Quick Start Guide

Model 9640

A short guide to the operation of the

9640 Microprocessor Circumferential Welding Control

Jetline Engineering, 15 Goodyear Street, Irvine, CA 92618

Telephone: (949) 951-1515 • Fax: (949) 951-9237
Web Site: www.jetline.com • E-mail: sales@jetline.com
2
Safety
Welding
Arc welding can be hazardous, ensure that you
protect yourself and others from injury or death.
Welding is safe when precautions are taken. Do
not weld on closed containers and remove flam-
mable materials from the vicinity of the weld
area.
Protect yourself from the following hazards:
Electric Shock
This equipment is electrically powered. Turn off
the equipment when not in use. The electrode and
work circuit are electrically live when the system
is switched on. Do not touch the electrode if you
are in contact with the ground connection.
Arc Rays
Arc rays produce intense visible and invisible
rays that can burn your eyes and skin. Wear dark
3
colored, protective clothing and a headshield fitted
with a proper shade of filter to protect your eyes.
Fumes and Gases
Welding causes visible and invisible fumes and
gases. Avoid breathing these and do not operate
the equipment in a confined area.
Gas Cylinders
Welding gas is stored in cylinders under high pres-
sure. Ensure cylinders are upright and secured.
Moving Parts
Make sure that all doors, panels and guards are in
place before operating the equipment. Do not wear
loose clothing when operating the system.
Detailed safety instructions can be found in the
operation and maintenance manual for the 9640
control.
Introduction

Thank you for purchasing a Jetline product
equipped with our new, advanced 9640 series
microprocessor controller. This guide is in-
tended to give you all the information you need
to start to run your system. Because of the way
we have produced the 9600 series controls, they
are simple to use and can be operated with a
minimum of instruction. Please feel free to go
ahead, switch on and start to use your control
- you will be amazed at how easy it is.
The 9600 series of controls, however, has
been designed with many powerful features to
produce better welding results. We therefore
recommend you to study the comprehensive
operation manual supplied with this control for
information on all the many features and benefits
of the equipment.
Let’s get started.....
(Turn to page 5)

UP

TRAV SPEED 7.0rpm

DOWN ADJUST

SERIES 9600 CONTROL

EMERGENCY
STOP

REV FOR

POWER START STOP

4
Controls
The push-button power switch is used
to provide primary power to the 9640
control. The first press of the switch
POWER turns on the control. The screen will
become active and display the start-
up message. A second press of this push-button
switches the control off.
UP These two touch pads are used to
scroll the display up and down. The
down touch pad scrolls down the
DOWN display - this takes you through the
various control options in a logical order. The
up touch pad is used to go back through the lines
of the display options. In the standard operating
mode of the 9640 control, these touch pads have
no other purpose.
The adjustment knob is used to
change the value which is currently
displayed. You will note that the
ADJUST
knob “increments”, each incremental
movement of the knob increases the value by
its smallest increment. If the knob is rotated
quickly, you will see that the numbers increase or
decrease faster. The knob can be used to preset
the speed before the motor starts or to change
the speed when the motor is running.
These two touch pads are used to
jog the travel in a reverse or for-
ward direction. When the touch
REV FOR
pad is pressed, travel will begin in the direction
selected and will coninue as long as the touch
pad is pressed. When the touch pad is released,
the travel will stop.
5
In addition to the jog facility provided by the
touch pads, they are capable of providing two
more functions.
Rapid Jog: This is achieved by pressing the for-
ward or reverse touch pad, releasing it for a very
short time, then pressing and holding it again.
Jogging will continue and, after a short time, will
speed up to the “rapid” speed (this speed is selected
during a setup routine which is described in the
operation and maintenance manual for the 9640
control). Rapid jogging will continue until the
touch pad is released or the end of travel or home
limit switch is encountered.
Maintained Jog: This is achieved by first pressing
the forward or reverse touch pad and, while still
pressing this pad, pressing and releasing the start
button. The forward or reverse touch pad can then
be released. The travel device will move at rapid
speed until it is stopped by either pressing the stop
button or by the travel device encountering the end
of travel or home limit switch.
Depressing and releasing the start push-
button will start the travel which will
continue until the stop or emergency
START stop button is pressed or an end of travel
or home limit switch is encountered.
If a welding power supply is connected, pressing
the start button will initiate the weld sequence
which will continue until the weld time has
elapsed, the end of weld limit switch is encoun-
tered or the stop button or emergency stop button
is pressed.
Pressing the start push-button while the forward
or reverse touch pad is pressed will initiate main-
tained, rapid speed jog.
Controls (continued)

Depressing and releasing the stop

push-button will stop the travel and, if
the system is connected to a welding
STOP
power supply and welding is taking
place, will send a signal to the power supply to
initiate the final weld sequence.

The emergency stop push-button is a

large, red mushroom-headed switch
EMERGENCY
designed to stop all operations quickly
STOP
in the event of an emergency. When
pressed, the travel and welding operation (if
welding is taking place) will be immediately
stopped and power will be removed from the
motor. To reactivate the system, the switch must
be reset by being pulled out. After reactivation,
the travel or weld procedure must be restarted in
the normal way using the start button.

6
Display

UP

TRAV SPEED 1.8rpm

Weld Time 36.4sec

ADJUST
DOWN

The 9640 control has been designed to be easy

to use. Its operation is made easier by the use of
the display which guides you through the setup
process and, during the welding sequence, tells
you what is happening.
The display has two lines of text, the upper line
is the primary one. This is the line that is used
to set the value of the parameter you are set-
ting. This is done by calling up the line for the
parameter required and then turning the adjust
knob to increase or decrease the value.
The second line is used to display status messag-
es (information) about the progress of the weld
sequence to let you know what stage the process
is in. This line is normally only displayed after
the start push-button has been pressed.
The next pages provide you with a detailed de-
scription of the display options, they show the
messages you will see on both the upper and
lower lines of the display.
However, feel free to “try out” the display and
the setting of values - you cannot cause any
damage to the unit and it will help to familiarize
you with your control.

7
Display Screens - Upper line
Screen 1 WELCOME SCREEN
Jetline Engineering
Model 9640
This screen appears automatically when the unit
is switched on and remains on the screen for ap-
proximately 3 seconds. It identifies the model
of the control.
The next screen will appear automatically.
Screen 2 TRAVEL SPEED
TRAV SPEED 0.7rpm
When the second screen appears it displays the
current level of travel speed. If this speed is
correct, the start button can be pressed to initiate
travel or the weld sequence.
Speed will be displayed in RPM (revolutions
per minute), IPM (inches per minute of surface
speed) or CPM (centimeters per minute of
surface speed). The indicated speed changes
from RPM to surface speed if a diameter size
is entered (see Screen 4 ). Selection of IPM or
CPM is made during the setup of the system (this
routine is described in the Operation Manual for
the 9640 control).
If it is desired to change the speed, this is done
by turning the adjust knob to increase or de-
crease the speed as necessary. As the change
is made, the number on the display changes
accordingly.
Press the touch pad with the down arrow to
proceed to the next screen.
8
Screen 3 TORCH LIFT
TORCH LIFT Out
This screen permits you to manually operate
the torch lift. When the screen reads Out, the
torch lift will be in a retracted position prior to
the start of the weld sequence. The pneumatic
torch lift can be lowered by turning the adjust
knob to In. No other screen can be selected
until the adjust knob is turned to place the torch
in the Out position.
The lowering of the torch lift brings the torch
to the weld position to permit you to correctly
preset the arc gap.
Press the touch pad with the down arrow to
proceed to the next screen.
Screen 4 PART DIAMETER
DIAMETER 5.60in
This screen permits you to set a diameter for
the part you are welding. If you set a diameter
of 0.00, the display will read out in revolutions
per minute.
The diameter is set by turning the adjust knob
to increase or decrease its value. As the change
is made, the number on the display changes ac-
cordingly.
The maximum diameter which can be entered
is 999.99 inches (or centimeters - if the system
is set up for metric readings).
Press the touch pad with the down arrow to
proceed to the next screen.
Display Screens - Upper line (continued)
Screen 5 START DELAY
START DELAY 2.8sec
This screen allows a start rotation delay to be set
by turning the adjust knob to increase or decrease
its value. As the change is made, the number on
the display changes accordingly.
When the start button is pressed to start the weld
or rotation sequence, travel will be inhibited un-
til the start delay has timed out. After the start
delay has elapsed, travel will commence.
The maximum start delay which can be entered
is 99.9 seconds.
Press the scroll down arrow to proceed to the
next screen.
Screen 6 STOP DELAY
STOP DELAY 3.9sec
This screen allows a stop rotation delay to be set
by turning the adjust knob to increase or decrease
its value. As the change is made, the number on
the display changes accordingly.
When the stop button is pressed to stop the weld
or rotation sequence, travel will continue until
the stop delay has timed out. After the stop delay
has elapsed, travel will cease.
The maximum stop delay which can be entered
is 99.9 seconds.
Press the scroll down arrow to proceed to the
next screen.
9
Screen 7 WELD TIMER
WELD TIMER On
This screen allows you to turn the weld timer On
or Off, this is done by turning the adjust knob.
If the weld timer is set to On, the weld length
will be time based. The weld time starts at the
same moment as the start delay time. When the
weld time has timed out, (as the time proceeds,
it will be seen to count down on the screen), a
signal is sent to the power supply to start the
downslope and the end of weld routine, the stop
delay time will also be signaled to start.
Press the touch pad with the down arrow to
proceed to the next screen.
If Weld Timer (Screen 7) is set to On, the next
screen will appear. If the Weld Timer is set to
Off, the next screen will be Screen 9.
Screen 8 WELD TIME
WELD TIME 86.5sec
The weld time is set by turning the adjust knob
to increase or decrease its value. As the change
is made, the display changes accordingly. This
feature is used when the control is connected to
a power supply as well as the rotation device.
The maximum weld time which can be entered
is 999.9 seconds.
Press the touch pad with the down arrow to
proceed to the next screen.
Display Screens - Upper line (continued)

Screen 9 PASS COUNTER

PASS COUNTER 2

This screen permits the number of desired weld

passes to be entered. This facility will only be
active if the weld timer is turned to Off and
the circumferential fixture is fitted with limit
switches.
The number of weld passes required should be
specified by turning the adjust knob to increase
or decrease the value. As the change is made, the
number on the display changes accordingly.
The number of passes can be set from 1 to 99.
Press the touch pad with the down arrow to
proceed to the next screen.
Screen 10 TRAVEL SPEED (Locked)

TRAV SPEED 2.5rpm

Adjustment Locked

This is the final control screen and it is similar to

screen 2, however, with this screen displayed, it
is impossible to make any changes to the travel
speed setting. This screen has been created
so that any accidental movement of the adjust
knob cannot inadvertently affect the travel speed
setting.
To change the travel speed, press the touch pad
with the down arrow to proceed to screen 2.
This is the final screen in the operator mode
of control.

10
Display Screens - Lower line
Display Screens - Lower Line
The second line of the display is reserved for
messages that inform the status of the system.
These messages fall into one of three catego-
ries:
• Messages that appear prior to welding.
• Messages that can appear at any time.
• Messages that appear during a weld sequence.
PRE-WELD MESSAGES
Speed Adjustment Locked
TRAV SPEED 0.7rpm
Adjustment Locked
This message is displayed when the operation of
the adjust knob is locked out. When this mes-
sage is displayed, the adjust knob has no effect
and the travel speed cannot be altered.
High Limit
TRAV SPEED 0.0rpm
Cannot go any higher
This message will be displayed whenever the
adjust knob is turned clockwise and the upper
limit of the parameter being adjusted has been
reached. The message remains on the screen
until the value of the parameter is reduced below
the limit.
This message also appears during welding if the
upper limit of speed is reached, in this case, the
message appears only as long as the adjust knob
is being turned clockwise.
11
Low Limit
TRAV SPEED 0.2rpm
Cannot go any lower
This message is displayed whenever the adjust
knob is turned counterclockwise and the lower
limit of the parameter being adjusted has been
reached. The message will remain on the screen
until the value of the parameter is increased
above the limit.
This message also appears during welding if the
lower limit of speed is reached, in this case, the
message appears only as long as the adjust knob
is being turned counterclockwise.
Jog forward
TRAV SPEED 4.0rpm
Jog Forward
Whenever the forward jog touch pad is pressed,
the screen will display the message shown above.
Travel will proceed in a forward direction at the
pre-programmed forward jog speed setting (this
speed is set in the setup mode of operation of the
9640 control and is described in the Operation
Manual for the 9640 control).
Rotation will continue as long as the touch pad
is pressed. The message will remain on the
screen for as long as the travel is being jogged
forward.
Display Screens - Lower line (continued)
Jog reverse
TRAV SPEED 2.0rpm
Jog Reverse
Whenever the reverse jog touch pad is pressed,
the screen will display the message shown above.
Travel will proceed in a reverse direction at the
pre-programmed reverse jog speed setting (this
speed is set in the setup mode of operation of the
9640 control and is described in the Operation
Manual for the 9640 control).
Rotation will continue as long as the touch pad
is pressed. The message will remain on the
screen for as long as the travel is being jogged
in reverse.
Rapid jog forward
TRAV SPEED 7.5rpm
Jog Forward Rapid
When the forward jog touch pad is pressed,
released for a short time, then pressed and held
again, after a short period of time the rotation
will speed up to the pre-programmed rapid
forward jog speed (this speed is set in the setup
mode of operation of the 9640 control and is
described in the Operation Manual for the 9640
control).
Rotation will continue at rapid speed as long
as the touch pad is pressed. The message will
remain on the screen as long as the fixture is
rotating at this speed.
12
Rapid jog reverse
TRAV SPEED 7.5rpm
Jog Reverse Rapid
When the reverse jog touch pad is pressed,
released for a short time, then pressed and held
again, after a short period of time the rotation
will speed up to the pre-programmed rapid for-
ward jog speed (this speed is set in the setup
mode of operation of the 9640 control and is
described in the Operation Manual for the 9640
control).
Rotation will continue at rapid speed as long
as the touch pad is pressed. The message will
remain on the screen as long as the fixture is
rotating at this speed.
Maintained forward
TRAV SPEED 10.0rpm
Maintained Forward
When the forward jog touch pad is pressed and
held until the start button is pressed and released,
the travel device will rotate forward at maximum
speed and will continue to do so until the stop
button is pressed.
This message will remain on the screen as long
as the fixture is rotating.
Display Screens - Lower line (continued)
Maintained reverse
TRAV SPEED 10.0rpm
Maintained Reverse
When the reverse jog touch pad is pressed and
held until the start button is pressed and released,
the travel device will rotate backwards at maxi-
mum speed and will continue to do so until the
stop button is pressed.
The message will remain on the screen as long
as the fixture is rotating.
Jogging disabled
STOP DELAY 3.9sec
Jogging Disabled
This message is displayed when a jog touch pad
is pressed while the system is in any program-
ming screen.
Whenever the control is being set up (start or
stop delays are being set), or whenever the
system is in setup or calibration mode, travel
is disabled.
Jogging can only take place when the control
is displaying the travel speed screen (Screens
2 or 10).
13
ANYTIME MESSAGES
Emergency stop
TRAV SPEED 0.0rpm
Emergency Stop On
If the emergency stop button is pressed, the
above message will be displayed. This can oc-
cur at any time and the message will remain on
the screen until after the emergency stop button
is reset by pulling out the knob.
DURING WELD MESSAGES
PTL start delay
TRAV SPEED 0.7rpm
PTL Start Dly 3.6sec
This message will be displayed after the start
button has been pressed (or a remote start signal
has been received) and during the time that the
PTL start delay is timing out. Time counts down
from the pre-programmed value to zero.
This message will only be displayed if the auto-
matic torch lift facility is set to On, (the torch
lift facility is switched on and off in the setup
mode of operation of the 9640 control and is
described in the Operation Manual for the 9640
control).
Display Screens - Lower line (continued)
Waiting for arc on
TRAV SPEED 0.7rpm
Waiting for Arc On
At the end of the PTL start delay time, the 9640
sends a signal to the welding power supply to
initiate the arc. If the arc wait mode has been
set to On, this screen will be displayed until
the control has received a signal from the power
supply indicating that the arc has been correctly
established. This will avoid the weld sequence
starting before the arc is fully established.
(The arc wait mode is switched on and off in
the setup mode of operation of the 9640 control
and is described in the Operation Manual for
the 9640 control).
Start delay
TRAV SPEED 0.7rpm
Start Delay 2.6sec
The travel start delay will be initiated and the
above message will be displayed as follows:
When the start signal (local or remote) is given
(if Auto torch lift is Off or PTL start delay time
is 0).
At the end of the PTL start delay time (if arc wait
mode is Off and Auto torch lift is On).
After the arc has been established (if arc wait
mode is set to On).
Time counts down from the pre-programmed
value (as set in Screen 5) to zero. At the end of
this time, rotation starts at the pre-programmed
travel speed.
14
Sensing delay
TRAV SPEED 0.7rpm
Sensing Delay 0.8sec
After any of the above delays have timed out,
and following the initiation of the travel, this
message will be displayed (providing that
Closed Loop Mode is On).
The message will continue to be displayed dur-
ing the time that the closed loop sensing delay
is timing out. Time counts down from the pre-
programmed value to zero. During this time,
the travel speed runs in open loop.
(The closed loop mode settings are adjusted
in the calibration mode. This routine is de-
scribed in the Operation Manual for the 9640
control).
Weld Time
TRAV SPEED 0.7rpm
Weld Time 142.3sec
If the Weld Timer is set to On (screen 7) and
after the arc has been established, the weld time
is started. The weld time is displayed and counts
down from the pre-programmed value (as set in
Screen 8) to zero.
If the Weld Timer is set to Off (screen 7), the
weld time will be displayed when the arc is
initiated and will count up to indicate the weld
elapsed time.
Display Screens - Lower line (continued)
Stop delay
TRAV SPEED 0.7rpm
Stop Delay 5.7sec
The above message will be displayed after the
stop push-button is pressed, the weld timer has
timed out or a remote stop signal has been given
to the 9640 control. Time counts down from
the pre-programmed value to zero. During this
time the travel continues at the pre-programmed
travel speed. At the end of the stop delay time,
rotation stops.
PTL stop delay
TRAV SPEED 0.7rpm
PTL Stop Delay 2.9sec
This message will be displayed after the travel
has stopped and during the time that the PTL stop
delay is timing out. Time counts down from the
pre-programmed value to zero.
This message appears when the welding system
is fitted with a solenoid-operated pneumatic
torch lift and the torch lift facility is switched
On.
(The torch lift facility is switched on and off in
the setup mode of operation of the 9640 control
and is described in the Operation Manual for
the 9640 control).
15
Home delay
TRAV SPEED 0.7rpm
Home Delay 1.4sec
This message will be displayed after the PTL
stop delay time has elapsed, or if there is no PTL
stop delay, at the end of the stop delay time.
Time counts down from the pre-programmed
value to zero.
At the end of the Home Delay time, the fixture
will rotate at maximum speed in reverse until
the home limit switch is encountered, at which
time, the rotation will stop.
Returning Home
TRAV SPEED 10.0rpm
Returning Home
This message will be displayed whenever the
fixture is rotating back to the home position at
the end of the weld. The display will remain on
the screen until the fixture has reached the home
limit switch.
At Forward Limit
TRAV SPEED 0.7rpm
At Forward Limit
This message will be displayed whenever the
forward jog touch pad is pressed and the fixture
is at the forward limit. Under these circum-
stances, jogging in this direction is not possible.
It will be necessary to jog the rotation in the
reverse direction to move away from the limit
switch.
Display Screens - Lower line (continued)

At Reverse Limit

TRAV SPEED 0.7rpm

At Reverse Limit

This message will be displayed whenever the

reverse jog touch pad is pressed and the fixture
is at the home limit. Under these circumstances,
jogging in this direction is not possible. It will
be necessary to jog the rotation in the forward
direction to move away from the limit switch.
Reset to Proceed

TORCH LIFT In
Reset to Proceed

This message will be displayed whenever the

manual torch lift (Screen 3) is selected to the In
position. This will cause the torch lift (if fitted)
to operate to bring the torch into the weld posi-
tion. This facility is provided to permit the torch
to workpiece relationship to be checked before
the weld sequence is started. In this condition,
the scroll touch pads are deactivated.

16
Specifications

Product: Model 9640 Control Connection for welding power supply:

Outputs: Power supply start/stop
Weight: 16 lbs. (7 kg.) Emergency stop
Dimensions: Inputs: Arc on
Height: 8 in (200 mm) Pulse lock-out
Width: 10 in (250 mm) Downslope start
Depth: 6 in (150 mm) Connection for second 9600 control:
Outputs: Sequence start/stop
Input: 120/240VAC, 1phase, 50/60Hz. Emergency stop
3/2 amps Pulse lock-out
Power Cord: 6 ft (1.8 m) long Input: Emergency stop
Connection for motor:
Processor: Intel 80C196KC, 20 Mhz. Outputs: Motor voltage
Display: 2 x 20 Backlit LCD Torch lift
Inputs: Tach-generator voltage
Connections: Power Supply End of weld limit switch
Second 9600 series control End of travel limit switch
Home limit switch
Motor (90VDC Permanent Magnet)

17