9660 Seam Tracker Manual Rev f

7/30/2019 9660 Seam Tracker Manual Rev f

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OPERATION MANUAL

for Cyclomatic Series

Seam Tracker Systems

JetlineEngineering,15GoodyearStreet,IrvineCA 92618Telephone:949-951-1515Fax:949-951-9237

Website: www.jetline.com www.cyclomatic.comE-mail: [email protected]

IMPORTANT

RevisedApril2012

Readthismanualcarefullybeforeinstalling,commissioningoroperatingthisproduct.


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LIMITEDWARRANTY

JetlineEngineering,ofIrvine,California,U.S.A.,warrantsallnewequipmenttobefreefromdefectsinmaterialandworkmanshipfortheperiodofone(1)year,providedthattheequipmentisinstalledandoper-

atedaccordingtoinstructions.

JetlineEngineeringsobligationunderthiswarrantyisexpresslylimitedtoreplacingorrepairingandde-fectivepartorcorrectinganymanufacturingdefectwithoutchargeduringthewarrantyperiod,ifJetlinesin-spectionconfirmstheexistenceofsuchdefects.JetlinesoptionofrepairorreplacementwillbeF.O.B.FactoryatIrvine,California,andthereforenocompensationfortransportationcostsofanykindwillbeal-

lowed.

Thewarrantyperiodbeginsonthedateofsaletotheoriginal-purchaseuseroftheequipment.

JetlineEngineeringwillnotbeliableforanylossorconsequentialdamageorexpenseaccruingdirectlyorindirectlyfromtheuseofequipmentcoveredbythiswarranty.

ThiswarrantysupersedesallpreviousJetlineWarrantiesandisexclusivewithnootherguaranteesorwarrantiesexpressedorimplied.


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NOTICE

Theinstallation,operationandmaintenanceguidelinessetoutinthismanualwillenableyoutomaintaintheequipmentinpeakconditionandachievemaximumeffi-ciencywithyourweldingoperation.Pleasereadtheseinstructionscarefullytobecomeawareofeveryadvantage.

CAUTION

Onlyexperiencedpersonnelfamiliarwiththeoperationandsafepracticeofweldingequipment

shouldinstalland/orusethisequipment.


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Overview

Overview ......................................................... vi

TableofContents .................................................... vii

TableofTables ...................................................... x

TableofFigures ..................................................... xii

SafetyPrecautions .................................................... xv

A.ArcWelding................................................. xv

B.ElectricShock................................................ xv

C.ArcRays .................................................. xv

D.FumesandGases.............................................. xvi

E.Cylinders .................................................. xvi

F.Welding ................................................... xvi

G.MovingParts................................................ xvii

H.EMFInformation ............................................. xvii

I.PrincipalSafetyStandards ......................................... xvii

TST ControlSystem ................................................... 1

DescriptionOfEquipment ........................................... 1

Operation.................................................... 19

Installation ................................................... 21

Maintenance .................................................. 27

DrawingsandPartsLists............................................ 33

Troubleshooting ................................................ 65

CircuitDescriptions .............................................. 71

SchematicsandBlockDiagrams........................................ 75

OptionalEquipment .............................................. 80

PTST ControlSystem .................................................. 81

PTST SeamTrackingSystem ......................................... 81

PTST Operation ................................................ 89

PTST Installation ............................................... 94PTST Maintenance .............................................. 105

PTST DrawingsandPartsLists........................................ 107

PTST Troubleshooting ............................................ 113

PTST SchematicsandBlockDiagrams.................................... 117

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OVERVIEW 9660SERIESSEAMTRACKERCONTROLLER


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TableofContents

SafetyPrecautions .................................................... xv

A.ArcWelding................................................. xv

B.ElectricShock................................................ xv

C.ArcRays .................................................. xv

D.FumesandGases.............................................. xvi

E.Cylinders .................................................. xvi

F.Welding ................................................... xvi

G.MovingParts................................................ xvii

H.EMFInformation ............................................. xvii

I.PrincipalSafetyStandards ......................................... xvii

TST ControlSystem ................................................... 1

DescriptionOfEquipment ........................................... 1

ControlUnit ............................. 1

Operation.................................................... 19

DriveCable ............................ 19

Cross-SlideAssembly ......................... 19

Omni-GuideSensorandAccessories ..................... 19PrincipleofOperation ........................ 19

5-AxisMount ............................ 19

ControlPendantandCableAssembly .................... 20SpecialLengthCableAssemblies ...................... 20

StandardOptions ........................... 20

TipSelectionGuide .......................... 20

Installation ................................................... 21

Cross-SlideAssemblyMounting ...................... 21

Omni-GuideSensorMounting ....................... 21

Omni-GuideSensorTips ........................ 22

Omni-GuideSensorVerticalSpringForceAdjustment ............... 22

Omni-GuideSensorsand5-AxisMountAssembly ................ 22

ControlPendantInstallation ....................... 22

ControlUnitInstallation ........................ 22

WeldHeadInstallation ......................... 22

SystemInterconnection ......................... 23

DuringOperation ........................... 23NOTE ............................. 23

DuringMechanicalAdjustments ...................... 23

DuringElectricalAdjustments ....................... 23

InitialSet-upInstructions ........................ 24OperatingSequence ........................ 24

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WorkEngagementSequence ...................... 24ManualOperations ......................... 24AutomaticOperations ........................ 24SidetrackForceAdjustment ...................... 24

Maintenance .................................................. 27

MaintenanceRequirements ........................ 27

ControlUnitAssembly ......................... 27

ControlPendantandCableAssembly .................... 27

Cross-SlideAssembly ......................... 27

Omni-GuideSensorAssembly ....................... 28

MountingBrackets .......................... 28

PreventiveMaintenanceSchedule ...................... 28MonthlyMaintenance ........................ 28Omni-GuideSensorAssembly ..................... 28

ProbeBracketAssembly ....................... 28QuarterlyMaintenance........................ 28TorchBracketAssembly ....................... 28Cables ............................. 29

PendantAssembly ......................... 29CrossSlides ........................... 29SemiAnnualMaintenance ....................... 29ControlUnitAssembly ........................ 29

Omni-GuideSensorCalibrationProcedure ................... 29ToolsRequired .......................... 29Omni-GuideSensorInterfaceCircuitry................... 29CalibrationOfTheOmni-GuideSensorAssembly ............... 30

ServoAmplifierCircuitryCalibration .................... 31TollsRequired .......................... 31

DrawingsandPartsLists............................................ 33

Troubleshooting ................................................ 65

RecommendedSparesforTroubleshooting ................... 65

HelpfulHints ............................ 68Hint#1-LapJointWeldingApplications .................. 68Hint#2-CircumferentialWeldingApplications ................ 68Hint#3-CrossSlidetoSensorRelationship ................. 68Hint#4-SensorRotated180 Degrees .................. 69

CircuitDescriptions .............................................. 71

SystemWiringDiagram ......................... 71

MainBoardAssembly ......................... 71VoltageRegulation ......................... 72ControlCircuitryDescription...................... 72Omni-GuideSensorInterface ...................... 72

PendantControl .......................... 73ServoAmplifier .......................... 73

AdvanceProgrammingOptionComponents ................. 74SchematicsandBlockDiagrams........................................ 75

OptionalEquipment .............................................. 80

RotaryTableBracket .......................... 80

PTST ControlSystem .................................................. 81

PTST SeamTrackingSystem ......................................... 81

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FeaturesApplications ......................... 81TimedCycleFunction ........................ 81

AutoCutoffFunction ........................ 81SwitchedAuto-DisableFunction ..................... 82TackCutoffFunction ........................ 82

Features .............................. 83ZSearchFeature.......................... 83LockoutFeature .......................... 84CraterFillDelay ......................... 84

HorizontalRetractDelay ....................... 86VerticalSearchDelay ........................ 86SidetrackDisableatNull ....................... 87

PTST Operation ................................................ 89

UserInterface ............................ 89J3OutputRelayConnector ...................... 89J4InputConnector ......................... 89

multi-systemoperation ......................... 90Start.............................. 90

EmergencyStop .......................... 90

SynchronizedTiming(NullInput) .................... 90Cutoff ............................. 90VerticalDisableandHorizontalDisable .................. 90

OperationalPrecautions ........................ 90ZSearchFeature.......................... 90VerticalandHorizontalDisable ..................... 90TackFunction .......................... 91

RemoteInterfaceConnections ..................... 91

FieldInstallation ........................... 91

ControlPendant ........................... 91

ControlBox ............................ 91PTST SeamTrackingSystem ...................... 92RemoteInterfaceConnectorAssembly ................... 92

ProgramSwitchSettings ........................ 92

PTST Installation ............................................... 94

PTST Programming .......................... 94

PTST ProgrammingoftheFeatures ..................... 94

PTST PreliminaryCheckoutProcedure .................... 95

PTST CheckoutProcedure ........................ 98

SequenceofOperation ......................... 98ExampleOne ........................... 98ExampleTwo .......................... 100

SeamTrackerGroundingandCabling .................... 102

PTST Maintenance .............................................. 105

PTST DrawingsandPartsLists........................................ 107

PTST Troubleshooting ............................................ 113

InterfacingtheSeamTrackertoOtherEquipment ................ 113SubassemblyInterface........................ 113

General.............................. 113RecommendedTroubleshootingEquipment. ................. 113SetupandGeneralInformation ..................... 113

PTST SchematicsandBlockDiagrams.................................... 117

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TableofTables

DescriptionOfEquipment

Table1-TST40SystemSpecifications ..................................... 2

Table2-TST250SystemSpecifications .................................... 3

Table3-Omni-GuideSensorTipsPartsList .................................. 4

Table4-FilletsandV-Grooves ......................................... 5

Table5-ButtTypeJoints ............................................ 5

Table6-AdjacentorParallel .......................................... 5

Table7-TackWeldGrooves .......................................... 5

Table8-TackWeldFillet ............................................ 6

Table9-TackWeldOver-Ride ......................................... 6

Table10-TubeMills .............................................. 6

Table11-MSP40LoadSpecifications .................................... 18

Table12-MSP250LoadSpecifications.................................... 18

Operation

Installation

Maintenance

DrawingsandPartsLists

Table13-Omni-GuideSensorPartsList ................................... 37

Table14-MSP40cross-slidePartsList .................................... 39

Table15-MSP250Cross-SlidePartsList................................... 41




Table19-9660SSeamTrackerControlPartsList .............................. 49

Table20-9660S-100ControlPendantPartsList ............................... 51

Table21-PowerSwitchAssemblyPartsList ................................. 52

Table22-TransformerAssemblyPartsList.................................. 53

Table23-MotorDriverHeatsinkAssemblyPartsLists ........................... 54

Table24-MotorDriverHeatsinkAssemblyPartsLists(Cont.) ....................... 55

Table25-VoltageSelectorSwitchAssemblyPartsList ........................... 56

Table26-DriveConnectorHarnessAssemblyPartsList........................... 57

Table27-PendantConnectorHarnessAssemblyPartsList ......................... 58

Table28-Std.TorchClampBracketPartsList ................................ 59

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Table29-OptionalUniversalBracketPartsList ............................... 60

Table30-U-Bracket(TST40)PartsList ................................... 61

Table31-5-AxisMountPartsList ...................................... 62

Table32-5-AxisMountPartsList(Cont.) .................................. 63Troubleshooting

Table33-Troubleshooting .......................................... 65

Table34-VoltageTestPoints ......................................... 66

Table35-DriveSignalTestPoints ...................................... 66

Table36-Omni-GuideSensorTestPoints .................................. 66

Table37-RecommendedSpareParts ..................................... 66

CircuitDescriptions

SchematicsandBlockDiagrams

OptionalEquipment

PTST SeamTrackingSystem

PTST Operation

Table39-PTST ProgrammingOptionDipSwitchDescriptions ....................... 91

Table40-PTST ProgrammingOptionPrograms,FactoryDefault ...................... 93

PTST Installation

Table41-ProgramValues,Example1 .................................... 98

Table42-ProgramValues,Example2 .................................... 100

Table43-9660P ControlProgramWorksheet ................................ 104

PTST Maintenance

PTST DrawingsandPartsLists

Table44-9660P ControlPartsList ..................................... 109

Table45-9660P-100PendantPartsList ................................... 111

Table46-RemoteInput/OutputConnectorHarnessPartsList ....................... 112

PTST Troubleshooting

PTST SchematicsandBlockDiagrams

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TableofFigures

DescriptionOfEquipment

Figure1-TST40SystemComponents ..................................... 2

Figure2-TST250SystemComponents .................................... 3

Figure3-Omni-GuideSensorTips ....................................... 4

Figure4-TipSelection,FilletandV-Groove.................................. 5

Figure5-TipSelection,ButtTypeJoints.................................... 5

Figure6-TipSelection,AdjacentorParallel.................................. 5

Figure7-TipSelection,TackWeldGroove .................................. 5

Figure8-TipSelection,TackWeldFillet ................................... 6

Figure9-TipSelection,TackWeldOver-Ride ................................. 6

Figure10-TipSelection,TubeMills ...................................... 6

Figure11-InterconnectionDiagram ...................................... 7

Figure12-MSP40Cross-SlideMountingDimensions............................. 8

Figure13-MSP250Cross-SlideMountingDimensions ............................ 9

Figure14-MSP4505x5Cross-SlideMountingDimensions ........................ 10

Figure15-MSP45010x10Cross-SlideMountingDimensions ....................... 11

Figure16-9660Sand9660P ControlMountingDimensions......................... 12

Figure17-9660S-100and9660P-100PendantMountingDimensions ................... 13

Figure18-Omni-GuideSensorMounting(Std.Bracket)........................... 14

Figure19-Omni-GuideSensorMounting(Univ.Bracket) .......................... 14

Figure20-VerticalForceAdjustments .................................... 15

Figure21-TorchClampMountingBracket.................................. 16

Figure22-UniversalMountingBracket ................................... 17

Figure23-Opt.U-BracketMountingBracket(TST40) ........................... 17

Figure24-SideView,MSP40......................................... 18

Figure25-SideView,MSP250 ........................................ 18

Figure26-LoadSpecificationsEnvelopeTopView ............................. 18

Operation

Installation

Figure27-TrackingDiagram ......................................... 25

Figure28-SidetrackForceAdjustment .................................... 25

Maintenance

DrawingsandPartsLists

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Figure29-SeamTrackerMainBoardLayout ................................ 33

Figure30-SidetrackForceAdjustment .................................... 34

Figure31-Omni-GuideSensorExplodedView ............................... 36

Figure32-MSP40cross-slideExplodedView ................................ 38Figure33-MSP250Cross-SlideExplodedView ............................... 40

Figure34-MSP450Cross-SlideExplodedView ............................... 44

Figure35-9660SSeamTrackerControlExplodedView........................... 48

Figure36-9660S-100ControlPendantExplodedView ........................... 50

Figure37-PowerSwitchAssemblyExplodedView ............................. 52

Figure38-TransformerAssemblyExplodedView .............................. 53

Figure39-MotorDriverHeatsinkAssemblyExplodedView ........................ 54

Figure40-VoltageSelectorSwitchassemblyExplodedView ........................ 56

Figure41-DriveConnectorHarnessExplodedView............................. 57Figure42-PendantConnectorHarnessExplodedView ........................... 58

Figure43-Std.TorchClampBracket,1103-0017 .............................. 59

Figure44-OptionalUniversalBracket,1103-0009.............................. 60

Figure45-U-Bracket(TST40),1103-0025 .................................. 61

Figure46-5-AxisMount ........................................... 62

Troubleshooting

Figure47-9660SControlSignalFlow .................................... 67

Figure48-SensorAngleonLapJoints .................................... 68

Figure49-SensorOrientationonTanks,PressureVesselsandPipes..................... 68Figure50-CrossSlidetoSensorRelationship,Correct............................ 69

Figure51-CrossSlidetoSensorRelationship,Incorrect ........................... 69

Figure52-SensorRotated180Degrees ................................... 70

CircuitDescriptions

Figure53-9660S-100PendantSchematic,StandardSeamTracker ..................... 75

SchematicsandBlockDiagrams

Figure54-9660SSeamTrackerBlockDiagram ............................... 76

Figure55-9660SSeamTrackerBlockDiagram(Cont.) ........................... 77

Figure56-MotorDriverHeatsinkSchematicDiagram............................ 78

OptionalEquipment

Figure57-RotaryTableBracket ....................................... 80

PTST SeamTrackingSystem

Figure58-ZSearchFeature.......................................... 83

Figure59-TimedMode ............................................ 84

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Figure60-AutoCutoff,DownCutoff..................................... 85

Figure61-AutoCutoff,UpCutoff ...................................... 85

Figure62-TackCutoffMode ......................................... 86

PTST OperationPTST Installation

Figure63-PTST ProgrammingOptionTimedMode ............................. 95

Figure64-PTST ProgrammingOptionAutoDownCutoff.......................... 96

Figure65-PTST ProgrammingOptionAutoUpCutoff ........................... 96

Figure66-PTST ProgrammingOptionTackCutoff ............................. 97

Figure67-PTST ProgrammingOptionZSearchFeature .......................... 97

Figure68-PTST TimeLine,ExampleOne .................................. 99

Figure69-PTST ProgrammingOptionTimeLine,ExampleTwo ..................... 101

PTST Maintenance

PTST DrawingsandPartsLists

Figure70-PTST ControlBoardLayout ................................... 107

Figure71-9660P ControlExplodedView .................................. 108

Figure72-9660P-100PendantExplodedView ............................... 110

Figure73-RemoteConnectorHarnessExplodedView ........................... 112

PTST Troubleshooting

Figure74-9660P ControlSignalFlow.................................... 115

PTST SchematicsandBlockDiagrams

Figure75-9660P-100PendantSchematic.................................. 117

Figure76-9660P ControlBlockDiagram .................................. 118

Figure77-9660P ControlBlockDiagram(Cont.) ............................. 119

Figure78-RemoteInputInterfaceConnections............................... 120

Figure79-RemoteOutputInterfaceConnections .............................. 121

Figure80-9660P Multi-SystemOperationandWiring ........................... 122

Figure81-9660P Auto-DisableOperationandWiring ........................... 123

Figure82-9660P ControltoMillerAutoMInterface............................ 124

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Safety Precautions

A. ARC WELDING

ArcWeldingcanbehazardous.Protectyourselfandothersfrompossibleseriousinjuryordeath.Keepchildrenaway.Pacemakerwearerskeepawayuntilconsultingyourdoctor.Inwelding,asinmostjobs,exposuretocertainhaz-ardsoccurs.Weldingissafewhenprecautionsaretaken.ThesafetyinformationgivenbelowisonlyasummaryofthemorecompletesafetyinformationthatwillbefoundintheSafetyStandardslistedatthe

endofthissection.ReadandfollowallSafetyStan-dards.Haveallinstallation,operation,maintenanceandre-

pairworkperformedonlybyqualifiedpeople.

B. ELECTRIC SHOCK

Touchingliveelectricalpartscancausefatalshocksorsevereburns.Theelectrodeandworkcircuitiselectri-callylivewhenevertheoutputison.Theinputpowercircuitandmachineinternalcircuitsarealsolivewhenpowerison.Whenusingmechanizedwirefeed,thewire,wirereel,driverollhousingandallmetal

partstouchingtheweldingwireareelectricallylive.Incorrectlyinstalledorimproperlygroundedequip-mentisahazard.

1 Do not touch live electrical parts.

2 Wear dry, hole-free insulating gloves and appro-priate body protection.

3 Disconnect input power before installing or ser-vicing this equipment. Lockout/Tagout input

power according to OSHA 29 CFR 1910.147(see Safety Standards).

4 Properly install and ground this equipment ac-cording to the operation manual and national,state and local codes.

5 Always verify the supply ground-check and besure that input power cord ground wire is prop-erly connected to ground terminal in disconnect

box or that cord plug is connected to a properlygrounded receptacle outlet.

6 When making input connections, attach propergrounding conductor first - double-check con-nections.

7 Frequently inspect input power cord for damageor bare wiring. Replace cord immediately ifdamaged - bare wiring can kill.

8 Turn off all equipment when not in use.

9 If earth grounding of the workpiece is required,ground it directly with a separate cable - do notuse work clamp or work cable.

10 Do not touch electrode if you are in contact withthe work, ground, or another electrode from adifferent machine.

11 Use only well-maintained equipment. Repair or

replace damaged parts at once. Maintain unit ac-cording to manual.

12 Wear a safety harness if working above floorlevel.

13 Keep all panels and covers securely in place.

14 Clamp work cable with good metal-to-metalcontact to workpiece or worktable as near theweld as practical.

C. ARC RAYSArcrayscanburneyesandskin;noisecandamagehearing;flyingslagorsparkscaninjureeyes.Arcraysfromtheweldingprocessproduceintensevisibleandinvisible(ultravioletandinfrared)raysthatcanburneyesandskin.Noisefromsomepro-cessescandamagehearing.Chipping,grindingandweldcoolingthrowoffpiecesofmetalorslag.

1 Use approved ear plugs or ear muffs if noiselevel is high.

2 Use a welding helmet fitted with a proper shade

of filter to protect your face and eyes whenwelding or watching.

3 Wear approved safety glasses with side shields.

4 Use protective screens or barriers to protect oth-ers from flash and glare; warn others not towatch the arc.

5 Wear protective clothing made from durable,flame-resistant material (wool and leather) andfoot protection where necessary.

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D. FUMES AND GASES

Fumesandgasescanbehazardoustoyourhealth.Weldingproducesfumesandgases.Breathingthesefumesandgasescanbehazardoustoyourhealth.

1 Keep your head out of the fumes. Do notbreathe the fumes.

2 If inside, ventilate the area and/or use exhaust atthe arc to remove welding fumes and gases.

3 If ventilation is poor, use an approvedair-supplied respirator.

4 Read the Material Safety Data Sheets (MSDS)and the manufacturer's instruction for metals,consumables, coatings, cleaners, and degreasers.

5 Work in a confined space only if it is well venti-lated, or while wearing an air-supplied respira-

tor. Always have a trained watch person nearby.

6 Do not weld in locations near degreasing, clean-ing, or spraying operations. The heat and rays ofthe arc can react with vapors to form highlytoxic and irritating gases.

7 Do not weld on coated metals, such as galva-nized, lead or cadmium plated steel, unless thecoating is removed from the weld area, the areais well ventilated, and if necessary, while wear-ing an air-supplied respirator. The coatings andany metals containing these elements can give

off toxic fumes if welded.

E. CYLINDERS

Cylinderscanexplodeifdamaged.

Shieldinggascylinderscontaingasunderhighpres-sure.Ifdamaged,acylindercanexplode.Sincegascylindersarenormallypartoftheweldingprocess,besuretotreatthemcarefully.

1. Protect compressed gas cylinders from exces-sive heat, mechanical shocks, slag, open flames,

sparks, and arcs.

2. Install cylinders in an upright position by secur-ing to a stationary support or cylinder rack to

prevent falling or tipping.

3. Keep cylinders away from any welding or otherelectrical circuits.

4. Never weld on a pressurized cylinder - explo-sion will result.

5. Use only correct shielding gas cylinders, regula-tors, hoses and fittings designed for the specificapplication; maintain them and associated partsin good condition.

6. Turn face away from valve outlet when openingcylinder valve.

7. Keep protective cap in place over valve exceptwhen cylinder is in use or connected for use.

8. Read and follow instructions on compressed gascylinders, associated equipment, and CGA pub-lication P-1 listed in Safety Standards.

F. WELDING

Weldingcancausefireor explosion.

Weldingonclosedcontainers,suchastanks,drums,orpipes,cancausethemtoblowup.Sparkscanflyofffromtheweldingarc.Theflyingsparks,hotworkpiece,andhotequipmentcancausefiresand

burns.Accidentalcontactofelectrodetometalobjectscancausesparks,explosion,overheating,orfire.Checkandbesuretheareaissafebeforedoinganywelding.

1. Protect yourself and others from flying sparksand hot metal.

2. Do not weld where flying sparks can strikeflammable material.

3. Remove all flammables within 35 ft (10.7 m) ofthe welding arc. If this is not possible, tightlycover them with approved covers.

4. Be alert that welding sparks and hot materialsfrom welding can easily go through small cracksand openings to adjacent areas.

5. Watch for fire, and keep a fire extinguishernearby.

6. Do not weld on closed containers such as tanks,drums, or pipes, unless they are properly pre-

pared according to AWSF4.1 (see safety Stan-dards).

7. Connect work cable to the work as close to thewelding area as practical to prevent weldingcurrent traveling long, possibly unknown pathsand causing electric shock and fire hazards.

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8. Wear oil-free protective garments such asleather gloves, heavy shirt, cuffless trousers,high shoes, and a cap.

G. MOVING PARTS

Movingparts,suchasfans,rotors,andbeltscancutfingersandhandsandcatchlooseclothing.

1. Keep all doors, panels, covers, and guardsclosed and securely in place.

2. Have only qualified people remove guards orcovers for maintenance and troubleshooting asnecessary.

H. EMF INFORMATION

ConsiderationsAboutWeldingandtheEffectsofLowFrequencyElectricandMagneticFields.

ThefollowingisaquotationfromtheGeneralCon-clusionsSectionoftheU.S.Congress,OfficeofTech-nologyAssessment,BiologicalEffectsofPowerFrequencyElectric&MagneticFields-BackgroundPaper,OTA-BP-E-53(Washington,DC:U.S.Govern-mentPrintingOffice,May1989):"....thereisnowaverylargevolumeofscientificfindingsbasedonexperimentsatthecellularlevelandfromstudieswithanimalsandpeoplewhichclearlyestablishthatlowfrequencymagneticfieldscaninter-actwith,andproducechangesin,biologicalsystems.Whilemostofthisworkisofveryhighquality,theresultsarecomplex.Currentscientificunderstandingdoesnotyetallowustointerprettheevidenceina

singlecoherentframework.Evenmorefrustrating,itdoesnotyetallowustodrawdefiniteconclusionsabutquestionsofpossibleriskortoofferclearsci-ence-basedadviceonstrategiestominimizeoravoid

potentialrisks."Toreducemagneticfieldsintheworkplace,usethefollowingprocedures:

1. Keep cables close together by twisting or tapingthem.

2. Arrange cables to one side and away from theoperator.

3. Do not coil or drape cables around the body.

4. Keep welding power source and cables as faraway as practical.

5. Connect work clamp to workpiece as close tothe weld as possible.

AboutPacemakers:

Theaboveproceduresareamongthosealsonormallyrecommendedforpacemakerwearers.Consultyourdoctorforcompleteinformation.

I. PRINCIPAL SAFETY STANDARDS

Referenceasapplicable

SafetyinWeldingandCutting,ANSIStandardZ49.1,fromAmericanWeldingSociety,550N.W.LeJeuneRd,Miami,FL 33126SafetyandHealthStandards,OSHA 29CFR1910,fromSuperintendentofDocuments,U.S.GovernmentPrintingOffice,Washington,D.C.20402

NationalElectricCode,NFPA Standard70fromNa-tionalFireProtectionAssociation,BatterymarchPark,Quincy,MA 02269RecommendedSafePracticesforthePreparationforWeldingandCuttingofContainersThatHaveHeldHazardousSubstances,AmericanWeldingSocietyStandardAWSF4.1,fromAmericanWeldingSociety,550N.W.LeJeuneRd,Miami,FL 33126

SafeHandlingofCompressedGasesinCylinders,CGA PamphletP-1,fromCompressedGasAssocia-tion,1235JeffersonDavisHighway,Suite501,Arlington,VA 22202CodeforSafetyinWeldingandCutting,CSA Stan-dardW117.2,fromCanadianStandardsAssociation,StandardsSales,178RexdaleBoulevard,Rexdale,Ontario,CanadaM9W 1R3SalesPracticesforOccupationandEducationalEyeandFaceProtection,ANSIStandardZ87.1,fromAmericanNationalStandardsInstitute,1430Broad-way,NewYork,NY 10018CuttingandWeldingProcesses,NFPA Standard51B,fromNationalFireProtectionAssociation,BatterymarchPark,Quincy,MA 02269

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TST Control System

DESCRIPTION OF EQUIPMENTJetlineEngineeringSeamTrackerSystemsareusedfortorchpositioninginautomatedweldingprocessesrequiringaconstanttorchpositionwithrespecttothe

jointtobewelded.Thesystemcanbeconfiguredforvariouscombinationsofmanualandautomaticposi-tioningmaneuvers.

A typicalstandardJetlineEngineeringSeamTrackerSystem(see Figure1-TST40SystemComponentsand Figure2-TST250SystemComponents,begin-ningonpage 2)consistsofaControlUnitAssembly,DriveCableAssembly,Cross-SlideAssembly,

Omni-GuideSensorAssembly(withstandard1/8"balltipandextensionrod)5AxisMount,TorchClampBracket,andControlPendantAssembly.AnoptionalUniversalBracketisalsoavailableinaddi-tiontotheTorchClampBracket.Theuser'sweldingtorchorweldheadisnormallymountedtotheadapter

platewhichisapartofthecross-slideassemblypro-vidingtwo-axispositioningcontrolofthetorch.

TheOmni-GuideSensorAssemblyisnormallymountedtotheweldingtorchviathetorchclamp

bracket,butcanoptionallybemountedtotheuniver-salbracket.ThesensortipontheOmni-GuideSensorcontactsthejointtobeweldedandsensesanyhori-

zontalorverticalmovementoftheweldjointwithre-specttotheweldingtorch.

Thecontrolunitcontainsthesolidstateelectroniccontrolsthatapplythepropervoltagetothemotorsonthecross-slideassemblytocorrectthepositioninger-rordetectedbytheOmni-GuideSensor.JetlineEngi-neeringSeamTrackerSystemswillcorrect

positioningerrorswithin.005inchesandprovidevar-iousproportionalcorrectionspeeds.

Thecontrolpendantassembly,connectedtothecon-trolunitviaacable(attached),providesthecontrolsusedtoinitiallypositionthecross-slidesandstartthe

trackingoperation.Thependantassemblyismadesothatthefaceplateandcablecanberemovedfromthe

pendantenclosureallowingthependantfaceplateto

bemountedtoanothercontrolconsolewithoutre-wiringthependantassembly.

Includedwiththependantassemblyaremountingbracketstomountittoafixtureandanattachablehooktoallowconvenientlocationchangesasrequired

bytheoperatororapplication.

CONTROL UNIT

The 9660 SeriesSeamTrackingControllerisaheavygaugesteelenclosurecontainingtheelectroniccir-cuitryusedinthesystem.Solidstatecircuitsareusedtoprovidelong,trouble-freeoperation.Thestandard

unitoperateson115/230VAC,50/60Hzcommercialpower,capableofsupplyingapproximately5ampspeakcurrent.Theunithasalightedpowerswitchandfuseholdermountedontheexterioroftheunit.

Thesystemisoperatedfromthecontrolslocatedonthecontrolpendantassemblywhichconnectstothecontrolunit.A sealedheatsinkmountedonthesideofthecontrolunitallowsforconvectioncoolingofheatdissipatingdevices,whilepreventingdustanddirtfromenteringtheenclosure.

The9660SeriesControlunitissoldintwomodels,i.e.,9660SStandardSeamTrackingControllerand

the9660P ProgrammableSeamTrackingController.ThesystemsthesecontrollersareconfiguredintoaretheTactileSeamTracking(TST)andtheProgramma-

bleTactileSeamTracking(PTST)systems,respec-tively,andthisconventionisusedthroughoutthismanual.

Twoblankpanels,locatedonthefrontcoverandthebottomrightoftheenclosure,allowprovisionforfac-toryandfieldinstallationofthePTST ProgrammableSeamTrackingOption(seePTST ProgrammableSeamTrackingOptionbeginningonpage 81).

Thetwoconnectorslocatedonthebottomoftheunit

provideforconnectionofthecontrolpendantcableandthedrivecabletothecross-slideassembly.

9660SERIESSEAMTRACKERCONTROLLER DESCRIPTIONOFEQUIPMENT

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DESCRIPTIONOFEQUIPMENT 9660SERIESSEAMTRACKERCONTROLLER

2

DESCRIPTION SPECIFICATIONS RATINGLoadCapacity 6(152mm)fromFaceplate 40lbs.(18Kg)

StandardStrokeLength VerticalxHorizontal 3(76mm)x3(76mm)

Non-StandardStrokeLength VerticalxHorizontal 6(152mm)x6(152mm)

MinimumEnvelope StandardStroke3(76mm)x3(76mm) 12(305mm)Diameter

TrackingAccuracy MaximumCorrectionRate24 ipm (610mm/min.) Within.005(1.27mm)

TrackingControls Manual Up/DownandLeft/Right

Automatic Left/RightSidetrackandOff

DriveSystemPrecisionBallScrewwithMechanicalOverride

Clutch

ControlUnit EnclosureStandard NEMA StyleSealedenclosurewithprovi-

sionsforplug-inoptions

RemoteControlPendant Enclosure

Handheldormountedsteelenclosurecontaining

manualandautomatictrackingcontrolswithprovi-


CrossSlideCable StandardLength 10 (3M)

Omni-GuideSensorCable StandardLength 4 (1.2M)

PowerCable StandardLength 6 (1.8M)

PendantCable StandardLength 10 (3M)

Weights Cross-slide Assembly(cableincl.) 10lbs.(4.1Kg)

Omni-GuideSensor 1lb.(.45Kg)

ControlUnit(powercableincl.) 33 lbs.(15Kg)

RemoteControlPendant(cableincl.) 4lbs.(1.8Kg)

TorchBracket, TIG 1lb.(.45Kg)

TorchClampBracket 2lb.(.9Kg)

5-AxisMount 3lbs.(1.4Kg)

Plug-inOption PTST ProgrammingOption AdvancedProgrammingControl

TABLE 1 - TST40 SYSTEM SPECIFICATIONS

FIGURE 1 - TST40 SYSTEM COMPONENTS


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3

FIGURE 2 - TST250 SYSTEM COMPONENTS

DESCRIPTION SPECIFICATIONS RATING

LoadCapacity 12(305mm)fromFaceplate200lbs.(91Kg)Derated15lbs./inch(6.8Kg/25.4

mm)beyond12(305mm)

StandardStrokeLength VerticalxHorizontal5(127mm)x5(127mm)or

10(254mm)X10(254mm)

Non-StandardStrokeLength VerticalxHorizontal10(254mm)x10(254mm)InboardDriveAssy

24(610mm)x24(610mm)OutboardDriveAssy

MinimumEnvelope StandardStroke5(127mm)x5(127mm) 17(431mm)Diameter

TrackingAccuracyMaximumCorrectionRate0-32ipm(813

mm/min.)Within.005(1.27mm)

TrackingControls Manual Up/DownandLeft/Right

Automatic Left/RightSidetrackandOff

DriveSystem PrecisionBallScrew

ControlUnit EnclosureStandard NEMA StyleSealedenclosurewithprovi-


RemoteControlPendant Enclosure

Handheldormountedsteelenclosurecontaining

manualandautomatictrackingcontrolswithprovi-


Cross-Slide Cable StandardLength 10 (3M)

Omni-GuideSensorCable StandardLength 4 (1.2M)

PowerCable StandardLength 6 (1.8M)

PendantCable StandardLength 10 (3M)

Weights Cross-slide Assembly(5x5) 38lbs.(16Kg)

Omni-GuideSensor 1lb.(.45Kg)

ControlUnit (powercable incl.) 33lbs.(15Kg)

RemoteControlPendant(cableincl.) 4lbs.(1.8Kg)

TorchBracket, TIG 1lb.(.45Kg)

TorchClampBracket 2lb.(.9Kg)

5-AxisMount 3lbs.(1.4Kg)

Plug-inOption PTST ProgrammingOption AdvancedProgrammingControl

TABLE 2 - TST250 SYSTEM SPECIFICATIONS


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4

FIGURE 3 - OMNI-GUIDE SENSOR TIPS

Model# Description Part# AlternatePart#

TX03 3ExtensionTip 179746 1110-2107

PT006 1/16DiameterRound 179747 1106-1974

PT012 1/8DiameterRound 179748 1106-1923

PT025 1/4DiameterBall 179749 1106-2032

PT038 3/8DiameterBall 179750 1106-2024

PT050 DiameterBall 179751 1106-2016

PT063 5/8DiameterBall 179752 1106-2008

PT075 3/4DiameterBall 179753 1106-1991

PT100 1DiameterBall 179754 1106-1982

ST01 Blade&Roller 179755 1103-0262

ST03 StraightSideExtension 179756 1103-0271

ST04 CurvedExtension 179758 1103-0301

ST07 TackWeldGroove 179759 1103-0289

ST08 TackWeldFillet 179760 1103-0327

ST09 TackWeldOver-ride 179761 1103-0297

ST11 CurvedTip 179763 1103-0505

ST12 SingleWheelTip 179765 1103-0319

ST13 TwinTipAssembly N/A 1103-1209

TABLE 3 - OMNI-GUIDE SENSOR TIPS PARTS LIST


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5

FIGURE 4 - TIP SELECTION, FILLET AND V-GROOVE

FIGURE 5 - TIP SELECTION, BUTT TYPE JOINTS

FIGURE 6 - TIP SELECTION, ADJACENT OR PARALLEL

FIGURE 7 - TIP SELECTION, TACK WELD GROOVE

Model Description

PT006 1/16Dia.Round

PT012 1/8Dia.Round

PT025 1/4Dia.Ball

PT038 3/8Dia.Ball

PT050 Dia.Ball

PT063 5/8Dia.Ball

PT075 3/4Dia.Ball

PT100 1Dia.Ball

TABLE 4 - FILLETS AND V-GROOVES

Model Description

ST01 BladeandRoller

TABLE 5 - BUTT TYPE JOINTS

Model Description

ST04 CurvedSideExtension

TABLE 6 - ADJACENT OR PARALLEL

Model Description

ST07 TackWeldGroove

TABLE 7 - TACK WELD GROOVES


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6

FIGURE 8 - TIP SELECTION, TACK WELD FILLET

FIGURE 9 - TIP SELECTION, TACK WELD OVER-RIDE

FIGURE 10 - TIP SELECTION, TUBE MILLS

Model Description

ST03 TackWeldFillet

ST08 StraightSideExtension

TABLE 8 - TACK WELD FILLET

Model Description

ST09 TackWeldOver-ride

TABLE 9 - TACK WELD OVER-RIDE

Model Description

ST11 SingleWheel

TABLE 10 - TUBE MILLS


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7

FIGURE 11 - INTERCONNECTION DIAGRAM


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8

FIGURE 12 - MSP40 CROSS-SLIDE MOUNTING DIMENSIONS


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9

FIGURE 13 - MSP250 CROSS-SLIDE MOUNTING DIMENSIONS


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10

FIGURE 14 - MSP450 5 X 5 CROSS-SLIDE MOUNTING DIMENSIONS


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11

FIGURE 15 - MSP450 10 X 10 CROSS-SLIDE MOUNTING DIMENSIONS


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12

FIGURE 16 - 9660S AND 9660P CONTROL MOUNTING DIMENSIONS


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13

FIGURE 17 - 9660S-100 AND 9660P-100 PENDANT MOUNTING DIMENSIONS


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14

FIGURE 18 - OMNI-GUIDE SENSOR MOUNTING (STD. BRACKET)

FIGURE 19 - OMNI-GUIDE SENSOR MOUNTING (UNIV. BRACKET)


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15

FIGURE 20 - VERTICAL FORCE ADJUSTMENTS


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16

FIGURE 21 - TORCH CLAMP MOUNTING BRACKET


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17

FIGURE 22 - UNIVERSAL MOUNTING BRACKET

FIGURE 23 - OPT. U-BRACKET MOUNTING BRACKET (TST40)


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18

FIGURE 24 - SIDE VIEW, MSP40

FIGURE 25 - SIDE VIEW, MSP250

AInches 6 7 8 9

Wlbs. 40 30 20 10

BInches 6 7 8 9

CInches 3 3.5 4 4.5

DInches 2 2 2 2

TABLE 11 - MSP40 LOAD SPECIFICATIONS

AInches 12 16 20 24

Wlbs. 250 190 130 70

BInches 12 16 20 24

CInches 4 4 4 4

DInches 3 3 3 3

TABLE 12 - MSP250 LOAD SPECIFICATIONS

FIGURE 26 - LOAD SPECIFICA-TIONS ENVELOPE TOP VIEW

NOTE

1> CenterofGravity(CG)ofload(W)tobewithinenvelope.

2> ST600BLoadRatingsdeterminedwiththeloweraxisposi-tioned horizontallyandupperaxispositionedvertically.


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OPERATION

DRIVE CABLE

Thedrivecable connectsthecross-slideassemblytothecontrolunit.Itisusedtotransmitsignalsand

powerbetweentheunits.Thestandarddrivecableis10feetlong(forlongerlengths,consultourfactory).

CROSS-SLIDE ASSEMBLY

Theseamtrackercross-slideassembliesarelightweightcompactdesignsconsistingoftwomotorizedlinearslidesmountedatrightanglestoprovideX-Yaxispositioning.Guidancealongeachaxisisaccom-

plishedthroughtheuseofballbearing vee wheelsrid-ingonhardenedsteeltrackswhichareinturnmountedtothickwallaluminumchannelsectionsformingthebasicstructure.

Wheelsandtracksarefactoryadjustedtoremoveplayandprovidesmoothuniformmotionalongthefullstroke.A DCgearmotorcoupledtoadrivescrewpro-

videslinearmotionalongeachaxis.Thedrivescrewsareballbearingmounted,andarespeciallycon-structedtofreewheelattheendoftravelineachdi-rection.Thispreventsdamageshouldtheunitreachtheendofstrokeandeliminatestheneedforlimitswitches.

Seamtrackermodelnumbersindicatetheacceptableloadratingofthecross-slideassembly,e.g.,MSP40isratedat40lbs.Load(see Table1-TST40SystemSpecifications and Table12-MSP250LoadSpecifications, beginningonpage 2).

TheMSP250Bcrossslidehasabrakemountedonverticalaxismotorshaftatthetopoftheslideassem-

bly.Withpowerremovedeitherbyswitchingpoweroffordisconnectingthecontrolcable,thebrakeisen-gagedandpreventscreepintheslideswhenheavyloadsareapplied.

Electricalconnectionsaremadeatthejunctionboxorthemotorcovermountedtothelowerslidedependingonthemodel.ConnectorsareprovidedforattachingthecontrolandOmni-GuideSensorcablestotheslideassembly.

Anadapterplateisfurnishedwhichmountstothefaceplateofthecross-slides.Insulationisprovided

betweenthefaceplateandadapterplateaswellasontheOmni-GuideSensormounttopermitmountingofelectrically"hot"torchesorweldheadswithoutdan-gerofelectricalcurrentsshortingtothedriveunitorworkpiece.Holescanbeaddedtotheadapterplateformountingwirefeeder,weldhead,torch,wirespool,etc.TorchclampbracketsarefurnishedtomounttheOmni-GuideSensorintheproperpositionrelativetothetorchandseam.Optionalmounting

bracketry isalsoavailableoncertainmodels.

OMNI-GUIDE SENSOR AND ACCESSORIES

TheJetlineEngineeringOmni-GuideSensorAssem-blyisatwo-axissensingdevice.Whenconnectedtotheappropriatecontrolelectronics,deflectionofthe

pivotedrodendresultsinanelectricalsignalpropor-tionaltotheamountofdeflectionfromasetnullposi-tion.Bycausingtheendoftherodtorideinagrooveoralongtheedgeofaworkpiece,thepositionofthematerialtobeweldedcanbeindicated.SignalsfromtheOmni-GuideSensoraretranslatedbythecontrolunitwhichinturnprovidesdrivesignalstothemotorsontheslides,thuskeepingtheweldheadpositioned

properlyrelativetotheseam.

A standard1/8"diameterroundendtipandtipexten-sionareprovidedwitheachunit.Otherstandardtipsareavailableforapplicationsonmostweldjointcon-figurations.Someofthesetipsareshownin Figure3-Omni-GuideSensorTips onpage 4,alongwithase-lectiontableforstandardtipsin Table3-Omni-GuideSensorTipsPartsList onpage 4.

Theballstyletipshaveacobaltsteelballatthetipend.A shieldedOmni-GuideSensorcable,4'lengthis

providedforsysteminterconnection.

Principle ofOperation

TheOmni-GuideSensorrodendisspringloadedtoprovidecenteringaboutanullpositioninthehorizon-taldirectionandatthesametimeforcetheroddowntowardtheworkpieceintheverticaldirection.

A flatgroovelengthwisealongthecylindricaloutercaseoftheOmni-GuideSensorprovidesorientationandistobepositionedawayfromtheworkpiece.

Twoadditionalgroovesareprovidedforspecialappli-cations(see Figure18-Omni-GuideSensorMount-ing(Std.Bracket) onpage 14).

ThesensingdeviceusedintheJetlineEngineeringOmni-GuideSensorisdesignedforruggednessandsimplicityofoperation.Itconsistsofatwo-axisvari-ablereluctancesensorwhichisfullyencapsulatedintheendhousingofthesensor.Movementsofamag-neticcouplingblockontheendofthesensorrodcausesanelectricalimbalanceinthesensorcoils,re-sultinginanindicationofroddeflectionfromthenull

position.Thisuniqueapproachrequiresnomechani-calcontactbetweenthesensorrodandthecontrolcir-

cuitry,thustheunitisruggedandresistanttowearordamagefromnormaluse.

5-AXIS MOUNT

The5-axismountsupportsandpositionstheOmni-GuideSensorrelativetotheweldtorch.Itin-cludesamanualcross-slideassemblyandaninsulatedarmassembly.Themanualcross-slidesallowfinepo-sitioningovera1.5inchrangeintheverticalandhori-zontalaxes.TheinsulatedarmassemblyclampstheOmni-GuideSensorandpermitsadjustmentofitsan-

9660SERIESSEAMTRACKERCONTROLLER OPERATION

19


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gularorientationtotheweldtorchinthreedifferentplanes.

NOTE

Specialnon-standard5-axismountsofupto6

inchesinstrokelengtharealsoavailable.

CONTROL PENDANT AND CABLE ASSEMBLY

Thestandardcontrolpendanthastwosealedrockerswitchesandonesealedjoystickswitchmountedinanaluminumhousingsuitableforhandheldormountedoperation.Theswitchesare:RockerSwitches

MODE (Manual/Automatic)

SIDETRACK (Left/Off/Right)

JoystickSwitch

MANUAL (Up/Down) and (Left/Right)

Thecontrolpendantconnectstothecontrolunitwith

a10footstandardcableattached.

SPECIAL LENGTH CABLE ASSEMBLIES

Speciallengthcablesandextensioncablescanbemadetoorderforthecontrolpendanttothecontrolunitinlengthsto60feetandforthecross-slideas-semblytothecontrolunitupto95feet.

NOTE

Longlength,non-standardcablesnormallyre-

quireheaviergaugeconductorstoreducevolt-

agedrop.Consultfactorybeforemakingcable

lengthchangesfromstandardassystemperfor-mancemaybeaffected.

STANDARD OPTIONS

Severalstandardoptionsareavailableforusewithstandardseamtrackersystems.Theseoptionsincludeelectronicfeaturesforspecialweldingoperationcon-trolsandothermechanicaloptions(e.g.,RotaryTableBracketillustratedin Figure57-RotaryTableBracket onpage 80)toenhancethesystemperfor-manceandadaptability.TheseoptionsaredescribedintheOptionalEquipment section.

TIP SELECTION GUIDEThesetipsareusedformostconventionalfilletandV-Groovejoints.Smalldiameterballsaregenerallyutilizedonthinmachinecutpartswithouttacksorspatter.Largerdiametersaregenerallyutilizedonroughercutpartstoallowsmoothermovementovergrooves,multipasswelds,tacks,splatter,etc.Exam-

plesofthesetipsandapplicationsareillustratedinFigures 3, 4, 5, 6, 7, 8, 9 and 10 beginningonpage 4.

OPERATION 9660SERIESSEAMTRACKERCONTROLLER

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21


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OMNI-GUIDE SENSOR TIPS

Omni-GuideSensortipsareinstalledandremovedbytighteningorlooseningthesetscrewsinthetips.TheOmni-GuideSensorrodorextensionrodshouldbefullyinsertedintothetipforproperinstallation.

OMNI-GUIDE SENSOR VERTICAL SPRING

FORCE ADJUSTMENTCyclomaticOmni-GuideSensor'sareequippedwithafeaturetoallowmechanicaladjustmentofverticalspringforce.Thisfeatureisusefulforoptimizingop-erationinvariousweldingapplications.

OnthesideoftheOmni-GuideSensorcaseoppositethekey-waygrooveisaslotapproximatelyoneinchlong.Inthisslotisa panhead screw,whichwhenloosenedturncanbemovedtovariouspositionsintheslot.ThelocationofthisscrewdeterminestheamountofverticalforcethattheOmni-GuideSensorexertsonthework-pieceduringtracking.Movethescrewawayfromtherodendandtowardtheconnec-

tortoachievemaximumspringforce(Figure20-Ver-ticalForceAdjustments onpage 15).Movethescrewtowardtherodendtoachieveminimumspringforce.Varyingdegreesofforceoccuratintermediateposi-tionsbetweenthetwoextremes.

IMPORTANT

Re-tightenthescrewoncetheproperad-

justmenthasbeenmade.

Minimumforceisrecommendedwhenside-trackingacrossawork-piecesurfaceoccurs.ThedragonthetipisminimizedandtheOmni-GuideSensor

willmoveatamoreuniformspeedandisnotlikelytostopprematurelyduetoroughnessorfrictionoftheworksurface.

MaximumforceissuggestedwhentrackingVgroovesathighratesofspeedorwhenthegrooveisshallowandnotwelldefined.Theincreasedpressure

providesmoretrackingforceinthedownwarddirec-tion.

OMNI-GUIDE SENSORS AND 5-AXIS MOUNTASSEMBLY

ThestandardTST250modelisfurnishedwithatorch

clampmountingbracketdesignedtofitmostweldtorchesandgivepropermountingfortheOmni-GuideSensor5-axismount. Figure21-TorchClampMountingBracket onpage 16 illustratesatypicalmountingwiththetorchclampbracketattachedtothe

barrelofthetorch.

AnoptionaluniversalbracketisalsoavailablefortheTST250.Designedforamultitudeofconfigurationstofitmostweldheads,thesebracketscanbeextendedtoseveralpositionsaswellasreversed, Figure19-

Omni-GuideSensorMounting(Univ.Bracket) onpage 14 illustratestypicalmounting.Thestandard ST40modelisfurnishedwitha"U"shapedmetalbracketformountingtheOmni-GuideSensormanualslideassembly.A setofVclampsis

providedforclampingatorchbarrel.Severalholepat-ternsareprovidedforalternatemounting.Theadapter

plateonthe ST40maybeinvertedtoprovideanaddi-

tionalconfiguration.Themounting bracketry usedontheTST250canalsobeusedonmodelTST40,ifre-quired.

CONTROL PENDANT INSTALLATION

Theseamtrackercontrolpendantisconstructedfromaruggedsteelhousingwithmountingbrackets(seeFigure17-9660S-100and9660P-100PendantMountingDimensions onpage 13).Thecontrol

pendanthasastandardcablelengthof10feet.Specialcablelengthsareavailableuponrequest.

Completecontroloftheseamtrackersystemisachievedthroughthesealedrockerswitcheswhichareinthecoverofthecontrolpendant.Manualoperationoftheverticalandhorizontalaxes,sidetracktotherightorleftandautomaticcontrol,aswellasthePTST ProgrammingOptionplug-infortheSeamTracker,arehandledwiththecontrolpendantassembly.

CONTROL UNIT INSTALLATION

Onpage 12, Figure16-9660Sand9660P ControlMountingDimensions showsthesizeandlocationofholesformountingthecontrolunitintheproperposi-tion.Itshouldbelocatedforreadyaccesstothe

powerswitchandallowclearanceforopeningthe

hingeddoor.Thisallowsforinspection,replacementofpartsorinstallationoftheAdvancedProgrammingControlcomponents,whennecessary.

Anotherimportantconsiderationistomakecertainthatthecontrolunithasunrestrictedairflowoverthecoolingfinstoassureadequatecoolingduringopera-tion.

A chassisgroundlugislocatednearthepowercord/RFI Filterconnection.Caremustbetakenthatthisbeconnectedtoasolidearthground(ProtectiveEarthorPE)inahighnoiseenvironment.AllsystemcomponentsexcepttheOmni-GuideSensorandcon-trolpendantareconnectedtochassisgroundthroughcableshields.

WELD HEAD INSTALLATION

Weldheadinstallationismadebyboltingtheweldheadtothecross-slideassemblyadapterplate.This

platecanhaveadditionalholesdrilledtoaccommo-datetheusersweldhead,asrequired.Theusermustensurethatanyaddedholesorholepatternspermit

properorientationoftheweldheadandtorchaxistothedriveaxis.Review Figure11-Interconnection

INSTALLATION 9660SERIESSEAMTRACKERCONTROLLER

22


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Diagram onpage 7 and Figure19-Omni-GuideSen-sorMounting(Univ.Bracket) onpage 14 priortoas-semblyoftheweldheadtotheadapterplate,and

beforedrillinganyadditionalholes.

SYSTEM INTERCONNECTION

Oncethecross-slideassemblyandcontrolunitareproperlymounted,thecablescanbeconnectedforop-eration.Onpage 12, Figure16-9660Sand9660PControlMountingDimensions showsconnectorar-rangementonthecontrolunit.Connectthecontrol

pendanttoJ1onthecontrolunit.Thedrivecable con-nectstoJ2.

NOTE

ModelST40drivecable ispermanently

attachedtotheslideassembly.Onall

othermodelsitisaseparatecableassem-

blywhichalsohasaconnectoratthe

slide.

Additionalconnectorsmaybeusedinconjunctionwithvariousoptionstoproviderelayswitchingforre-moteinitiationofweldingpower,carriage,travel,etc.Theseconnectorsmountintheprovidedblankpanelwhenused(seeAdvancedProgrammingControl).

TheOmni-GuideSensorcableassemblyconnectstheOmni-GuideSensortothejunctionboxorconnectoronthecross-slideassembly.Referto Figure11-In-terconnectionDiagram onpage 7,whichillustrates

typicalsysteminterconnection.

WARNING

Foryourownsafetyandtoensureproperoperationofthisequipment,readthisman-ualandalloperatingprecautionsbeforeop-eratingtheequipment.

a)ReadthisentireOperator'sManual

priortooperationoftheJetlineEngi-

neeringSeamTrackerSystem.

b)Besurethatadequateeyeprotectionandven-

tilationisprovidedinthevicinityofthewelding

area.

Besurethatallinsulatorsandprotectivecovers

onthetorchandtorchleadconnectionsarein

place.

Withthepoweroff,checkthefollowingconnectionsontheseamtrackersystem:

Control Unit to Cross-Slides

Cross-Slides to Omni-Guide Sensor

Control Pendant

Insurethatallareproperlyinstalledpriortoapplyingpowertothecontrolunit.Insureallcablesareofadequatelengthandclearof

movingpartstopreventpossibledamageduringoperation.

DURING OPERATION

Keepfingers,hands,etc.awayfromthecross-slidesduringoperationoftheseamtracker.

NOTE

Whenunitisonandinmanualmode,

downwarddriftmayoccurunderheavy

loadconditions.Directionsforcorrecting

thisconditioncanbefoundintheTROUBLE-

SHOOTINGsection.

DURING MECHANICAL ADJUSTMENTS

EnsurethattheACpowerisdisconnectedfrom

thecontrolunittopreventpossibleshockwhen

adjustingthecontrolunit,andaccidentalopera-

tionofmovingpartsbeingadjusted.

DURING ELECTRICAL ADJUSTMENTS

Donotdisconnectconnectorsorremovecircuit

boardswhenthepowerisconnectedatthecon-

trolunit.

9660SERIESSEAMTRACKERCONTROLLER INSTALLATION

23


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INITIAL SET-UP INSTRUCTIONS

Totakefulladvantageofseamtrackerstrokecapabil-ity,thecross-slideassemblyshouldbepositionedatthecenterofbothhorizontalandverticalstrokes.Weldtorchmountingshouldbesuchthatitisapproxi-matelyinitsnominalweldingpositionrelativetotheweldjoint.Thisthenallowsforerrorcompensationinalldirectionsduringwelding.Thereareexceptionstothis,however.

Forexample,youmaywantthemajorityoftheverti-calstroketobeavailableformanuallydrivingtheslidesupwardandclearofthepartafterweldingforinspection,partremovalandinsertionofanewpart.WhenmountingtheOmni-GuideSensorandits

bracketry ,adjustthebracketsandmountinghardwaretopositiontheOmni-GuideSensorintheproperrela-tionshiptothetorch(see Figure18-Omni-GuideSensorMounting(Std.Bracket) and Figure19-Omni-GuideSensorMounting(Univ.Bracket) begin-ningonpage 14).KeepthemanualOmni-GuideSen-sorcross-slidesatapproximatelytheircenterpositiontopermitfineadjustmentlater.

CertainweldjointconfigurationswillrequireuseoftheSidetrackfeatureoftheseamtrackersystem.Thesidetrackingforcerequiredshouldbesetupatthistime.FollowtheinstructionsunderOperatingSequence,page 24,toplacetheOmni-GuideSensorinposition.

Operating Sequence

Work Engagement Sequence

TheuserinsuresthattheSeamTrackerSystemhasbeenproperlyinstalledandtheinitialset-uphasbeenmade.Next,ACpowerisconnectedtothecontrolunit.ThecontrolunitpowerswitchisturnedCW totheONposition.TheSwitchLampshouldturnOn,indicatingthatthesystemisreadyforoperation(ifthelightisnoton,refertotheTroubleshootingSectionlaterinthismanual).

TheusercannowoperatetheSeamTrackerSystemmanuallyaccordingtotheinstructionsinthismanual.Reviewtheseinstructionsbeforeallowingtheseamtracker/sensortotouchtheworkand/orbegintrackingtheseam.Thenproceedasfollows:

Manually drive the vertical axis down until theOmni-Guide Sensor contacts the work and its rod isapproximately parallel to the case (vertical null).

Adjust the manual Omni-Guide Sensor cross-slides sothat the torch arc gap is in its approximate desired po-sition.

Insure the Sidetrack switch is in the desired position, ifnecessary.

Switch from MAN to AUTO at the control pendant,the Omni-Guide Sensor will now seek its true null au-tomatically.

Fine adjustments can now be made using the manualOmni-Guide Sensor cross-slides to attain finalcross-seam and arc gap positions.

The unit is now ready for operation under weld condi-tions.

Theusermustnowconsidertheweldtobemade,thenselectthesystemtooperateinoneoftwomodes,

manualorautomatic.Manual Operations

Manualoperationsarecontrolledbytheuseratthecontrolpendant.Theuserselectsthismodebypush-ingtheMANsideoftheMODEswitch.Thisactionallowstheusertobeabletomovethecross-slideassemblytoadesiredpositionbyuseofthejoystickswitchonthependantassembly.

Theseswitchesaremomentaryswitchesandwillcausetheindicatedmovementtooccuronlywhende-

pressedandheld.Releaseoftheswitchcausesthemovementtostop.

TheSidetrackswitchisnotactiveduringmanualop-erations.

Automatic Operations

Automaticoperationsarealsoselectedbytheuseratthecontrolpendant.Thismodeisengagedbydepress-ingtheAUTOsideoftheMODEswitch.Auto-matictrackingoperationsaredirectedbythecontrolunitasitrespondstosignalsfromtheOmni-GuideSensorandthetypeofjoint beingtracked.

TheSidetrackswitchselectsthetrackingmode.ThesemodesareLEFT,OFF,andRIGHT Sidetrackmodes.

LEFT andRIGHT modescauseaconstanttrackingpressuretobeexertedinthedirectionselected.TheOFFmodeisusedwhereneutralorequalsideforcesarerequired.

SidetrackForceAdjustment

AdjustmentofSidetrackForceispossiblethroughtheuseoftheadjustmentpotentiometerontheSeamTrackerMainBoard(see Figure28-SidetrackForceAdjustment onpage 25)inthecontrolbox.Thisadjustmentvariesthepressuretotheleftorright,de-

pendingupontheSidetrackswitchposition.A CCWrotationoftheknobreducesthispressureandaCWrotationincreasesthepressure(see Figure28-Side-trackForceAdjustment onpage 25).


24


43/148

9660SERIESSEAMTRACKERCONTROLLER INSTALLATION

25

FIGURE 27 - TRACKING DIAGRAM

FIGURE 28 - SIDETRACK FORCE ADJUSTMENT


44/148


26


45/148

MAINTENANCE

MAINTENANCE REQUIREMENTS

CyclomaticSeamTrackerSystemsaredesignedfortrouble-freeoperationandnormallyrequireonlymin-imalpreventivecareandcleaning.Thissectionofthe

usersmanualprovidesinstructionsformaintaininguserserviceableitems.Thesuggestedrepairproce-dureforalluserserviceableitemsistoremoveandre-

placedefectiveassembliesorparts.Servicepersonnelemployedbytheusershouldbefamiliarwithelectri-calandelectronicequipmentorelseserviceproblemsshouldbecorrectedbyfactoryauthorizedrepresenta-tives.

CONTROL UNIT ASSEMBLY

Thecontrolunitassembly(Figure35-9660SSeamTrackerControlExplodedView onpage 48)consistsofanenclosurehousingthemajorelectronicassem-

bliesoftheseamtrackersystem.Maintenanceisgen-

erallylimitedtoperiodicdustingoftheenclosure.Theusershouldensurethattheunitisnotoperatedwiththeaccessdooropenand/oroptionplatesandcableconnectormountingholesopen.Theusershouldexer-cisecautioninoperatingtheunitifithasbeeninad-vertentlyexposedtoexcessivedustorliquidcontamination,sincesuchconditionsmaycauseelec-tricalshortingand/ormalfunctioningoftheelectri-cal/electronicsassemblies.Theusershouldconsultwiththefactoryifsuchconditionshaveoccurred.Re-

pairofthecontrolunitassemblyisgenerallylimitedtoaremoveandreplaceoperation.

NOTE

Iftheusershoulddecidetorepairunau-

thorizeditems,thentheusershouldexer-

cisecautionwhenrepairingthecontrol

unitsubassembliesandprintedcircuit

boards,sincetheserepairscanvoidthewarranty.

WARNING

Whenrepairingthecontrolunitassembly,

disconnectA.C.powerfromtheunitbe-

foreopeningtheaccessdoorandturnthe

powerswitchtoOFF.

Assembliesandpartswhichareauthorizedforuserreplacementarelistedin Table19-9660SSeamTrackerControlPartsList onpage 49.Replacementshouldbeperformedaftertheuserhasdeterminedthatthepartorassemblytobereplacedisthecauseofasystemproblem(seeTroubleshootingonpage 65).

Replacementofthefusedoesnotrequireaccesstothehousinginterior;however,theblowingofthefusemayindicateothersystemproblems.Thefuseisre-

placedbyunscrewingthefuseholderlid,removing

andreplacingtheblownfusewithanewfuse.ThenrestorepowerandturnONsystemtoperformatestrun.

Replacementoftheprintedcircuitboard,theMainboard,involvesdisconnectingtheconnectorstotheboard,removingthemountingscrews,andreplacingtheMainboardwithanother.

TheservicepersonshouldexercisecareinremovingtheMainboardtoensurethatexcessiveforceisnot

placedontheconnectorsorcomponentsontheboardandthatthemountingscrewsarenotovertightened.

TheMainboardisheldbyeightscrewstostand-offsmountedintheenclosure.Disconnectallnecessarycablingattheconnectionplugsprovided.RemovethemountingscrewsandtheMainboard.InstallanotherMainboardandtightenthemountingscrewsuntilsnug;donotovertightenasdamagetotheboardandenclosurestandoffsmayresult.

ReplacementofHeatsinkassemblyisaccomplishedbytheremovalofsixscrewsandthedisconnectionoftheappropriateconnectors.Replacewithaworkingassembly.Individualtransistorsmaybereplacedbyremovingtwoscrewsandthedefectivepart(easiestiftheheatsinkisoutofthecontrolunit.)Thereplace-mentpartmaythenbeinstalledintheexistingsocket

provided,usingheatsinkcompound(ThermalCom-pound)onthetransistorstoensuregoodheattransfer.Securethereplacedtransistorswiththetwoscrews).

Replacementofotheruserserviceableitemsistobeperformedaccordingtonormalmaintenanceandre-pairstandards,usuallyinvolvingtheremovalof

mountinghardware,unpluggingtheoldunit,mount-ingthereplacementpartandreconnectingtheconnec-tors.

CONTROL PENDANT AND CABLE ASSEMBLY

Maintenanceofthecontrolpendantandcableassem-blyistoperiodicallyremovedust,soot,metalparti-cles,slag,etc.,fromthefaceplate.

Repairofthecontrolpendantandcableassemblyislimitedtoreplacementofdefectiveunits(see Figure36-9660S-100ControlPendantExplodedView on

page 50).A wiringdiagramincludescontrolpendant

schematicsfortroubleshootingpurposes(see Figure53-9660S-100PendantSchematic,StandardSeamTracker onpage 75).

CROSS-SLIDE ASSEMBLY

Thecross-slideassemblyshouldbemaintainedbype-riodicinspectionsforwornmovingparts(e.g.ballscrews,couplings,magneticbrakes).Furthermainte-nanceincludesremovingexcessdust,weldslag,soot,etc.,fromtheassemblies.Ifanyconnectorsorparts

9660SERIESSEAMTRACKERCONTROLLER MAINTENANCE

27


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aredamagedduringoperation,thedefectivepartsshouldbereplacedassoonaspractical.

Repairofthecross-slideislimitedtothereplacementofdefectivepartsandadjustmentofthe Dual-VeeGuideRailstoremoveplaybetweenwheelsandrails.Explodedviewsofthecross-slidesinFigures 32 and33 andtheirpartslistsinTables 14 and 15 arepro-

videdtoaidinpartsorderingandreplacementbegin-ningonpage 38.The Dual-Vee Guidesareadjustedbylooseningtheirretainingscrew,adjusting,andre-tighteningthescrews.

OMNI-GUIDE SENSOR ASSEMBLY

TheOmni-GuideSensorAssemblymayrequiread-justmentasnotedintheInstallationsectionunder Fig-ure20-VerticalForceAdjustments onpage 15 andintheOperationsectionunderInitialSetupInstructions.

Otherwisekeeptheunitfreeofdustandslag.TheOmni-GuideSensorAssemblyistoberemovedandreplacedonly.TheOmni-GuideSensorAssemblyisshowninanexplodedview Figure31-Omni-GuideSensorExplodedView withthepartslistsin Table13-Omni-GuideSensorPartsList beginningonpage 37forreference.

MOUNTING BRACKETS

Eachdriveunitisprovidedwithanadapterplateformountingtothefaceplate.Thisplateisfurnishedfordrillingtosuittherequirementsoftheintendedappli-cation.

IMPORTANT

Thefaceplateshouldnotberemoved,

drilledortapped,astheguidewheelsand

drivescrewunitarefactoryadjusted,and

thus,alignmentmaybeaffected.Usethe

adapterplateonlyformountingpurposes.

A bracketassemblyisfurnishedformountingthemanualslidesandincludesatorchclampbracketformountingtothebarreloftheweldingtorch.Thetwo-axismanualslidesandOmni-GuideSensorad-

justmentbracket,aswellastheOmni-GuideSensorAssembly,mounttothisbracket.TheMSP250crossslideassemblycanalsobeprovidedwithanoptionalUniversalMountingBracketdesignedtoaccommo-

dateawidevarietyofweld-headsandtorches.

TheTST40issuppliedwithaU-ShapedBracketKit.ProvisionsarealsomadeforusingthiskitonanTST250,ifdesired.

TheDrawingsandPartsListsareprovidedtoaidinpartsorderinginformationandforpartsreplacementforeachoftheseMountingBracketsbeginningon

page 59.

PREVENTIVE MAINTENANCE SCHEDULE

Thefollowingscheduleisprovidedtoassistinpre-formingtimelymaintenancetothesystemtomaintainoptimumperformancefromthesystem.

MonthlyMaintenance

Omni-GuideSensorAssembly

Proper Function

ThereshouldbespringtensionontheSensorRodthroughouttheentirehorizontaltravel.

Test

CleanslagandsplatterfromOmni-GuideSen-

sorsrod&tip.Noticethatthesensorrodis

sprungdownward.Withtheindexfingerand

thumb,graspthesensorrodandmoveitupward

slightlywhilekeepingslightupwardpressureon

thesensorrod,moveitleftandrightvery

slightlyandveryslowly.Ifthereisanyplayhorizontally(un-sprungmovement),the

Omni-GuideSensorAssemblyshouldbere-

pairedorreplaced.

NOTE

Therewillalwaysbespringtensionpressing

downwardontheOmni-GuideSensorsrod.

ProbeBracket Assembly

(BracketthatholdsOmni-GuideSensor)

Proper Function

Allowstheoperatortopositionthetorchovertheweldseam.Itshouldbesnug,enoughtoal-

lowtheoperatortopositionthetorchacrossthe

weldseambutwithoutplayinthebracketitself.

Noplayshouldexistinthebracket.

Test

Cleanthebrackettoremoveweldsplatterand

dust.GrasptheOmni-GuideSensorAssemblys

outercaseandtrytomoveitleft,up,rightand

down.Ifyoufeelplayinthebracket,trytopin-

pointwhichaxisitisin.Thereare3setscrews

oneachaxisbase,simplytightenthemuntilthereisntanyplay.

QuarterlyMaintenance

TorchBracket Assembly

Proper Function

Holdsthetorchfirmlytothecross-slideassem-

blyatthedesiredangle.

MAINTENANCE 9660SERIESSEAMTRACKERCONTROLLER

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Test

Cleandirtfrombracketandtorch.Checkthe

torchtobesureitisheldtight.Ifnot,tighten

boltsthatholdthetorchtothebracket.

Cables

Checkforproperinstallation.

Allcablesshouldbeconnectedtightlytothere-

spectivereceptacles.Besurethatthecablesdo

nothavesharpbendsinthemandthattheinsula-

tionofthecableisnotfrayedorcracked.

Pendant Assembly

Checkforproperfunction

Thependantassemblyshouldbeclean.

Maintenanceforthependantassemblysimply

involvescleaningdust,slag,etc.fromtheface

plate.Verifytheswitchfunctionnormallyand

thattheJoystickswitchreturnstoitscenter

postion.

Cross Slides

Proper Function

Verifythatthecross-slideassemblytravelsthe

fulllengthofitsstrokeoneachaxis.

Test

Checkforaxialplayoneachaxis.

Step # 1 - Center the Slides

Positionslidesinthecenteroftheirstrokes.Put

onehandonthemotorassembly(ontheleft

handslideofthehorizontal(lower)axisonmost

crossslides).Usingyourotherhand,pushthe

cross-slidesfaceplate/adaptorplatetowardthe

motorandthenpullitbackawayfromthemotor

assembly.Ifnoplayisfelt,goontostep#2.

Ifyoufeelanyplayontheloweraxis;noticethe

drivescrew;ifitmovesbackandforth(notspin-

ning),theassemblyneedsshimmed.

Step # 2 - Check for Play, Horizontal

Ifthedrivescrewdoesnotmovebackandforth,

trytospinthe dual-vee wheelswithouttheslide

moving.Iftheydonotspin,gotostep#3.

Ifboththewheelsdonotspinandthedrive

screwdoesnotmovebackandforthandthereis

stillplayintheloweraxis,thedrivescrewis

showingwearandmayneedtobereplaced.

Step # 3 - Check for Play, Vertical

Checkthevertical(upper)axis,usingthesame

procedurestartingwithStep#1.

Semi AnnualMaintenance

ControlUnit Assembly

Besurethecontrolunitisturnedoffandunplug.Usingclean,dryairblowoutdustfromtheinsideofthecontrolunit.

Besureallotherconnectionsinthecontrolunitareseatedfirmlyintheirreceptaclesandreconnectthe

powercordtoanelectricaloutlet.Turnpoweronandcheckforproperoperation.

OMNI-GUIDE SENSOR CALIBRATION PROCE-

DUREThisprocedurewilldescribethecalibrationtobeper-formedonallOmni-GuideSensorsformaintenance

purposes.

Tools Required

DigitalVolt-Meter(D.V.M.)capableofreading3placestotherightofthedecimalpoint.

TodeterminewhethercalibrationoftheOmni-GuideSensorisrequiredcanbedoneusingthestepsex-

plainedearlierinMonthlyMaintenancesectionofthePreventiveMaintenanceScheduleonpage 28.

Inaddition,calibrationcanberequired,ifduringop-eration,thecrossslidesdriftleftorrightwhiledrivingdownwardinsearchoftheseamwhenSidetrackisintheoffposition.

Omni-GuideSensor Interface Circuitry

Step # 1 - Power on the Control

TurnthePOWERSWITCHtotheONposition.

Let

theSeamTrackerwarmupfor15minutes.

Step # 2 - Connect the Calibration Tool

ConnecttheCalibrationTooltotheOmni-Guide

cable,ifavailable.

Step # 3 - Connect the D.V.M.

Connectthegroundleadofthedigitalvolt-meter

tothegroundtestpointTP11(GND)onthe

mainboardoftheseamtrackercontrol.(See

Figure29-SeamTrackerMainBoardLayout on

page 33.)Connectthepositiveleadofthedigi-


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talvolt-metertotheHorizontalProbetestpoint

TP10(HP)onthemainboard.

Step # 4 - Adjust Horizontal

Adjustthe trimpot labeledHA onmainboard

untilthedigitalvolt-meterreads.000VDC

.005VDC.

Omni-GuideSensorInterfacecircuitisnowcali-brated.

Step # 5 - Remove the Calibration Tool

DisconnecttheCalibrationToolfromthe

Omni-Guidecable.

Calibration Of TheOmni-GuideSensorAssem-bly

Step # 1 - Connect the Sensor

ConnecttheOmni-GuideSensorAssemblytobe

testedtothesensorcable.HoldtheOmni-GuideSensorsothatthegroovesarefacingtheupward

direction(12o'clock)duringtesting.

Step # 2 - Connect the D.V.M. to VP

MovethepositiveleadoftheDigitalVoltmeter

fromHorizontalProbe(HP)testpointtothe

VerticalProbe(VP)testpointonthemainboard.

Step # 3 - Verify Reading

Verifythatthedigitalvolt-meterreads+4 VDC

minimumintherestposition.

Step # 4 - Vertical Deflection Reading

Pushthelowerrodtowardtheupward(vertical

direction)andverifythatthedigitalvolt-meter

reads-4 VDC 1 VDC minimuminthevertical

direction.

Step # 5 - Vertical Check Complete

Thereisnoverticaladjustmentofthe

Omni-GuideSensorAssembly.Thistestchecks

forcorrectverticaloperationoftheOmni-Guide

SensorAssembly.

Step # 6 - Connect the D.V.M. to HP

Now,movethepositiveleadofthedigital

volt-meterbacktotheHorizontalProbe(HP)

testpointmainboard.

Step # 7 - Right Horizontal Deflection Reading

Push(deflect)theOmni-GuideSensorslower

rodbyhandinaslightlyupwardandhorizontal

rightdirectionandholdit.Thedigital

volt-metershouldread+4 VDC minimuminthis

direction.

Step # 8 - Left Horizontal Deflection Reading

DothesamethingasinStep#7,butdeflectthe

lowerrodinthefull,lefthorizontaldirection.

Thedigitalvolt-metershouldreada-4 VDC

minimuminthisdirection.

Step # 9 - Verify Mechanical and Electrical Null

Push(deflect)andreleasethelowerrodina

slightlyupwardandfullhorizontalrightdirec-

tionandletthelowerrodoftheOmni-Guide

Sensorsettle.Thereadingonthedigital

volt-metershouldbebetween0 VDC and+.050

VDC withtherodatrest.Preformthesame

lowerroddeflectionasabove,butintheoppo-

sitehorizontaldirection--left.Thereadingon

thedigitalvolt-metershouldbebetween0 VDC

and-.050 VDC withtherodatrest.

Step # 10 - Adjusting the Sensors Mechanical Null

Ifthevolt-meterreadingismorethan.050V

from0ineitherdirection,thentheOmni-Guide

Sensormustbecenteredinthehorizontalaxis.

Thisisaccomplishedbyturningtheadjusting

screwinsidetheOmni-GuideSensorAssembly

(SeeItem#31in Figure31-Omni-GuideSen-

sorExplodedView).Theadjustingscrewisac-

cessiblethroughaholeinthecaseandcanbe

turnedwith3/32"hexkey.A setscrewisin-

sertedintotheaccessholeandcanberemoved

witha1/8"hexkey;setscrewpreventsdustand

dirtfromgettingintotheinternalpartsofthe

Omni-GuideSensorAssembly.

Step # 11 - Adjust the Sensors Horizontal Null

Tocenterthehorizontalaxis,performthefol-

lowing:

Push the lower rod vertically until the adjusting screwcan be reached with the hex key.

Turn the adjusting screw slightly and remove the hex

key.

Push and release rod, as in Step # 9, in both directions.Observe the digital volt-meter reading when the rodreturns to its rest position. The voltage reading cannotexceed .050VDC in either direction (+ or -).

Repeat the above steps until the readings are achieved.Replace setscrew using a thread locking compound to

prevent the setscrew from becoming loose.

EndofCalibration.


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SERVO AMPLIFIER CIRCUITRY CALIBRATION

Thisproceduredescribesthecalibrationtechniquesneededtoforregularmaintenance.Thisisusefulandmaybecomenecessarytoperformwhenamotororheatsinktransistorisreplaced.Whenthesecompo-nentsarereplacedduringtroubleshootingorregularmaintenance,thefeedbacktothiscircuitryalsochanges,makingthiscalibrationnecessary.

Tolls Required

DigitalVolt-Meter(D.V.M.)capableofreading3placestotherightofthedecimalpoint.

Oscilloscope

Step # 1 - Adjust HI and VI Full Clock-Wise

AdjusttheServoAmplifierCircuitrytrim-pots

HorizontalCurrent(HI)andVerticalCurrent

(VI)fullClock-Wise.

Step # 2 - Monitor TP4 and TP8

Monitorthe+15 VDC (TP4)and-15VDC

(TP8)testpointsonmainboardwithadigital

volt-metertoverifyvoltageinandoutofServo

AmplifierCircuitryonthemainboard.Usetest

pointTP11(GND)asreferenceforthe

volt-meter.

Step # 3 - Connect the Oscilloscope to TP2

ConnectanoscilloscopetotheVerticalError

(VE)testpointmainboard,TP2.


Observeonoscilloscopeapproximate0 VDC.

Step # 5 - Adjust VI Trimpot Counter Clock-Wise

AdjusttheVerticalCurrent(VI)Trim-potCoun-

terClock-Wise(CCW)untilsignalontheoscil-

loscopebeginstooscillate.

Step # 6 - Adjust VI Trimpot Clock-Wise

SlowlyadjusttheVerticalCurrent(VI)Trim-pot

Clock-Wise(CW)untiltheoscillationjuststops,

thenadjustthetrim-potCW anadditionalfour

(4)turns.


Onthependant,movethejoystickswitchupand

observetheverticalslidemovingupandobserve

onoscilloscopeapproximately+15 VDC.

NOTE

Someripplemaybeseen,thisistypical

Step # 8 - Repeat Step 7

PerformthesamefunctionasinStep#7,

butonlyinthedownpositiononthejoy-

stick.Observetheverticalslidemoves

downandobserveontheoscilloscope,

approximately-15 VDC.

NOTE

Someripplemaybeseen,thisistypical.

Step # 9 - Verify Reading and No Movement

Releasethejoystickonthependantandobserve

approximately0 VDC ontheoscilloscopeand

observeonthecross-slides,nodrivemovement.

Step # 10 - Connect the Oscilloscope to TP1

ConnectanoscilloscopetotheHorizontalError

(HE)testpointonthemainboard,TP1andob-serveapproximately0 VDC.

Step # 11 - Adjust HI trimpot Counter Clock-Wise

AdjusttheHorizontalCurrent(HI)Trim-pot

CounterClock-Wise(CAW)untilsignalonthe

oscilloscopebeginstooscillate.

Step # 12 - Adjust HI Trimpot Clock-Wise

SlowlyadjusttheHorizontalCurrent(HI)

Trim-potClock-Wise(CW)untiltheoscillation

juststops,thenadjustthetrim-potCW anaddi-

tionalfour(4)turns.


Onthependant,movethejoystickswitch

rightandobservethehorizontalslide

moverightandobserveontheoscilloscopeob-

serveapproximately+15 VDC.

NOTE


Step # 14 - Repeat Step 13

PerformthesamefunctionasinStep#

13,butonlyintheleftpositiononthejoystick.

Observeontheoscilloscopeapproximately-15

VDC andobservethehorizontalslidemovingto

theleft.

NOTE



31


50/148

Step # 15 - Verify Reading and No Movement

Releasethejoystickonthependantandobserve

approximately0 VDC ontheoscilloscopeand

observeonthecross-slides,nodrivemovement.

ThiscompletestheServoAmplifierCircuitryonthemainboard.


32


51/148

DRAWINGS AND PARTS LISTS

9660SERIESSEAMTRACKERCONTROLLER DRAWINGSANDPARTSLISTS

33

FIGURE 29 - SEAM TRACKER MAIN BOARD LAYOUT


52/148

34

DRAWINGSANDPARTSLISTS 9660SERIESSEAMTRACKERCONTROLLER

0

1

2

34 5

6

7

8

9

SIDETRACK FORCEADJUSTMENT

P/N 1101-2002-3 Rev.

P/N 1101-2002-31 Rev. A 3/2002

Assembly

Board

Seam Tracker Main Board

TP8

-15v

TP11

GND

TP5

+6v TP6

VP

TP10

HP

TP2

VE

TP1

HE

BIAS CAL.

SidetrackAdjustment

Potentiometer

FIGURE 30 - SIDETRACK FORCE ADJUSTMENT


53/148


35


54/148

36


FIGURE 31 - OMNI-GUIDE SENSOR EXPLODED VIEW


55/148


37

Item

No.QPA UM

Part

No.Description

1 2.000 EA 970010-100 SCREW,2-56X.12CR1F SBZ

2 1.000 EA 1110-1119 OUTERCASE

3 1.000 EA 2360-1109 PINROLL.0938 DIA X.750LG

4 1.000 EA 1106-0811 SHORTINGBAR ASSY

5 2.000 EA 970004-101 SCR 2-56X.19CR1P SSP

6 1.000 EA 1110-1194 COLLAR

7 1.000 EA 970043-001 SCREW,SET,1/4-28X.19 HHC SBZ

8 4.000 EA 1116-0484 SETSCREWPIVOT

8 AR EA 3070-0082 TORQUESEAL

9 1.000 EA 1110-1062 SHIELD,Omni-GuideSensor

10 1.000 EA 979006-375 RING RTNG EXTERNALSHAFT.375

12 1.000 EA 1110-2093 INSULATOR,OMNIGUIDE

14 1.000 EA 1110-1054 LOWERROD

16 2.000 EA 2360-0404 SPRINGEXT.(HORIZ AXIS)

17 1.000 EA 1110-1208 SUPPORT,LEVERARM

18 4.000 EA 970000-201 SCREW,4-40X.19CR1P SBZ

19 3.000 EA 970000-102 SCREW,4-40X.25CR1P SBZ

20 1.000 EA 1106-0838 SENSORMODULE

21 2.000 EA 970000-202 SCREW,4-40X.25CR1P SBZ

22 1.000 EA 1110-1046 SHIELDCONNECTOR

23 1.000 EA 1110-1216 ARMLEVER

24 1.000 EA 1110-1224 ARMLEVER

25 1.000 EA 1110-2387 POSTSPRING

26 1.000 EA 1110-2441 RODUPPER

26 1.000 EA 1110-2417 SLEEVESHORTINGBAR

27 1.000 EA 1110-1232 SLIDEADJUSTING

28 1.000 EA 1110-1241 PINELLIPTICALADJUST

29 1.000 EA 1110-1071 BEARINGSLIDE

30 4.000 EA 2360-0030 SPHERE1/8INCHROMESTEELG25

31 1.000 EA 1116-0514 SCR 4-40X.75 HSC SBZ N

32 2.000 EA 2360-1117 PINDOWEL HRD .125X.500LG

33 1.000 EA 972014-001 NUT4-40HSSNL

34 1.000 EA 2360-0331 SPRING

35 1.000 EA 1106-3205 SPRINGSLIDE ASSY36 2.000 EA 1110-1101 CLAMPROD

37 1.000 EA 1110-1089 SLEEVE

38 2.000 EA 974000-002 WSR F#4.312X.125X.032 SBZ

TABLE 13 - OMNI-GUIDE SENSOR PARTS LIST


56/148

38


FIGURE 32 - MSP40 CROSS-SLIDE EXPLODED VIEW


57/148


39

Item

NoQPA UM

Part

No3X3

Part

No6X6Description

1 1.000 EA 1110-0007 1110-0066 BASEUPP-ST40

2 1.000 EA 1110-0015 1110-0074 BASE LWR ST40

3 2.000 EA 1110-2310 1110-2310 PLATEEND-ST40

4 4.000 EA 1116-0000 1116-0034 SEAMTRACKERRAIL -ST40

6 2.000 EA 1110-0121 1110-0155 BARRAIL ADJ

8 2.000 EA 1116-0042 1116-0077 ASSY SCR ACTR ST40

10 2.000 EA 1110-0180 1110-0091 COVERRETAINER-ST40

12 2.000 EA 1112-0008 1112-0016 COVERRETAINER

14 2.000 EA 1110-0198 1110-0198 BEARINGHOUSINGST40A

15 2.000 EA 1110-0210 1110-0210 NUT HOUSING-ST40A

16 1.000 EA 1110-0171 1110-0171 FACEPLATE-ST40

17 1.000 EA 1110-0236 1110-0236 ADAPTERPLATEST40

18 2.000 EA 1117-0587 1117-0587 MOTOR-ST40

19 4.000 EA 1116-0115 1116-0115 SET SCR HALFDOG-MOD

20 2.000 EA 1116-0107 1116-0107 COVERGEAR-ST40

21 1.000 EA 1106-0048 1106-0048 JUNCTIONBOX ASSY -ST40

22 4.000 EA 2000-0015 2000-0058 COVERTELESCOPING.50X1.0X3.5 STRK

24 8.000 EA 2360-0552 2360-0552 WHEEL GUIDEDUAL VEE #2

25

9660 Seam Tracker Manual Rev f

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