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Jetline 9600 Series Operation Manual

Microprocessor controller
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OM-9629-04-2005
OPERATION MANUAL
for 9629
Microprocessor
Controller
April 2005
IMPORTANT
Read this manual carefully before installing,
commissioning or operating this product.
Jetline Engineering, 15 Goodyear Street, Irvine, CA 92618
Telephone: (949) 951-1515 • Fax: (949) 951-9237
Web Site:
www.jetline.com
• E-mail:
sales@jetline.com

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Summary of Contents for Jetline 9600 Series

  • Page 1 OPERATION MANUAL for 9629 Microprocessor Controller April 2005 IMPORTANT Read this manual carefully before installing, commissioning or operating this product. Jetline Engineering, 15 Goodyear Street, Irvine, CA 92618 Telephone: (949) 951-1515 • Fax: (949) 951-9237 Web Site: www.jetline.com • E-mail: sales@jetline.com...
  • Page 2 9629 Microprocessor Controller - 2 -...
  • Page 3 Jetline’s inspection confirms the existence of such defects. Jetline’s option of repair or replacement will be F.O.B. factory at Irvine, California, and therefore no compensation for transportation costs of any kind will be allowed.
  • Page 4 9629 Microprocessor Controller NOTICE The installation, operation and maintenance guidelines set out in this manual will enable you to maintain the equipment in peak condition and achieve maximum efficiency with your welding opera- tion. Please read these instructions carefully to become aware of every advantage. CAUTION Only experienced personnel familiar with the operation and safe practice of welding...

  • Page 5: Table Of Contents

    9629 Microprocessor Controller Table of Contents Section I Safety Precautions ......................7 A. Arc Welding ......................7 B. Electric Shock .......................7 C. Arc Rays ........................8 D. Fumes and gases ....................8 E. Cylinders .......................8 F. Welding .........................9 G. Moving Parts ......................9 H. EMF Information ....................9 I.
  • Page 6 9629 Microprocessor Controller - 6 -...

  • Page 7: Section I

    9629 Microprocessor Controller Section I. Safety Precautions Wear dry, hole-free insulating gloves and appropriate body protection. WARNING Disconnect input power before installing or servicing this equipment. Lockout/ta- gout input power according to OSHA 29 CALIFORNIA PROPOSITION 65 WARNING CFR 1910.147 (see Safety Standards). This product contains chemicals, including lead, Properly install and ground this equipment known to the state of California to cause cancer,...

  • Page 8: Arc Rays

    9629 Microprocessor Controller Arc Rays 3. If ventilation is poor, use an approved air- supplied respirator. Arc rays can burn eyes and skin; noise can Read the Material Safety Data Sheets damage hearing; flying slag or sparks can injure (MSDS) and the manufacturer’s instruction for eyes.

  • Page 9: Welding

    9629 Microprocessor Controller 3. Keep cylinders away from any welding or 4. Be alert that welding sparks and hot materials other electrical circuits. from welding can easily go through small cracks and openings to adjacent areas. 4. Never weld on a pressurized cylinder - ex- 5.

  • Page 10: Principal Safety Standards

    9629 Microprocessor Controller “..there is now a very large volume of scientific Principal Safety Standards findings based on experiments at the cellular level and from studies with animals and people Reference as applicable which clearly establish that low frequency magnetic fields can interact with, and produce Safety in Welding and Cutting, ANSI Standard changes in, biological systems.

  • Page 11: Introduction

    Setup Mode: of which have the same hardware design. Each 9600 series control is rendered unique by its This mode is used during the setting up of the own custom designed firmware to facilitate the unit.

  • Page 12: Section Iii Specifications

    9629 Microprocessor Controller Section III Specifications Applications For use with wire feed mechanisms: 9629 Used for standard cold wire feed- 8 ¾” (222mm) - CWF-10B - CWF-10B/4R 9629-0 Used for precision cold wire feeders ” Dia 8” - CWF-20C (8mm) (200mm) Connections: 9629-P...

  • Page 13: Section Iv Description

    9629 Microprocessor Controller Section IV Description The 9629 control is a microprocessor-based control designed for the control of wire feed, primarily for TIG and plasma welding. The WIRE SPEED 26.5ipm 9629 is one of a series of controls designed for ease-of-use and for accurate control of various ADJUST DOWN...

  • Page 14: Controls

    9629 Microprocessor Controller Section V. Controls Rapid Jog: This is achieved by pressing the forward or reverse touch pad for a short time, The push-button power switch is used releasing it and then quickly pressing it again. Wire feed will start and, after a short time, will to provide primary power to the 9629 control.

  • Page 15: Section Vi Modes Of Operation

    This screen allows a start delay to be set by turning the adjust knob to increase or decrease its value. As the change is made, the number on Jetline Engineering the display changes accordingly. (This feature is Model 9629 active only if remote start is used).
  • Page 16 9629 Microprocessor Controller Try different start delay times for yourself. the motor will reverse and travel at the wire retraction speed defined in the set-up mode The start delay time can be set from 0 to 99.9 (See Screen 11) for the length of time set in seconds.
  • Page 17 9629 Microprocessor Controller Screen 7 WIRE SPEED (Locked) adjust knob is turned clockwise and the upper limit of the parameter being adjusted has been reached. The message remains on the screen WIRE SPEED 40.ipm until the value of the parameter is reduced below Adjustment Locked the limit.
  • Page 18 9629 Microprocessor Controller Jog reverse as the touch pad is pressed. The message will remain on the screen as long as wire is feeding at this speed. WIRE SPEED 33.0ipm Jog Reverse Maintained forward Whenever the reverse jog touch pad is pressed, WIRE SPEED 150.0ipm the screen will display the message shown...
  • Page 19 9629 Microprocessor Controller Sensing delay Jogging can only take place when the control is displaying the travel speed screen (Screens 2 or 7). WIRE SPEED 40.0ipm ANYTIME MESSAGES Sensing Delay 0.8sec Emergency stop After the start delay has timed out, this message will be displayed (providing that the Closed WIRE SPEED 0.0ipm...

  • Page 20: Set-Up Mode

    9629 Microprocessor Controller Set-up Mode set by turning the adjust knob to increase or decrease its value. This mode is used to set up the various jog speeds and other functions. To enter the set up mode, As the change is made, the number on the display the following procedure must be followed: changes accordingly.
  • Page 21 9629 Microprocessor Controller The wire will retract at the retract speed when- The low speed should be set to a value high ever the wire stops feeding forward (excepting enough to avoid a ball being formed on the end during jog operations). of the wire during the pulse background time.

  • Page 22: Calibration Mode

    9629 Microprocessor Controller decrease its value. As the change is made, the Calibration Screens number on the display changes accordingly. Screen 17 CLOSED LOOP MODE The high pulse time can be set from 0.05 to 5.00 seconds. CLOSED LOOP MODE On Press the touch pad with the down arrow to proceed to the next screen.
  • Page 23 If this happens, contact Jetline acceleration time of the motor. It is recommend- to verify the correct speed to be entered in this ed to always allow a short time for the system to screen.
  • Page 24 If this happens, contact Jetline to Screen 23 TACH HIGH INPUT verify the correct speed to be entered.
  • Page 25 9629 Microprocessor Controller Screen 27 SET SPEED instructions on how to carry out calibration for maintenance purposes, refer to the calibration instructions in the maintenance section of this SET SPEED Remote manual. The low output can be set to a minimum number This screen permits the setting of the wire feed of 0.
  • Page 26 9629 Microprocessor Controller SCREEN 29 REMOTE LOW INPUT Screen 31 HOUR METER REMOTE LO INPUT 90 HOUR METER 1752hrs This screen indicates the number of hours that The Remote Low Input value represents the DC reference voltage value received by the control the wire feeder has been running.

  • Page 27: Section Vii Operational Sequence

    9629 Microprocessor Controller Section VII. Operational Sequence Remote Start/Stop Press START button Press STOP button Signal Wire Wire Wire Start Delay = 0 Wire Stop Delay = 0 Start Stop Delay Delay Wire Start Delay Wire Stop Delay greater than 0 greater than 0 Wire Start Delay Wire Stop Delay...

  • Page 28: Section Viii Mechanical Installation

    9629 Microprocessor Controller Section VIII. Mechanical Installation The 9629 control is mounted in a steel enclosure with a hinged front panel to facilitate servicing. The front panel consists of a polycarbonate overlay with tactile switches and integrated touch pads. 8 ¾” Three Amphenol connectors are located on the (222mm) right side of the enclosure, the fuse is located...

  • Page 29: Section Ix Electrical Installation

    (if one is being hand side of the module there are two jumpers, used in the system). Jetline can provide stan- these are marked J1A and J1B. These should dard connecting cables to be connected to the be set as shown in the diagram below.
  • Page 30 9629 control is connected to the current cumstances, it can be interfaced with a PLC, background signal through these connections, it power supply or other control interface. Jetline will allow a signal to be passed to the arc length can provide standard connecting cables to be control.
  • Page 31 S3 CONNECTOR The S3 connector is used to connect the 9629 control to the wire feed motor. Jetline can pro- vide standard connecting cables to be connected to the S3 connector on the 9629 control. If you need to provide your own cable, it should be...

  • Page 32: Interconnections

    9629 and the power supply. Power appropriate Amphenol connectors are available supplies from other manufacturers can be used, from Jetline. Special length cables can be made if so, consult Jetline for details of interconnec- to order. tion cables and required interfaces.
  • Page 33 Arc Length Control Addition In addition to being interconnected with the welding power supply, the 9629 control can 9629 to arc length control. also be interconnected with a Jetline arc length Cable: 9600S1-ALC-3 (for 9690 ALC control) control. 9629 to welding power supply.
  • Page 34 9629 Microprocessor Controller It is possible to produce a complete rotational system by interfacing the 9629 control with an arc length control and with a 9640 controlled Cable: 9600S1-ALC-3 rotational fixture. This creates a completely in- 9629 to 9640 control tegrated welding system where the operation of Cable: 9600S2-S2-3 the start button on the 9640 control initiates the...
  • Page 35 9629 Microprocessor Controller system by interfacing the 9629 control with an arc length control and with a 9627 controlled carriage. This creates a completely integrated Cable: 9600S1-ALC-3 welding system where the operation of the start 9629 to 9627 control button on the 9627 control initiates the start of Cable: 9600S2-S2-3 the weld sequence.

  • Page 36: Maintenance

    Enter the calibration mode of the 9629 by press- ing and holding both forward and reverse jog should contact Jetline for technical support. touch pads and at the same time pressing a re- leasing the power push-button switch. Continue...
  • Page 37 9629 Microprocessor Controller Set wire feed speed (SET) Use the adjust knob to reset the low input num- ber to the new number calculated in the routine This is the speed at which the wire feeder has above. been set to run. Switch the control off and on and then repeat Displayed wire feed speed (DISPLAY) the test.

  • Page 38: Regular Maintenance

    In addition to the weekly and monthly mainte- feel free to do so. If there is a large discepancy, nance routines, check the following: contact Jetline for further instructions as this • Check the touch pad areas to ensure that...

  • Page 39: Section Xi Parts List

    9629 Microprocessor Controller Section XI. Parts List The following pages provide a detailed parts The following parts lists are included in this list of the 9629 control. They are arranged so manual, their page numbers are: that the parts list on the left hand page is for the assembly illustrated on the adjacent right hand 9600 Enclosure ..........40 page.
  • Page 40 9629 Microprocessor Controller 9600 ENCLOSURE Recommended Item Part Level Level Description 9600-1 Complete Enclosure ..........1 9600-105 Cabinet ..............1 27F794 Fuse Holder ..............1 9600-CAB-S1 Cable Assembly ............1 9600-CAB-S2 Cable Assembly ............1 9600-CAB-S3 Cable Assembly ............1 C-1318-006-BL Power Cord ..............1 AS-25-5 Power Supply ............1 81F4550 RFI Filter ..............1 9600-110...
  • Page 41 9629 Microprocessor Controller MAIN SUB-PANEL GROUND GROUND Figure 1 Enclosure - 41 -...
  • Page 42 9629 Microprocessor Controller 9600 ENCLOSURE (Door) Recommended Item Part Level Level Description 9600-1 Complete Enclosure ..........1 9600-105 Cabinet ..............1 9600-100 Overlay (Not illustrated) ..........1 9600-10 Processor Board ............1 ABW3B-R Mushroom Head, 29 mm .........1 AYW400 Switch Operator ............1 TWC01 Contact - Normally Closed ........1 9600-LCD Display ..............1 AML21EBA2AA...
  • Page 43 9629 Microprocessor Controller Figure 2 Enclosure (Door) - 43 -...

  • Page 44: Section Xii Pcb Descriptions

    -5V. This jumper is factory set for your 9629 Connects to the start and stop push-buttons to initiate control and should not be changed without approval and end a weld sequence. from Jetline. J7 - Serial Port Connector TEST POINTS This is unused in current 9629 models.
  • Page 45 9629 Microprocessor Controller NVRAM (Includes Lithium Battery) Start/Stop Switches Figure 3 9600-10 Board - 45 -...
  • Page 46 9629 Microprocessor Controller Please refer to the illustration on the opposite page for details of the parts and test points. JP1-3 - Tachometer Voltage Range 9600-11R Isolation Board Ranges are as follows: CONNECTORS 0 to 10VDC Input Range J1 - Power Supply Connector 0 to 33VDC Input Range The main 5VDC is supplied on this connector.
  • Page 47 9629 Microprocessor Controller TP10 TP12 TP11 To 9600-10 J2 J4 To Cable 9600-CAB-S3 To Motor Drive J7 To Solid State Relay J8 J6 To Cable 9600-CAB-S2 J5 To Cable 9600-CAB-S1 To Emergency Stop Switch J9 To Power Supply J1 9600-10 (Digital) Figure 4 9600-11R Board...

  • Page 48: Section Xiii Electrical Diagrams

    9629 Microprocessor Controller Section XIII. Electrical Diagrams & Charts The following pages include electrical diagrams for the various parts of the 9629 Microprocessor Controller. They also show, in chart form, all the screens which appear on the 9629 during its operation.

  • Page 49: Electrical Diagrams The Diagrams Included In This Manual Are As Follows: S1 Connector - Pin Identification

    9629 Microprocessor Controller S1 CONNECTOR - 49 -...

  • Page 50: S2 Connector - Pin Identification

    9629 Microprocessor Controller S2 CONNECTOR - 50 -...

  • Page 51: S3 Connector - Pin Identification

    9629 Microprocessor Controller S3 CONNECTOR - 51 -...

  • Page 52: Interconnection Diagram

    9629 Microprocessor Controller - 52 -...
  • Page 53 9629 Microprocessor Controller - 53 -...

  • Page 54: Operating Mode

    9629 Microprocessor Controller MODEL 9629 WIRE FEEDER CONTROL SCREEN OPERATING MODE DEFAULT J e t l i n e E n g i n e e r i n g These two lines display when the control is first switched on and stay on for about 3 seconds, the screen then automatically 9 6 2 9...

  • Page 55: Set-Up Mode

    9629 Microprocessor Controller MODEL 9629 WIRE FEEDER CONTROL SCREEN SET-UP MODE DEFAULT F W D S P E X X X % R E V S P E X X X % R A P I D S P E E D X X X % R E T R A S P E...

  • Page 56: Calibration Mode

    9629 Microprocessor Controller MODEL 9629 WIRE FEEDER CONTROL SCREEN CALIBRATION MODE DEFAULT C L O O D E O f f L O O X . X % 99.9 10.0 S E N X . X s D I S P Actual u a l X X .

  • Page 57: Information Screens

    9629 Microprocessor Controller MODEL 9629 WIRE FEEDER CONTROL INFORMATION SCREENS (Lower Line) CONDITION A d j u s t m e n t L o c k e d Displays when adjust knob operation is locked out and wire feed speed cannot be altered. C a n n o t a n y h i g h e r...

  • Page 58: Index

    9629 Microprocessor Controller Index Jog Forward ........ 17 Adjustment knob ......14 Ramp Time ........16 Jog Reverse ......... 18 Anytime Messages ...... 19 Rapid Jog ........14 Jogging Disabled ......18 Applications ........12 Rapid Jog Forward ......18 Rapid Jog Reverse .......18 Rapid Speed ........20 Remote High Input ......25 Loop Sensing ......

This manual is also suitable for:

9629 series9629-09629-p9629-hw9629-r1

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