimum value is 0.000 and Maximum is 999.999. OFF 13 TOUCH RETRACT - ON OR OFF (With ALC only) PROGRAM DIAMETER TOUCH RETRACT ALC LOCK OUT 1.000 OFF 0.0 ALC LOCKOUT (With ALC only) PROGRAM TOUCH RETRACT ALC LOCK OUT PTL OFF 0.0 CRATER TIME PTL CRATER TIME (With MIG/SAW only) 1.000 1.0 PTL DELAY ARC Crater Time is the amount of time the 9700T will wait for the power supply to finish the crater before going to the next step. This screen will only appear if Configuration Mode / Mode is MIG/SAW. llu PTL (PNEUMATIC TORCH LIFT) PROGRAM ALC LOCK OUT ALC Lockout is the amount of time that the Travel unit will supply a lock out signal after the weld power supply goes into downslope. This screen will only appear if Configuration Mode / ALC Lockout is Yes. llu PROGRAM DIAMETER If set On then the ALC will perform a torch retract before starting the weld. If set Off, the ALC will start without a touch retract. This screen will only appear if Configuration Mode / ALC in Sys is Yes and Configuration Mode is TIG. 0.0 llu If the right button is pressed you will go into the PTL sub menu. This screen will only appear if Configuration Mode / PTL in Sys is Yes. See PTL section for details of this sub menu. 0.2 DELAY ARC PROGRAM PTL DELAY ARC TRAV START DLY llu 0.2 0.4 Allow the travel to start before the command is given to the power to Start. The time is how long after the travel starts before the start command is given. Wait for Arc will be set to No. This screen will only appear if Configuration Mode / Delay Arc is Yes. 14 TRAVEL START DELAY PROGRAM DELAY ARC TRAV START DLY END OF WELD 0.2 0.4 TIME END OF WELD – TIME, EVENT OR DISTANCE PROGRAM TRAV START DLY END OF WELD VALUE 0.4 TIME 20.0 VALUE TRAV STOP DLY TIME TRAV STOP DLY RTH DLY TRAVEL STOP DELAY 20.0 0.5 Trav Stop Dly is the amount of time that the travel is engaged after the beginning of downslope. Minimum value is 0.0 and Maximum value is 10.0. OFF RETURN TO HOME DELAY PROGRAM TRAV STOP DLY This is the time, number of events (event switch tripped) or distance of the weld when downslope will start. 20.0 0.5 PROGRAM VALUE If End of Weld is Time, then Value is the Time of the weld in seconds. If End of Weld is Event, then Value is the number of times that the event switch needs to be tripped to end the weld. If End of Weld is distance, then the value is the distance that has to be traveled to end the weld. In a linear system, the distance is in the Units set and in a rotational system the distance is in degrees of rotation. Distance is only allowed if Configuration Mode / Encoders is Yes. The beginning of downslope is defined as the time after the End of Weld. VALUE PROGRAM END OF WELD If Configuration Mode / Wait for Arc is Yes, then this is the amount of time after the arc on signal is received that travel is turned on. If Wait for Arc is No, then this is the amount of time after the contact signal is given to the power supply before the travel is turned on. 0.5 RTH DLY OFF FINGER DLY OFF RTH Dly is the length of time after the beginning of downslope before the unit performs a return to home. If it is set to Off, no return to home will be done. Minimum value is Off and Maximum value is 10.0. This screen will only appear if Configuration Mode/ Home Switch is Yes. 15 FINGER RELEASE DELAY PROGRAM RTH DLY OFF FINGER DLY OFF ARC STOP DLY 0.5 ARC STOP DELAY PROGRAM FINGER DLY ARC STOP DLY AUX1 OFF 0.0 llu AUX1 AUX2 0.0 llu llu AUX2 CALIBRATION If the right button is pressed you will go into the AUX1 sub menu. This screen will only appear if Configuration Mode/ AUX1 Name has been assigned, then that name that will appear in the menu. See AUX1 sub menu section for details. PROGRAM SUB MENU / AUX2 PROGRAM AUX1 Arc Stop Dly is length of time after the beginning of downslope before the 9700T removes the power supply contact. Minimum value is 0.0 and Maximum value is 10.0. This screen will only appear if Configuration Mode / Arc Stop Dly is Yes. PROGRAM SUB MENU / AUX1 PROGRAM ARC STOP DLY Finger Dly is the length of time after the beginning of downslope before the unit performs a finger release. If it is set to Off, no finger release will be done. Minimum value is Off and Maximum value is 10.0. This screen will only appear if Configuration Mode / AFR in Sys is Yes. llu llu llu If the right button is pressed you will go into the AUX2 sub menu. This screen will only appear if Configuration Mode/ AUX2 Name has been assigned, then that name that will appear in the menu. See AUX2 sub menu section for details. 16 CALIBRATION PROGRAM AUX1 CALIBRATION CONFIGURATION llu llu llu CONFIGURATION PROGRAM CALIBRATION CONFIGURATION SKIP llu llu llu SKIP RUN llu llu RUN GO TO HOME If the right button is pressed you will go into the SKIP sub menu. This screen will only appear if Configuration Mode / Skip Enable is Yes. See SKIP sub menu section for details. NORMAL RUN PROGRAM SKIP If the right button is pressed you will go into the Configuration Mode sub menu. If a password was selected it must first be entered before you can get into the sub menu. The password is a five digit Alpha/Numeric and is set by turning the knob to change each place. The right arrow moves to the next character to the right and left arrow moves back to the left. On the fifth and last character when entering the password, press the right key; if correct you will enter the sub menu, if not you will be returned to the main menu. See appendix B for details of this sub menu. SKIP PROGRAM CALIBRATION If the right button is pressed you will go into the Calibration Mode sub menu. If a password was selected, it must first be entered before you can get into the sub menu. The password is a five digit Alpha/Numeric and is set by turning the knob/dial to change each place. The right arrow moves to the next character to the right and the left arrow moves back to the left. On the fifth and last character when entering the password, press the right key; if correct you will enter the sub menu, if not you will be returned to the program menu. See appendix A for details of this sub menu. llu NORMAL llu Run is either Normal, Dry, Travel or the name of Aux1. In Dry when start is pressed the 9700T will not activate the power supply contact, but you will have travel. Also, when you are in Dry, Dry Run will appear in the upper left corner of the display. If Normal the weld will run normally and show Run in the upper left corner. If in either Travel or the name of Aux1 that drive will be active and the other one will not. The upper left corner will show which channel is active. 17 3. MOVE SCREENS Pressing the left arrow in any of the move screens will save the entire program to the permanent memory of the 9700T. HOME POSITION MOVE RUN NORMAL GO TO HOME llu PTL POSITION OUT PNEUMATIC TORCH POSITION MOVE GO TO HOME llu PTL POSITION OUT TRAVEL IPM If the right button is pressed in Home Position the system will perform a return to home. It will stop when the limit switch is reached, the stop button is pressed, or the Estop is pressed. This screen will only appear if Configuration Mode / Home Switch is Yes. 12.1 By turning the knob/dial you can change the position of the pneumatic torch. IN positions the torch next to the work and OUT positions the torch away from the work. This screen will only appear if Configuration Mode / PTL in Sys is Yes. 4. PTL SCREENS To get out of the PTL sub menu all you have to do is press the left arrow. START DELAY PTL PTL START DLY STOP DLY DISABLE 0.0 0.0 STOP DELAY PTL START DLY STOP DLY PTL The PTL moves into weld position at the start of the weld, this is the delay before continuing the weld sequence. Minimum value is 0.0, Maximum value is 10.0. 0.0 0.0 This is the delay after the beginning of downslope before the PTL is moved back out of the way. Minimum value is 0.0, Maximum value is 10.0. DISABLE 18 PTL DISABLE PTL 0.0 STOP DLY PTL DISABLE PTL is enable or disable. If enable then the PTL will move during the weld. If disable the PTL will stay in the position that began weld sequence. 0.0 START DLY 5. AUX1/2 SCREENS To get out of the AUX1 sub menu all you have to do is press the left arrow. Also if you do have an auxiliary output the name shown will be what is programmed in Configuration Mode / AUX1/2. START DELAY AUX1 AUX1 DISABLE 0.0 0.0 START DLY STOP DLY STOP DELAY AUX1 0.0 0.0 START DLY STOP DLY AUX1 Stop Dly is the amount of time that the auxiliary output is shorted after the beginning of downslope. Minimum value is 0.0, Maximum value is 10.0. DISABLE AUX1 ENABLE/DISABLE AUX1 0.0 STOP DLY AUX1 If Configuration Mode / Wait for Arc is Yes, then this is the amount of time after the arc on signal is received until the auxiliary output is activated. If Wait for Arc is No, then this is the amount of time after the contact signal is given until the auxiliary output is activated. Minimum value is 0.0, Maximum value is 10.0. DISABLE START DLY AUX1 is enable or disable. If enable then the auxiliary output signal will be activated during the weld. If disable the auxiliary output will stay open. 0.0 6. SKIP SCREENS This is a highly specialized operation. To get out of the skip sub menu all you have to do is press the left arrow. 19 SKIP WELD SKIP NUM OF WELDS 4 SKIP WELD ENABLE SKIP TYPE TIME SKIP JOG TYPE SKIP SKIP WELD ENABLE SKIP TYPE TIME VALUE VALUE NUM OF WELDS SKIP VALUE TIME 10.1 4 This is the amount of time or distance that will be moved during the jog segment. Note: Jog speed is in the direction set up in Configuration Mode / Weld Direction and speed is set by Configuration Mode / Rapid Jog. SKIP NUMBER SKIP NUM OF WELDS 10.1 4 SKIP WELD ENABLE VALUE SKIP TYPE defines how the Jog is measured by time or distance. 10.1 SKIP SKIP TYPE SKIP WELD is enable or disable. If enable, then when start is pressed a skip weld will started. This is the number of welds for a single pass. If the number is set to 0 then the system will continue to run until the stop button is pressed. 20 SECTION IV WELD SCREEN 1 12 12.1 RUN WELD TRAVEL IPM ARC PTL WIRE LINE 1 LINE 2 LINE 3 LINE 4 LINE 1 The RUN on the left is highlighted to show that the 9770T is in the run state. The number on the right is only shown if you are doing a Skip Weld. It will show which weld cycle that is engaged. LINE 2 The label of the line informs you of the current state of the weld schedule. The states that can be shown are as follows: PTL WAIT, TOUCH, WAIT ARC, START DLY, WELD, STOP DLY, END and JOG. If the number is counting down it is how long that segment of the weld schedule is left. If it is counting up it is how long we have been in that segment. The reason for this is some segments we know how long they will be and other (i.e. TOUCH) we have to wait. If you are programmed for weld distance and are in the WELD segment or JOG segment the number shown will be how far we have left to move. LINE 3 This line shows the actual or the programmed travel speed as set in the Calibration Mode menu. If the line is highlighted that means that the speed can be changed by using the dial. If the weld speed is changed, the new speed will be used for the next weld, but will not be saved to permanent memory unless it is saved after the weld is finished. To save go back to program menu and press the left arrow button. During JOG of a skip weld this line is blank since we will be traveling at jog speed. LINE 4 This line shows the status of various outputs and inputs. If ARC is highlighted then the 9700T is receiving a valid arc on signal. If PTL is highlighted then the pneumatic torch is in the down position. If the WIRE is highlighted the 9700T is giving a start signal to the wire feeder. 21 SECTION V ERROR/ESTOP SCREENS ARC ERROR If Configuration Mode / Wait for Arc is yes and during the weld the arc goes out the weld will stop and this message will appear. To get out just press the Stop button. ARC ERROR FORWARD LIMIT If while welding you reach the forward limit, the weld will stop and this message will appear. To get out just press the Stop button. FOR LIMIT RUN ESTOP PTL POSITION OUT TRAVEL IPM 12 ADJUST ESTOP If the 9700T is in ESTOP at any time it will display in the upper right corner of the screen. In addition the back light for the display will flash so it can be easily seen. UNLOCKED 22 SECTION VI MECHANICAL INSTALLATION The 9700T control is mounted in a steel enclosure with a hinged front panel to facilitate servicing. The front panel consists of a polycarbonate overlay with tactile switches and integrated touch pads. Three Amphenol connectors are located on the right side of the enclosure. When planning the location of the 9700T control, sufficient access for the connections should be provided at the right hand side of the unit, we recommend allowing a space not less than 5” (125 mm). The front panel is hinged for servicing purposes. The hinge is located at the left hand side of the enclosure so it is important that you do not locate the 9700T too close to an obstruction on the left side which would block the full opening of the door. Plates are provided on the rear of the enclosure with four mounting holes, two at the top and two at the bottom. The location and size of these holes is shown on the figure below. Use ¼” (6 mm) diameter screws to secure the control to the mounting face. We recommend that the control be mounted so that front panel is vertical or sloped back at an angle of no more than 30° from the vertical. The vertical or slightly sloping front panel position will prove to be best for the operator. Because the control includes a digital display, the best location will be where the display is close to eye height from the floor. The vertical front panel orientation ensures that the LCD display is clearly visible - avoid a location where very bright light falls on the display, this causes a reflection from the transparent overlay and make it difficult to clearly read the display. 23 Figure 3: Sheet Metal Enclosure showing dimensions for mounting. 24 SECTION VII ELECTRICAL INSTALLATION A. Input Power The 9700T control is designed to operate on either 115VAC or 230VAC 50/60HZ and is fitted with a 10 amp circuit breaker suitable for either voltage. The unit is typically configured for your choice of voltage prior to shipment. The unit ships with a standard 6 foot length cable for 115/120 VAC only input. If it is necessary to change the input voltage, this can be done as follows: Make sure no power is apply to unit during this procedure. Open the front door of the unit and locate the motor control module (Picture of jumpers on motor drive). At the top, left hand side of the module there are two jumpers, these are marked J1A and J1B. These should be set as shown in the diagram below. Figure 4: Input Voltage change over. Since the 9700T is fitted with an IEC 60320-1 C14 power receptacle you will need to get a power cord with an IEC 60320-1 C13 connector rated for 250VAC to use with 220/230VAC. B. Output Connections All output connections to and from the 9700T control use Amphenol connectors. There are three Amphenol connectors, the lower one is marked S1, the center one is S2 and the upper one is S3. Interconnection of the 9700T control with associated equipment is shown on the following pages. 25 Figure 5: Remote Amphenol Connectors-Pin locations, designations, and suggested wiring. 26 Figure 6: Location of keyway on connector @ 6 o’clock. S1 CONNECTOR The S1 connector is used to connect the 9700T control to the welding power supply. Miller Welding Automation can provide standard connecting cables to be connected to the S1 connector on the 9700T control. If you need to provide your own cable, it should be fitted with the following: Amphenol plug 97-3106A-20-27S Cord Grip 97-3057-1012-1 Pin Connection Details Connections should be made as shown below. TOUCH RETRACT COMPLETE (Pins A & B) Function: When this circuit is completed, the 9700T knows that the 9790 has completed a touch retract sequence. Electrical: You can connect a dry relay contact or an open collector signal, Pin A is high, Pin B is low. Either one must handle 12VDC at 4mA. ARC ON INPUT (Pins C & D) Function: This is used to delay the travel device until the arc is established. Electrical: You can connect a dry relay contact or an open collector signal, Pin C is high, Pin D is low. Either one must handle 12VDC at 4mA. PULSE LOCKOUT INPUT (Pins E & F) Function: When the control is connected to a power supply with pulse current facilities, it is sometimes necessary to synchronize arc length control or wire feed with the current pulsing. When the control is connected to the current background signal through these connections, the signal will be passed to the arc length control and/or wire feeder (if they are connected). Electrical: You can connect a dry relay contact or an open collector signal, Pin E is high, Pin F is low. Either one must handle 12VDC at 4mA. 27 POWER SUPPLY CONTACTOR OUTPUT (Pins G & H) Function: This contact closes to initiate the welding arc. The contact will open when the 9700T weld timer times out or the stop button is pressed, signaling downslope, crater fill or arc off (depending on the power supply). Electrical: We supply a dry relay contact capable of handling 110VAC at 0.6A. EMERGENCY STOP OUTPUT CONTACT (Pins I & J) Function: When the emergency stop button is pressed, this contact will open up. This will prohibit the power supply from initiating or maintaining a welding arc. Electrical: We supply a dry relay contact capable of handling 110VAC at 0.6A. PULSE LOCKOUT OUTPUT (Pins K & L) Function: Permits the 9700T to pass a pulse signal to another device. This signal would be used if it is desired to pulse a third party control. It is not used with Miller Welding Automation 9600 series controlled equipment. The signal from these pins directly follows the Pulse Lockout Input signal. Electrical: This is an open collector output, Pin K is high, Pin L is low. ALC DOWN/STOP (Pins M & N) Function: This contact closes to initiate torch to move down. The contact will close when the 9700T wants the torch to move down and complete a touch retract. This signal will remain active until be stop the touch retract or we get back a valid touch retract complete. Or as the Stop output that goes to a power supply. Electrical: We supply a dry relay contact capable of handling 110VAC at 0.6A. S2 CONNECTOR The S2 connector is used to connect the 9700T control to a 9700W wire feed control or to an arc length control. In certain circumstances, it can be interfaced with a PLC or other control interface. Miller Welding Automation can provide standard connecting cables to be connected to the S2 connector on the 9700T control. If you need to provide your own cable, it should be fitted with the following: Amphenol plug 97-3106A-20-27P Cord Grip 97-3057-1012-1 Pin Connection Details Connections should be made as shown below. REMOTE START INPUT (Pins A & B) Function: When this circuit is completed, the 9700T control will start the programmed sequence. Can be a momentary or maintained start depending on the 9700T configuration. If maintained, removing the start signal during the middle of the weld will start a downslope sequence. Electrical: You can connect a dry relay contact or an open collector signal, Pin A is high, Pin B is low. Either one must handle 12VDC at 4mA. 28 EMERGENCY STOP INPUT (Pins C & D) Function: When this circuit is opened, the 9700T control will initiate an emergency stop sequence. Electrical: You can connect a dry relay contact or an open collector signal, Pin C is high, Pin D is low. Either one must handle 12VDC at 4mA. Logic must be normally closed. REMOTE STOP INPUT (Pins E & F) Function: When remote start input is configured as momentary start input, these are the pins that are used as inputs as the stop or to put the system into downslope. Electrical: You can connect a dry relay contact or an open collector signal, Pin E is high, Pin F is low. Either one must handle 12VDC at 4mA. REMOTE START OUTPUT (Pins G & H) Function: When the “Arc On” signal has been received by the control, this contact closes, relaying the signal to a wire feeder or other device to initiate its function. This contact opens during the stop sequence. Electrical: We supply a dry relay contact capable of handling 110VAC at 0.6A. REMOTE EMERGENCY STOP OUTPUT (Pins I & J) Function: When the emergency stop button is pressed, this contact will open. This will prohibit the operation of the secondary 9629 control. Electrical: We supply a dry relay contact capable of handling 110VAC at 0.6A. PULSE LOCKOUT OUTPUT (Pins K & L) Function: Permits the 9700T to pass a pulse signal to another device, i.e. an arc length control or a wire feeder. The signal from these pins directly follows the Pulse Lockout Input signal. Electrical: This is an open collector output, Pin K is high, Pin L is low. REMOTE SPEED INPUT (Pins M & N) Function: The 9700T can be configured to permit the travel speed to be set by a remote analog input signal. The signal is supplied to these pins from the remote device. Electrical: Requires 0 to 10VDC input signal. Pin M is high, Pin N is low. Input impedance is 60K. S3 CONNECTOR The S3 connector is used to connect the 9700T control to the motor which it is controlling. Miller Welding Automation can provide standard connecting cables to be connected to the S3 connector on the 9700T control. If you need to provide your own cable, it should be fitted with the following: Amphenol plug 97-3106A-22-19P Cord Grip 97-3057-1012-1 If 9700T-0 Amphenol plug 97-3106A-22-14P Cord Grip 97-3057-1012-1 29 Pin Connection Details Connections should be made as shown below. Note: Pins H and K are reserved. MOTOR OUTPUT CONNECTION (Pins A & B) Function: To supply voltage to the carriage drive motor. If Pin A is positive voltage with respect to Pin B, the motor will rotate in a clockwise direction. If it is negative, motor rotation will be counterclockwise. Electrical: We supply 90VDC to the motor. If 9700T-0 Function: Supply 0-10Volt signal for another motor driver to supply the drive current needed for that motor. Electrical: Output 0-10 signal for motor speed TACHOMETER INPUT (Pins C & D) Function: To receive a voltage signal from the tachometer mounted on the motor which drives the carriage. The signal is used to provide digital speed indication on the display and also to provide closed loop facilities. Electrical: We accept a 0 to 100VDC signal. The signal is conditioned in the 9700T control. HOME LIMIT SWITCH INPUT (Pins E & J) Function: To stop travel in the reverse direction when a connected limit switch is closed. This permits the programming of a home sequence to enable the weld sequence to start at the same point each time. Electrical: The limit switch must be able to handle 12VDC at 4mA, Pin E is high, Pin J is low. FORWARD LIMIT SWITCH INPUT (Pins F & J) Function: To stop travel in the forward direction when a connected limit switch is closed. This avoids the carriage running off the track. Electrical: The limit switch must be able to handle 12VDC at 4mA, Pin F is high, Pin J is low. DOWN SLOPE LIMIT SWITCH INPUT (Pins G & J) Function: To initiate the end of weld sequence when closed. When stop sequence is initiated, a signal will be sent to the welding power supply to start the current downslope. Electrical: The limit switch must be able to handle 12VDC at 4mA, Pin G is high, Pin J is low. PTL OUTPUT (Pins L & M) Function: To open and close a solenoid valve operating the pneumatic torch retract slide. Electrical: We supply a dry relay contact capable of handling 110VAC at 0.6A. which closes to bring the torch into the welding position. AFR OUTPUT/AUX2 (Pins N & P) 30 Function: A one second relay closure to do an auto finger release or AUX 2 output Electrical: We supply a dry relay contact capable of handling 110VAC at 0.6A. which closes to release the fingers or AUX2 output. If 9700T-0 ENABLE OUTPUT (Pins K & R) Function: A relay contact for motor enable. Electrical: We supply a dry relay contact capable of handling 250VAC at 10A which closes to start motor FORWARD OUTPUT (Pins U & V) Function: A relay contact for motor forward. Electrical: We supply a dry relay contact capable of handling 250VAC at 10A which closes to start motor forward. REVERSE OUTPUT (Pins S & T) Function: A relay contact for motor reverse. Electrical: We supply a dry relay contact capable of handling 250VAC at 10A which closes to start motor reverse. S4 CONNECTOR (OPTIONAL) The S4 connector is used to connect the 9700T to read in an optional encoder to be able to program the 9700T using distance. Amphenol plug 97-3106A-14S-6P Cord Grip 97-3057-1007-1 Pin Connection Details Connections should be made as shown below. Note: Pins H and K are reserved. ENCODER POWER 5VDC (Pins A & B) Function: To supply power to the optical encoder. Electrical: Pin A is 5VDC and Pin B is GND A ENCODER PHASE (Pins C & D) Function: Read in phase A of the optical encoder Electrical: Pin C is A+ and Pin D is A-. B ENCODER PHASE (Pins E & F) Function: Read in phase B of the optical encoder 31 Electrical: Pin E is B+ and Pin F is B-. 32 C. Interconnections The 9700T control can be connected to other devices to provide more complete control of the welding process. Standard length cables, complete with the appropriate Amphenol connectors are available from Miller Welding Automation. Special length cables can be made to order. Note: The Miller TIG welding power supplies are available with a special 28-pin connectors, this permits easy communication between the 9700T and the power supply. Power supplies from other manufacturers can be used. Various remote interfaces for different power sources are available-consult the Miller Welding Automation factory for best fit regarding your application and power source model. In this case the carriage drive motor is connected to, and controlled by the 9700T control which also is connected to a Miller power supply. Wire Feeder Addition In addition to being interconnected with the welding power supply, the 9700T control can also be interconnected with a Miller Welding Automation wire feeder. All Miller Welding Automation wire feeders use a 9700W series control giving them complete compatibility with the 9700T. When the 9700T carriage control is connected to the 9700W wire feeder control, the 9700T acts as the primary control and the 9700W acts as the secondary unit. This means that the complete weld sequence can be initiated by pressing the start button on the 9700T control. The weld and travel sequence will be automatically started and, at the same time, a signal will be sent to the 9700W wire feeder control to initiate the wire feed start sequence. When the stop signal is given, either by pressing the stop button on the 9700T control or by this control receiving a limit switch or encoder end of travel signal, the stop sequence set in the 9700W wire feeder control will also be automatically initiated. 33 Figure 7: Typical Miller Welding Automation System Interconnection Schematic for a GTAW and Wire Feeder. NOTE: Fixture shown is rotation but connection same for linear. Arc Length Control Addition In addition to being interconnected with the welding power supply, the 9700T control can also be interconnected with a Miller Welding Automation arc length control. When the 9700T carriage control is interconnected with a Miller Welding Automation arc length control, the 9700T passes lockout signals from the welding power supply to the arc length control. These lockout signals are used to inhibit the movement of the arc length control actuator during pulse background and slope times. This avoids the torch diving into the weld pool during these times. 34 Figure 8: Typical Miller Welding Automation System Interconnection Schematic for a GTAW and Arc Length Control. NOTE: Fixture shown is rotation but connection same for linear. ALC & Wire Feeder Addition It is possible to interface the 9700T control with an arc length control and a wire feeder as well as the welding power supply. This creates a completely integrated welding system where the operation of the start button on the 9700T control initiates the start of the weld sequence. The preset start time delays which have been set on the 9700T carriage control, 9700W wire feed control and 9790 arc length control operate automatically to provide coordinated start of the various parameters. At the end of the weld, operation of the 9700T stop push-button initiates a controlled end of weld sequence with downslope and wire and travel stop delays. 35 Figure 9: Typical Miller Welding Automation System Interconnection Schematic for a GTAW with Wire Feeder and Arc Length Control. NOTE: Fixture shown is rotation but connection same for linear. 36 SECTION VIII MAINTENANCE A. Calibration Your 9700T longitudinal travel control has been precisely calibrated before shipment - no further calibration is necessary on receipt of the equipment. There are two types of calibration routines, they are: Initial Calibration This routine is carried out only if major changes have been made to the system. Typical reasons for carrying out this type of calibration would be: • A change of the drive mechanism gearing to produce a different output speed. • The integration of the 9700T control with a third party carriage. In the event that you wish to carry out initial calibration, for the above or for other reasons, you should contact Miller Welding Automation for technical support. There is also a possibility that you could suffer a total loss of the preset calibration, this is very unlikely, but could be caused by: - Failure and subsequent replacement of the main CPU board. - Unauthorized tampering with the system. To avoid unwanted downtime and cost in the event of this type of failure, it is recommended that, on receipt of the control, you call up the calibration mode and make and store a written copy of all the calibration values. Touch-up Calibration Please follow what is written in the Auto Calibration section. 37 B. Regular Maintenance Your 9700T control requires a minimum of maintenance. The following checks should be carried out on a regular basis: Weekly: • Clean the front polycarbonate overlay panel with a soft cloth - pay particular attention to the window area. Do not use any abrasive cleaning materials. • Check the functionality of the controls, adjust knob and push button switches. • Check interconnecting cables for cuts or burns. • Check security of Amphenol connections. Monthly: In addition to the weekly maintenance routine, check the following: • Check that the sequence of operation is satisfactory. Annually: In addition to the weekly and monthly maintenance routines, check the following: • Check the touch pad areas to ensure that there is no undue wear or splitting of the polycarbonate surface. • Carry out the calibration routine to ensure optimum, accurate operation of the control. • Check the interior of the control for possible loose connections and/or components caused by vibration or knocks. • Check the interior of the control for signs of overheating of wires and/or components. 38 SECTION IX PARTS LISTS The following pages provide a detailed parts list of the 9700T control. Item numbers shown in the parts list refer to those items referenced by the balloon in the drawing. Each parts list shows the main assembly as item 1, all the quantities shown are the quantities used to make the main assembly. Two columns are included in the list to show the spare parts recommended to be stocked by the user. The two levels can be defined as follows: Level 1 These are the spares recommended for US domestic users whose use of the product does not exceed 2000 hours per year. Level 2 These are the spares recommended for International users of the product or for US domestic users who will use the product in excess of 2000 hours per year 39 9700T Enclosure Recommended Item Part No. No. Description 1 9700-1 Complete, assembled control Enclosure ........................ 1 2 9700-105 Cabinet Sheet metal only ................................................ 1 4 9700-CAB-S1 Cable Assembly Remote S1 ............................................. 1 5 9700-CAB-S2 Cable Assembly Remote S2 ............................................. 1 6 9700-CAB-S3 Cable Assembly Remote S3 ............................................. 1 7 C-1318-006-BL Power Cord 6 foot Right Angle 76803............................. 1 8 AS-25-5 Power Supply RS-25-5 ..................................................... 1 9 81F4550 RFI Filter 240D10 ............................................................. 1 10 9700-110 Sub-Panel ........................................................................ 1 11 240D10 Solid State Relay SSR1 ..................................................... 1 1 12 9700-11 Isolation Board 9600-11R................................................ 1 1 13 KBMG-212D Motor Drive Module ....................................................... 1 1 14 9700-CAB-MWH Wire Harness - Main (Not illustrated) ............................. 1 15 9700-CAB-SWH Wire Harness - Signal (Not illustrated)............................ 1 16 9700-CAB-AWH Wire Harness - Analog (Not illustrated) .......................... 1 Qty 40 Level Level I II 11 13 12 6 5 10 7 Door 9 8 41 9700T Enclosure Door Recommended Item Part No. No. Description 1 9700-1 Complete Enclosure ........................................................ 1 2 TA35-CFTRF100CO Circuit Breaker CB1 ......................................................... 1 3 9700T-100 Overlay Front Panel......................................................... 1 4 9700-10 Processor Board CPU Board ............................................ 1 5 ABW3B-R Mushroom Head, 29 mm, E Stop .................................... 1 6 AYW400 Switch Operator .............................................................. 1 7 TWC01 Contact - Normally Closed .............................................. 1 1 8 9700-LCD Display ............................................................................. 1 1 9 AML21EBA2AA Push-button Switch - Momentary................................... 2 10 AML51-E10R Red Cap - Extended ......................................................... 1 11 AML51-F10G Green Cap - Small ............................................................ 1 12 AML71-SCB Center Barrier.................................................................. 1 13 AML71-SEB End Barrier ...................................................................... 2 14 RE16-V24AC1 Encoder only ................................................................... 1 15 DD-75-2-6MM Adjust Knob only for Encoder ......................................... 1 Qty 42 Level Level I II 1 1 1 1 1 4 2 43 SECTION X PCB DESCRIPTIONS 9700-10 Microcontroller Board (CPU BOARD) Located on inside of control door. CONNECTORS J1 - Power Supply Connector The main 5VDC is supplied on this connector. If there is no 5VDC, the unit will not operate. J2 - Analog Input/ Output Connector This sends and receives the analog signals that are on the 9600-11 board. J3 - Keypad Connector This allows the membrane style front panel to be connected to the microcontroller. J4 - Display Connector This connects to the display which provides programming and operational information. J5 - Discrete Input/ Output Connector Connects to the 9600-11 board and transfers and receives digital information. J6 - Start/Stop & Encoder Connector Connects to the start and stop push-buttons to initiate an end of weld sequence and the encoder to receive pulses to increment and decrement the screen display. J12 - Relay Connector Used for Pulse Lockout at the end of the weld and to start the ALC touch retract. J13 – Spare Input Connector This is unused in current 9700T models. J14 – Spare Output Connector This is unused in current 9700T models. J15 – Spare Analog Output Connector This is unused in current 9700T models. J16 - Encoder Connector Only used if an encoder is attached to the 9700W. 44 COMPONENTS SW1 - Reset Switch This restarts the program sequence in the same way as a power down at the main power switch. SW2 - Dip Switch This dip switch is used to setup the configuration of the 9700T module. Do not change unless instructed by Miller Welding Automation. Longitudinal – Bit 4 Off, Bit 5 Off Rotational/Circumferential – Bit 4 On, Bit 5 Off Reserved – Bits 1 & 3 Off Rabbit Processor – Bit 4 On (20-101-1093), Bit 4 Off (20-101-1154) R36 – Variable Resistor This variable resistor is used to control the contrast of the display. TEST POINTS TP1 – 9700-10 5 Volt Used to check the 5 Volts going to the 9700-10 board. TP2 – 9700-10 Ground When measuring the signals of this board, connect your isolated instrument ground lead here. TP3 – Analog Input 1 Connect the red lead of your meter here to measure the analog signal from the tachometer. This value has been scaled on the 9600-11R board. TP4 - Analog Output 1 Connect the red lead of your meter here to measure the analog signal going to the motor controller. TP5 – Analog Input 2 Connect the red lead of your meter here to measure the analog signal from the remote input. This value has been scaled on the 9600-11R board. TP6 - Analog Output 2 Connect the red lead of your meter here to measure the analog signal going to the spare output. 9600-11R Isolation Board- Located inside enclosure near output amphenol connectors. 45 CONNECTORS J1 - Power Supply Connector The main 5VDC is supplied on this connector. If there is no 5VDC, the relays and isolation circuits will not operate. J2 - Analog Input/ Output Connector This sends and receives analog signals to and from the 9600-10 board. J3 - Digital Input/ Output Connector This allows the 9700-10 microcontroller board to control the relays and read the optical isolators. J4 - Motion Connector This connects through the Amphenol connector to the limit switches and tachometer to feed their signals to the 9600-11 board. J5 - Power Supply Connector Connects through the Amphenol connector to the welding power supply and sends and receives information to and from it. J6 - Auxiliary Unit Connector Connects through the Amphenol S2 connector to a second 9700 control or a PLC. J7 - Motor Control Connector This sends a -10VDC to +10VDC signal to the motor control module to control the speed of the motor. J8 - Emergency Stop Condition Connector This connection is for an emergency stop condition. It energizes a solid state relay that controls power to the motor control. J9 - Emergency Stop Connector This is where the emergency stop switch is tied. If the circuit is broken, the system will disable movement. COMPONENTS SW1 - Remote Emergency Stop Selector Switch In the “up” position (towards CR7), the remote emergency stop function is overridden. In the “down” position (towards J9), the remote emergency stop function is active. JP1-3 - Tachometer Voltage Range Ranges are as follows: JP1 0 to 10VDC Input Range 46 JP2 0 to 33VDC Input Range JP3 0 to 100VDC Input Range TEST POINTS TP1 - +5V Ground This is used when checking signal levels at the J3 header. TP2 - +12V Isolated Ground This is used when checking signal levels on the headers J5 and J6. TP5 & TP6 - Tachometer Voltage This is the signal which is being received from the tachometer connected to the drive motor. The voltage readings should match those at the tachometer. TP7 & TP8 - Motor Control Voltage This is the voltage level being sent to the motor control module. It should be a -10VDC to +10VDC signal. TP9 - Analog Common This is the analog common from the 9700-10 board. You should use this when measuring signals at TP10 and TP11. TP10 - Tachometer Signal This is the signal which is being received from the tachometer connected to the drive motor. The signal has been scaled by the jumpers JP1-3. This signal is then sent to the 9700 -10 board and read into the processor. TP11 - Motor Control Signal This signal is from the microcontroller, it will be isolated and sent to the motor control module. TP12 - Remote Speed Signal This checks that the remote speed signal, 0 to 5VDC will be proportional to the speed signal. 47 SECTION XI ELECTRICAL DIAGRAMS The following pages include electrical diagrams for the 9700T Microprocessor Controller. 9700 T Schematic for the actual control 9700 T Interconnection Diagram showing as a reference a complete system. Your actual system might differ from that shown and should be referred to by Job # for exact details. 48 49 50 APPENDIX A CALIBRATION SUB MENU MODE You enter the Calibration mode from the program mode. To get out of the calibration sub menu all you have to do is press the left arrow. When you leave the calibration sub menu all settings will be saved to the main calibration permanent memory. Default Password is CALIB CLOSED LOOP MODE CALIB AUTO CAL CLOSED LOOP LOOP SENSING llu ON 1.0 LOOP SENSING CALIB CLOSED LOOP LOOP SENSING SENSING DLY ON 1.0 2.0 SENSING DLY DISPLAY 1.0 2.0 ACTUAL DISPLAY HI LMT Sensing Dly is the amount of time after the drive is turned on before the closed looping is enabled. This allows a stable reading from the motor before making any changes. Minimum value is 0.0 and Maximum value is 10.0. DISPLAY – ACTUAL OR SET SPEED CALIB LOOP SENSING Loop sensing is the percentage of the error that will be added or subtracted to correct the speed. Adjustments are made every 20 msec. Minimum value is 0.1 and Maximum value is 99.9. SENSING DELAY CALIB LOOP SENSING Closed loop can be either on or off. When on the unit will read the feedback from the travel motor and adjust the voltage output to make sure travel at the correct speed. If off, the system will work in open loop. 1.0 ACTUAL 3.000 Display is Actual or Set. If in Actual when welding, the display will show the feedback speed of the motors. If in Set, the speed shown will be the set speed for the motors. 51 HI LIMIT CALIB DISPLAY HI LMT HI OUT ACTUAL 3.000 8.532 HI OUT CALIB HI LMT HI OUT HI IN 3.000 8.532 18.092 HI IN LOW LMT 8.532 18.092 0.060 LOW LMT LOW OUT 18.092 0.060 0.421 LOW OUT LOW IN Low Lmt is the lower limit of the travel speed. If it is a rotational system the limit will be in RPM. If it is a linear system, it will be the min speed in Configuration Mode / Units. Minimum value is 0.000 and Maximum value is 999.999. LOW OUT CALIB LOW LMT Hi In is the voltage of the feedback from the motor when running at the high limit. Minimum value is 0.000 and Maximum value is 100.000. LOW LIMIT CALIB HI IN Hi Out is the voltage that is put out of the 9700-10 board to reach the upper limit of the travel motor. Minimum value is 0.000 and Maximum value is 10.000. HI IN CALIB HI OUT Hi Lmt is the upper limit of the travel speed. If it is a rotational system the limit will be in RPM. If it is a linear system, it will be the maximum speed in Configuration Mode / Units. Minimum value is 0.000 and Maximum value is 3000.000. 0.060 0.421 0.385 Low Out is the voltage that is put out of the 9700-10 board to reach the lower limit of travel motor. Minimum value is -1.000 and Maximum value is 10.000. 52 LOW IN CALIB LOW OUT LOW IN INPUT JUMPER 0.421 0.385 J2 INPUT JUMPER CALIB LOW IN INPUT JUMPER SET SPEED 0.385 J2 LOCAL J2 SET SPEED LOCAL REMOTE HI 9.682 SET SPEED LOCAL REMOTE HI 9.682 0.219 REMOTE LOW UNITS Remote hi is the voltage on the remote input pins that will cause the travel to run at the high speed. Minimum value is 0.000 and Maximum value is 10.000. REMOTE LOW CALIB REMOTE HI Set Speed is either local or remote. In local the speed is controlled by the panel. In remote the speed is controlled by the voltage between the remote input pins. REMOTE HI CALIB REMOTE LOW Input Jumper is J1, J2, or J3 and lets the system know which jumper on the 9600-11R board is installed. J1 is for input voltage of the tachometer up to 10 volts, J2 is for up to 33 volts and J3 is for up to 100 volts. SET SPEED CALIB INPUT JUMPER Low In is the voltage of the feedback from the motor when running at the low limit. Minimum value is -1.000 and Maximum value is 100.000. 9.682 0.219 Remote low is the voltage on the remote input pins that will cause the travel to run at the low speed. Minimum value is 0.000 and Maximum value is 10.000. INCH 53 UNITS – INCH OR CM CALIB REMOTE LOW UNITS SWITCH MOTOR 0.219 INCH NO SWITCH MOTOR CALIB UNITS Set the units for the system to either inch or cm (centimeters). INCH SWITCH MOTOR NO SWITCH JOG NO Switch Motor is either no or yes. If yes it switches the direction on the motor to match the forward direction of the system. SWITCH JOG CALIB SWITCH MOTOR NO SWITCH JOG NO UNIPOLAR OUTPUT NO Switch Jog is either no or yes. If yes, it just switches the direction of travel jogging to help match the direction of the arrows on the panel. UNIPOLAR OUTPUT CALIB SWITCH JOG NO UNIPOLAR OUTPUT NO SWITCH INPUT NO Unipolar Output is either yes or no. If no the output of the 9700-10 board is from +/- 10 volts. If Yes the output is 0 to 10 volts with a relay contact for reverse. SWITCH INPUT CALIB UNIPOLAR OUTPUT NO SWITCH INPUT NO UNIPOLAR INPUT NO Switch input is either yes or no. If no, the input voltage is not switched in the software. If yes it switches the polarity of the input lines so that it reads a forward direction when moving forward. 54 UNIPOLAR INPUT CALIB SWITCH INPUT NO UNIPOLAR INPUT NO CPR 512 CPR – COUNTS PER ROTATION CALIB UNIPOLAR INPUT CPR GEAR NO 512 8.954 GEAR PASSWORD 512 8.954 llu PASSWORD BACKUP 8.954 llu llu BACKUP RESTORE If the right button is pressed, the user is allowed to see and change the password for the calibration sub menu. If the password is set to all blanks, then you do not need a password to get into the sub menu. Use the dial to change the blinking character and the right and left button to move to different characters. To get out press the right button when at the far right character. Password is always 5 characters. BACKUP CALIB PASSWORD Gear is the ratio between the motor speed and the gear speed. Minimum value is 0.001 and Maximum value is 99.999. This screen will only appear if Configuration Mode / Encoder in Sys is Yes. SUB MENU PASSWORD CALIB GEAR CPR is the counts per rotation on the motor encoder. Minimum value is 1 and Maximum value is 2000. This screen will only appear if Configuration Mode / Encoder in Sys is Yes. GEAR RATIO CALIB CPR Unipolar Input is either yes or no. If no, the input from the motor can be both positive and negative voltage depending on direction. If yes, the input voltage is always positive no matter which direction the motor is running. llu llu llu If the right arrow is pressed the 9700T copies all of the calibration parameters to the backup memory. 55 RESTORE CALIB BACKUP RESTORE HOUR METER llu llu 4 HOUR METER CALIB RESTORE HOUR METER AUTO CAL llu 4 AUTO CAL CLOSED LOOP Hour Meter shows how long the motor attached to the travel has run. This is not weld time. llu AUTO CALIBRATION SUB MENU CALIB HOUR METER If the right arrow is pressed the 9700T copies all of the calibration parameters from the backup memory to the main memory. 4 llu ON Pressing the right arrow will enter the user into the Auto Cal sub menu. See appendix C for details on each auto calibration sub menu and how to run auto calibration. 56 APPENDIX B CONFIGURATION SUB MENU MODE You enter the Configuration mode from the program mode. To get out of the configuration sub menu all you have to do is press the left arrow. When you leave the calibration sub menu all settings will be saved to the main configuration permanent memory. Default Password is CONFI FORWARD JOG CONFIG WELD DIRECTION FWD FWD JOG 25 25 REV JOG REVERSE JOG CONFIG FWD JOG REV JOG RAPID JOG Fwd Jog is the percentage of the high speed that is moved when jogging forward. Minimum value is 5 and Maximum value is 100 25 25 75 Rev Jog is the percentage of the high speed that is moved when jogging reverse. Minimum value is 5 and Maximum value is 100. . RAPID JOG CONFIG RAPID JOG 25 75 ALC IN SYS YES REV JOG Rapid Jog is the percentage of the high speed that is moved when doing a rapid jog or return to home. Minimum value is 5 and Maximum value is 100. ALC IN SYSTEM CONFIG RAPID JOG 75 ALC IN SYS YES LIFT START OFF ALC in Sys is either yes or no. If yes, allows set up for options that involve the ALC to be displayed. 57 LIFT START (With ALC only) CONFIG ALC IN SYS YES LIFT START OFF MODE TIG Lift Start is either on or off. Let’s the system know if the arc is started by high freq (no) or by lift start (yes). MIG, TIG, OR PLASMA WELDING MODE CONFIG LIFT START OFF MODE TIG WIRE IN SYS YES Mode is MIG/SAW, TIG, or Plasma. If MIG/SAW or Plasma, touch retract is removed from the main menu. WIRE IN SYSTEM CONFIG MODE TIG WIRE IN SYS YES PTL IN SYS YES Wire in Sys is either Yes or No. If yes, when in the run screen, wire will be displayed on the bottom line. PTL IN SYSTEM CONFIG WIRE IN SYS YES PTL IN SYS YES HOME SWITCH YES PTL in Sys is either Yes or No. If yes, then the line items that involve the PTL will be shown in the main menu. HOME SWITCH CONFIG PTL IN SYS YES HOME SWITCH YES AFR IN SYS YES Home Switch is either Yes or No. If yes, then the line items for return to home will be shown in the main menu. AFR – AUTO FINGER RELEASE CONFIG HOME SWITCH YES AFR IN SYS YES END LOCKOUT YES AFR in Sys is either Yes or No. If yes then the line item for Finger Dly will be shown in the main menu. 58 END LOCKOUT CONFIG AFR IN SYS YES END LOCKOUT YES ARC STOP DLY YES ARC STOP DELAY CONFIG END LOCKOUT YES ARC STOP DLY YES AUX1 NAME llu ARC STOP DLY YES AUX1 NAME llu llu AUX2 NAME llu llu ENCODER YES By pressing the right arrow you will be able to enter the name for the AUX2 output. This is the name that will be shown in the name menu and on the run screen. The name is limited to 5 alpha/numeric characters. ENCODER CONFIG AUX2 NAME llu ENCODER YES TACHOMETER YES Encoder is either Yes or No. If yes then CPR and Gear Ratio appear in Calibration and Distance can be selected in the End of Weld. TACHOMETER CONFIG ENCODER YES TACHOMETER YES SKIP ENABLE By pressing the right arrow you will be able to enter the name for the AUX1 output. This is the name that will be shown in the name menu and on the run screen. The name is limited to 5 alpha/numeric characters. AUX2 NAME CONFIG AUX1 NAME ARC Stop Dly is either Yes or No. If yes, then the line item for ARC Stop Dly will be shown in the main menu. AUX1 NAME CONFIG AUX2 NAME If TIG or Plasma ALC Lockout will appear in the program screen to lockout ALC during downslope. If MIG/SAW Create Time will appear in the program screen which add a delay if need to before allowing the travel to move again. Tachometer is either Yes or No. If yes, then the a tachometer for the speed of the motor is attached to the 9700T MAINTAIN 59 SKIP ENABLE CONFIG TACHOMETER YES SKIP ENABLE NO EXT START MAINTAIN EXT START CONFIG SKIP ENABLE EXT START POWER START NO MAINTAIN SINGLE POWER START DELAY ARC MAINTAIN SINGLE NO DELAY ARC PASSWORD Power Start is Single, N/O Stop, N/C Stop, or Inv Stop. Single the power supply only comes out to Power Supply Contactor. For N/O Stop, the Power Supply Contactor pulses for 1 sec to start and Stop (ALC Down) closes for 1 sec. N.C Stop is the same as N/O Stop but the logic for the stop is normally closed and opens for 1 sec to stop. Inv Stop is the same as single except the Stop is just the inverse of the Power Supply Contactor. DELAY ARC CONFIG POWER START Ext Start is Maintain, Mom-STP N/O, Mom-STP N/C or None. If Maintain then the travel module will run the weld sequence as long as the external start connector signal is shorted together. If Mom-STP N/O, Mom-STP N/C then the travel module will start on a momentary closure of the external start pins. For Mom-STP N/O the system will stop by closing the external stop pins. For Mom-STP N/C the system will stop by opening the external stop pins. None, the external start and stop pins are not used. POWER START CONFIG EXT START Skip Enable is either Yes or No. If yes, then the line item SKIP is shown in the program menu and the 9700T can be programmed to do skip welding. SINGLE NO llu Delay Arc allows that travel to start before the power supply is turned on. If Delay Arc is turns on Wait for Arc will be turned off when leaving the Configuration Menu. 60 PASSWORD, CONFIGURATION SUB MENU CONFIG DELAY ARC PASSWORD JOB NUMBER NO llu llu MILLER WELDING AUTOMATION JOB NUMBER CONFIG PASSWORD JOB NUMBER VERSION llu llu 1.000 VERSION SET DP llu SET DECIMAL POINTS SET DP 1.000 1 BACKUP llu Set DP is for the number of decimal points that can be displayed when setting the travel speed. Minimum value is 1 and Maximum value is 3. BACKUP CONFIG SET DP 1 BACKUP llu llu RESTORE Shows the version number of the firmware in your unit. 1.000 1 CONFIG VERSION Pressing the right button will show you the Miller Welding Automation Job Number that this 9700T shipped out on. When the job number is displayed you can press either the left or right arrow key to get out. FIRMWARE VERSION CONFIG JOB NUMBER Pressing the right button allows that user to see and change the password for the configuration sub menu. If the password is set to all blanks, then you do not need a password to get into the sub menu. If the right arrow is pressed, the 9700T copies all of the configuration parameters to the backup memory. 61 RESTORE CONFIG RESTORE llu llu WAIT FOR ARC YES BACKUP If the right arrow is pressed, the 9700T copies all of the configuration parameters from the backup to the main memory. WAIT FOR ARC CONFIG RESTORE llu WAIT FOR ARC YES WELD DIRECTION FWD Wait for Arc is either yes or no. In yes, after the power supply contact is given, the 9700T waits for an Arc On signal before moving on. In no, it continues on with the weld sequence. WELD DIRECTION CONFIG WAIT FOR ARC YES WELD DIRECTION FWD FWD JOG 25 Weld Direction is either Fwd (Forward) or Rev (Reverse) as set up in Calibration / Switch Motor. This sets the direction of travel during the weld. 62 APPENDIX C AUTO CALIBRATION Tools required are a tape measure, masking tape, and marker pen. This allows for physical measurement and references of the distance or length travelled. You need to run the calibration at a speed near the upper limit and a speed near the lower limit. Running two tests, one high and one low, allows the setting of the two extremes. This is important for the proper operation and display values on the 9700T. 1) Backup the existing calibration numbers just in case of a mistake or you want to return to them. Do this by going into the Calibration menu and making the Backup line item highlighted and then pressing the right arrow key. This will copy the Calibration numbers from the main memory on the 9700T-10 board to the backup location found on the Rabbit microcontroller board. (Note: If an error is made and you want to restore the values before you started go to the Calibration menu and make the Restore line item highlighted and then press the right arrow key). 2) Go into the Auto Cal sub menu. 3) Choose a speed and time that you want to run the test for. Make sure that the travel device has enough room to travel without running into a travel limit. Use a whole number for the distance that should be moved so you know how close the calibration is (i.e. 60 ipm of travel speed for 20 seconds should be 20 inches). Enter in the time and value for the speed to run. 4) Pressing the Start button causes the device to move. On the screen you will see the amount of time left in the run and what speed the 9700T thinks that it is running. During the calibration run you can stop the system by pressing either the left arrow key, the stop button or the estop button. (Note: you need a complete run to be able to recalculated calibration numbers.) 5) After the allotted time the screen will allow you to enter how far the travel device has moved by entering the data into the Actual line. (Note: Please make sure that you enter how far the travel has moved and NOT to convert these numbers to inches per minute. The 9700T knows how long the calibration was on and will take care of time for you.) 6) Change the menu until the Set is highlighted. At this point press the right arrow and the 9700T will do the calculations to change the input and output numbers. You can check by running again at the same time and speed used in item 3 or you can change to the other end of the calibration. Rotation Notes: Press right button when on Time changes to Rotation. When in Rotation you are programming how many rotations that you want the part to make during the calibration. At the end of the test, the part should be back at the same spot it started, if not the value is how far off the mark it is. If it went past the mark the distance entered needs to positive, if the mark is short the distance entered needs to be negative. To get out of the Auto Cal sub menu all you have to do is press the left arrow in any line except Move. When you go back to the Operator mode any changes to the calibration numbers will be saved in permanent memory. 63 TIME AUTO CAL llu SET TIME VALUE IPM 60.00 8.00 VALUE AUTO CAL TIME VALUE IPM DIAMETER 60.00 8.00 1.000 DIAMETER MOVE 8.00 1.000 tll llu MOVE ACTUAL 1.000 tll llu 0.000 ACTUAL READ This menu line will allow the user to use the right and left buttons to move the travel. Note: Other screen in Auto Cal the left arrow will move the user out of the Auto Calibration sub menu. ACTUAL AUTO CAL MOVE This is the diameter of the part/chuck that is being used as a check. Note: this will not show up in linear configured systems. MOVE AUTO CAL DIAMETER This is the speed that the calibration will run. DIAMETER AUTO CAL VALUE IPM This is the amount of time that the Auto calibration will run. If have a rotational system a right arrow press will change the label to Revolutions. The 9700T calculates the time needed for that many revolutions. Another right arrow press will change it back to Time. tll llu 0.000 0.01 After running the test, this is the actual distance that was moved during the test if it was programmed by time. If the test was programmed using revolutions then it is the distance off from that number of revolutions. If the move is short then you enter in distance as a minus number, if over you enter the distance as a positive number. 64 READ AUTO CAL ACTUAL READ SET 0.000 0.01 llu SET AUTO CAL READ SET TIME After running a test this is the distance that the unit thought that it moved. Note: This number cannot be changed. 0.01 llu 60.00 By pressing the right arrow button the unit will look at all the numbers and make the changes to the input and output numbers. During the calculations the display will show you CALC LOW (low speed run) or CALC HIGH (high speed run). Error conditions will need to be cleared with the stop button and the calibration number will not be changed. Last Page 65
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