Miller JETLINE 9629 WIRE FEED CONTROL Owner's manual

April 2005

IMPORTANT

Read this manual carefully before installing,

commissioning or operating this product.

OPERATION MANUAL

for 9629

Microprocessor

Controller

Jetline Engineering, 15 Goodyear Street, Irvine, CA 92618

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

Web Site: www.jetline.com • E-mail: [email protected]

OM-9629-04-2005

9629 Microprocessor Controller

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9629 Microprocessor Controller

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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 operated according to instructions.

Jetline Engineering’s obligation under this warranty is expressly limited to replacing or repairing

any defective part or correcting any manufacturing defect without charge during the warranty period,

if Jetline’s inspection conrms 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.

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 guaran-

tees or warranties expressed or implied.

9629 Microprocessor Controller

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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 efciency 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

equipment should install and/or use

this equipment.

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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. Principal Safety Standards ..................................................................................10

Section II Introduction .....................................................................................................................11

Section III Specications ..................................................................................................................12

Section IV Description ......................................................................................................................13

Section V Controls ...........................................................................................................................14

Section VI Modes of Operation ........................................................................................................15

A. Operator Mode ....................................................................................................15

B. Set-up Mode ........................................................................................................20

C. Calibration Mode ................................................................................................22

Section VII Operational Sequence .....................................................................................................27

Section VIII Mechanical Installation ...................................................................................................28

Section IX Electrical Installation ......................................................................................................29

A. Input Power .........................................................................................................29

B. Output Connections ............................................................................................29

C. Interconnections ..................................................................................................32

Section X Maintenance ....................................................................................................................36

A. Calibration ...........................................................................................................36

B. Regular Maintenance ..........................................................................................38

Section XI Parts List .........................................................................................................................39

Section XII PCB Descriptions ............................................................................................................44

Section XIII Electrical Diagrams .........................................................................................................48

Index ...............................................................................................................................58

9629 Microprocessor Controller

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9629 Microprocessor Controller

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Section I.

Safety Precautions

WARNING

CALIFORNIA PROPOSITION 65 WARNING

This product contains chemicals, including lead,

known to the state of California to cause cancer,

and birth defects or other reproductive harm.

Wash hands after use. §248224

A. Arc Welding

Arc Welding can be hazardous. Protect your-

self and others from possible serious injury or

death. Keep children away. Pacemaker wear-

ers keep away until consulting your doctor.

In welding, as in most jobs, exposure to certain

hazards occurs. Welding is safe when precau-

tions 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 Standards.

Have all installation, operation, maintenance

and repair work performed only by qualied

people.

B. Electric Shock

Touching live electrical parts can cause fatal

shocks or severe burns. The electrode and work

circuit is electrically 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 equipment is

a hazard.

1. Do not touch live electrical parts.

2.

Wear dry, hole-free insulating gloves and

appropriate body protection.

3. Disconnect input power before installing

or servicing this equipment. Lockout/ta-

gout input power according to OSHA 29

CFR 1910.147 (see Safety Standards).

4. Properly install and ground this equipment

according 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 properly 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 rst - double-

check connections.

7.

Frequently inspect input power cord for

damage or bare wiring. Replace cord im-

mediately 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 con-

tact 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 according to manual.

12. Wear a safety harness if working above

oor 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.

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C. Arc Rays

Arc rays can burn eyes and skin; noise can

damage hearing; ying 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 processes can damage hearing. Chip-

ping, 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 tted with a proper

shade of lter to protect your face and eyes when

welding or watching.

3. Wear approved safety glasses with side

shields.

4. Use protective screens or barriers protect

others from ash and glare; warn others not to

watch the arc.

5. Wear protective clothing made from durable,

ame-resistant material (wool and leather) and

foot protection where necessary.

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 conned space only if it is well

ventilated, or while wearing an air-supplied

respirator. Always have a trained watch person

nearby.

6. Do not weld in locations near degreasing,

cleaning, 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 gal-

vanized, lead or cadmium plated steel, unless

the coating is removed from the weld area, the

area is well ventilated, and if necessary, while

wearing 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

pressure. If damaged, a cylinder can explode.

Since gas cylinders are normally part of the

welding process, be sure to treat them care-

fully.

1. Protect compressed gas cylinders from exces-

sive heat, mechanical shocks, slag, open ames,

sparks, and arcs.

2. Install cylinders in an upright position by

securing to a stationary support or cylinder rack

to prevent falling or tipping.

9629 Microprocessor Controller

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3. Keep cylinders away from any welding or

other electrical circuits.

4. Never weld on a pressurized cylinder - ex-

plosion will result.

5. Use only correct shielding gas cylinders,

regulators, hoses and ttings designed for the

specic application; maintain them and associ-

ated parts in good condition.

6. Turn face away from valve outlet when open-

ing 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

publication P-1 listed in Safety Standards.

F. Welding

Welding can cause re or explosion.

Welding on closed containers, such as tanks,

drums, or pipes, can cause them to blow up.

Sparks can y off from the welding arc. The

ying sparks, hot workpiece, and hot equipment

can cause res and burns. Accidental contact of

electrode to metal objects can cause sparks, ex-

plosion, overheating, or re. Check and be sure

the area is safe before doing any welding.

1. Protect yourself and others from ying sparks

and hot metal.

2. Do not weld where ying sparks can strike am-

mable material.

3. Remove all ammables 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 re, and keep a re extinguisher

nearby.

6. Do not weld on closed containers such as

tanks, drums, or pipes, unless they are properly

prepared according to AWSF4.1 (see safety

Standards).

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 re hazards.

8. Wear oil-free protective garments such as

leather gloves, heavy shirt, cufess trousers,

high shoes, and a cap.

G. Moving Parts

Moving parts, such as fans, rotors, and belts can

cut ngers and hands and catch loose clothing.

1. Keep all doors, panels, covers, and guards

closed and securely in place.

2. Have only qualied people remove guards

or covers for maintenance and troubleshooting

as necessary.

H. EMF Information

Considerations About Welding and the Ef-

fects of Low Frequency Electric and Magnetic

Fields

The following is a quotation from the General

Conclusions Section of the U.S. Congress, Of-

fice of Technology Assessment, Biological

Effects of Power Frequency Electric & Mag-

netic Fields - Background Paper, OTA-BP-E-53

(Washington, DC: U.S. Government Printing

Ofce, May 1989):

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“.... there is now a very large volume of scientic

ndings based on experiments at the cellular

level and from studies with animals and people

which clearly establish that low frequency

magnetic elds can interact with, and produce

changes in, biological systems. While most of

this work is of very high quality, the results are

complex. Current scientic understanding does

not yet allow us to interpret the evidence in a

single coherent framework. Even more frustrat-

ing, it does not yet allow us to draw denite

conclusions abut questions of possible risk or to

offer clear science-based advice on strategies to

minimize or avoid potential risks.”

To reduce magnetic elds 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 Ofce, Washington, D.C.

20402

National Electric Code, NFPA Standard 70 from

National Fire Protection Association, Battery-

march Park, Quincy, MA 02269

Recommended Safe Practices for the Prepara-

tion 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 Cylin-

ders, CGA Pamphlet P-1, from Compressed Gas

Association, 1235 Jefferson Davis Highway,

Suite 501, Arlington, VA 22202

Code for Safety in Welding and Cutting, CSA

Standard W117.2, from Canadian Standards

Association, Standards Sales, 178 Rexdale Bou-

levard, 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 Broadway, New York, NY 10018

Cutting and Welding Processes, NFPA Standard

51B, from National Fire Protection Association,

Batterymarch Park, Quincy, MA 02269

9629 Microprocessor Controller

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Section II

Introduction

This detailed technical manual is meant to

be used in conjunction with the 9629 Quick

Start manual and the manual for the wire feed

mechanism which you have purchased. The

Quick Start manual is written for the operator

and deals only with the routine operation of

the control. This technical manual provides

details of the set up and calibration procedures

for the control as well as providing information

about the interfacing of the system with other

9600 series controls and ancillary controls. It

also provides troubleshooting and maintenance

information.

The 9629 microprocessor controller has been

developed to provide high quality, precision

control of all Jetline wire feeders. The quality

design and workmanship of this control will

provide many years of dependable service. Its

modern technology will help to provide you with

top quality repeatable weld results. The 9629 is

one of a series of microprocessor controls, all

of which have the same hardware design. Each

9600 series control is rendered unique by its

own custom designed rmware to facilitate the

set up and operation of the control.

The 9629 control is a microprocessor based

control designed and built to provide low cost,

accurate, repeatable control of the wire feed

motor. It is available in two versions:

9629 This control includes a motor controller

and can therefore be connected directly

to the wire feed motor. It is used for

motors used on all standard wire feeders

and provides wire feed accuracy levels

suitable for most applications.

9629-0 This control does not include a motor

controller. Instead, it provides a 0 to

+10VDC enable contact which can be

used to control a precision motor con-

trol module and a precision motor. In

this format, the unit can be used to feed

wire for the most demanding applica-

tions where the ultimate in accuracy

and consistency are demanded.

The system has three modes of operation. Please

turn to the indicated page to obtain more details

of these modes.

Operator Mode:

This is the mode used by the welding operator

to run the unit. It permits wire speed, start and

stop delays and retract time to be adjusted.

Turn to page 15

Setup Mode:

This mode is used during the setting up of the

unit. It permits the setting of the jog speed and

retract speeds.

Turn to page 19

Calibration Mode:

In this mode, the closed loop can be turned on

and off, the unit can be set for inch or metric

units and the calibration can be checked and

set.

Turn to page 22

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Section III

Specications

Applications

For use with wire feed mechanisms:

9629 Used for standard cold wire feed-

ers

- CWF-10B

- CWF-10B/4R

9629-0 Used for precision cold wire

feeders

- CWF-20C

9629-P This option can be added to

provide wire pulsing, either

synchronous with the current

pulsing or separately timed.

9629-HW This option can be added to

provide slope up of the wire feed

speed for hot wire welding.

9629-R1 This option can be added to allow

remote control of the wire feed

speed.

Processor: Intel

®

80C196KC, 20 MHz.

Display: 2 x 20 Backlit LCD

Panel: Polycarbonate overlay

Input: 120/240VAC, 1 ph, 50/60 Hz

3/2 Amps

Power cord: 6 ft. (1.8 m) long

8”

(200mm)

16” Dia

(8mm)

5

Connections:

Motor (90VDC Permanent Magnet)

Output: Motor voltage

Input: Tach-generator voltage

Second 9600 Control

Output: Emergency Stop

Input: Emergency Stop, Pulse Lockout

Dimensions:

Weight: 16 lb (7 kg)

Height: 8” (200 mm)

Width: 10” (250 mm)

Depth: 6” (150 mm)

8 ¾”

(222mm)

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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

9629 is one of a series of controls designed for

ease-of-use and for accurate control of various

drive motors for different weld applications.

The 9629 is packaged in a conveniently-sized

enclosure with Amphenol connectors. The en-

closure has four mounting holes to permit it to

be fastened to the face of a travel carriage or to a

control podium. The front panel is a membrane

overlay with a backlit LCD display and switches

to control the setup and operation of the unit.

The 9629 control has been designed to be easy

to use. Its operation is made easier by the use of

the display which guides you through the setup

process and, during the welding sequence, tells

you what is happening.

DOWN

UP

WIRE SPEED 26.5ipm

ADJUST

The display has two lines of text, the upper line

is the primary one. This is the line that is used

to set the value of the parameter you are setting.

This is done by calling up the line for the param-

eter required and then turning the adjust knob to

increase or decrease the value. The second line

is used to display status messages (information)

about the progress of the weld sequence to let

you know what stage the process is in. Most of

these messages are normally only displayed after

the start push-button has been pressed.

WIRE SPEED 26.5ipm

SERIES 9600 CONTROL

POWER STOPSTART

REV FOR

UP

DOWN

EMERGENCY

STOP

ADJUST

9629 Microprocessor Controller

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The push-button power switch is used

to provide primary power to the 9629

control. The rst press of the switch

turns on the control. The screen will

become active and display the start-up message.

A second press of this push-button switches the

control off.

These two touch pads are used to

scroll the display up and down. The

down touch pad scrolls down the

display - this takes you through the

various control options in a logical order. The

up touch pad is used to go back through the lines

of the display options. In the standard operating

mode of the 9629 control, these touch pads have

no other purpose.

The adjustment knob is used to change

the value which is currently displayed.

You will note that the knob “incre-

ments”, each incremental movement

of the knob increases the value by its smallest

increment. If the knob is rotated quickly, you

will see that the numbers increase or decrease

faster. The knob can be used to preset the speed

before the motor starts or to change the speed

when the motor is running.

These two touch pads are used to

jog the wire in a reverse or forward

direction. When the touch pad is

pressed, wire feed will begin in the direction

selected and will continue as long as the pad is

pressed. When the touch pad is released, wire

feed will stop. In addition to the jog facility

provided by the touch pads, they are capable of

providing two more functions.

POWER

UP

DOWN

ADJUST

REV

FOR

Rapid Jog: This is achieved by pressing the

forward or reverse touch pad for a short time,

releasing it and then quickly pressing it again.

Wire feed will start and, after a short time, will

speed up to the “rapid” speed. Rapid wire feed

will continue until the touch pad is released.

Maintained Jog: This is achieved by first

pressing the forward or reverse touch pad and,

while still pressing this touch pad, pressing and

releasing the start button. The forward or reverse

switch can then be released. Wire will feed at

rapid speed until it is stopped by pressing the

stop button. This feature is useful for feeding

wire through the conduit after the wire spool has

been changed.

Depressing and releasing the start

push-button will start the weld se-

quence which will continue until

the stop or emergency stop button is

pressed. Pressing the start push-button while

the forward or reverse touch pad is pressed will

initiate maintained, rapid wire feed.

Depressing and releasing the stop

push-button will immediately stop

the wire feed.

The emergency stop push-button is a

large, red mushroom-headed switch

designed to stop all operations quickly

in the event of an emergency. When

pressed, the wire feed will be immediately

stopped and power will be removed from the

motor. To reactivate the system, the switch must

be reset by being pulled out. After reactivation,

wire feed must be restarted in the normal way

using the start button.

START

STOP

EMERGENCY

STOP

Section V.

Controls

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Section VI.

Modes of Operation

A. Operator Mode

This is the mode which is used by the operator to

run the wire feeder. The system is automatically

set to this mode when the control is switched

on.

To set the conditions for operation, the operator

can scroll through the various screens and make

the appropriate changes. These changes will be

displayed on the top line of the display.

As the system is operating, various informa-

tion messages appear on the lower line of the

display.

Display Screens - Upper Line

Screen 1 WELCOME SCREEN

This screen appears automatically when the unit

is switched on and remains on the screen for ap-

proximately 3 seconds. It identies the model

of the control.

The next screen will appear automatically.

Screen 2 WIRE SPEED

When the second screen appears, it displays the

current level of wire feed speed. If this speed

is correct, the start button can be pressed to im-

mediately initiate wire feed. If the 9629 is part

of a system, a remote signal can initiate the start

delay prior to the wire feeding.

Jetline Engineering

Model 9629

WIRE SPEED 40.0ipm

Speed will be displayed in IPM (inches per min-

ute) or CPM (centimeters per minute). Selection

of IPM or CPM is made in the calibration mode

(see Screen 30).

If it is desired to change the speed, this is done

by turning the adjust knob to increase or de-

crease the speed as necessary. As the change

is made, the number on the display changes

accordingly.

The wire feed speed can be adjusted from the

minimum to maximum value which has been

set in the calibration mode (see Screens 21 and

24).

Press the touch pad with the down arrow to

proceed to the next screen.

Screen 3 START DELAY

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

the display changes accordingly. (This feature is

active only if remote start is used).

When the remote start signal is received, wire

feed will be inhibited until the start delay has

timed out. After the start delay has elapsed,

wire feed will commence at the speed which

has been preset.

The start delay is used to start wire feeding at the

correct time in the weld start up sequence. If the

9629 controlled wire feeder is part of a system

and a power supply with current upslope is be-

ing used, it is recommended to initiate wire feed

when the current has sloped up to about 75% of

its weld value. This will ensure that the weld

pool is correctly established before wire starts to

feed. If, for example, the total time for initial

current and upslope is set to two seconds on the

welding power supply, a wire start delay of ap-

proximately 1.5 seconds would be appropriate.

START DELAY 2.8sec

9629 Microprocessor Controller

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Try different start delay times for yourself.

The start delay time can be set from 0 to 99.9

seconds.

Press the touch pad with the down arrow to

proceed to the next screen.

Screen 4 STOP DELAY

This screen allows a stop delay to be set by turn-

ing the adjust knob to increase or decrease its

value. As the change is made, the number on

the display changes accordingly. (This feature

is only active if remote stop is used).

When the remote stop signal is received, wire

feed will continue until the stop delay has timed

out. After the stop delay has elapsed, wire feed

will stop.

The stop delay time can be set from 0 to 99.9

seconds.

The stop delay is used to stop the wire feed at

the correct time in the weld sequence. If the

wire feeder is part of a system and a power

supply with current downslope is being used,

it is recommended to stop the wire feed when

the current has sloped down to about 60% of its

weld value. If the total downslope time is set

to 10 seconds, a travel stop delay of 4 seconds

would be appropriate. Try different stop delay

times for yourself.

Press the touch pad with the down arrow to

proceed to the next screen.

Screen 5 WIRE RETRACT

This screen allows a time to be set during which

the wire retracts. When the wire feed stops,

the motor will reverse and travel at the wire

retraction speed dened in the set-up mode

(See Screen 11) for the length of time set in

this screen. The time can be set by turning the

adjust knob to increase or decrease its value. As

the change is made, the number on the display

changes accordingly.

Wire retract is used to avoid the wire freezing

into the weld pool at the end of the weld. The

retract time should be set to retract the wire out

of the pool but not so far that it moves outside

the gas shield. This would cause the end of the

wire, which is still hot as it leaves the weld pool,

to oxidize.

The wire retract time can be set from 0.0 to 9.9

seconds.

Press the touch pad with the down arrow to

proceed to the next screen.

If the control is supplied with the 9629-HW

Hot Wire Control option, the following screen

will appear.

Screen 6 RAMP TIME

This screen allows a time to be set during which

the wire speed ramps up from zero to the pro-

grammed wire feed speed level. The time can

be set by turning the adjust knob to increase or

decrease its value. As the change is made, the

number on the display changes accordingly.

The ramp time facility is used to provide a

gradual speed increase of the wire at the start of

a hot wire weld. This avoids “stubbing” of the

wire until the weld pool has grown large enough

to accept the high wire feed speed.

The ramp time can be set from 0.0 to 99.9 sec-

onds.

Press the touch pad with the down arrow to

proceed to the next screen.

STOP DELAY 3.9sec

WIRE RETRACT 0.3sec

RAMP TIME 4.7sec

9629 Microprocessor Controller

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Screen 7 WIRE SPEED (Locked)

This is the nal control screen and is similar to

Screen 2. However, with this screen displayed,

it is impossible to make any changes to the wire

feed speed setting. This screen has been created

so that any accidental movement of the adjust

knob cannot inadvertently affect the wire feed

speed setting.

To change travel speed, press the touch pad with

the up or down arrow to proceed to screen 2.

Display Screens - Lower Line

The second line of the display is reserved for

messages that inform the status of the system.

These messages fall into one of three catego-

ries:

• Messages that appear prior to welding.

• Messages that can appear at any time.

• Messages that appear during a weld se-

quence.

PRE-WELD MESSAGES

Speed Adjustment Locked

This message is displayed when the operation of

the adjust knob is locked out. When this mes-

sage is displayed, the adjust knob has no effect

and the wire feed speed cannot be altered.

High Limit

This message will be displayed whenever the

adjust knob is turned clockwise and the upper

limit of the parameter being adjusted has been

reached. The message remains on the screen

until the value of the parameter is reduced below

the limit.

This message also appears during welding if the

upper limit of wire feed speed is reached, in this

case, the message appears only as long as the

adjust knob is being turned clockwise.

Low Limit

This message is displayed whenever the adjust

knob is turned counterclockwise and the lower

limit of the parameter being adjusted has been

reached. The message will remain on the screen

until the value of the parameter is increased

above the limit.

This message also appears during welding if the

lower limit of wire feed speed is reached, in this

case, the message appears only as long as the

adjust knob is being turned counterclockwise.

Jog forward

Whenever the forward jog touch pad is pressed,

the screen will display the message shown

above. Wire will feed forward at the pre-pro-

grammed forward jog speed setting (this speed

is set in the setup mode of operation of the 9629

control - see Screen 8).

Forward wire feed will continue as long as the

touch pad is pressed. The message will remain

on the screen for as long as the wire is being

jogged forward.

WIRE SPEED 40.ipm

Adjustment Locked

WIRE SPEED 150.0ipm

Cannot go any higher

WIRE SPEED 40.ipm

Adjustment Locked

WIRE SPEED 3.6ipm

Cannot go any lower

WIRE SPEED 65.0ipm

Jog Forward

9629 Microprocessor Controller

- 18 -

STOP DELAY 3.9sec

Jogging Disabled

Jog reverse

Whenever the reverse jog touch pad is pressed,

the screen will display the message shown

above. Wire will retract at the pre-programmed

reverse jog speed setting (this speed is set in the

setup mode of operation of the 9629 control -

see Screen 9).

Wire retraction will continue as long as the touch

pad is pressed. The message will remain on

the screen for as long as the wire feed is being

jogged in reverse.

Rapid jog forward

When the forward jog touch pad is pressed, re-

leased for a short time and then pressed and held,

after a short period of time, the wire feed will

speed up to the pre-programmed rapid forward

jog speed (this speed is set in the setup mode of

operation of the 9629 control - see Screen 10).

Wire feed will continue at rapid speed as long

as the touch pad is pressed. The message will

remain on the screen as long as the wire is feed-

ing at this speed.

Rapid jog reverse

When the reverse jog touch pad is pressed, re-

leased for a short time and then pressed and held,

after a short period of time, the wire feed will

speed up to the pre-programmed rapid reverse

jog speed (this speed is set in the setup mode of

operation of the 9629 control - see Screen 10).

Wire feed will continue at rapid speed as long

as the touch pad is pressed. The message will

remain on the screen as long as wire is feeding

at this speed.

Maintained forward

When the forward jog touch pad is pressed and

held until the start button is pressed and released,

the wire will feed forward at maximum speed

and will continue to do so until the stop button

is pressed.

This message will remain on the screen as long

as the wire is feeding.

Maintained reverse

When the reverse jog touch pad is pressed and

held until the start button is pressed and re-

leased, the wire will retract at maximum speed

and will continue to do so until the stop button

is pressed.

The message will remain on the screen as long

as the wire is retracting.

Care should be taken when using this facility to

maintain tension on the wire spool or the wire

may spring off the spool and become tangled.

Jogging disabled

This message is displayed when a jog touch pad

is pressed while the system is in any program-

ming screen.

Whenever the control is being set up (start or

stop delays are being set), or whenever the

system is in setup or calibration mode, travel

is disabled.

WIRE SPEED 33.0ipm

Jog Reverse

WIRE SPEED 90.0ipm

Jog Reverse Rapid

WIRE SPEED 90.0ipm

Jog Forward Rapid

WIRE SPEED 50.0ipm

Maintained Reverse

WIRE SPEED 150.0ipm

Maintained Forward

9629 Microprocessor Controller

- 19 -

Jogging can only take place when the control

is displaying the travel speed screen (Screens

2 or 7).

ANYTIME MESSAGES

Emergency stop

If the emergency stop button is pressed, the

above message will be displayed. This can oc-

cur at any time and the message will remain on

the screen until after the emergency stop button

is reset by pulling out the knob.

DURING WELD MESSAGES

Remote Start Enabled

If the wire has been started by a remote signal,

this message is displayed. This message is also

displayed after an emergency stop has been

activated and reset and the remote run signal is

still active (even though the wire is not feeding).

This message is displayed until the remote run

signal is reset.

Start delay

If the wire feeder is being controlled from an

external source and, after a remote start signal

has been given to the 9629 control, the above

message is displayed. Time counts down from

the pre-programmed start delay value to zero.

At the end of this time, the wire starts to feed at

the pre-programmed wire feed speed.

Sensing delay

After the start delay has timed out, this message

will be displayed (providing that the Closed

Loop Mode is On, Screen 17).

The message will continue to be displayed dur-

ing the time that the closed loop sensing delay

is timing out. Time counts down from the pre-

programmed value (as set in Screen 19) to zero.

During this time, the speed runs in open loop.

Stop delay

The above message will be displayed after a

remote stop signal has been given to the 9629

control. Time counts down from the pre-pro-

grammed value to zero. During this time wire

continues to feed at the pre-programmed wire

feed speed. At the end of the stop delay time,

wire stops feeding.

Wire Retract

This message is displayed after the wire feed

has stopped and during the time that the wire is

retracting. The time (as set in Screen 5) counts

down to zero, during this time, the wire retracts

as the speed set in Screen 11.

WIRE SPEED 0.0ipm

Emergency Stop On

WIRE SPEED 0.0ipm

Start Delay 2.6sec

WIRE SPEED 40.0ipm

Remote Start Enabled

WIRE SPEED 40.0ipm

Stop Delay 3.1sec

WIRE SPEED 40.0ipm

Sensing Delay 0.8sec

WIRE SPEED 95.0ipm

Wire Retract 0.2sec

9629 Microprocessor Controller

- 20 -

REV JOG SPEED 25%

B. Set-up Mode

This mode is used to set up the various jog speeds

and other functions. To enter the set up mode,

the following procedure must be followed:

• Press and hold both up and down scroll touch

pads.

• While pressing the touch pads, press and re-

lease the power on push-button switch.

• Continue to press the up and down scroll

touch pads until the rst welcome screen has

changed to the rst set up screen (approximately

3 secs).

• Remove the pressure from the touch pads.

You are now in the set-up mode.

Set-up Screens

Screen 8 FORWARD JOG SPEED

This screen allows the forward jog speed to be

set by turning the adjust knob to increase or

decrease its value.

As the change is made, the number on the display

changes accordingly. The forward jog speed is

set as a percentage of the maximum wire feed

speed.

The wire will jog forward at the forward jog

speed whenever the forward jog touch pad is

pressed .

The forward jog speed can be set from 0 to

100%.

Press the touch pad with the down arrow to

proceed to the next screen.

Screen 9 REVERSE JOG SPEED

This screen allows the reverse jog speed to be

set by turning the adjust knob to increase or

decrease its value.

As the change is made, the number on the display

changes accordingly. The reverse jog speed is a

percentage of the maximum wire feed speed.

The wire will retract at the reverse jog speed

whenever the reverse jog touch pad is pressed.

The reverse jog speed can be adjusted from 0

to 100%.

Press the touch pad with the down arrow to

proceed to the next screen.

Screen 10 RAPID SPEED

This screen allows the rapid jog speed to be set.

This is achieved by turning the adjust knob and

as this knob is turned, the value of the speed is

increased or decreased. As the change is made,

the number on the display changes accordingly.

The rapid speed is set as a percentage of the

maximum wire feed speed.

The wire will jog forward or will retract at the

rapid jog speed whenever the forward or reverse

jog touch pad is pressed, released and pressed

again.

The rapid speed can be set from 0 to 100%.

Press the touch pad with the down arrow to

proceed to the next screen.

Screen 11 RETRACT SPEED

This screen allows the retract speed to be set by

turning the adjust knob to increase or decrease

its value. As the change is made, the number

on the display changes accordingly. The retract

speed is set as a percentage of the maximum

wire feed speed.

RAPID SPEED 70%

RETRACT SPEED 80%

FWD JOG SPEED 40%

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Miller JETLINE 9629 WIRE FEED CONTROL Owner's manual

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Miller JETLINE 9629 WIRE FEED CONTROL Owner's manual

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