Jetline 9600 Series Operation Manual Download Page 1

Page: 1 / 58

April 2005

IMPORTANT

Read this manual carefully before installing,

commissioning or operating this product.

OPERATION MANUAL

for 9629

Microprocessor

Controller

Jetline Engineering, 15 Goodyear Street, Irvine, CA 92618

Telephone: (949) 951-1515 • Fax: (949) 951-9237

Web Site:

www.jetline.com

• E-mail:

[email protected]

OM-9629-04-2005

Summary of Contents for 9600 Series

Page 1: ...alling commissioning or operating this product OPERATION MANUAL for 9629 Microprocessor Controller Jetline Engineering 15 Goodyear Street Irvine CA 92618 Telephone 949 951 1515 Fax 949 951 9237 Web Si...

Page 2: ...9629 Microprocessor Controller 2...

Page 3: ...during the warranty period if Jetline s inspection confirms the existence of such defects Jetline s option of repair or replacement will be F O B factory at Irvine California and therefore no compens...

Page 4: ...you to maintain the equipment in peak condition and achieve maximum efficiency with your welding opera tion Please read these instructions carefully to become aware of every advantage CAUTION Only ex...

Page 5: ...tions 12 Section IV Description 13 Section V Controls 14 Section VI Modes of Operation 15 A Operator Mode 15 B Set up Mode 20 C Calibration Mode 22 Section VII Operational Sequence 27 Section VIII Mec...

Page 6: ...9629 Microprocessor Controller 6...

Page 7: ...talled or improperly grounded equipment is a hazard 1 Do not touch live electrical parts 2 Wear dry hole free insulating gloves and appropriate body protection 3 Disconnect input power before installi...

Page 8: ...arc to remove welding fumes and gases 3 If ventilation is poor use an approved air supplied respirator 4 Read the Material Safety Data Sheets MSDS and the manufacturer s instruction for metals consum...

Page 9: ...thin 35 ft 10 7 m of the welding arc If this is not possible tightly cover them with approved covers 4 Be alert that welding sparks and hot materials from welding can easily go through small cracks an...

Page 10: ...for pacemaker wearers Consult your doctor for complete information I Principal Safety Standards Reference as applicable Safety in Welding and Cutting ANSI Standard Z49 1 from American Welding Society...

Page 11: ...e control The 9629 control is a microprocessor based control designed and built to provide low cost accurate repeatable control of the wire feed motor It is available in two versions 9629 This control...

Page 12: ...d to provide slope up of the wire feed speed for hot wire welding 9629 R1 This option can be added to allow remote control of the wire feed speed Processor Intel 80C196KC 20 MHz Display 2 x 20 Backlit...

Page 13: ...e 9629 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 h...

Page 14: ...touch pads they are capable of providing two more functions POWER UP DOWN ADJUST REV FOR Rapid Jog This is achieved by pressing the forward or reverse touch pad for a short time releasing it and then...

Page 15: ...reen 30 If it is desired to change the speed this is done by turning the adjust knob to increase or de crease the speed as necessary As the change is made the number on the display changes accordingly...

Page 16: ...nd travel at the wire retraction speed defined in the set up mode See Screen 11 for the length of time set in this screen The time can be set by turning the adjust knob to increase or decrease its val...

Page 17: ...ed The message remains on the screen until the value of the parameter is reduced below the limit This message also appears during welding if the upper limit of wire feed speed is reached in this case...

Page 18: ...setup mode of operation of the 9629 control see Screen 10 Wire feed will continue at rapid speed as long as the touch pad is pressed The message will remain on the screen as long as wire is feeding at...

Page 19: ...me the wire starts to feed at the pre programmed wire feed speed Sensing delay After the start delay has timed out this message will be displayed providing that the Closed Loop Mode is On Screen 17 Th...

Page 20: ...be set by turning the adjust knob to increase or decrease its value As the change is made the number on the display changes accordingly The reverse jog speed is a percentage of the maximum wire feed s...

Page 21: ...r on the display changes ac cordingly The low speed is set as a percentage of the maximum wire feed speed The low speed should be set to a value high enough to avoid a ball being formed on the end of...

Page 22: ...629 control into the calibra tion mode Calibration Screens Screen 17 CLOSED LOOP MODE This screen allows the closed loop mode to be turned On or Off this is achieved by turning the adjust knob When th...

Page 23: ...een Screen 21 HIGH LIMIT This screen allows the maximum speed of the wire feeder to be set by turning the adjust knob to increase or decrease the value Following the pre delivery calibration routine t...

Page 24: ...nce section of this manual The high input can be set to a maximum number of 1023 The minimum number which can be set is one digit more than the number set for the tach low input Screen 26 Press the to...

Page 25: ...ith the down arrow to proceed to the next screen TACH LOW INPUT 94 Screen 27 SET SPEED This screen permits the setting of the wire feed speed to be either Local or Remote If the control is set to Loca...

Page 26: ...Inches the wire feed speed will be set and indicated in inches per minute When the control is set for Metric the wire feed speed will be set and indicated in centimeters per minute This screen is for...

Page 27: ...or stops rotating DRIVE MOTOR Wire Stop Delay greater than 0 Wire Start Delay Wire Start Delay times out Wire drive motor starts rotating Wire Start Delay 0 Wire Start Delay greater than 0 Loop Sensin...

Page 28: ...s 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 drawing on the right side of this page Us...

Page 29: ...15VAC 230VAC B Output Connections All output connections to and from the 9629 control are made by Amphenol connectors There are threeAmphenol connectors the lower one is marked S1 the center one is S2...

Page 30: ...treated as a stop signal REMOTE EMERGENCY STOP INPUT Pins C D Function When this circuit is opened the 9629 control will initi ate an emergency stop sequence Electrical You can connect a dry relay con...

Page 31: ...ing Amphenol plug 3106A 22 19P Cord Grip 97 3057 1012 1 Pin Connection Details Connections should be made as shown below Note Pins E F G H J K L M N and P are reserved MOTOR OUTPUT CONNECTION Pins A B...

Page 32: ...pply This is necessary if the 9629 control is fitted with the pulse option and it is desired to synchronize the pulsing of the wire with the pulsing of the weld current Note The Miller range of TIG we...

Page 33: ...upply to the S2 connector on the 9629 control This signal can be used to provide wire pulsing which is synchronized with the current pulsing The arc length control is connected to the S1 connector on...

Page 34: ...trol 9629 wire feed control and 9690 arc length control operate automatically to provide coordinated start of the various parameters At the end of the weld operation of the 9640 stop push button initi...

Page 35: ...control 9629 wire feed control and 9690 arc length control operate automatically to provide coordinated start of the various parameters At the end of the weld operation of the 9627 stop push button i...

Page 36: ...arried out on a regular basis to verify the correct calibration of the wire feeder and to carry out any small touch up corrections which may be desired from time to time Prior to carrying out this typ...

Page 37: ...set the low input num ber to the new number calculated in the routine above Switch the control off and on and then repeat the test Check the resulting wire feed speed to verify that it is now accurate...

Page 38: ...e digit an exact match between the ACTUAL and DISPLAY value may be impossible because of resolution limitations In this case the closest Low Input value should be selected After making all the necessa...

Page 39: ...s shown are the quantities used to make the main assembly Two columns are included in the list to show the spare parts which it is recommended should be stocked by the user The two levels can be defin...

Page 40: ...y 1 6 9600 CAB S3 Cable Assembly 1 7 C 1318 006 BL Power Cord 1 8 AS 25 5 Power Supply 1 9 81F4550 RFI Filter 1 10 9600 110 Sub Panel 1 11 240D10 Solid State Relay 1 1 12 9600 11 Isolation Board 1 1 1...

Page 41: ...9629 Microprocessor Controller 41 Figure 1 Enclosure SUB PANEL GROUND MAIN GROUND...

Page 42: ...6 AYW400 Switch Operator 1 7 TWC01 Contact Normally Closed 1 1 8 9600 LCD Display 1 1 9 AML21EBA2AA Push button Switch Momentary 2 1 1 10 AML51 E10R Red Cap Extended 1 11 AML51 F10G Green Cap Small 1...

Page 43: ...9629 Microprocessor Controller 43 Figure 2 Enclosure Door...

Page 44: ...gnals to and from all the vari ous devices on the board U3 Digital to Analog Converter DAC Receives digital information from the microcon troller and converts it to an analog value to control the moto...

Page 45: ...9629 Microprocessor Controller 45 Figure 3 9600 10 Board J6 To Start Stop Switches NVRAM Includes Lithium Battery...

Page 46: ...ied If the circuit is broken the system will disable move ment COMPONENTS SW1 Remote Emergency Stop Selector Switch In the up position towards CR7 the remote emergency stop function is overridden In t...

Page 47: ...rd J3 To 9600 10 Digital J4 To Cable 9600 CAB S3 J6 To Cable 9600 CAB S2 J5 To Cable 9600 CAB S1 TP3 TP4 TP6 TP5 TP10 TP11 TP8 TP7 TP1 TP2 To Motor Drive J7 To Solid State Relay J8 To Emergency Stop S...

Page 48: ...to their reduction to a single page size Full size prints of any of these drawings are available free of charge on application to our Electrical Engineering Department Electrical Diagrams The diagram...

Page 49: ...9629 Microprocessor Controller 49 S1 CONNECTOR...

Page 50: ...9629 Microprocessor Controller 50 S2 CONNECTOR...

Page 51: ...9629 Microprocessor Controller 51 S3 CONNECTOR...

Page 52: ...9629 Microprocessor Controller 52...

Page 53: ...9629 Microprocessor Controller 53 Interconnection Diagram...

Page 54: ...99 9 99 9 9 9 99 9 1 0 1 0 0 3 2 0 W I R E S P E E D 7 These two lines display when the control is first switched on and stay on for about 3 seconds the screen then automatically advances to the next...

Page 55: ...ption has been included in the control F W D J G S P E X X X 8 10 100 50 O E D R E V J G S P E X X X 9 10 100 50 O E D R A P I D S P E E D X X X 10 10 100 75 O n O f f P U L S D W I R 12 R E T R A T S...

Page 56: ...0 9 9 1 0 19 S S G X N A e Y c s e u a l 20 D I S P Y A Actual e t r c P A t L X X X X i p m X I G H L I T M I 21 0 0 9999 9 Depends on the model H H I G U U T X X P 0 4095 4095 22 H O X X T T A C I...

Page 57: ...Displays when a jog touch pad is depressed while the system is in a programming screen Displays whenever the emergency stop button is depressed and remains on until it is reset Displays during wire fe...

Page 58: ...se 22 Low Speed 21 M Maintained Forward 18 Maintained Jog 14 Maintained Reverse 18 Maintenance 36 Mechanical Installation 28 Microcontroller Board 9600 10 44 O Operating Mode 54 Operational Sequence 2...

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