Miller JETLINE 9900 Owner's manual

Brand: Miller

Model: JETLINE 9900

Type: Owner's manual

This manual is also suitable for

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15 Goodyear Street, Irvine, California 92618 U.S.A.

Tel: (949) 951-1515 Fax: (949) 951-9237

9900 Software Calibration Guide

July, 2013

15 Goodyear Street, Irvine, California 92618 U.S.A.

Tel: (949) 951-1515 Fax: (949) 951-9237

A. 9900 Software Calibration

Before you make any changes it is recommended that you make a copy of the configuration file.

To do this go into the Channels Configuration Editor and press the “Save As” button on the

bottom of the screen. Change the name by adding today’s date so you can quickly tell when it

was copied. After making a copy open the old file so that all the changes will be made in the

original file. If you need to bring back the old file, just open the saved file and use “Save As”

and change its name back to the original file.

For all channels except ARC, the Closed Loop Sensitivity must be changed to 0 during the

calibration procedure. Write down what the number is, so it can be restored when you are

finished.

CURRENT Channel Configuration Editor Screen

Press Blue Button to Show Auto Calibration Boxes

Blue Button

Set to Zero for Open Loop Mode

When Calibrating Weld Current

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Channel Configuration Editor, Calibration Term Definitions

RANGE

Units: Units of Measure for the channel. When doing calibration checks, make measurements

using the same units as selected here. Note that the Travel channel’s units of measure change

from Rotational (RPM) to Surface Speed (Linear IPM, CPM) in the weld program when there is

a non-zero value entered in the Diameter field.

Minimum Value: This is the minimum controlled value for the channel. No value for this

channel can be entered in below this value in the weld program. This value should not be

changed during a touch up calibration.

Maximum Value: This is the maximum controlled value for the channel. No value for this

channel can be entered in above this value in the weld program. This value should not be

changed during a touch up calibration.

EQUIVALENT DC REFERENCE VOLTS

Out Minimum Value: This is the analog voltage that is put out by the 9900-10 board when the

channel is operated at the minimum value. Changing this number changes the Actual (measured)

value of the controlled device when near the minimum setting.

Out Maximum Value: This is the analog voltage that is put out by the 9900-10 board when the

channel is operated at the maximum value. Changing this number changes the Actual (measured)

value of the controlled device when near the maximum setting.

In Minimum Value: This is the input voltage that comes into the module from the feedback

transducer for the channel, when operating at the minimum setting. Changing this number

changes the read back display on the 9900 screen. It does not change the Actual (measured)

value, only the Displayed value when in the open loop mode. Making this number higher makes

the display read lower and vice versa.

In Maximum Value: This is the input voltage that comes into the module from the feedback

transducer for the channel, when operating at the maximum setting. Changing this number

changes the read back display on the 9900 screen. It does not change the Actual (measured)

value, only the Displayed value when in the open loop mode. Making this number higher makes

the display read lower and vice versa.

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Tel: (949) 951-1515 Fax: (949) 951-9237

Touch Up Calibration Procedure

Write a test program that will run each channel, but when you want to calibrate a channel, use

Dry Run and turn off every channel but the one that you are testing. For your test program,

make sure that the ALC is locked out in every segment. Also make sure to turn off Wait for Arc

and Touch Retract. Do not have any pulsing in your program for calibration. It is best to do the

calibration program in the Standard Mode.

To do a complete calibration you will need to run each channel near the high end of its range and

then near the low end of the range. You will need an independent test transducer for each of the

channels to measure parameter values and compare them to the 9900 program values:

For the Weld Current channel(s) you should have a calibrated current shunt or clamp-on

ammeter.

For Arc Voltage channel(s) you should have a 0 to 30 volt DC test power supply and a calibrated

DVM.

For Travel channel(s) you should have a calibrated tachometer with surface speed wheel capable

of measuring distance traveled.

Alternatively, depending on accuracy and traceability required, you could use the ammeter on

the welding power source for the weld current channel, a voltmeter and three 9 volt batteries for

the voltage channel, and do time/distance measurements for the travel and wire channels.

Touch Up Calibration Using Auto Calibration Routine (Analog Channels)

Weld Current Channel

1) Set up the system to weld. Make sure gas and water are on and set up some thick material or a

copper block to weld on during the calibration check. Use a tungsten size that will hold up to the

maximum current that will be used, for a few seconds. Set your test weld program to weld near

the high end of the weld current range (300 amps in the example screen). Call up the weld

program to run then de-select the unneeded channels from the Dry Run screen.

2) Connect the weld current test transducer or prepare to take readings from the welding power

supply if using that as the reference.

3) Run the program in the main weld segment for at least 8 seconds.

4) After running the test program, go into the Channel Configuration Editor and select the Current

channel that you are working with. First you will need to press the blue button. After you press

the Blue button, the calibration boxes will open up. Also, a green and a red button will appear.

The green button (marked “C”) is the “calculate” button, the red button is marked “U” and is the

“undo” button.

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Tel: (949) 951-1515 Fax: (949) 951-9237

Weld Current Configuration Editor Showing Auto Calibration Boxes

The Program, Read, Diameter and Time boxes will be filled in with what was just run. Next,

enter in the Actual value that you measured. After you enter in the Actual value, press the green

button (calculate) once. When you press the green button you will see the In and Out numbers

change. You will also see that the green button turns grey, so you can not press it again. If you

have made a mistake, or would like to go back, press the Red button (undo). After the changes

you will need to press the Save button to keep what you have just done. You can now run the

calibration in the other half of the range.

5) Set the weld current in the test program to run near the low limit (15 amps in the example

screen). When ready, run the test program as in Step 3 above.

6) After running the test program at the lower current, go to the Current Channel in the Channel

Configuration Editor. Press the Blue button, to open the calibration boxes. Press the green

button to calculate the new calibration values. Save the values.

Green Button --

CALCULATE

Red Button --

UNDO

Auto Calibration Boxes

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Tel: (949) 951-1515 Fax: (949) 951-9237

7) Go back and run the weld current at a couple of different points through the range to verify

accuracy and linearity to the desired tolerance. You can repeat the auto calibration sequence for

increased accuracy if needed.

8) When satisfied with calibration results, set the Closed Loop Sensitivity number back to the

original value. Record the final calibration values for future reference.

Arc Channel (With Arc Length Control)

1) There is no welding when calibrating the Arc Channel. Only the 9900 Displayed value is adjusted

in this step. You will need a calibrated DC test power supply capable of 0 to 30 VDC at 0.2A or

more. Alternatively you could use three 9 volt batteries and a calibrated DVM as a substitute

DC voltage source. Set up your test weld program to run near the high end of the arc voltage

range (30 volts is good). Call up the weld program to run then de-select the unneeded channels

from the Dry Run screen.

2) Turn off the welding power source and then connect the test power supply to the torch and the

work. Connect the negative output of the test power supply to the torch electrode (connecting

to the tungsten is ok) and connect the positive output to the Work ground. Turn on the test

power supply and set to 30.0 volts. If there is excessive current flowing from the test power

supply (20ma or more), disconnect the electrode weld cable (torch cable) from the welding

power supply.

If using the 9 volt batteries instead of the test power supply, connect all three in series then

connect the negative side to the torch electrode and positive to Work ground. Immediately

connect a DVM across the batteries. If the voltage is continually dropping, disconnect the

electrode weld cable from the welding power supply. Leave the voltmeter connected for

monitoring the voltage during the test. The voltage should be near 27 volts and should not drop

significantly during the test.

3) Run the weld program and let it run in the main weld segment for at least 8 seconds. Note the

voltage reading on the test power supply or on the batteries then press the Stop button.

4) Go into the Channel Configuration Editor and select the Arc channel that you are working with.

First you will need to press the blue button. After you press the Blue button, the calibration

boxes will open up. Also, a green and a red button will appear. The green button (marked “C”)

is the “calculate” button, the red button is marked “U” and is the “undo” button.

15 Goodyear Street, Irvine, California 92618 U.S.A.

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Arc Channel Configuration Editor Screen

Press Blue Button to Show Calibration Boxes

The Program, Read, Diameter and Time boxes will be filled in automatically with what was just

run. Next, enter in the Actual value that was displayed on the test power supply or the value you

measured across the batteries during the run. After you enter in the Actual value, press the green

button (calculate) once. When you press the green button you will see the In numbers change.

You will also see that the green button turns grey, so you can not press it again. If you have

made a mistake, or would like to go back, press the Red button (undo). After the changes you

will need to press the Save button to keep what you have just done. You can now run the

calibration in the other half of the range.

Do Not Change Closed Looping

Parameters When Calibrating Voltage

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Tel: (949) 951-1515 Fax: (949) 951-9237

Arc Channel Configuration Editor Showing Auto Calibration Boxes

5) Adjust the output of the test power supply to 6 volts. If using batteries, move the output leads

to use just one battery (9 volts).

6) Set the Arc voltage in the test program to run near the low limit (6 volts in the example screen).

When ready, run the test program as in Step 3 above.

7) After running the test program at the lower voltage, go to the Arc Channel in the Channel

Configuration Editor. Press the Blue button, to open the calibration boxes. Press the green

button to calculate the new calibration values. Save the values.

8) Go back and run the test weld program and vary the voltage on the test power supply to check

the voltage read back values at a few points in the range of 6 to 30 volts. If using batteries, try

one battery, then two, then three to verify accuracy. You can repeat the auto calibration

sequence for increased accuracy if needed.

9) When satisfied with calibration results, record the final calibration values for future reference.

15 Goodyear Street, Irvine, California 92618 U.S.A.

Tel: (949) 951-1515 Fax: (949) 951-9237

Rotation Travel Channel

1) There is no welding when calibrating the Rotation Travel Channel. You will need a calibrated test

tachometer with surface speed wheel and distance readout. Alternatively you can do a

time/distance measurement using tape measure and stopwatch (or timed weld program). Set

up your test weld program to run near the high end of the rotation travel range (in the upper

10% of the speed range). In the weld program, enter the diameter of the faceplate or tooling

that you intend to use to measure surface speed. It is recommended to not use any Initial,

Upslope, Downslope or Final segments in the calibration test weld program (enter “0” for

times). Call up the test weld program to run then de-select the unneeded channels from the

Dry Run screen.

2) Connect the travel tachometer or prepare to take distance measurements on the tooling

diameter. Be sure this diameter is the same as what is entered in the test weld program.

3) Run the program in the main weld segment for at least 30 seconds.

4) After running the test program, go into the Channel Configuration Editor and select the Rotation

Travel channel that you are working with. First you will need to press the blue button. After

you press the Blue button, the calibration boxes will open up. Also, a green and a red button

will appear. The green button (marked “C”) is the “calculate” button, the red button is marked

“U” and is the “undo” button.

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Tel: (949) 951-1515 Fax: (949) 951-9237

Analog Travel (Rotation) Configuration Editor Showing Auto Calibration Boxes.

There are Two Analog Travel Channels in this Example (Subindex 1 and 2).

Use Next and Prev to Toggle Between Them (Rotation and Boom).

5) The Program, Read, Diameter and Time boxes will be automatically filled in with what was just

run. Next, enter in the Actual value that you measured. Do not multiply or divide your

measurement to compensate for times less than or greater than 1 minute, this is automatically

compensated for in the application program. Enter only the Actual value, do not change the

other fields at this time. After you enter in the Actual value, press the green button (calculate)

once. When you press the green button you will see the In and Out numbers change. You will

also see that the green button turns grey, so you can not press it again. If you have made a

mistake, or would like to go back, press the Red button (undo). After the changes you will need

to press the Save button to keep what you have just done. You can now run the calibration in

the other half of the range.

6) Set the rotation travel speed in the test program to run near the low limit (lower 10% of the

speed range). When ready, run the test program as in Step 3 above.

Auto Calibration Boxes

Green Button --

CALCULATE

Red Button --

UNDO

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Tel: (949) 951-1515 Fax: (949) 951-9237

7) After running the test program at the lower travel speed, go to the Rotation Travel Channel in

the Channel Configuration Editor. Press the Blue button, to open the auto calibration boxes.

Enter the new Actual (measured) value then press the green button to calculate the new

calibration values. Save the values.

8) Go back and run the rotation at a couple of different points through the range to verify accuracy

and linearity to the desired tolerance. You can repeat the auto calibration sequence for

increased accuracy if needed.

9) When satisfied with calibration results, set the Closed Loop Sensitivity number back to the

original value. Record the final calibration values for future reference.

Linear Travel Channel

1) There is no welding when calibrating the Linear Travel Channel. You will need a calibrated test

tachometer with surface speed wheel and distance readout. Alternatively you can do a

time/distance measurement using tape measure and stopwatch (or timed weld program). Set

up your test weld program to run near the high end of the rotation travel range (in the upper

10% of the speed range. It is recommended to not use any Initial, Upslope, Downslope or Final

segments in the calibration test weld program (enter “0” for times). Call up the test weld

program to run then de-select the unneeded channels from the Dry Run screen.

2) Connect the travel tachometer or prepare to take distance measurements on the carriage or

boom.

3) Run the program in the main weld segment for at least 30 seconds.

4) After running the test program, go into the Channel Configuration Editor and select the Linear

Travel channel that you are working with. First you will need to press the blue button. After

you press the Blue button, the auto calibration boxes will open up. Also, a green and a red

button will appear. The green button (marked “C”) is the “calculate” button, the red button is

marked “U” and is the “undo” button.

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Tel: (949) 951-1515 Fax: (949) 951-9237

Boom Travel (Linear) Configuration Editor Showing Auto Calibration Boxes.