Miller JETLINE 9660 TACTILE SEAM TRACKER REV F Owner's manual

Miller
Brand
Miller
Model
JETLINE 9660 TACTILE SEAM TRACKER REV F
Category
Welding System
Type
Owner's manual

This manual is also suitable for

OPERATION MANUAL
for Cyclomatic Series
Seam Tracker Systems
JetlineEngineering,15GoodyearStreet,IrvineCA 92618
Telephone:949-951-1515·Fax:949-951-9237
Website: www.jetline.com · www.cyclomatic.com
E-mail: [email protected]
IMPORTANT
RevisedApril2012
Readthismanualcarefullybeforeinstalling,
commissioningoroperatingthisproduct.
LIMITEDWARRANTY
JetlineEngineering,ofIrvine,California,U.S.A.,warrantsallnewequipmenttobefreefromdefectsin
materialandworkmanshipfortheperiodofone(1)year,providedthattheequipmentisinstalledandoper-
atedaccordingtoinstructions.
JetlineEngineering’sobligationunderthiswarrantyisexpresslylimitedtoreplacingorrepairingandde-
fectivepartorcorrectinganymanufacturingdefectwithoutchargeduringthewarrantyperiod,ifJetline’sin-
spection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al
-
lowed.
Thewarrantyperiodbeginsonthedateofsaletotheoriginal-purchaseuseroftheequipment.
JetlineEngineeringwillnotbeliableforanylossorconsequentialdamageorexpenseaccruingdirectly
orindirectlyfromtheuseofequipmentcoveredbythiswarranty.
ThiswarrantysupersedesallpreviousJetlineWarrantiesandisexclusivewithnootherguaranteesor
warrantiesexpressedorimplied.
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effi
-
ciencywithyourweldingoperation.Pleasereadtheseinstructionscarefullytobecome
awareofeveryadvantage.
CAUTION
Onlyexperiencedpersonnelfamiliarwiththe
operationandsafepracticeofweldingequipment
shouldinstalland/orusethisequipment.
Overview
Overview ......................................................... vi
TableofContents .................................................... vii
TableofTables ...................................................... x
TableofFigures ..................................................... xii
SafetyPrecautions .................................................... xv
A.ArcWelding................................................. xv
B.ElectricShock................................................ xv
C.ArcRays .................................................. xv
D.FumesandGases.............................................. xvi
E.Cylinders .................................................. xvi
F.Welding ................................................... xvi
G.MovingParts................................................ xvii
H.EMFInformation ............................................. xvii
I.PrincipalSafetyStandards ......................................... xvii
TST ControlSystem ................................................... 1
DescriptionOfEquipment ........................................... 1
Operation.................................................... 19
Installation ................................................... 21
Maintenance .................................................. 27
DrawingsandPartsLists............................................ 33
Troubleshooting ................................................ 65
CircuitDescriptions .............................................. 71
SchematicsandBlockDiagrams........................................ 75
OptionalEquipment .............................................. 80
PTST ControlSystem .................................................. 81
PTST SeamTrackingSystem ......................................... 81
PTST Operation ................................................ 89
PTST Installation ............................................... 94
PTST Maintenance .............................................. 105
PTST DrawingsandPartsLists........................................ 107
PTST Troubleshooting ............................................ 113
PTST SchematicsandBlockDiagrams.................................... 117
vi
OVERVIEW 9660SERIESSEAMTRACKERCONTROLLER
TableofContents
SafetyPrecautions .................................................... xv
A.ArcWelding................................................. xv
B.ElectricShock................................................ xv
C.ArcRays .................................................. xv
D.FumesandGases.............................................. xvi
E.Cylinders .................................................. xvi
F.Welding ................................................... xvi
G.MovingParts................................................ xvii
H.EMFInformation ............................................. xvii
I.PrincipalSafetyStandards ......................................... xvii
TST ControlSystem ................................................... 1
DescriptionOfEquipment ........................................... 1
ControlUnit ............................. 1
Operation.................................................... 19
DriveCable ............................ 19
Cross-SlideAssembly ......................... 19
Omni-GuideSensorandAccessories ..................... 19
PrincipleofOperation ........................ 19
5-AxisMount ............................ 19
ControlPendantandCableAssembly .................... 20
SpecialLengthCableAssemblies ...................... 20
StandardOptions ........................... 20
TipSelectionGuide .......................... 20
Installation ................................................... 21
Cross-SlideAssemblyMounting ...................... 21
Omni-GuideSensorMounting ....................... 21
Omni-GuideSensorTips ........................ 22
Omni-GuideSensorVerticalSpringForceAdjustment ............... 22
Omni-GuideSensorsand5-AxisMountAssembly ................ 22
ControlPendantInstallation ....................... 22
ControlUnitInstallation ........................ 22
WeldHeadInstallation ......................... 22
SystemInterconnection ......................... 23
DuringOperation ........................... 23
NOTE ............................. 23
DuringMechanicalAdjustments ...................... 23
DuringElectricalAdjustments ....................... 23
InitialSet-upInstructions ........................ 24
OperatingSequence ........................ 24
9660SERIESSEAMTRACKERCONTROLLER TABLEOFCONTENTS
vii
WorkEngagementSequence ...................... 24
ManualOperations ......................... 24
AutomaticOperations ........................ 24
SidetrackForceAdjustment ...................... 24
Maintenance .................................................. 27
MaintenanceRequirements ........................ 27
ControlUnitAssembly ......................... 27
ControlPendantandCableAssembly .................... 27
Cross-SlideAssembly ......................... 27
Omni-GuideSensorAssembly ....................... 28
MountingBrackets .......................... 28
PreventiveMaintenanceSchedule ...................... 28
MonthlyMaintenance ........................ 28
Omni-GuideSensorAssembly ..................... 28
ProbeBracketAssembly ....................... 28
QuarterlyMaintenance........................ 28
TorchBracketAssembly ....................... 28
Cables ............................. 29
PendantAssembly ......................... 29
CrossSlides ........................... 29
SemiAnnualMaintenance ....................... 29
ControlUnitAssembly ........................ 29
Omni-GuideSensorCalibrationProcedure ................... 29
ToolsRequired .......................... 29
Omni-GuideSensorInterfaceCircuitry................... 29
CalibrationOfTheOmni-GuideSensorAssembly ............... 30
ServoAmplifierCircuitryCalibration .................... 31
TollsRequired .......................... 31
DrawingsandPartsLists............................................ 33
Troubleshooting ................................................ 65
RecommendedSparesforTroubleshooting ................... 65
HelpfulHints ............................ 68
Hint#1-LapJointWeldingApplications .................. 68
Hint#2-CircumferentialWeldingApplications ................ 68
Hint#3-CrossSlidetoSensorRelationship ................. 68
Hint#4-SensorRotated180° Degrees .................. 69
CircuitDescriptions .............................................. 71
SystemWiringDiagram ......................... 71
MainBoardAssembly ......................... 71
VoltageRegulation ......................... 72
ControlCircuitryDescription...................... 72
Omni-GuideSensorInterface ...................... 72
PendantControl .......................... 73
ServoAmplifier .......................... 73
AdvanceProgrammingOptionComponents ................. 74
SchematicsandBlockDiagrams........................................ 75
OptionalEquipment .............................................. 80
RotaryTableBracket .......................... 80
PTST ControlSystem .................................................. 81
PTST SeamTrackingSystem ......................................... 81
viii
TABLEOFCONTENTS 9660SERIESSEAMTRACKERCONTROLLER
FeaturesApplications ......................... 81
TimedCycleFunction ........................ 81
AutoCutoffFunction ........................ 81
SwitchedAuto-DisableFunction ..................... 82
TackCutoffFunction ........................ 82
Features .............................. 83
ZSearchFeature.......................... 83
LockoutFeature .......................... 84
CraterFillDelay ......................... 84
HorizontalRetractDelay ....................... 86
VerticalSearchDelay ........................ 86
SidetrackDisableatNull ....................... 87
PTST Operation ................................................ 89
UserInterface ............................ 89
J3OutputRelayConnector ...................... 89
J4InputConnector ......................... 89
multi-systemoperation ......................... 90
Start.............................. 90
EmergencyStop .......................... 90
SynchronizedTiming(NullInput) .................... 90
Cutoff ............................. 90
VerticalDisableandHorizontalDisable .................. 90
OperationalPrecautions ........................ 90
ZSearchFeature.......................... 90
VerticalandHorizontalDisable ..................... 90
TackFunction .......................... 91
RemoteInterfaceConnections ..................... 91
FieldInstallation ........................... 91
ControlPendant ........................... 91
ControlBox ............................ 91
PTST SeamTrackingSystem ...................... 92
RemoteInterfaceConnectorAssembly ................... 92
ProgramSwitchSettings ........................ 92
PTST Installation ............................................... 94
PTST Programming .......................... 94
PTST ProgrammingoftheFeatures ..................... 94
PTST PreliminaryCheckoutProcedure .................... 95
PTST CheckoutProcedure ........................ 98
SequenceofOperation ......................... 98
ExampleOne ........................... 98
ExampleTwo .......................... 100
SeamTrackerGroundingandCabling .................... 102
PTST Maintenance .............................................. 105
PTST DrawingsandPartsLists........................................ 107
PTST Troubleshooting ............................................ 113
InterfacingtheSeamTrackertoOtherEquipment ................ 113
SubassemblyInterface........................ 113
General.............................. 113
RecommendedTroubleshootingEquipment. ................. 113
SetupandGeneralInformation ..................... 113
PTST SchematicsandBlockDiagrams.................................... 117
9660SERIESSEAMTRACKERCONTROLLER TABLEOFCONTENTS
ix
TableofTables
DescriptionOfEquipment
Table1-TST40SystemSpecifications ..................................... 2
Table2-TST250SystemSpecifications .................................... 3
Table3-Omni-GuideSensorTipsPartsList .................................. 4
Table4-FilletsandV-Grooves ......................................... 5
Table5-ButtTypeJoints ............................................ 5
Table6-AdjacentorParallel .......................................... 5
Table7-TackWeldGrooves .......................................... 5
Table8-TackWeldFillet ............................................ 6
Table9-TackWeldOver-Ride ......................................... 6
Table10-TubeMills .............................................. 6
Table11-MSP40LoadSpecifications .................................... 18
Table12-MSP250LoadSpecifications.................................... 18
Operation
Installation
Maintenance
DrawingsandPartsLists
Table13-Omni-GuideSensorPartsList ................................... 37
Table14-MSP40cross-slidePartsList .................................... 39
Table15-MSP250Cross-SlidePartsList................................... 41
Table16-MSP250Cross-SlidePartsList................................... 42
Table17-MSP450Cross-SlidePartsList................................... 45
Table18-MSP450Cross-SlidePartsList................................... 46
Table19-9660SSeamTrackerControlPartsList .............................. 49
Table20-9660S-100ControlPendantPartsList ............................... 51
Table21-PowerSwitchAssemblyPartsList ................................. 52
Table22-TransformerAssemblyPartsList.................................. 53
Table23-MotorDriverHeatsinkAssemblyPartsLists ........................... 54
Table24-MotorDriverHeatsinkAssemblyPartsLists(Cont.) ....................... 55
Table25-VoltageSelectorSwitchAssemblyPartsList ........................... 56
Table26-DriveConnectorHarnessAssemblyPartsList........................... 57
Table27-PendantConnectorHarnessAssemblyPartsList ......................... 58
Table28-Std.TorchClampBracketPartsList ................................ 59
x
TABLEOFTABLES 9660SERIESSEAMTRACKERCONTROLLER
Table29-OptionalUniversalBracketPartsList ............................... 60
Table30-U-Bracket(TST40)PartsList ................................... 61
Table31-5-AxisMountPartsList ...................................... 62
Table32-5-AxisMountPartsList(Cont.) .................................. 63
Troubleshooting
Table33-Troubleshooting .......................................... 65
Table34-VoltageTestPoints ......................................... 66
Table35-DriveSignalTestPoints ...................................... 66
Table36-Omni-GuideSensorTestPoints .................................. 66
Table37-RecommendedSpareParts ..................................... 66
CircuitDescriptions
SchematicsandBlockDiagrams
OptionalEquipment
PTST SeamTrackingSystem
PTST Operation
Table39-PTST ProgrammingOptionDipSwitchDescriptions ....................... 91
Table40-PTST ProgrammingOptionPrograms,FactoryDefault ...................... 93
PTST Installation
Table41-ProgramValues,Example1 .................................... 98
Table42-ProgramValues,Example2 .................................... 100
Table43-9660P ControlProgramWorksheet ................................ 104
PTST Maintenance
PTST DrawingsandPartsLists
Table44-9660P ControlPartsList ..................................... 109
Table45-9660P-100PendantPartsList ................................... 111
Table46-RemoteInput/OutputConnectorHarnessPartsList ....................... 112
PTST Troubleshooting
PTST SchematicsandBlockDiagrams
9660SERIESSEAMTRACKERCONTROLLER TABLEOFTABLES
xi
TableofFigures
DescriptionOfEquipment
Figure1-TST40SystemComponents ..................................... 2
Figure2-TST250SystemComponents .................................... 3
Figure3-Omni-GuideSensorTips ....................................... 4
Figure4-TipSelection,FilletandV-Groove.................................. 5
Figure5-TipSelection,ButtTypeJoints.................................... 5
Figure6-TipSelection,AdjacentorParallel.................................. 5
Figure7-TipSelection,TackWeldGroove .................................. 5
Figure8-TipSelection,TackWeldFillet ................................... 6
Figure9-TipSelection,TackWeldOver-Ride................................. 6
Figure10-TipSelection,TubeMills ...................................... 6
Figure11-InterconnectionDiagram ...................................... 7
Figure12-MSP40Cross-SlideMountingDimensions............................. 8
Figure13-MSP250Cross-SlideMountingDimensions ............................ 9
Figure14-MSP4505x5Cross-SlideMountingDimensions ........................ 10
Figure15-MSP45010x10Cross-SlideMountingDimensions ....................... 11
Figure16-9660Sand9660P ControlMountingDimensions ......................... 12
Figure17-9660S-100and9660P-100PendantMountingDimensions ................... 13
Figure18-Omni-GuideSensorMounting(Std.Bracket)........................... 14
Figure19-Omni-GuideSensorMounting(Univ.Bracket) .......................... 14
Figure20-VerticalForceAdjustments .................................... 15
Figure21-TorchClampMountingBracket.................................. 16
Figure22-UniversalMountingBracket ................................... 17
Figure23-Opt.U-BracketMountingBracket(TST40) ........................... 17
Figure24-SideView,MSP40......................................... 18
Figure25-SideView,MSP250 ........................................ 18
Figure26-LoadSpecificationsEnvelopeTopView ............................. 18
Operation
Installation
Figure27-TrackingDiagram ......................................... 25
Figure28-SidetrackForceAdjustment .................................... 25
Maintenance
DrawingsandPartsLists
xii
TABLEOFFIGURES 9660SERIESSEAMTRACKERCONTROLLER
Figure29-SeamTrackerMainBoardLayout ................................ 33
Figure30-SidetrackForceAdjustment .................................... 34
Figure31-Omni-GuideSensorExplodedView ............................... 36
Figure32-MSP40cross-slideExplodedView ................................ 38
Figure33-MSP250Cross-SlideExplodedView ............................... 40
Figure34-MSP450Cross-SlideExplodedView ............................... 44
Figure35-9660SSeamTrackerControlExplodedView........................... 48
Figure36-9660S-100ControlPendantExplodedView ........................... 50
Figure37-PowerSwitchAssemblyExplodedView ............................. 52
Figure38-TransformerAssemblyExplodedView .............................. 53
Figure39-MotorDriverHeatsinkAssemblyExplodedView ........................ 54
Figure40-VoltageSelectorSwitchassemblyExplodedView ........................ 56
Figure41-DriveConnectorHarnessExplodedView............................. 57
Figure42-PendantConnectorHarnessExplodedView ........................... 58
Figure43-Std.TorchClampBracket,1103-0017 .............................. 59
Figure44-OptionalUniversalBracket,1103-0009 .............................. 60
Figure45-U-Bracket(TST40),1103-0025 .................................. 61
Figure46-5-AxisMount ........................................... 62
Troubleshooting
Figure47-9660SControlSignalFlow .................................... 67
Figure48-SensorAngleonLapJoints .................................... 68
Figure49-SensorOrientationonTanks,PressureVesselsandPipes..................... 68
Figure50-CrossSlidetoSensorRelationship,Correct............................ 69
Figure51-CrossSlidetoSensorRelationship,Incorrect ........................... 69
Figure52-SensorRotated180°Degrees ................................... 70
CircuitDescriptions
Figure53-9660S-100PendantSchematic,StandardSeamTracker ..................... 75
SchematicsandBlockDiagrams
Figure54-9660SSeamTrackerBlockDiagram ............................... 76
Figure55-9660SSeamTrackerBlockDiagram(Cont.) ........................... 77
Figure56-MotorDriverHeatsinkSchematicDiagram............................ 78
OptionalEquipment
Figure57-RotaryTableBracket ....................................... 80
PTST SeamTrackingSystem
Figure58-ZSearchFeature.......................................... 83
Figure59-TimedMode ............................................ 84
9660SERIESSEAMTRACKERCONTROLLER TABLEOFFIGURES
xiii
Figure60-AutoCutoff,DownCutoff..................................... 85
Figure61-AutoCutoff,UpCutoff ...................................... 85
Figure62-TackCutoffMode ......................................... 86
PTST Operation
PTST Installation
Figure63-PTST ProgrammingOptionTimedMode ............................. 95
Figure64-PTST ProgrammingOptionAutoDownCutoff.......................... 96
Figure65-PTST ProgrammingOptionAutoUpCutoff ........................... 96
Figure66-PTST ProgrammingOptionTackCutoff ............................. 97
Figure67-PTST ProgrammingOptionZSearchFeature .......................... 97
Figure68-PTST TimeLine,ExampleOne .................................. 99
Figure69-PTST ProgrammingOptionTimeLine,ExampleTwo ..................... 101
PTST Maintenance
PTST DrawingsandPartsLists
Figure70-PTST ControlBoardLayout ................................... 107
Figure71-9660P ControlExplodedView .................................. 108
Figure72-9660P-100PendantExplodedView ............................... 110
Figure73-RemoteConnectorHarnessExplodedView ........................... 112
PTST Troubleshooting
Figure74-9660P ControlSignalFlow.................................... 115
PTST SchematicsandBlockDiagrams
Figure75-9660P-100PendantSchematic .................................. 117
Figure76-9660P ControlBlockDiagram .................................. 118
Figure77-9660P ControlBlockDiagram(Cont.) ............................. 119
Figure78-RemoteInputInterfaceConnections ............................... 120
Figure79-RemoteOutputInterfaceConnections .............................. 121
Figure80-9660P Multi-SystemOperationandWiring ........................... 122
Figure81-9660P Auto-DisableOperationandWiring ........................... 123
Figure82-9660P ControltoMillerAutoMInterface ............................ 124
xiv
TABLEOFFIGURES 9660SERIESSEAMTRACKERCONTROLLER
Safety Precautions
A. ARC WELDING
ArcWeldingcanbehazardous.Protectyourselfand
othersfrompossibleseriousinjuryordeath.Keep
childrenaway.Pacemakerwearerskeepawayuntil
consultingyourdoctor.
Inwelding,asinmostjobs,exposuretocertainhaz
-
ardsoccurs.Weldingissafewhenprecautionsare
taken.Thesafetyinformationgivenbelowisonlya
summaryofthemorecompletesafetyinformation
thatwillbefoundintheSafetyStandardslistedatthe
endofthissection.ReadandfollowallSafetyStan
-
dards.
Haveallinstallation,operation,maintenanceandre
-
pairworkperformedonlybyqualifiedpeople.
B. ELECTRIC SHOCK
Touchingliveelectricalpartscancausefatalshocksor
severeburns.Theelectrodeandworkcircuitiselectri-
callylivewhenevertheoutputison.Theinputpower
circuitandmachineinternalcircuitsarealsolive
whenpowerison.Whenusingmechanizedwirefeed,
thewire,wirereel,driverollhousingandallmetal
partstouchingtheweldingwireareelectricallylive.
Incorrectlyinstalledorimproperlygroundedequip
-
mentisahazard.
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 be
sure that input power cord ground wire is prop
-
erly connected to ground terminal in disconnect
box or that cord plug is connected to a properly
grounded receptacle outlet.
6 When making input connections, attach proper
grounding conductor first - double-check con
-
nections.
7 Frequently inspect input power cord for damage
or bare wiring. Replace cord immediately if
damaged - 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 not
use work clamp or work cable.
10 Do not touch electrode if you are in contact with
the work, ground, or another electrode from a
different 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 floor
level.
13 Keep all panels and covers securely in place.
14 Clamp work cable with good metal-to-metal
contact to workpiece or worktable as near the
weld as practical.
C. ARC RAYS
Arcrayscanburneyesandskin;noisecandamage
hearing;flyingslagorsparkscaninjureeyes.
Arcraysfromtheweldingprocessproduceintense
visibleandinvisible(ultravioletandinfrared)rays
thatcanburneyesandskin.Noisefromsomepro
-
cessescandamagehearing.Chipping,grindingand
weldcoolingthrowoffpiecesofmetalorslag.
1 Use approved ear plugs or ear muffs if noise
level is high.
2 Use a welding helmet fitted with a proper shade
of filter to protect your face and eyes when
welding 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 to
watch the arc.
5 Wear protective clothing made from durable,
flame-resistant material (wool and leather) and
foot protection where necessary.
9660SERIESSEAMTRACKERCONTROLLER SAFETY
xv
WARNING
D. FUMES AND GASES
Fumesandgasescanbehazardoustoyourhealth.
Weldingproducesfumesandgases.Breathingthese
fumesandgasescanbehazardoustoyourhealth.
1 Keep your head out of the fumes. Do not
breathe the fumes.
2 If inside, ventilate the area and/or use exhaust at
the arc to remove welding fumes and gases.
3 If ventilation is poor, use an approved
air-supplied respirator.
4 Read the Material Safety Data Sheets (MSDS)
and the manufacturer's instruction for metals,
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 of
the arc can react with vapors to form highly
toxic and irritating gases.
7 Do not weld on coated metals, such as galva-
nized, lead or cadmium plated steel, unless the
coating is removed from the weld area, the area
is well ventilated, and if necessary, while wear-
ing an air-supplied respirator. The coatings and
any metals containing these elements can give
off toxic fumes if welded.
E. CYLINDERS
Cylinderscanexplodeifdamaged.
Shieldinggascylinderscontaingasunderhighpres
-
sure.Ifdamaged,acylindercanexplode.Sincegas
cylindersarenormallypartoftheweldingprocess,be
suretotreatthemcarefully.
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 other
electrical 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 specific
application; maintain them and associated parts
in good condition.
6. Turn face away from valve outlet when opening
cylinder valve.
7. Keep protective cap in place over valve except
when cylinder is in use or connected for use.
8. Read and follow instructions on compressed gas
cylinders, associated equipment, and CGA pub
-
lication P-1 listed in Safety Standards.
F. WELDING
Weldingcancausefireor explosion.
Weldingonclosedcontainers,suchastanks,drums,
orpipes,cancausethemtoblowup.Sparkscanfly
offfromtheweldingarc.Theflyingsparks,hot
workpiece,andhotequipmentcancausefiresand
burns.Accidentalcontactofelectrodetometalobjects
cancausesparks,explosion,overheating,orfire.
Checkandbesuretheareaissafebeforedoingany
welding.
1. Protect yourself and others from flying sparks
and hot metal.
2. Do not weld where flying sparks can strike
flammable material.
3. Remove all flammables within 35 ft (10.7 m) of
the welding arc. If this is not possible, tightly
cover them with approved covers.
4. Be alert that welding sparks and hot materials
from welding can easily go through small cracks
and openings to adjacent areas.
5. Watch for fire, and keep a fire extinguisher
nearby.
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 the
welding area as practical to prevent welding
current traveling long, possibly unknown paths
and causing electric shock and fire hazards.
SAFETY 9660SERIESSEAMTRACKERCONTROLLER
xvi
8. Wear oil-free protective garments such as
leather gloves, heavy shirt, cuffless trousers,
high shoes, and a cap.
G. MOVING PARTS
Movingparts,suchasfans,rotors,andbeltscancut
fingersandhandsandcatchlooseclothing.
1. Keep all doors, panels, covers, and guards
closed and securely in place.
2. Have only qualified people remove guards or
covers for maintenance and troubleshooting as
necessary.
H. EMF INFORMATION
ConsiderationsAboutWeldingandtheEffectsof
LowFrequencyElectricandMagneticFields.
ThefollowingisaquotationfromtheGeneralCon
-
clusionsSectionoftheU.S.Congress,OfficeofTech
-
nologyAssessment,BiologicalEffectsofPower
FrequencyElectric&MagneticFields-Background
Paper,OTA-BP-E-53(Washington,DC:U.S.Govern-
mentPrintingOffice,May1989):
"....thereisnowaverylargevolumeofscientific
findingsbasedonexperimentsatthecellularleveland
fromstudieswithanimalsandpeoplewhichclearly
establishthatlowfrequencymagneticfieldscaninter-
actwith,andproducechangesin,biologicalsystems.
Whilemostofthisworkisofveryhighquality,the
resultsarecomplex.Currentscientificunderstanding
doesnotyetallowustointerprettheevidenceina
singlecoherentframework.Evenmorefrustrating,it
doesnotyetallowustodrawdefiniteconclusions
abutquestionsofpossibleriskortoofferclearsci
-
ence-basedadviceonstrategiestominimizeoravoid
potentialrisks."
Toreducemagneticfieldsintheworkplace,usethe
followingprocedures:
1. Keep cables close together by twisting or taping
them.
2. Arrange cables to one side and away from the
operator.
3. Do not coil or drape cables around the body.
4. Keep welding power source and cables as far
away as practical.
5. Connect work clamp to workpiece as close to
the weld as possible.
AboutPacemakers:
Theaboveproceduresareamongthosealsonormally
recommendedforpacemakerwearers.Consultyour
doctorforcompleteinformation.
I. PRINCIPAL SAFETY STANDARDS
Referenceasapplicable
SafetyinWeldingandCutting,ANSIStandardZ49.1,
fromAmericanWeldingSociety,550N.W.LeJeune
Rd,Miami,FL 33126
SafetyandHealthStandards,OSHA 29CFR1910,
fromSuperintendentofDocuments,U.S.Government
PrintingOffice,Washington,D.C.20402
NationalElectricCode,NFPA Standard70fromNa
-
tionalFireProtectionAssociation,BatterymarchPark,
Quincy,MA 02269
RecommendedSafePracticesforthePreparationfor
WeldingandCuttingofContainersThatHaveHeld
HazardousSubstances,AmericanWeldingSociety
StandardAWSF4.1,fromAmericanWeldingSociety,
550N.W.LeJeuneRd,Miami,FL 33126
SafeHandlingofCompressedGasesinCylinders,
CGA PamphletP-1,fromCompressedGasAssocia
-
tion,1235JeffersonDavisHighway,Suite501,
Arlington,VA 22202
CodeforSafetyinWeldingandCutting,CSA Stan
-
dardW117.2,fromCanadianStandardsAssociation,
StandardsSales,178RexdaleBoulevard,Rexdale,
Ontario,CanadaM9W 1R3
SalesPracticesforOccupationandEducationalEye
andFaceProtection,ANSIStandardZ87.1,from
AmericanNationalStandardsInstitute,1430Broad-
way,NewYork,NY 10018
CuttingandWeldingProcesses,NFPA Standard51B,
fromNationalFireProtectionAssociation,
BatterymarchPark,Quincy,MA 02269
9660SERIESSEAMTRACKERCONTROLLER SAFETY
xvii
SAFETY 9660SERIESSEAMTRACKERCONTROLLER
xviii
TST Control System
DESCRIPTION OF EQUIPMENT
JetlineEngineeringSeamTrackerSystemsareused
fortorchpositioninginautomatedweldingprocesses
requiringaconstanttorchpositionwithrespecttothe
jointtobewelded.Thesystemcanbeconfiguredfor
variouscombinationsofmanualandautomaticposi
-
tioningmaneuvers.
A typicalstandardJetlineEngineeringSeamTracker
System(see Figure1-TST40SystemComponents
and Figure2-TST250SystemComponents,begin
-
ningonpage 2)consistsofaControlUnitAssembly,
DriveCableAssembly,Cross-SlideAssembly,
Omni-GuideSensorAssembly(withstandard1/8"
balltipandextensionrod)5AxisMount,Torch
ClampBracket,andControlPendantAssembly.An
optionalUniversalBracketisalsoavailableinaddi
-
tiontotheTorchClampBracket.Theuser'swelding
torchorweldheadisnormallymountedtotheadapter
platewhichisapartofthecross-slideassemblypro-
vidingtwo-axispositioningcontrolofthetorch.
TheOmni-GuideSensorAssemblyisnormally
mountedtotheweldingtorchviathetorchclamp
bracket,butcanoptionallybemountedtotheuniver-
salbracket.ThesensortipontheOmni-GuideSensor
contactsthejointtobeweldedandsensesanyhori
-
zontalorverticalmovementoftheweldjointwithre
-
specttotheweldingtorch.
Thecontrolunitcontainsthesolidstateelectronic
controlsthatapplythepropervoltagetothemotorson
thecross-slideassemblytocorrectthepositioninger
-
rordetectedbytheOmni-GuideSensor.JetlineEngi
-
neeringSeamTrackerSystemswillcorrect
positioningerrorswithin.005inchesandprovidevar
-
iousproportionalcorrectionspeeds.
Thecontrolpendantassembly,connectedtothecon
-
trolunitviaacable(attached),providesthecontrols
usedtoinitiallypositionthecross-slidesandstartthe
trackingoperation.Thependantassemblyismadeso
thatthefaceplateandcablecanberemovedfromthe
pendantenclosureallowingthependantfaceplateto
bemountedtoanothercontrolconsolewithout
re-wiringthependantassembly.
Includedwiththependantassemblyaremounting
bracketstomountittoafixtureandanattachable
hooktoallowconvenientlocationchangesasrequired
bytheoperatororapplication.
CONTROL UNIT
The 9660 SeriesSeamTrackingControllerisaheavy
gaugesteelenclosurecontainingtheelectroniccir
-
cuitryusedinthesystem.Solidstatecircuitsareused
toprovidelong,trouble-freeoperation.Thestandard
unitoperateson115/230VAC,50/60Hzcommercial
power,capableofsupplyingapproximately5amps
peakcurrent.Theunithasalightedpowerswitchand
fuseholdermountedontheexterioroftheunit.
Thesystemisoperatedfromthecontrolslocatedon
thecontrolpendantassemblywhichconnectstothe
controlunit.A sealedheatsinkmountedonthesideof
thecontrolunitallowsforconvectioncoolingofheat
dissipatingdevices,whilepreventingdustanddirt
fromenteringtheenclosure.
The9660SeriesControlunitissoldintwomodels,
i.e.,9660SStandardSeamTrackingControllerand
the9660P ProgrammableSeamTrackingController.
Thesystemsthesecontrollersareconfiguredintoare
theTactileSeamTracking(TST)andtheProgramma
-
bleTactileSeamTracking(PTST)systems,respec
-
tively,andthisconventionisusedthroughoutthis
manual.
Twoblankpanels,locatedonthefrontcoverandthe
bottomrightoftheenclosure,allowprovisionforfac
-
toryandfieldinstallationofthePTST Programmable
SeamTrackingOption(seePTST Programmable
SeamTrackingOptionbeginningonpage 81).
Thetwoconnectorslocatedonthebottomoftheunit
provideforconnectionofthecontrolpendantcable
andthedrivecabletothecross-slideassembly.
9660SERIESSEAMTRACKERCONTROLLER DESCRIPTIONOFEQUIPMENT
1
DESCRIPTIONOFEQUIPMENT 9660SERIESSEAMTRACKERCONTROLLER
2
DESCRIPTION SPECIFICATIONS RATING
LoadCapacity 6”(152mm)fromFaceplate 40lbs.(18Kg)
StandardStrokeLength VerticalxHorizontal 3”(76mm)x3”(76mm)
Non-StandardStrokeLength VerticalxHorizontal 6”(152mm)x6”(152mm)
MinimumEnvelope StandardStroke3”(76mm)x3”(76mm) 12”(305mm)Diameter
TrackingAccuracy MaximumCorrectionRate24 ipm (610mm/min.) Within.005”(1.27mm)
TrackingControls Manual Up/DownandLeft/Right
Automatic Left/RightSidetrackandOff
DriveSystem
PrecisionBallScrewwithMechanicalOverride
Clutch
ControlUnit Enclosure
Standard NEMA StyleSealedenclosurewithprovi
-
sionsforplug-inoptions
RemoteControlPendant Enclosure
Handheldormountedsteelenclosurecontaining
manualandautomatictrackingcontrolswithprovi
-
sionsforplug-inoptions
CrossSlideCable StandardLength 10’ (3M)
Omni-GuideSensorCable StandardLength 4’ (1.2M)
PowerCable StandardLength 6’ (1.8M)
PendantCable StandardLength 10’ (3M)
Weights Cross-slide Assembly(cableincl.) 10lbs.(4.1Kg)
Omni-GuideSensor 1lb.(.45Kg)
ControlUnit(powercableincl.) 33lbs.(15Kg)
RemoteControlPendant(cableincl.) 4lbs.(1.8Kg)
TorchBracket, TIG 1lb.(.45Kg)
TorchClampBracket 2lb.(.9Kg)
5-AxisMount 3lbs.(1.4Kg)
Plug-inOption PTST ProgrammingOption AdvancedProgrammingControl
TABLE 1 - TST40 SYSTEM SPECIFICATIONS
FIGURE 1 - TST40 SYSTEM COMPONENTS
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Miller JETLINE 9660 TACTILE SEAM TRACKER REV F Owner's manual

Miller
Brand
Miller
Model
JETLINE 9660 TACTILE SEAM TRACKER REV F
Category
Welding System
Type
Owner's manual
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