Alc-401 Arc Length Control Manual

Transcript

OPERATION MANUAL for ALC-401 Arc Length Control Effective with Serial Number 010157 February 26, 2001 IMPORTANT Read this manual carefully before installing, commissioning or operating this product. Jetline Engineering, Inc., 15 Goodyear Street, Irvine, CA 92618 Telephone: (949) 951-1515 • Fax: (949) 951-9237 -ii- LIMITED WARRANTY Jetline Engineering, Inc., 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, Inc.'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 confirms the existence of such defects. Jetline's option of repair or replacement will be F.O.B. factory at Irvine, California, and therefore no compensation for transportation costs of any kind will be allowed. The warranty period begins on the date of sale to the original-purchase user of the equipment. Jetline Engineering, Inc. 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. -iii- NOTICE The installation, operation and maintenance guidelines set out in this manual will enable you to maintain the equipment in peak condition and achieve maximum efficiency with your welding 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. -iv- ALC-401 Arc Length Control Table of Contents Section I . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A. Arc Welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C. Arc Rays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D. Fumes and Gases . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E. Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F. Welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G. Moving Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H. EMF Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I. Principal Safety Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . -1-1-1-1-2-2-2-3-3-3- Section II . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A. Control, Part # 9690 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B. Actuator, Part # ALC-401-60C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C. Interconnection Cable, Part # ALC-401-CAB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . -5-5-5-5-5- Section III . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A. Actuator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B. Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . -6-6-6-7- Section IV . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A. Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B. Actuator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C. Interconnection Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D. Optional Items . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . -8-8-8-9-9-9- Section V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation and Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A. Actuator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B. Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C. Torch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D. Interconnections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E. Ground Rod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . -10-10-10-11-11-11-12- Section VI . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . -13Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . -13Section VII . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A. Operator Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B. Display Screens - Upper Line . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C. Display Screens - Lower Line . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . -v- -14-14-14-14-17- ALC-401 Arc Length Control E. F. Setup Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . -19Calibration Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . -20- Section VIII . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . -25Part Lists . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . -25Section IX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PCB Descriptions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A. 9600-10 Microcontroller Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B. 9690-11 Isolation Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C. 9690-12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D. 9690-13 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . -32-32-32-35-38-38- Section X . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . -40Electrical Diagrams & Charts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . -40- -vi- ALC-401 Arc Length Control Section I 4. Safety Precautions 5. WARNING A. Arc Welding 6. 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. 7. In welding, as in most jobs, exposure to certain hazards 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 Standards. 8. 9. Have all installation, operation, maintenance and repair work performed only by qualified people. 11. B. 12. 10. Electric Shock 13. 14. 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. 2. 3. C. Properly install and ground this equipment according to the operation manual and national, state and local codes. 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. When making input connections, attach proper grounding conductor first - double-check connections. Frequently inspect input power cord for damage or bare wiring. Replace cord immediately if damaged - bare wiring can kill. Turn off all equipment when not in use. If earth grounding of the workpiece is required, ground it directly with a separate cable - do not use work clamp or work cable. Do not touch electrode if you are in contact with the work, ground, or another electrode from a different machine. Use only well-maintained equipment. Repair or replace damaged parts at once. Maintain unit according to manual. Wear a safety harness if working above floor level. Keep all panels and covers securely in place. Clamp work cable with good metal-to-metal contact to workpiece or worktable as near the weld as practical. Arc Rays Arc rays can burn eyes and skin; noise can damage hearing; flying slag or sparks can injure eyes. Do not touch live electrical parts. Wear dry, hole-free insulating gloves and appropriate body protection. Disconnect input power before installing or servicing this equipment. Lockout/tagout input power according to OSHA 29 CFR 1910.147 (see Safety Standards). 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. Chipping, grinding and weld cooling throw off pieces of metal or slag. 1. 2. -1- Use approved ear plugs or ear muffs if noise level is high. Use a welding helmet fitted with a proper ALC-401 Arc Length Control 3. 4. 5. D. shade of filter to protect your face and eyes when welding or watching. Wear approved safety glasses with side shields. Use protective screens or barriers to protect others from flash and glare; warn others not to watch the arc. Wear protective clothing made from durable, flame-resistant material (wool and leather) and foot protection where necessary. E. 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 carefully. 1. Fumes and Gases 2. 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. 3. 4. 1. 2. 3. 4. 5. 6. 7. 2. Cylinders Keep your head out of the fumes. Do not breathe the fumes. If inside, ventilate the area and/or use exhaust at the arc to remove welding fumes and gases. If ventilation is poor, use an approved airsupplied respirator. Read the Material Safety Data Sheets (MSDS) and the manufacturer's instruction for metals, consumables, coatings, cleaners, and degreasers. Work in a confined space only if it is well ventilated, or while wearing an air-supplied respirator. Always have a trained watch person nearby. 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. Do not weld on coated metals, such as galvanized, 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. 5. 6. 7. 8. F. Protect compressed gas cylinders from excessive heat, mechanical shocks, slag, open flames, sparks, and arcs. Install cylinders in an upright position by securing to a stationary support or cylinder rack to prevent falling or tipping. Keep cylinders away from any welding or other electrical circuits. Never weld on a pressurized cylinder explosion will result. Use only correct shielding gas cylinders, regulators, hoses and fittings designed for the specific application; maintain them and associated parts in good condition. Turn face away from valve outlet when opening cylinder valve. Keep protective cap in place over valve except when cylinder is in use or connected for use. Read and follow instructions on compressed gas cylinders, associated equipment, and CGA publication P-1 listed in Safety Standards. 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. Do not weld where flying sparks can strike Protect yourself and others from flying sparks and hot metal. flammable material. -2- ALC-401 Arc Length Control 3. 4. 5. 6. 7. 8. G. Remove all flammables within 35 ft (10.7 m) of the welding arc. If this is not possible, tightly cover them with approved covers. Be alert that welding sparks and hot materials from welding can easily go through small cracks and openings to adjacent areas. Watch for fire, and keep a fire extinguisher nearby. Do not weld on closed containers such as tanks, drums, or pipes, unless they are properly prepared according to AWSF4.1 (see safety Standards). 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. Wear oil-free protective garments such as leather gloves, heavy shirt, cuffless trousers, high shoes, and a cap. 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 science-based advice on strategies to minimize or avoid potential risks." To reduce magnetic fields in the work place, use the following procedures: 1. 2. 3. 4. 5. Moving Parts About Pacemakers: Moving parts, such as fans, rotors, and belts can cut fingers and hands and catch loose clothing. 1. 2. H. Keep cables close together by twisting or taping them. Arrange cables to one side and away from the operator. Do not coil or drape cables around the body. Keep welding power source and cables as far away as practical. Connect work clamp to workpiece as close to the weld as possible. The above procedures are among those also normally recommended for pacemaker wearers. Consult your doctor for complete information. Keep all doors, panels, covers, and guards closed and securely in place. Have only qualified people remove guards or covers for maintenance and troubleshooting as necessary. 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 EMF Information Considerations About Welding and the Effects of Low Frequency Electric and Magnetic Fields Safety and Health Standards, OSHA 29 CFR 1910, from Superintendent of Documents, U.S. Government Printing Office, Washington, D.C. 20402 The following is a quotation from the General Conclusions Section of the U.S. Congress, Office of Technology Assessment, Biological Effects of Power Frequency Electric & Magnetic Fields - Background Paper, OTA-BP-E-53 (Washington, DC: U.S. Government 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 interact with, and produce changes in, biological systems. While most of this work is of very high National Electric Code, NFPA Standard 70 from National Fire Protection Association, Batterymarch Park, Quincy, MA 02269 -3- ALC-401 Arc Length Control 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 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 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 Broadway, New York, NY 10018 Cutting and Welding Processes, NFPA Standard 51B, from National Fire Protection Association, Batterymarch Park, Quincy, MA 02269 -4- ALC-401 Arc Length Control Section II Introduction B. This detailed technical manual is designed for use by the operator, supervisor and engineer. It provides a detailed explanation of the installation, operation and maintenance of the equipment. This new design actuator provides many advantages over previous models. The torch carrying slide is driven through a ball screw and is guided on two hardened and ground shafts using recirculating ball bushings. This provides movement with very low friction resulting in smoother travel, increased response and larger weight carrying capacity. The ALC-401 arc length control system consists of three elements: A. Actuator, Part # ALC-401-60C Control, Part # 9690 The actuator is enclosed in a steel cover to provide dependable operation in areas of high temperature as may be encountered in hard surfacing and deep groove applications. The 9690 microprocessor control brings state of the art control to the task of maintaining a consistent arc length in GTAW (TIG) and PAW (Plasma) welding processes. A simplified front panel layout provides less confusion for the operator by avoiding a multitude of switches and dials. The LCD display guides the user through set up and maintenance tasks as well as providing informational messages as the weld proceeds. The quality design and manufacturing of the unit, along with its technical simplicity, will provide many years of trouble-free, dependable service. Electronic touch retract is standard on the unit, this proven method is particularly suitable when small diameters are being employed. The touch retract function can be disabled through the control for plasma welding applications. C. The control is designed specifically to control the movement of the arc length control actuator, prior to, during and after welding. Providing that all the necessary precautions have been taken with the installation, the control is fully compatible within the electrical noise environment encountered during GTAW (TIG) and PAW (Plasma) welding. Interconnection Cable, Part # ALC-401-CAB The control is connected to the actuator by a cable with Amphenol® connections at both ends. The standard cable (supplied with a system) is 10 ft (3 m) long. Interconnection cables up to 75 ft (23 m) are acceptable and are available as optional items. For applications requiring longer interconnection cables, call Jetline for advice. -5- ALC-401 Arc Length Control Section III Specifications A. Actuator Part # ALC-401-60C Two actuators are available for the ALC-401 Arc Length Control system. They differ only in the length of stroke. 4 (100) CRS 20 (500) 4 (100) CRS The standard actuator (supplied with a standard system) has a stroke length of 6" (150 mm). The alternative unit has a stroke length of 12" (300 mm). 621 Drive: Recirculating Ball Screw Mechanism: Recirculating Ball Bushings Mounting: Holes 2 x 13/32" (10 mm) diameter Mounting: Positions Four alternate positions 4" (100 mm) centers Torch: Holder Universal vee-clamp type Torch: Diameters 3/4" to 1½" (19 to 38 mm) Weight: Capacity 40 lb (18 kg) at the centerline of the torch-holder Max. Drive: Speed 30 IPM (750 mm/min) 4 (100) CRS (165) 158 (41) 3 (75) 6 (150) STROKE 621 (165) CRS ALTERNATE MOUNTING POSITIONS 138 (35) DIA 721 (19) Overall Dimensions Length: 20" (500 mm) Width: 4½" (115 mm) Depth: 3" (75 mm) Weight: -6- 22 lb (10 kg) 681 (155) ALC-401 Arc Length Control B. Control Part # 9690 S3 S2 S1 Voltage: Range 5 to 35 DC or AC Accuracy: +0.1% or 0.1 Volt (Whichever is the greater) Starting: Arc Gap 0 to 0.25" (6 mm) Start Delay: 0 to 99.9 seconds Stop Retract: Distance 0 to 6" (150 mm) -7- Processor: Intel® 80C196KC, 20 MHZ. Display: 2 x 20 Backlit LCD Panel: Polycarbonate Overlay Input: 120/240 VAC, 50/60 Hz Single Phase, 200 VA Power Cord: 8 ft (2.4 m) long Control: Weight 24 lb (11 kg) ALC-401 Arc Length Control Section IV Description A. The ALC-401-6 Arc Length Control system is designed to maintain a consistent arc length during the GTAW (TIG) and Plasma (PAW) welding processes. This is achieved by means of a closed-loop servo system. The welding voltage is sensed and sent to the control which analyzes it, compares it with the reference signal (the desired arc voltage which has been entered into the program) and then sends commands to cause the drive motor to extend or retract the actuator. The actuator carries the welding torch whose position relative to the part being welded is therefore adjusted. The 9690 control is enclosed in a dust-tight enclosure with a hinged door. Connections are made using three Amphenol® connectors: B. S1 Connector C. S2 Connector D. S3 Connector Control Actuator • Interconnection Cable Actuator cable Remote Pendant cable Cable to auxiliary controls The control is protected by a 3 amp cartridge fuse, a 10 ft (3 m) power cable is provided. The control accepts input voltages from 100 to 250 VAC. The complete system consists of the following elements: • • Control The control is microprocessor based, this provides enhanced operation and ease of use. Instructions are entered and messages are displayed on the control’s LCD display. In addition to the display, the front panel overlay incorporates touch pads and an encoder knob to select and enter information. Part # 9629 ALC-401-60C (6" (150 mm) stroke) ALC-401-CAB (10 ft (3 m) long) The control has three modes of operation: Optional items include: • Actuator • Interconnection Cable • Cable to connect to 9500 control Cable to connect to 9600 control Pendant Control • • Operator Mode: This is the mode which is active whenever the unit is switched on. IN this mode, the operator can change the desired arc voltage as well as being able to set sensitivity and select manual/auto mode. ALC-401-60C-12 (12" (300 mm) stroke) ALC-401-CAB-xx (“xx” represents the cable length in feet) (Max: 75ft (23 m) ALC-401-CAB95 (3 ft (1 m) long) 9600S1-ALC-3 (or S2) (3 ft (1 m) long) RP-401 Set-up Mode: When this mode is selected, it is possible for a supervisor to select and adjust certain parameters, such as jog speeds. Calibration Mode: This mode is used whenever it is necessary to check the unit’s calibration or to make other significant changes. -8- ALC-401 Arc Length Control B. Actuator C. Two actuators are available, they are of identical construction, the only difference is the length of stroke. The standard unit has a stroke length of 6" (150 mm), the optional unit has a stroke length of 12" (300 mm). Interconnection Cable The standard interconnection cable is 10 ft (3 m) long and fitted with Amphenol® connectors at both ends. Because of the unique design of the system, it is possible to situate the control up to 75 ft (23 m) away from the actuator. Jetline can provide special length cables, if it is desired to make these yourself, it will be necessary to use the following: The drive unit consist of a torch slide mechanism which rides on two hardened and ground steel rods using recirculating ball bushings. Motion is imparted through a ball screw and nut driven by a geared DC servo motor. The use of recirculating ball bushings results in extremely smooth movement with high sensitivity and responsiveness. Actuator Connector: Cord Grip: Control Connector: Cord Grip: Cable The actuator mechanism is protected by a metal cover with dust protection for the moving torch slide. At the end of the torch slide, a torch holder is provided suitable for the securing of a wide range of different style torches. A switch is mounted at the top of the actuator, this permits the operator to manually jog the torch up or down prior to welding. D. 3106A-20-33S 97-3057-1012-1 3106A-20-33P 97-3057-1012-1 18ga, 6 pairs, Shielded Optional Items Auxiliary Interconnection Cable A cable is available to connect the arc length control to a Jetline 9500 System Controller. This cable permits signals to and from the two units to be exchanged to provide integrated control. A mounting plate is provided at the rear of the actuator to secure the unit to the welding fixture. The mounting plate can be repositioned vertically on the actuator in increments of 4" (100 mm). This facility provides a convenient way of positioning the actuator relative to the fixture and the part to be welded. Remote Pendant Control The RP-401 Pendant Control is designed for applications where the operator cannot easily reach the arc length control from the weld point. The control is complete with a 15 ft (4½ m) long cable and plug and includes the following functions: Voltage sensing leads are provided, these connect to a filter circuit within the actuator mechanism. The purpose of the filter circuit is to protect the actuator and control from the effects of high voltage and high frequency signals. • • • -9- Voltage Control (10 turn potentiometer) Voltage Sensing Lockout Switch Jog Up/Down Switch ALC-401 Arc Length Control Section V Installation and Setup A. On receipt of the equipment, carefully check to ensure that there is no damage caused by shipping or incorrect handling. Securely mount the actuator to the welding fixture using the bracket on the rear face of the actuator. Ensure that the mounting point is rigid to avoid vibration at the torch when the unit is operating, especially if it is mounted on a moveable carriage or similar device. The mounting bracket has two holes at 6½" (165 mm) centers, use 3/8" (10 mm) screws to secure the actuator. If the position of the actuator is too high or too low, the mounting bracket can be repositioned on the back of the actuator in 4" (100 mm) increments. The normal mounting is with the actuator vertical, however, the actuator is designed to function satisfactorily in any orientation. Correct installation of the system will ensure efficient, trouble-free operation. Although the equipment has been designed and manufactured to operate within a GTAW (TIG) or Plasma (PAW) welding environment, it is still very important to pay attention to its installation, especially to adequate grounding and interconnection. The drawing below shows the required interconnection for a typical installation, the equipment should be installed as follows: Actuator HF GROUNDING WIRE BLACK SENSE LEAD INTERCONNECTION CABLE (ALC-401-CAB) WELDING CABLE RED SENSE LEAD ACTUATOR CONTROL POWER SUPPLY FIXTURE GROUND ROD -10- ALC-401 Arc Length Control Mount the welding torch in the torch holder bracket at the lower end of the actuator slide. The bracket is designed to hold torches with diameters from 3/4" to 1½" (19 to 38 mm). For special torches (as may be used for PTA applications), the torch holder may be removed and replaced by a special mounting bracket. Use 10 x 24 UNC screws to secure the special bracket to the torch holder. When using special brackets, take care not to overload the actuator. Its weight carrying capacity is a 238 (60) maximum load of 40 lb (18 kg) with a center of 3 4 (19) gravity in line with the 121 centerline of the 2 HOLES (38) 10 x 24 UNC original torch holder, 3 this is not more than 1 (75) 1/4" (29 mm) from the face of the torch Torch Holder holder. Mounting Holes B. Control The control should be mounted on a vertical surface at a convenient operating position for the operator and within the recommended cable length from the actuator. The control has four mounting holes for 5/16" (8 mm) diameter screws. Because of the advanced technology used in the control, there is little heat generated during the operation of the unit. It is not therefore necessary to allow large clearances around the control for cooling purposes. Some space should be allowed at the right hand side of the control, this is where the connections are made using Amphenol® connectors. If space is at a premium, right angle connectors are available from Jetline or your local electrical stockist. control (this is done by unscrewing and removing the two 10-32 button head screws using a 1/8" (3 mm) Allen wrench) in order to change the voltage input setting. The input voltage is changed from 110 to 220 volts by using a screwdriver and turning the range switch which is located on the transformer situated in the center of the lower part of the control box. It is important that, in addition to the conventional electrical ground on the mains supply, the control should be connected to the ground rod. A connector is provided for this purpose on the underside of the control cabinet. Use a 12 ga (3 mm2) cable fitted with a 1/4" (6 mm) lug at the control end. C. Torch The welding torch should be mounted in the clamp provided for this purpose on the lower end of the torch slide on the actuator. The torch can be mounted at any point along the length of the barrel, this permits wire guide positioners, camera and magnetic oscillation mounts to be accommodated on the barrel below the torch holder. D. Interconnections It is necessary to connect the red sense lead which exits the top of the actuator to the torch. Most machine type torches have a connection for this purpose. This connection can usually be found at the back end of the torch, inside the rubber insulator. The brass cable connector is threaded and a screw provided for the sense lead connection. If the torch does not have this connection, connect the red sense lead, either to the torch connection block (if one is provided), or to the welding power supply terminal. The cable provided is 3 ft (1 m) long. If it is necessary to extend this cable, use a well-insulated splice connection and a suitable length of Beldon® #9867 wire. This is a very high voltage wire, use of an inappropriate wire will lead to arc starting problems and interference with other equipment in the welding system. Care should be taken to keep the cable as short as possible and to avoid routing it close to metal parts of the fixture. The control is fitted with an 8 ft (2.4 m) long power cord. The cord has an integral 3-pin connector suitable for connection to standard U.S. 110 volt, single phase receptacles. If the unit is to be used with 220/240 volt, single phase, it will be necessary to cut off the 110 volt plug and secure a suitable plug to match the 220/240 volt receptacle in the country in which the unit is being used. It is now necessary to open the front panel of the -11- ALC-401 Arc Length Control A second wire exits the back of the actuator, this is the ground lead. It is a 16 ga (1.3 mm2) black wire which is 25 ft (7½ m) long. This should be connected to the workpiece ground as close as possible to the weld point. The wire should be kept as short as possible because this will decrease the electrical resistivity and provide better volt sensing. If it is necessary to extend this wire, use at least 16 ga (1.3 mm2) wire with a good splice, 14 ga (2 mm2) will provide lower resistance if the wire needs to be long. E. Ground Rod The drawing on page 6 shows the connections which it is recommended should be made to a ground rod. The ground rod should be installed close to the welding fixture and should be a 1" (25 mm) diameter copper or copper-plated bar which is driven 10 ft (3 m) deep into the ground. Consult the National Electrical Code or your local code for acceptable specifications. The use of a ground rod is of particular importance where HF is used intermittently or continuously in the GTAW (TIG) welding process. NOTE Do not operate the unit if the red sense and black ground leads are not connected. -12- ALC-401 Arc Length Control Section VI Controls The adjustment encoder knob is used to change the value of the parameter which is currently displayed on the screen display. You will note that the knob “increments”, each incremental movement of the knob changes the value of the displayed parameter by its smallest increment. This is very useful in allowing the amount of change to be known without having to view the display. If the knob is rotated quickly, the value increases or decreases faster. The knob can be used to preset to value before the arc is initiated or to change the value during welding. Most of the controls for the set-up and operation of the arc length control are mounted on the 9690 control. The only exception is the rocker switch located at the top of the actuator. This is used to provide manual up and down jog of the actuator slide. Front panel mounted controls include: The push-button power switch is used to provide primary power to the arc length control. The first 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 off the unit. These two touch pads are used to jog the actuator up or down. When the touch pad is pressed, the actuator will jog at the predetermined speed in the direction selected and will continue as long as the pad is pressed. When the touch pad is released, jogging will stop. In addition to the standard jog facility provided by the touch pads, they are capable of a second function: 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 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 9690 control, these touch pads have no other purpose. When the up or down touch pad is pressed for a short time, released and then quickly pressed and held again, jogging will start and, after a short time, speed up to the “rapid” speed. Rapid jogging will continue until the touch pad is released. This is a useful feature when it is necessary to move the actuator slide over a larger than normal distance. -13- ALC-401 Arc Length Control Section VII Operation A. If it is desired to change the arc voltage, either before the weld has started or during welding, this is done by turning the adjust knob to increase or decrease the voltage as necessary. As the change is made, the actuator will lift or lower the torch and the number on the display will change accordingly. Operator Mode This is the mode which is used by the operator during welding. The system is automatically set to this mode when the control is switched on. To select the conditions for operation, the operator can scroll up or down through the various screens and make the appropriate changes. The changes will be displayed on the upper line of the display. The arc voltage can be adjusted from the minimum to the maximum value which has been set in the calibration mode (see screens 12 and 14). B. Press the scroll down touch pad to proceed to the next screen. Display Screens - Upper Line Screen 1 WELCOME SCREEN Screen 3 Jetline Engineering Model 9690 SENSITIVITY This screen appears automatically when the unit is switched on and remains on the screen for approximately three seconds. It identifies the model of control. ARC VOLTAGE ARC VOLTAGE 50% This screen permits the sensitivity of the arc sensing to be adjusted. The sensitivity is actually the speed with which the actuator will move to adjust for a change in arc voltage. The adjustment can be made prior to welding or, if this screen is selected during the welding process, can be adjusted during welding. This latter feature is useful in certain weld conditions where the arc conditions are unstable and where it is desirable to lower the sensitivity to accommodate the unstable conditions. The next screen will appear automatically Screen 2 SENSITIVITY 10.0V If it is desired to change the sensitivity, this is done by turning the adjust knob to increase or decrease the value as required. As the change is made, the actuator response to arc variations will change and the number on the display will change accordingly. When the second screen appears, it displays the current level of arc voltage. If this voltage is correct, the weld can be started and, when the arc length control receives the signal indicating that the arc has been established, and after any start delay which may have been set, the unit will start to sense the arc voltage and make appropriate automatic adjustments to the arc length. Sensitivity can be adjusted from 0 to 99% where zero is the least sensitive condition and 99% is the highest sensitivity. It is recommended that a sensitivity of 50% be set during the initial use of the system. After the -14- ALC-401 Arc Length Control system has been in use for some time, the sensitivity should be adjusted to provide rapid response to arc voltage variations without too much “hunting”. The start delay time is initiated when the arc has been sensed. Automatic voltage control will be inhibited until after the start delay has timed out. At the end of the start delay time, the unit will respond to variations in arc voltage. Press the scroll down touch pad to proceed to the next screen. Screen 4 Start delay is used to ensure that the sensing of the arc voltage does not start too early. During welds where there is an upslope of welding current programmed, it is recommended that the arc voltage sensing be delayed until the welding current has risen to a value close to that being used for the main welding level. This will avoid undesirable movement of the actuator during the current slope. START GAP START GAP 0.06in The start delay time can be adjusted from 0 to 99.9 seconds. This screen allows the starting arc gap to be set. When the actuator, carrying the torch, is lowered to meet the workpiece, a sensing circuit detects when the electrode touches the part. At this point, the motor reverses to retract the actuator. The retraction distance (the starting arc gap) is set on this screen. Press the scroll down touch pad to proceed to the next screen. Screen 6 The arc gap will be displayed inches or millimeters. Selection of inches or metric readings is made in the calibration mode (see screen 18). RETRACT DELAY 4.3sec The starting arc gap distance is changed by turning the adjust knob to increase or decrease the distance. As the change is made, the number on the display changes accordingly. The retract delay is set by turning the adjust knob to increase or decrease the value. As the change is made, the number on the display changes accordingly. The starting arc gap distance can be adjusted from 0 to 0.25 inches (or 0 to 9.9 mm). The retract delay time is initiated when the unit senses that the arc is extinguished. During the retract delay time, the actuator is locked out. At the end of the retract delay time, the actuator retracts if a retract distance has been set (see screen 7). Press the scroll down touch pad to proceed to the next screen. Screen 5 START DELAY START DELAY RETRACT DELAY Retract delay is used to keep the torch close to the work during the post weld gas purge period. This ensures that adequate gas coverage is provided during the time that the weld pool is cooling. 1.8sec The retract delay time can be adjusted from 0 to 99.9 seconds. This screen allows a start delay to be set prior to welding by turning the adjust knob to increase or decrease the value. As the change is made, the number on the display changes accordingly. Press the scroll down touch pad to proceed to the next screen. -15- ALC-401 Arc Length Control Screen 8 Screen 7 MODE STOP RETRACT MODE STOP RETRACT AUTO 2.7in This screen sets the operation of the arc length control into manual or automatic operation. Turning the adjust knob will set the operation to Auto or Manual. In the Auto mode the arc length control responds to changes in arc voltage by moving the actuator to maintain the correct arc length. If the mode is set to Manual, the only way the actuator will move is by using the jog touch pads. After the retract delay time has elapsed, the motor will drive the actuator up and away from the part which has been welded. The distance which the torch is retracted is set on this screen. The stop retract distance will be displayed in inches or centimeters. Selection of inches or metric readings is made in the calibration mode (see screen 18). If this screen is selected during welding, the mode can be changed from automatic to manual and vice-versa.. This is a useful feature if an unstable condition develops temporarily during welding. During the unstable time, the arc length control can be switched to manual and then returned to automatic when the weld has stabilized. The stop retract distance is changed by turning the adjust knob to increase or decrease the distance. As the change is made, the number on the screen changes accordingly. The stop retract distance can be adjusted from 0 to 9.9 inches (or 0 to 25.0 cm). Care should be taken when entering the stop retract distance as it is possible to enter a distance greater than the length which the actuator can retract before it reaches the end of the slide. If this happens, no damage will be caused because movement will be stopped by the end of travel limit switch. However, the unit will be locked out for a period of time before the reset is active. This is the last of the screens in the operator mode. Press the scroll down touch pad to proceed to screen 2. Press the scroll down touch pad to proceed to the next screen. -16- ALC-401 Arc Length Control C. Rapid Jog Down Display Screens - Lower Line The second line of the display is reserved for messages that inform the status of the system. The line is divided into two parts, messages can appear individually on both the left and right part of the line. ARC VOLTAGE Jog Down Rapid LEFT SIDE MESSAGES Whenever the lower touch pad is pressed, released for a short time and then pressed and held, after a short period of time, the downward jog speed will increase to the maximum traverse speed of the actuator. Jog Down ARC VOLTAGE Jog Down 10.0V Auto Jogging will continue in the downward direction at maximum speed as long as the jog lower touch pad is pressed. The message will remain on the screen for as long as rapid downward jog is active. Whenever the lower touch pad is pressed, the screen will display the message shown above. The actuator will jog down at the predetermined jog down speed (this speed is set in the setup mode of operation - see screen 9). Rapid Jog Up ARC VOLTAGE Jog Up Rapid Jogging in the downward direction will continue as long as the jog lower touch pad is pressed. The message will remain on the screen for as long as downward jog is active. 10.0V Auto Whenever the raise touch pad is pressed, released for a short time and then pressed and held, after a short period of time, the upward jog speed will increase to the maximum traverse speed of the actuator. Jog Up ARC VOLTAGE Jog Up 10.0V Auto Jogging will continue in the upward direction at maximum speed as long as the jog raise touch pad is pressed. The message will remain on the screen for as long as rapid upward jog is active. 10.0V Auto Whenever the raise touch pad is pressed, the screen will display the message shown above. The actuator will jog up at the predetermined jog up speed (this speed is set in the setup mode of operation - see screen 10). Jogging in the upward direction will continue as long as the touch pad is pressed. The message will remain on the screen for as long as upward jog is active. -17- ALC-401 Arc Length Control This message is displayed after the unit senses that the arc has been extinguished and if a retract delay time has been programmed. During this time, the movement of the actuator slide is locked out. Arc Off ARC VOLTAGE Arc Off 10.0V Auto This message will be displayed on the screen whenever there is no arc on signal being received by the control. When this screen is displayed, the right side of the lower line displays a time, this time starts at the programmed value and counts down to zero. At the end of the retract delay time, the actuator slide retracts up and away from the completed weld. Arc On Stop Retract ARC VOLTAGE Arc On ARC VOLTAGE Stop Retract 10.0V Auto This message is displayed during the time that the actuator slide is retracting following the completion of a weld. If the retract distance is set longer than the stroke length available, this message will remain on the screen until the slide resets itself (this could take up to one minute but will probably be just a few seconds). This message will be displayed on the screen whenever an arc on signal is received by the control. Start Delay ARC VOLTAGE Start Delay 10.0V 1.2sec Touch Retract ARC VOLTAGE Touch Retract This message is displayed after an arc has been sensed by the unit and if a start delay time has been programmed. During this time, the control does not react to arc voltage variations. 10.0V Auto If a touch retract (arc gap) distance has been programmed - see screen 4, and the torch actuator has been jogged down until the electrode touches the part, this message is displayed during the time that the actuator retracts to the programmed retract distance. If the lower touch pad remains pressed, this message will stay on the screen until the touch pad is released - even if the touch retract operation is complete. When this screen is displayed, the right side of the lower line displays a time, this time starts at the programmed value and counts down to zero. At the end of the start delay time, the unit starts to react to changes in arc voltage. Retract Delay ARC VOLTAGE Retract Delay 10.0V Auto 10.0V 3.7sec -18- ALC-401 Arc Length Control D. Display Screens - Right Side Messages ARC VOLTAGE Start Delay Manual ARC VOLTAGE Arc Off E. Setup Mode This mode is used to set the jog speeds of the unit. To enter the setup mode, the following procedure must be followed: Auto 10.0V Auto This message will be displayed if the arc length control is in the auto mode as selected on screen 8 and the unit is sensing and reacting to the arc voltage. Lock ARC VOLTAGE Arc Off 1.2sec This message is always associated with a timing function. The left side of the lower line will show the parameter, the number on the right indicates the value of that parameter. The number counts down from the programmed value to zero as the parameter times out. 10.0V Manual This message will be displayed whenever the arc length control is in the manual mode as selected on screen 8. The screen will also be displayed, even if the unit is in the auto mode, whenever the unit is not actively sensing an arc or performing one of its other functions such as jogging, retracting or timing out. ARC VOLTAGE Arc Off 10.0V • Press and hold both up and down scroll touch pads. • While pressing the touch pads, press and release the power on pushbutton switch to switch on the unit. • Continue to press the up and down scroll touch pads until the first screen (screen 1) has changed to the first setup screen (screen 9). This will take approximately three seconds. • Remove the pressure from the touch pads. You are now in the setup mode and will see the following screen: 10.0V Lock Screen 9 This message will be displayed whenever the arc length control is in the auto mode and has received a signal “locking out” the sensing on a temporary basis. JOG DOWN SPEED JOG DOWN SPEED 40% This condition can apply in the event of pulsed welding where a signal is sent to the arc length control when the current is in the background state. During this period, the sensing will be disabled and the actuator slide movement will be locked. Value -19- ALC-401 Arc Length Control release the power on pushbutton switch to switch on the unit. This screen allows the jog down speed to be set by turning the adjust knob to increase or decrease its value. • Continue to press the raise and lower touch pads until the first screen (screen 1) has changed to the first calibration screen (screen 11). This will take approximately three seconds. • Remove the pressure from the touch pads. As the change is made, the number on the display changes accordingly. The jog down speed is set as a percentage of the maximum actuator traverse speed. The actuator will move down at the jog down speed whenever the lower jog touch pad is pressed. You are now in the calibration mode and will see the following screen: The jog down speed can be set from 10% to 100%. Press the down touch pad to proceed to the next screen. Screen 11 SET VOLTAGE Screen 10 JOG UP SPEED SET VOLTAGE JOG UP SPEED LOCAL 65% This screen permits the setting of the voltage to be Local or Remote. If the unit is set to Local, voltage will be set using the adjust knob on the front of the control. If the unit is set to Remote, the voltage is set by a remote device. In this case, the 9690 control accepts an analog signal from the remote controller and, through the calibration procedure, converts it into a required arc voltage level. This screen allows the jog up 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 jog up speed is set as a percentage of the maximum actuator traverse speed. The actuator will move up at the jog up speed whenever the raise jog touch pad is pressed. The jog up speed can be set from 10% to 100%. The remote feature would be used when the control is being used in conjunction with a Jetline 9500 System Controller, it can also be used with a remote PLC control or similar. Press the down touch pad to return to the jog down speed screen when all entries have been made. Press the down touch pad to proceed to the next screen. F. Screen 12 HIGH LIMIT Calibration Mode This mode is used to configure and calibrate the control. To enter the calibration mode, the following procedure must be followed: • Press and hold both raise and lower touch pads. • While pressing the touch pads, press and HIGH LIMIT 35.0V This screen allows the maximum arc voltage to be set by turning the adjust knob to increase or decrease the -20- ALC-401 Arc Length Control value. This value is the higher arc voltage range number and is also used for setting to higher “arc-on” limit. The high input can be set to a maximum number of 1023. The minimum number which can be set is 1 digit more than the number which is set for the low input (screen 15). Following the pre-delivery calibration routine, the high limit will be set at the factory and should not be changed when the system is received. Press the down touch pad to proceed to the next screen. It will be necessary to change this value only if the purpose for which the unit is being used changes significantly. In this case, contact Jetline to verify what value should be entered in this and the following screens. Screen 14 LOW LIMIT LOW LIMIT The high limit can be set to a maximum number of 99.9V. The minimum number which can be set is 0.1 volts more than the number which is entered for the low limit (screen 14). This screen allows the minimum arc voltage to be set by turning the adjust knob to increase or decrease the value. This value is the lower arc voltage range number and is also used for setting the lower “arc-on” limit. Press the down touch pad to proceed to the next screen. Following the pre-delivery calibration routine, the low limit will be set at the factory and should not be changed when the system is received. Screen 13 ACTUAL HIGH INPUT ACT HIGH INPUT 5.0V 895 It will be necessary to change this value only if the purpose for which the unit is being used changes significantly. In this case, contact Jetline to verify what value should be entered in this and the following screens. The high input represents the DC voltage value received by the control from the arc voltage (torch voltage) sense circuit with the arc voltage at the High Limit value and can be set by turning the adjust knob to increase or decrease the value. Changing this number will change the ALC Actual voltage display reading when welding near the high limit. The low limit can be set to a minimum number of 0.0V. The maximum number which can be set is 0.1 volts less than the number which is entered for the high limit (screen 12). Press the down touch pad to proceed to the next screen. Following the pre-delivery calibration routine, the high input will be set at the factory and should not normally be changed when the system is received. It will be necessary to change this value only during a calibration procedure if the procedure indicates that this is necessary. For detailed instructions on how to carry out calibration for maintenance and touch-up purposes, please refer to the calibration instructions in the maintenance section of this manual. -21- ALC-401 Arc Length Control The Set High Input value represents the DC reference voltage value received by the control from a remote pendant or voltage source that is adjusted to the High Limit voltage (maximum allowed arc voltage). This number can be changed by turning the adjust knob the increase or decrease its value. Changing this number will change the ALC Set voltage display reading when adjusting the arc voltage to the high limit using the remote pendant or voltage source. Screen 15 ACTUAL LOW INPUT ACT LOW INPUT 128 The Actual Low Input value represents the DC voltage value received by the control from the arc voltage (torch voltage) sense circuit with the arc voltage at the Low Limit value and can be set by turning the adjust knob to increase or decrease the value. Changing this number will change the ALC Actual voltage display reading when welding near the low limit. The set high input can be set to a maximum number of 1023. The minimum number which can be set is 1 digit more than the number which is entered for the set low input (screen 17). Press the down touch pad to proceed to the next screen. Following the pre-delivery calibration routine, the low input will be set at the factory and should not normally be changed when the system is received. Screen 17 SET LOW INPUT It will be necessary to change this value only during a calibration procedure if the procedure indicates that this is necessary. For detailed instructions on how to carry out calibration for maintenance and touch-up purposes, please refer to the calibration instructions in the maintenance section of this manual. SET LOW INPUT The Set Low Input value represents the DC reference voltage value received by the control from a remote pendant or voltage source that is adjusted to the Low Limit voltage (minimum allowed arc voltage). This number can be changed by turning the adjust knob the increase or decrease its value. Changing this number will change the ALC Set voltage display reading when adjusting the arc voltage to the low limit using the remote pendant or voltage source. The low input can be set to a minimum number of 0. The maximum number which can be set is 1 digit less than the number which is set for the high input (screen 13). If the system is set to Local in screen 11, pressing the down touch pad will display screen 18. If the system has been set to Remote in screen 11 the following screen will appear when the down touch pad is pressed. The set low input can be set to a minimum number of 0. The maximum number which can be set is 1 digit less than the number which is entered for the set high input (screen 16). Screen 16 SET HIGH INPUT SET HIGH INPUT 128 Press the down touch pad to proceed to the next screen. 895 -22- ALC-401 Arc Length Control (screen 3) do not require a dead band in most applications. Screen 18 UNITS The dead band can be set from 0 to 3.0 volts. UNITS Inches Press the down touch pad to proceed to the next screen. Screen 20 RETRACT SPEED This screen allows the units of measurement to be changes from Inches to Metric by turning the adjust knob. RETRACT SPEED When the system is set for Inches, jog speeds as well as touch and retract distances will be indicated in inches or inches per minute. When the control is set to Metric, the touch retract distance will be set in millimeters and all other distance measurements will be set in centimeters or centimeters per minute. This screen allows the retract speed to be set by turning the adjust knob to increase or decrease the value. As the change is made, the number on the screen changes accordingly. The retract speed is set as a percentage of the maximum actuator travel speed. This screen is intended for initial setup only. If the units are changed, the high and low limit numbers will need to be manually recalculated and entered. Changing the units of measurement only changes the title, i.e. IN or CM. The actuator will retract away from the work at the retract speed after the control has received an arc off signal and following the retract delay time (screen 5), if one is set. Press the down touch pad to proceed to the next screen. The retract speed can be set from 0 to 100%. Screen 19 DEAD BAND DEAD BAND 28% This is the last calibration screen, pressing the down touch pad will return you to the first calibration screen (screen 11). 0.3V When all entries have been made, press and release the power pushbutton to switch off the unit. A second press powers up the unit in the operator mode. The Dead Band allows a range of voltage to be entered within which the control will not react to any variations. The value is changed by turning the adjust knob to increase or decrease the number. The dead band will be the set arc voltage number (see screen 2) plus or minus the value entered in this screen. Dead band can be set for systems where an instability in the arc voltage is to be expected and where constant corrections to try to adjust for this instability are undesirable. This value should be set as small as possible because Jetline arc length controls are very responsive and, providing the sensitivity is correctly set -23- ALC-401 Arc Length Control -24- ALC-401 Arc Length Control Section VIII Part Lists The following pages provide a detailed parts list of all the elements of the ALC-401. They are arranged so the parts list on the left hand page corresponds to the assembly illustrated on the right hand page. Item numbers shown in the parts list refer to those numbers contained in the balloon in the drawing. The quantities shown are the number of items used in that particular assembly. The following parts lists are included in this manual. Their appropriate page numbers are listed: ALC-401-60C Actuator . . . . . . . . . . . . . . . . 26/27 9690 Enclosure Cabinet . . . . . . . . . . . . . . . . 28/29 9690 Enclosure Door . . . . . . . . . . . . . . . . . . 30/31 Two columns are included in the list to show the spare parts which are recommended to be stocked by the user. The two levels can be defined as follows: Level 1 These are the spares recommended for US domestic users whose use of the product does not exceed 2000 hours per year. Level 2 These are the spares recommended for international use of the product or for US domestic users who will use the product in excess of 2000 hours per year. -25- ALC-401 Arc Length Control ALC-401-60C ACTUATOR Item No. Part No. Description 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 ALC-401-60C ALC-401-60C-2 ALC-401-60C-3 ALC-401-60C-4 ALC-401-60C-5 ALC-401-60C-6 ALC-401-60C-7 ALC-401-60C-8 ALC-401-60C-9 477500 ALC-401-60C-11 SUPER-10 ALC-401-60C-13 455500 1/4x1/2x1/16 3/32x1/2 07904 GM9234E217 4501A 18391407 VCSPYR1 11/196 3102A-20-33S ALC-401-60C-24 ALC-401-60C-25 9714K64 ALC-401-60C-27 ALC-401-60C-28 Actuator Assembly - 6" (150 mm) Stroke . . . . . . . . Base . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Shaft Support, Outboard . . . . . . . . . . . . . . . . . . . . . . Shaft Support, Inboard . . . . . . . . . . . . . . . . . . . . . . . End Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Linear Slide Block . . . . . . . . . . . . . . . . . . . . . . . . . . Spacer Tube . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Slide Mount . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ball Bearing, Single Row . . . . . . . . . . . . . . . . . . . . . Linear Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Linear Ball Bearing . . . . . . . . . . . . . . . . . . . . . . . . . Ball Screw Assembly . . . . . . . . . . . . . . . . . . . . . . . . Ball Bearing, Double Row . . . . . . . . . . . . . . . . . . . . Washer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Roll Pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Coupling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Torch Holder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Rocker Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Limit Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Amphenol Socket . . . . . . . . . . . . . . . . . . . . . . . . . . . Mounting Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Wave Spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Brush Holder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Brush . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Qty -26- 1 1 1 1 1 1 2 1 1 1 2 4 1 1 1 2 1 1 1 1 2 2 1 1 1 1 1 2 Recommended Spares Level Level I II 1 2 2 2 2 2 ALC-401 Arc Length Control Figure 1 ALC-401-60C ACTUATOR -27- ALC-401 Arc Length Control 9690 ENCLOSURE Main Cabinet Item No. Part No. Description 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 9690 9690-105 27F794 AGC-3 C-1318-006-BL 3302 9690-CAB-S1 9690-CAB-S2 9690-CAB-S3 81F4550 9600-CAB-MWH 9600-CAB-SWH 9600-CAB2-AWH 120D3 12A8E 47F2062 14F410 65F1234 9690-11 9690-XFMR 9690-12 9690-13 Complete Enclosure . . . . . . . . . . . . . . . . . . . . . . . . . Cabinet (Enclosure and Door) . . . . . . . . . . . . . . . . . Fuse holder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fuse, 3 amp, 1 1/4" x 1/4" . . . . . . . . . . . . . . . . . . . . Power Cord, 8 ft (2.4 m) long . . . . . . . . . . . . . . . . . Cord Grip . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cable Assembly, S1 Connector . . . . . . . . . . . . . . . . Cable Assembly, S2 Connector . . . . . . . . . . . . . . . . Cable Assembly, S3 Connector . . . . . . . . . . . . . . . . Filter, RFI, 10kV . . . . . . . . . . . . . . . . . . . . . . . . . . . Wire Harness, Main (not illustrated) . . . . . . . . . . . . Wire Harness, Signal (not illustrated) . . . . . . . . . . . Wire Harness, Analog (not illustrated) . . . . . . . . . . Solid State Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . Servo Amplifier . . . . . . . . . . . . . . . . . . . . . . . . . . . . Capacitor, 4800MFD, 50V . . . . . . . . . . . . . . . . . . . . Mounting Bracket, Capacitor . . . . . . . . . . . . . . . . . . Terminal Strip . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Isolation Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Transformer Assembly . . . . . . . . . . . . . . . . . . . . . . . Power Supply Board, Brake . . . . . . . . . . . . . . . . . . . PWM Filter Board . . . . . . . . . . . . . . . . . . . . . . . . . . Qty -28- 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 Recommended Spares Level Level I II 5 10 1 1 1 1 1 1 ALC-401 Arc Length Control 15 16 17 9 22 8 19 7 18 3 110 220 6 14 5 2 20 21 10 Figure 2 MAIN ENCLOSURE -29- MAIN GROUND 4 ALC-401 Arc Length Control 9690 ENCLOSURE Door Item No. Part No. Description 1 2 3 4 5 6 7 8 9 10 11 9690 9690-105 9690-100 9600-10 9600-LCD AML21BBA2AB AML51-C10Y EVQ-VEMF0324B DD-75-2-6MM PSA-10L-050 9600-CAB-DWH Complete Enclosure . . . . . . . . . . . . . . . . . . . . . . . . . Cabinet (Enclosure and Door) . . . . . . . . . . . . . . . . . Polycarbonate Overlay (not illustrated) . . . . . . . . . . Processor Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . LCD Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Switch, Pushbutton, Maintained . . . . . . . . . . . . . . . Yellow Cap, Small, Square . . . . . . . . . . . . . . . . . . . Encoder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Knob, Encoder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Power Supply, 5V, 2 amp . . . . . . . . . . . . . . . . . . . . Wire Harness, Display (not illustrated) . . . . . . . . . . Qty -30- 1 1 1 1 1 1 1 1 1 1 1 Recommended Spares Level Level I II 1 1 1 1 1 1 ALC-401 Arc Length Control 8 9 5 6 4 10 2 Figure 3 DOOR -31- 7 ALC-401 Arc Length Control Section IX PCB Descriptions Please refer to the illustration on the opposite page for details of the parts and the test points. COMPONENTS A. CONNECTORS This is the main microcontroller of the 9690 control, it sends and receives signals to and from all the various devices on the board. J1 - Power Supply Connector U3 - Digital to Analog Converter (DAC) The main 5VDC is supplied on this connector. If there is no 5VDC, the unit will not operate. J2 - Analog Input/Output Connector Receives digital information from the microcontroller and converts it to an analog value to control the actuator. This sends and receives the analog signals that are on the 9690-11 board. U6 - Non-Volatile Random Access Memory (NVRAM) J3 - Keypad Connector All the calibration data, time delays and voltage values are held in this memory chip. Th protect against memory loss, the chip is battery backed. U1 - Microcontroller 9600-10 Microcontroller Board This allows the membrane style front panel to be connected to the microcontroller. Note: If this chip is removed, all data will be lost. J4 - Display Connector U7&U8 0 Erasable Programmable Read Only Memory (EPROM) This connects to the display which provides programming and operational information. J5 - Discrete Input/Output Connector These two chips store the program which controls the functions of the arc length control. Connects to the 9690-11 board and transfers and receives digital information. U9 - Electronic Programable Logic Device (EPLD) This has no function on the arc length control unit. This unit decodes digital addresses so that the microcontroller can read and write to the other devices on the board. J7 - Serial Port Connector S1 - Reset Switch This is unused in current arc length controls. This restarts the program sequence in the same way as a power down at the main power switch. J6 - Start/Stop Connector J8 - Encoder Connector JP1 - Jumper Connects to the encoder to receive pulses to increment and decrement the screen display. The DAC can provide an output of 0 to 10V or +5V to -5V. This jumper is factory set for your control and should not be changed without Jetline’s approval. J10 - Display back Light Connector Connects to the LCD display to permit the display to be made more or less bright for better viewing in various ambient lighting conditions. -32- ALC-401 Arc Length Control TEST POINTS TP1 - Digital Ground When measuring the digital level of signals on this board, connect your isolated instrument ground lead here. TP2 - Analog Ground When measuring the voltage of an analog channel, connect the black lead of your meter here. TP3 - Analog Channel 0 Connect the red lead of your meter here. This value has been scaled on the 9690-11 board. TP4 - Analog Channel 1 This is unused and reserved for future expansion. -33- ALC-401 Arc Length Control Display Contrast Adjust To To Power Display Supply Backlight J1 J10 + - To Display Discrete I/O To Encoder J8 To Keypad Microcontroller RS-422 Port J7 TP1 (Ground) NVRAM (Includes Lithium Battery) DAC JP1 (DAC Jumper) TP2 (AGrnd) J2 Analog I/O EPLD J6 To Start/Stop Switches EPROM (Lo Byte) EPROM (Hi Byte) TP4 (Ach1) Figure 4 9600-10 BOARD -34- TP3 (Ach0) 5V Voltage Ref. Adjust 5V Voltage Ref. ALC-401 Arc Length Control Please refer to the illustrations on the opposite page for details of the parts and test points. COMPONENTS B. In the "REM" (left, towards J7) position, S3 pins G and H must be short circuited for the 9690 to operate. Opening them causes an emergency stop condition. Switching SW1 left (towards the big capacitors) bypasses this. SW1 - Emergency Stop Selector Switch 9690-11 Isolation Board CONNECTORS J1 - 5V DC Power Supply Connector A 5V DC power supply is connected here. Pin 1 is positive. JP1 - N.O. / N.C. Select This jumper selects which relay contact is used for the motor drive enable signal. Jumpering pins 1 and 2 (left, toward board edge) selects the normally-open contact. Jumpering pins 2 and 3 (right, away from board edge) selects normally-closed. In the current 9690 design this is left at normally-open (left, pins 1 and 2). J2 - Analog Input/Output Connector This sends and receives analog signals and +/- 15V isolated power to and from the 9600-10 microcontroller board. J3 - Digital Input/Output Connector This allows the 9600-10 microcontroller board to control the relays and read the optical isolators. JP2 [This is the AC enhancement fudge jumper. I don't know what you want to say here.] Pins 1 and 2 (left) break the AC enhancement circuit. Pins 2 and 3 (right) give normal operation. J4 - AC/DC Power In/Out This connector receives transformer secondary AC power (24 V, center tap) on pins 1-3, and outputs unregulated ~35V DC on pins 4 and 5. TEST POINTS J5 - Actuator Connector TP1 - AC Enhancement Threshold This connects to the ALC actuator via 9690-CAB-S1. This is the threshold voltage detected by the AC enhancement circuitry. It is adjusted using trimpot P1 and is normally set to -70 mV DC. J6 - Pendant Connector This connects to the remote pendant or automation equipment via 9690-CAB-S2. TP2 - Analog Output (Arc Voltage) J7 - Automation Connector This connects to miscellaneous automation equipment via 9690-CAB-S3. This is the analog signal sent to the 9600-10 microcontroller board indicating the arc voltage. 0 to 5 V DC. J8 - Motor Drive Connector TP3 - Arc Polarity Motor speed control signal output (+/- 5 V) is on pins 1 and 2. Amplifier enable relay contact is on pins 3 and 4. This indicates if the arc voltage is above or below the threshold measured at TP1. J9 - Power Control Connector This is the gate signal in the arc voltage sample-andhold circuit. TP4 - Sample & Hold This outputs 12V DC in normal operation to a solid state relay. In emergency stop, this drops, cutting off power to the actuator's mechanical brake. TP5 - Buffer Output This is the arc voltage after being inverted (if necessary) to positive voltage. -35- ALC-401 Arc Length Control TP6 - 1/8 Arc Voltage Input This is approximately 1/8 of the arc voltage seen at the welding torch. TP7 - Electronic Touch Retract Voltage This is the voltage applied to the welding torch during electronic touch retract. It should be -12 V, and drop to near zero when the torch touches the work ground. TP8 - Electronic Touch Retract Signal This should be +12 V, and drop to -12 V when torch touches the work ground during electronic touch retract. TP9 - Switch Common This is the common for the up/down switches on the actuator and pendant. TP10 - +5V Circuit Common This is the "ground" for all 5V digital circuitry. TP11 - Touch Retract Threshold This is the threshold voltage detected by the electronic touch retract circuitry. It is adjusted using trimpot P3, and is normally set to -1 V DC. TP12 - ±12V Circuit Common This is the "ground" for the main ±12V analog circuitry. TP13 - Pendant Common This is the circuit common for the remote pendant. TP14 - Touch Retract Logical Signal This is the active-low logic signal sent to the 9600-10 microcontroller board indicating a touch retract. -36- ALC-401 Arc Length Control TP1 (AC Threshold) TP5 (A.C.E. 1st stage) TP11 (Touch retract threshold) TP8 (Work touched) TP14 (Bit 5) To Motor Drive TP7 (Touch retract voltage) J8 P3 R24 TR LEVEL TP6 (81 Arc voltage in) CR1 U13 U16 CR2 WORK SEEK To 9600-CAB2-AWH J2 (Analog to 9600-10) TP2 (81 Arc voltage out) J5 To 9600-CAB-S1 U12 U14 U17 CR5 CR3 U3 P1 NEG LEVEL U18 P2 U6 U5 U20 AC GAIN CR4 U15 JP2 To 9600-CAB-SWH J3 (Digital to 9600-10) U10 U1 J6 To 9690-CAB-S2 U2 ARC ON U8 VR2 U7 U9 J7 To 9690-CAB-S3 VR3 LOCKOUT U19 TP13 (Remote pendant common) TP10 (+5V Common) U4 VR1 + BR1 + SW1 REM E-STOP J1 J9 J4 + +5V Power In To Solid State Relay AC Power In DC Power Out - TP12 (±12V Common) Figure 5 9690-11 BOARD -37- TP4 (A.C.E. Gate) TP9 (Switch common) ALC-401 Arc Length Control Please refer to the illustrations on the opposite page for details of the parts and test points. C. D. 9690-13 CONNECTORS 9690-12 J1 - Input CONNECTORS J1 - AC Power Supply Connector This is connected to the motor armature output on the servo amplifier. A 24 V AC power supply is connected here. J2 - Output J2 - Enable Contact In This is connected to the actuator motor, via pins C and D of the S1 connector. A relay contact is connected here. When closed, power is applied to the actuator's mechanical brake (opening it), and the motor drive is enabled. J3 - Switched +24 V DC This connector outputs +24 V DC when J2 is closed, supplying power to the actuator's mechanical brake and opening it. J4 - Enable Contact Out This is the contact of a relay which is energized when J2 is closed. The contact (normally-open or normallyclosed) is selected with jumper JP1. COMPONENTS JP1 - N.O. / N.C. Select This jumper selects which relay contact is used for the motor drive enable signal. Jumpering pins 1 and 2 (up, away from board edge) selects the normally-open contact. Jumpering pins 2 and 3 (down, towards board edge) selects normally-closed. In the current 9690 design this is left at normally-closed (down, pins 2 and 3). -38- ALC-401 Arc Length Control D2 24V AC In J1 Enable Contact in from 9690-11 - J8 J2 1 BR1 C1 VR1 1 C2 D1 1 1 J3 Switched 24V DC out to S1 - pins K&L J4 Inhibit Contact to Motor Drive JP1 K1 1 Figure 6 9690-12 BOARD L1 To Motor Drive P2 - Pins 1&2 J1 C1 1 L2 Figure 9690-13 BOARD -39- 1 J2 To S1 Pins C&D ALC-401 Arc Length Control Section X Electrical Diagrams & Charts The following pages include electrical diagrams for the various parts of the ALC-401 arc length control system. Some drawings may be difficult to read due to their reduction to a single page size. Full size prints of these drawings are available free of charge on application to out Electrical Engineering Department. 9690 CONTROL Electrical Diagrams The diagrams included in this manual are as follows: S1 Connector - Pin identification S2 Connector - Pin identification S3 Connector - Pin identification Interconnection Diagram -40- ALC-401 Arc Length Control S1 CONNECTOR -41- ALC-401 Arc Length Control S2 CONNECTOR -42- ALC-401 Arc Length Control S3 CONNECTOR -43-