9660 seam tracker manual rev f
TRANSCRIPT
-
7/30/2019 9660 Seam Tracker Manual Rev f
1/148
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.
-
7/30/2019 9660 Seam Tracker Manual Rev f
2/148
-
7/30/2019 9660 Seam Tracker Manual Rev f
3/148
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.
-
7/30/2019 9660 Seam Tracker Manual Rev f
4/148
NOTICE
Theinstallation,operationandmaintenanceguidelinessetoutinthismanualwillenableyoutomaintaintheequipmentinpeakconditionandachievemaximumeffi-ciencywithyourweldingoperation.Pleasereadtheseinstructionscarefullytobecomeawareofeveryadvantage.
CAUTION
Onlyexperiencedpersonnelfamiliarwiththeoperationandsafepracticeofweldingequipment
shouldinstalland/orusethisequipment.
-
7/30/2019 9660 Seam Tracker Manual Rev f
5/148
-
7/30/2019 9660 Seam Tracker Manual Rev f
6/148
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
vi
OVERVIEW 9660SERIESSEAMTRACKERCONTROLLER
-
7/30/2019 9660 Seam Tracker Manual Rev f
7/148
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
9660SERIESSEAMTRACKERCONTROLLER TABLEOFCONTENTS
vii
-
7/30/2019 9660 Seam Tracker Manual Rev f
8/148
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
viii
TABLEOFCONTENTS 9660SERIESSEAMTRACKERCONTROLLER
-
7/30/2019 9660 Seam Tracker Manual Rev f
9/148
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
9660SERIESSEAMTRACKERCONTROLLER TABLEOFCONTENTS
ix
-
7/30/2019 9660 Seam Tracker Manual Rev f
10/148
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
Table16-MSP250Cross-SlidePartsList................................... 42
Table17-MSP450Cross-SlidePartsList................................... 45
Table18-MSP450Cross-SlidePartsList................................... 46
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
x
TABLEOFTABLES 9660SERIESSEAMTRACKERCONTROLLER
-
7/30/2019 9660 Seam Tracker Manual Rev f
11/148
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
9660SERIESSEAMTRACKERCONTROLLER TABLEOFTABLES
xi
-
7/30/2019 9660 Seam Tracker Manual Rev f
12/148
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
xii
TABLEOFFIGURES 9660SERIESSEAMTRACKERCONTROLLER
-
7/30/2019 9660 Seam Tracker Manual Rev f
13/148
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
9660SERIESSEAMTRACKERCONTROLLER TABLEOFFIGURES
xiii
-
7/30/2019 9660 Seam Tracker Manual Rev f
14/148
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
xiv
TABLEOFFIGURES 9660SERIESSEAMTRACKERCONTROLLER
-
7/30/2019 9660 Seam Tracker Manual Rev f
15/148
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.
9660SERIESSEAMTRACKERCONTROLLER SAFETY
xv
WARNING
-
7/30/2019 9660 Seam Tracker Manual Rev f
16/148
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.
SAFETY 9660SERIESSEAMTRACKERCONTROLLER
xvi
-
7/30/2019 9660 Seam Tracker Manual Rev f
17/148
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
9660SERIESSEAMTRACKERCONTROLLER SAFETY
xvii
-
7/30/2019 9660 Seam Tracker Manual Rev f
18/148
SAFETY 9660SERIESSEAMTRACKERCONTROLLER
xviii
-
7/30/2019 9660 Seam Tracker Manual Rev f
19/148
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
1
-
7/30/2019 9660 Seam Tracker Manual Rev f
20/148
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-
sionsforplug-inoptions
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
-
7/30/2019 9660 Seam Tracker Manual Rev f
21/148
9660SERIESSEAMTRACKERCONTROLLER DESCRIPTIONOFEQUIPMENT
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-
sionsforplug-inoptions
RemoteControlPendant Enclosure
Handheldormountedsteelenclosurecontaining
manualandautomatictrackingcontrolswithprovi-
sionsforplug-inoptions
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
-
7/30/2019 9660 Seam Tracker Manual Rev f
22/148
DESCRIPTIONOFEQUIPMENT 9660SERIESSEAMTRACKERCONTROLLER
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
-
7/30/2019 9660 Seam Tracker Manual Rev f
23/148
9660SERIESSEAMTRACKERCONTROLLER DESCRIPTIONOFEQUIPMENT
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
-
7/30/2019 9660 Seam Tracker Manual Rev f
24/148
DESCRIPTIONOFEQUIPMENT 9660SERIESSEAMTRACKERCONTROLLER
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
-
7/30/2019 9660 Seam Tracker Manual Rev f
25/148
9660SERIESSEAMTRACKERCONTROLLER DESCRIPTIONOFEQUIPMENT
7
FIGURE 11 - INTERCONNECTION DIAGRAM
-
7/30/2019 9660 Seam Tracker Manual Rev f
26/148
DESCRIPTIONOFEQUIPMENT 9660SERIESSEAMTRACKERCONTROLLER
8
FIGURE 12 - MSP40 CROSS-SLIDE MOUNTING DIMENSIONS
-
7/30/2019 9660 Seam Tracker Manual Rev f
27/148
9660SERIESSEAMTRACKERCONTROLLER DESCRIPTIONOFEQUIPMENT
9
FIGURE 13 - MSP250 CROSS-SLIDE MOUNTING DIMENSIONS
-
7/30/2019 9660 Seam Tracker Manual Rev f
28/148
DESCRIPTIONOFEQUIPMENT 9660SERIESSEAMTRACKERCONTROLLER
10
FIGURE 14 - MSP450 5 X 5 CROSS-SLIDE MOUNTING DIMENSIONS
-
7/30/2019 9660 Seam Tracker Manual Rev f
29/148
9660SERIESSEAMTRACKERCONTROLLER DESCRIPTIONOFEQUIPMENT
11
FIGURE 15 - MSP450 10 X 10 CROSS-SLIDE MOUNTING DIMENSIONS
-
7/30/2019 9660 Seam Tracker Manual Rev f
30/148
DESCRIPTIONOFEQUIPMENT 9660SERIESSEAMTRACKERCONTROLLER
12
FIGURE 16 - 9660S AND 9660P CONTROL MOUNTING DIMENSIONS
-
7/30/2019 9660 Seam Tracker Manual Rev f
31/148
9660SERIESSEAMTRACKERCONTROLLER DESCRIPTIONOFEQUIPMENT
13
FIGURE 17 - 9660S-100 AND 9660P-100 PENDANT MOUNTING DIMENSIONS
-
7/30/2019 9660 Seam Tracker Manual Rev f
32/148
DESCRIPTIONOFEQUIPMENT 9660SERIESSEAMTRACKERCONTROLLER
14
FIGURE 18 - OMNI-GUIDE SENSOR MOUNTING (STD. BRACKET)
FIGURE 19 - OMNI-GUIDE SENSOR MOUNTING (UNIV. BRACKET)
-
7/30/2019 9660 Seam Tracker Manual Rev f
33/148
9660SERIESSEAMTRACKERCONTROLLER DESCRIPTIONOFEQUIPMENT
15
FIGURE 20 - VERTICAL FORCE ADJUSTMENTS
-
7/30/2019 9660 Seam Tracker Manual Rev f
34/148
DESCRIPTIONOFEQUIPMENT 9660SERIESSEAMTRACKERCONTROLLER
16
FIGURE 21 - TORCH CLAMP MOUNTING BRACKET
-
7/30/2019 9660 Seam Tracker Manual Rev f
35/148
9660SERIESSEAMTRACKERCONTROLLER DESCRIPTIONOFEQUIPMENT
17
FIGURE 22 - UNIVERSAL MOUNTING BRACKET
FIGURE 23 - OPT. U-BRACKET MOUNTING BRACKET (TST40)
-
7/30/2019 9660 Seam Tracker Manual Rev f
36/148
DESCRIPTIONOFEQUIPMENT 9660SERIESSEAMTRACKERCONTROLLER
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.
-
7/30/2019 9660 Seam Tracker Manual Rev f
37/148
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
-
7/30/2019 9660 Seam Tracker Manual Rev f
38/148
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
20
-
7/30/2019 9660 Seam Tracker Manual Rev f
39/148
21
-
7/30/2019 9660 Seam Tracker Manual Rev f
40/148
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
-
7/30/2019 9660 Seam Tracker Manual Rev f
41/148
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
-
7/30/2019 9660 Seam Tracker Manual Rev f
42/148
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).
INSTALLATION 9660SERIESSEAMTRACKERCONTROLLER
24
-
7/30/2019 9660 Seam Tracker Manual Rev f
43/148
9660SERIESSEAMTRACKERCONTROLLER INSTALLATION
25
FIGURE 27 - TRACKING DIAGRAM
FIGURE 28 - SIDETRACK FORCE ADJUSTMENT
-
7/30/2019 9660 Seam Tracker Manual Rev f
44/148
INSTALLATION 9660SERIESSEAMTRACKERCONTROLLER
26
-
7/30/2019 9660 Seam Tracker Manual Rev f
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
-
7/30/2019 9660 Seam Tracker Manual Rev f
46/148
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
28
-
7/30/2019 9660 Seam Tracker Manual Rev f
47/148
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-
9660SERIESSEAMTRACKERCONTROLLER MAINTENANCE
29
-
7/30/2019 9660 Seam Tracker Manual Rev f
48/148
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.
MAINTENANCE 9660SERIESSEAMTRACKERCONTROLLER
30
-
7/30/2019 9660 Seam Tracker Manual Rev f
49/148
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.
Step # 4 - Verify Reading
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.
Step # 7 - Verify Reading
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.
Step # 13 - Verify Reading
Onthependant,movethejoystickswitch
rightandobservethehorizontalslide
moverightandobserveontheoscilloscopeob-
serveapproximately+15 VDC.
NOTE
Someripplemaybeseen,thisistypical.
Step # 14 - Repeat Step 13
PerformthesamefunctionasinStep#
13,butonlyintheleftpositiononthejoystick.
Observeontheoscilloscopeapproximately-15
VDC andobservethehorizontalslidemovingto
theleft.
NOTE
Someripplemaybeseen,thisistypical.
9660SERIESSEAMTRACKERCONTROLLER MAINTENANCE
31
-
7/30/2019 9660 Seam Tracker Manual Rev f
50/148
Step # 15 - Verify Reading and No Movement
Releasethejoystickonthependantandobserve
approximately0 VDC ontheoscilloscopeand
observeonthecross-slides,nodrivemovement.
ThiscompletestheServoAmplifierCircuitryonthemainboard.
MAINTENANCE 9660SERIESSEAMTRACKERCONTROLLER
32
-
7/30/2019 9660 Seam Tracker Manual Rev f
51/148
DRAWINGS AND PARTS LISTS
9660SERIESSEAMTRACKERCONTROLLER DRAWINGSANDPARTSLISTS
33
FIGURE 29 - SEAM TRACKER MAIN BOARD LAYOUT
-
7/30/2019 9660 Seam Tracker Manual Rev f
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
-
7/30/2019 9660 Seam Tracker Manual Rev f
53/148
9660SERIESSEAMTRACKERCONTROLLER DRAWINGSANDPARTSLISTS
35
-
7/30/2019 9660 Seam Tracker Manual Rev f
54/148
36
DRAWINGSANDPARTSLISTS 9660SERIESSEAMTRACKERCONTROLLER
FIGURE 31 - OMNI-GUIDE SENSOR EXPLODED VIEW
-
7/30/2019 9660 Seam Tracker Manual Rev f
55/148
9660SERIESSEAMTRACKERCONTROLLER DRAWINGSANDPARTSLISTS
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
-
7/30/2019 9660 Seam Tracker Manual Rev f
56/148
38
DRAWINGSANDPARTSLISTS 9660SERIESSEAMTRACKERCONTROLLER
FIGURE 32 - MSP40 CROSS-SLIDE EXPLODED VIEW
-
7/30/2019 9660 Seam Tracker Manual Rev f
57/148
9660SERIESSEAMTRACKERCONTROLLER DRAWINGSANDPARTSLISTS
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