OPERATION MANUAL

for Cyclomatic Series

Dual Interface Control

Revised December 2006

IMPORTANT

Read this manual carefully before installing,

commissioning or operating this product.

Jetline Engineering, 15 Goodyear Street, Irvine CA 92618

Telephone: 949-951-1515 · Fax: 949-951-9237
Web site: www.jetline.com · www.cyclomatic.com
E-mail: sales@jetline.com
 LIMITED WARRANTY

Jetline Engineering, of Irvine, California, U.S.A., warrants all new equipment to be free from defects in
material and workmanship for the period of one (1) year, provided that the equipment is installed and oper-
ated according to instructions.
Jetline Engineering’s obligation under this warranty is expressly limited to replacing or repairing and de-
fective part or correcting any manufacturing defect without charge during the warranty period, if Jetline’s in-
spection confirms the existence of such defects. Jetline’s option of repair or replacement will be F.O.B.
Factory at Irvine, California, and therefore no compensation for transportation costs of any kind will be al-
lowed.
The warranty period begins on the date of sale to the original-purchase user of the equipment.
Jetline Engineering will not be liable for any loss or consequential damage or expense accruing directly
or indirectly from the use of equipment covered by this warranty.
This warranty supersedes all previous Jetline Warranties and is exclusive with no other guarantees or
warranties expressed or implied.
 NOTICE

The installation, operation and maintenance guidelines set out in this manual will
enable you to maintain the equipment in peak condition and achieve maximum effi-
ciency with your welding operation. Please read these instructions carefully to become
aware of every advantage.

CAUTION

Only experienced personnel familiar with the

operation and safe practice of welding equipment
should install and/or use this equipment.
DUAL INTERFACE CONTROL OVERVIEW

Overview
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . iv
Table of Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . v
Table of Tables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . vii
Table of Figures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . viii
Safety
Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ix
Additional Safety Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xi
Dual Interface Control
Description of Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Drawing and Parts Lists . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Schematics and Block Diagrams. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Index
Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

iv
TABLE OF CONTENTS DUAL INTERFACE CONTROL

Table of Contents
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . iv
Table of Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . v
Table of Tables . . . . . . . . . . . . . . . . . . . . . . . . . . . . vii
Table of Figures . . . . . . . . . . . . . . . . . . . . . . . . . . . viii
Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Safety Precautions
Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ix
Note . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ix
Caution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ix
Warning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ix
Danger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ix
Safety Information . . . . . . . . . . . . . . . . . . . . . . . . . . . ix
Electric Shock . . . . . . . . . . . . . . . . . . . . . . . . . . . . ix
Fire Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . x
Additional Safety Hazards
Fire and Explosion . . . . . . . . . . . . . . . . . . . . . . . . . . . xi
Falling Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . xi
Hot Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xi
Moving Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . xi
Magnetic Fields Can Affect Pacemakers . . . . . . . . . . . . . . . . . . . . xi
Welding Wire . . . . . . . . . . . . . . . . . . . . . . . . . . . . xi
Flying Pieces Of Metal Or Dirt . . . . . . . . . . . . . . . . . . . . . . . xi
Overheated Equipment . . . . . . . . . . . . . . . . . . . . . . . . . xi
High Frequency. . . . . . . . . . . . . . . . . . . . . . . . . . . . xi
Safety References . . . . . . . . . . . . . . . . . . . . . . . . . . . xi
Dual Interface Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Description of Equipment
Description of Equipment . . . . . . . . . . . . . . . . . . . . . . . . 13
Dual Interface Control . . . . . . . . . . . . . . . . . . . . . . . . . 13
Operation
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Pendant Cable Assembly. . . . . . . . . . . . . . . . . . . . . . . . . 15
Remote Interface Cable Assembly . . . . . . . . . . . . . . . . . . . . . . 15
Start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Process Stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Horizontal Disable . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Arc Release (Null Input) . . . . . . . . . . . . . . . . . . . . . . . . . 15
Cutoff. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Vertical Disable . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Installation
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

v
DUAL INTERFACE CONTROL TABLE OF CONTENTS

During Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
During Mechanical Adjustments . . . . . . . . . . . . . . . . . . . . . . 17
During Electrical Adjustments . . . . . . . . . . . . . . . . . . . . . . . 17
Initial Set-up Instructions . . . . . . . . . . . . . . . . . . . . . . . . 18
DIP Switch Settings . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Arc Release Select . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Vertical Disable Select . . . . . . . . . . . . . . . . . . . . . . . . . 18
Horizontal Disable Select . . . . . . . . . . . . . . . . . . . . . . . . 18
User Interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Preliminary Checkout Procedure . . . . . . . . . . . . . . . . . . . . . . 18
Maintenance
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Maintenance Requirements . . . . . . . . . . . . . . . . . . . . . . . . 21
Drawing and Parts Lists
Drawing and Parts Lists . . . . . . . . . . . . . . . . . . . . . . . . . 23
Troubleshooting
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Schematics and Block Diagrams
Schematics and Block Diagrams . . . . . . . . . . . . . . . . . . . . . . 29
Index
Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

vi
TABLE OF TABLES DUAL INTERFACE CONTROL

Table of Tables
Dual Interface Control
Description of Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Drawing and Parts Lists . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Table 1 - Dual Interface Control Parts List . . . . . . . . . . . . . . . . . . . 25
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Schematics and Block Diagrams. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

vii
DUAL INTERFACE CONTROL TABLE OF FIGURES

Table of Figures
Dual Interface Control
Description of Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Figure 1 - Dual Pendant System Diagram . . . . . . . . . . . . . . . . . . . 14
Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Figure 2 - Dual Interface Control Mounting Dimensions . . . . . . . . . . . . . . 19
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Drawing and Parts Lists . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Figure 3 - Dual Interface Control Board Layout . . . . . . . . . . . . . . . . . 23
Figure 4 - Dual Pendant Exploded View . . . . . . . . . . . . . . . . . . . . 24
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Figure 5 - Dual Interface Control Schematic . . . . . . . . . . . . . . . . . . 29
Schematics and Block Diagrams. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Figure 6 - Pendant Cable Schematic . . . . . . . . . . . . . . . . . . . . . 30
Figure 7 - Remote Interface Schematic . . . . . . . . . . . . . . . . . . . . 31

viii

SAFETY
SAFETY PRECAUTIONS
THIS MANUAL HAS BEEN DESIGNED FOR
EXPERIENCED WELDING AND CUTTING
EQUIPMENT OPERATORS AND MUST BE READ
COMPLETELY BEFORE USING THIS EQUIP-
MENT. IF YOU LACK EXPERIENCE OR ARE UN-
FAMILIAR WITH THE PRACTICES AND SAFE
OPERATION OF WELDING AND CUTTING
EQUIPMENT, PLEASE CONSULT YOUR
FOREMAN. DO NOT ATTEMPT TO INSTALL,
OPERATE, OR PERFORM MAINTENANCE ON
THIS EQUIPMENT UNLESS YOU ARE QUAL-
IFIED AND HAVE READ AND UNDERSTOOD
THIS MANUAL. IF IN DOUBT ABOUT IN-
STALLING OR OPERATING THIS EQUIPMENT,
CONTACT YOUR DISTRIBUTOR OR THE CUS-
TOMER SERVICE DEPARTMENT OF ITW
JETLINE
DEFINITIONS
Throughout this manual, NOTE, CAUTION,
WARNING and DANGER are inserted to call atten-
tion to particular information. The methods used to
identify these highlights and the purpose for which
each is used, are as follows:
NOTE
Operational, procedural, and background
information which aids the operator in the
use of the machine, helps the service per-
sonnel in the performance of maintenance,
and prevents damage to the equipment.
CAUTION
An operational procedure which, if not fol-
lowed, may cause minor injury to the opera-
tor, service personnel and/or bystanders.
WARNING
An operational procedure which, if not fol-
lowed, may cause severe injury to the oper-
ator, service personnel and/or bystanders.
DANGER
An operational procedure which, if not fol-
lowed, will cause severe injury or even
death to the operator, service personnel or
bystanders.
ix
DUAL INTERFACE CONTROL
SAFETY INFORMATION
Safety is a combination of good judgment and proper
training. Operation and maintenance of any arc weld-
ing and cutting equipment involves potential hazards.
Individuals who are unfamiliar with cutting and weld-
ing equipment, use faulty judgment or lack proper
training, may cause injury to themselves and others.
Personnel should be alerted to the following potential
hazards and the safeguards necessary to avoid possi-
ble injury. In addition, before operating this equip-
ment, you should be aware of your employer's safety
regulations.
BE SURE TO READ THIS MANUAL BE-
FORE INSTALLING OR USING THIS
EQUIPMENT.
BE SURE TO READ AND FOLLOW ALL
AVAILABLE SAFETY REGULATIONS BE-
FORE USING THIS EQUIPMENT.
ELECTRIC SHOCK
THE VOLTAGES PRESENT IN THE
WELDING AND CUTTING ENVIRONMENT
CAN CAUSE SEVERE BURNS TO THE
BODY OR FATAL SHOCK. THE SEVERITY
OF ELECTRICAL SHOCK IS DETER-
MINED BY THE PATH AND THE AMOUNT
OF CURRENT THROUGH THE BODY.
A Install and continue to maintain equipment according
to USA Standard C1, National Electric Code.
B Never allow live metal parts to touch bare skin or any
wet clothing. Use only dry gloves.
C When welding or cutting in a damp area, or when
standing on metal, make sure you are well in-
sulated by wearing dry gloves, rubber soled
shoes, and by standing on a dry board or plat-
form.
D Do not use worn or damaged welding or torch cables.
Do not overload the cables. Use well maintained
equipment.
E When not welding/cutting, turn equipment OFF. Ac-
cidental grounding can cause overheating and
create a fire hazard. Do not coil or loop the ca-
ble around parts of the body.
F The ground cable should be connected to the work
piece as close to the work area as possible.
Grounds connected to building framework or
other locations remote to the work area reduce
efficiency and increase the potential hazard of
electric shock. Avoid the possibility of the weld-
DUAL INTERFACE CONTROL
ing or cutting current passing through lifting
chains, crane cables or other electrical paths.
G Keep everything dry you might touch, including
clothing, the work area, welding gun, torch and
welding or cutting machines. Fix water leaks
immediately. Do not operate equipment stand-
ing in water.
H Never use a cutting torch or welding gun which is
damaged or contains cracked housing.
I Refer to AWS-Z49.1 for grounding recommendations.
SKIN AND EYE BURNS RESULTING
FROM BODY EXPOSURE TO
ELECTRIC-ARC WELDING AND CUTTING
RAYS OR HOT METAL CAN BE MORE
SEVERE THAN SUNBURN.
A Use a proper face shield fitted with the correct filter
(#10 or greater) and cover plates to protect
your eyes, face, neck and ears from the sparks
and rays of the cutting/welding arc when
cutting/welding or observing cutting/welding.
Warn bystanders not to watch the arc and not
to expose themselves to the cutting/welding
arc rays or to hot metal.
B Wear flameproof gauntlet-type gloves, a heavy
long-sleeve shirt, cuff-less trousers,
high-topped shoes, and a welding helmet or
cap (for hair protection) to protect the skin
from arc rays and hot sparks or hot metal.
C Protect other nearby personnel from arc rays and
hot sparks with a suitable non-flammable par-
tition.
D Always wear safety glasses or goggles when in a
cutting or welding area. Use safety glasses with
side shields or goggles when chipping slag or
grinding. Chipped slag is hot and may travel a
considerable distance. Bystanders should also
wear safety glasses or goggles.
E Compressed gas cylinders are potentially dangerous,
refer to the suppliers for proper handling pro-
cedures.
F Wear ear plugs or other ear protection devices when
operating cutting or welding equipment.
FIRE SAFETY
HOT SLAG OR SPARKS CAN CAUSE A
SERIOUS FIRE WHEN IN CONTACT WITH
x
COMBUSTIBLE SOLIDS, LIQUIDS OR
GASES.
A Move all combustible materials well away from the
cutting area or completely cover materials
with a non-flammable covering. Combustible
materials include but are not limited to wood,
clothing, sawdust, gasoline, kerosene, paints,
solvents, natural gases, acetylene, propane,
and similar articles.
B Do not weld, cut or perform other hot work on used
barrels, drums, tanks or other containers until
they have been completely cleaned. There
must be no substances in the container which
might produce flammable or toxic vapors.
C For fire protection, have suitable extinguishing
equipment handy for instant use.
WELDING AND CUTTING FUMES AND
GASES, PARTICULARLY IN CONFINED
SPACES, CAN CAUSE DISCOMFORT
AND PHYSICAL HARM IF INHALED
OVER AN EXTENDED PERIOD OF TIME.
A At all times, provide adequate ventilation in the weld-
ing and cutting area by either natural or me-
chanical means. Do not weld or cut on
galvanized, zinc, lead, beryllium or cadmium
materials unless positive mechanical ventila-
tion is provided to prevent inhaling fumes and
gases from these materials.
B Do not weld or cut in locations close to chlorinated
hydrocarbon vapors coming from degreasing
or spraying operations. The heat of arc rays
can react with solvent vapors to form phos-
gene, a highly toxic gas, and other irritant
gases.
C If you develop momentary eye, nose or throat irrita-
tion during welding or cutting, it is an indica-
tion that the ventilation is not adequate. Stop
work and take the necessary steps to improve
ventilation in the welding or cutting area. Do
not continue to weld or cut if physical discom-
fort persists.
D Use an air supplied respirator if ventilation is not
adequate to remove all fumes and gases.
E Beware of gas leaks. Welding or cutting gases con-
taining argon are denser than air and will re-
place air when used in confined spaces. Do not
locate gas cylinders in confined spaces. When
not in use, shut OFF the gas supply at its source.

Refer to AWS Standard Z49.1 for specific ventilation
recommendations.
ADDITIONAL SAFETY HAZARDS
FIRE AND EXPLOSION
Fire and Explosion can result from placing
units on, over, or near combustible surfaces.
Do not install units on, over, or near com-
bustible surfaces.
Do not install unit near flammables.
FALLING EQUIPMENT
Falling Equipment can cause serious per-
sonal injury and equipment damage.
Use lifting eyes to lift unit only, not running
gear, gas cylinders, or any other accesso-
ries.
Use equipment of adequate capacity to lift
units.
If using fork lifts to move units, be sure
forks are long enough to extend beyond
opposite side of the unit.
HOT PARTS
Hot parts can cause severe burns.
Do not touch hot parts bare handed.
Allow cooling period before working on
gun or torch.
MOVING PARTS
Moving Parts can cause injury.
Keep away from moving parts, such as
fans.
Keep all doors, panels, covers, and
guards closed and securely in place.
Keep away from pinch points, such as
mechanical slides, drive rolls, carriage as-
semblies, etc.
MAGNETIC FIELDS CAN AFFECT
PACEMAKERS
Magnetic Fields from High Currents can af-
fect pacemaker operation.
Pacemaker wearers should keep away.
Wearers of pacemakers should consult
their doctors before going near arc weld-
xi
DUAL INTERFACE CONTROL
ing, gouging, plasma cutting, or spot
welding operations.
WELDING WIRE
Welding wire can cause puncture wounds.
Do not press gun trigger until instructed to
do so.
Do not point the gun toward any part of
the body, other people, or any metal when
threading welding wire through the gun.
FLYING PIECES OF METAL OR DIRT
Flying pieces of metal or dirt can injure
eyes.
Wear safety glasses with side shields or
face shields.
OVERHEATED EQUIPMENT
High output power for long durations can
cause equipment to overheat.
Allow cooling periods.
Reduce current or reduce duty cycle be-
fore starting to weld again.
Follow rated duty cycle.
HIGH FREQUENCY
High Frequency can cause electrical inter-
ference.
Take appropriate precautions to shield
sensitive electronic equipment, such as
computers, Programmable Logic
Controllers, etc.
Be sure to ground each component of the
system to one ground point, i.e., Earth
Ground (Earth) or Protective Earth (PE).
SAFETY REFERENCES
The following publications provide additional infor-
mation on important welding safeguards.
A ANSI/ASC 249.1-1988, American National Standard
"Safety in Welding and Cutting".
B Bulletin No. F4-1, "Recommended Safe Practices for
the Preparation for Welding and Cutting Con-
tainers and Piping that have held Hazardous
Substances".
C OSHA Safety and Health Standards, 29CFR 1910,
available from the United States Department of
Labor, Washington, DC 20210.
DUAL INTERFACE CONTROL
D NFPA Standard 51B, "Fire Prevention in Use of Cut-
ting and Welding Processes", available from the
National Fire Protection Association, 470 Atlan-
tic Avenue, Boston, MA 00210.
xii
E NEMA Standards Publication/No. EW1-1989, Elec-
tric Arc-Welding Apparatus, approved as ANSI
C87.1-1989. Available from National Electrical
Manufacturers Association, 155 E. 44th Street,
New York, NY 10017.
DESCRIPTION OF EQUIPMENT
Dual Interface Control
DESCRIPTION OF EQUIPMENT
Jetline’s Dual Interface Control is designed to inter-
face together two Jetline PTST Seam Tracking Sys-
tems, requiring minimal hardware and wiring from
the customer.
The Jetline Dual Interface Control replaces the origi-
nal pendant assembly normally shipped with each
Seam Tracking System. The Dual Interface Control
connects to each seam tracking system using two ca-
ble assemblies. These two cables are the Pendant
Cable assembly and the Remote Input Cable Assem-
bly, totaling four cables (two for each seam tracking
system).
The Pendant Cable Assembly is primarily a duplicate
of the original Pendant Assembly, providing all of the
functions as the original pendant, but allowing seam
tracking systems to communicate necessary informa-
tion.
The Remote Input Interface cable assembly is a dupli-
cate of the same cable assembly provided with each
seam tracking system with the PTST option installed.
13
DUAL INTERFACE CONTROL
The primary features offered by the Dual Interface
Control are:
• Synchronized Starts of the Seam Tracking Systems
• Allows the operator to control both seam tracking sys-
tems at one convenient location
• Minimal Wiring and Hardware requirements
• Easy interface to another remote console, using
switches or relays, or to a Programmable Logic Con-
trollers (PLC's) Output Contacts
DUAL INTERFACE CONTROL
The Dual Interface Control doesn't require any addi-
tional power to operate. It receives all power needed
from the seam tracking control units. The Dual Inter-
face Control is a heavy gauge steel enclosure housing
all of the electronics, connectors, etc.
The Dual Interface Control controls each system us-
ing rocker, joystick and pushbutton type switches and
lamps for process indication.
DUAL INTERFACE CONTROL DESCRIPTION OF EQUIPMENT

FIGURE 1 - DUAL PENDANT SYSTEM DIAGRAM

14
OPERATION
OPERATION
PENDANT CABLE ASSEMBLY
The pendant cable connects the Dual Interface Con-
trol to the control units. The cable is used to transmit
signals and power between the unit(s) and the Dual
Interface Control. The Dual Interface Control has one
10 feet length cable and one 20 feet length cable (for
longer length cables, consult our factory). See Figure
1 - Dual Pendant System Diagram.
REMOTE INTERFACE CABLE ASSEMBLY
Six input control lines used in conjunction with the
PTST seam tracker control unit to allow the operator
easy access to the features commonly used.
These control lines are:
• Start
• Emergency Stop
• Horizontal Disable
• Vertical Disable
• Null Input
• Cutoff
Below are definitions of each of these Remote Inputs
as they function with the Dual Interface Control.
When reviewing these definitions, please review the
9960 Series Seam Tracking System Manual, for addi-
tional information, applications and descriptions, be-
ginning in the 9660P Section. Also in the above
manual, please review the Multi-System Operation
and Wiring.
START
This signal is provided to the seam tracking system
via the Dual Interface Control's Start Button or from
the J8 connector on the Dual Pendant Interface board
assembly. This signal is provided to each system as
selected from the System Selector Switch. If System
A is the only system selected, then Seam Tracking
System A will be started, not both.
PROCESS STOP
This signal is provided to the seam tracking system
via the Dual Interface Control's Process Stop Button
or from the J8 connector on the Dual Pendant
Interface board assembly. This signal is provided to
each system without regard to the System Selector
Switch position. This signal will stop the welding
process of either of the systems operating.
HORIZONTAL DISABLE
Horizontal Disable is selected via a DIP Switch posi-
tion on the Dual Pendant Interface board assembly.
15
DUAL INTERFACE CONTROL
Selecting this feature will cause the selected system
not track horizontally during the welding process,
used by customers in multi-pass applications.
Vertical and Horizontal Disable will be initiated after
the seam tracker has achieved a null (Cycle Lamp On
and K1 relay energized). Vertical or Horizontal
Disable will inhibit the anti-jam feature of the seam
tracker. Care must be taken not to exceed the me-
chanical deflection capability of the Omni Guide Sen-
sor's lower rod and tip.
ARC RELEASE (NULL INPUT)
Arc Release or Null Input inhibits the seam tracking
system from energizing the K1 relay, typically used to
turn on the contactor of the welding power source.
This inhibit signal also prevents the the system from
initiating the Weld/Enable Time and will not allow the
welding process to start until the operator releases this
inhibit by pressing the Arc Release pushbutton on the
cover of the Dual Interface Control. This feature is
selected via a S1 DIP Switch on the dual pendant in-
terface assembly board. Selecting this feature gives
the operator the final say to start the welding process.
If this feature is not selected, the last seam tracking
system to achieve a null (locating the seam) will turn
on (or release) both seam tracking systems, Weld /
Enable Timer and K1 relays.
CUTOFF
This feature is used in applications where the opera-
tion may be interrupted, such that the Weld/Enable
timer need not be used.
The operator may elect to place a micro-switch at the
end of the weld seam or fixture or an encoder and
counter combination counting pulses/degrees of rota-
tion. The micro-switch closure or the counter's relay
output is placed between J8-4 and J8-5. This will in-
terrupt the cycle, placing the system in the Overlap
Mode of Operation.
This momentary contact closure could also be from an
encoder or PLC, to force the system into the Overlap
Mode of Operation, eliminating the Omni Guide Sen-
sor from sensing the end-of-weld. This is useful if the
weld bead is not uniform and the Omni Guide Sensor
has difficulty reliably and repeatably sensing the
end-of-weld.
No matter where in the Weld/Enable time cycle, if a
remote Cutoff input signal is received by the seam
tracker via the Dual Interface Control, the system is
forced to go into the Overlap mode of operation.
VERTICAL DISABLE
Vertical Disable is selected via a DIP Switch position
on the Dual Pendant Interface board assembly. Se-
lecting this feature will cause the selected system not
track vertically during the welding process, used by
DUAL INTERFACE CONTROL OPERATION

customers in multi-pass applications or when an AVC

is used to track the Arc Voltage, disregarding the
tactile input from the Omni Guide Sensor Assembly.

16
INSTALLATION
INSTALLATION
INFORMATION
ALL INSTALLATIONS TO BE MADE WITH
AC POWER OFF.
Typical Installation and setups can be reviewed in the
Jetline Seam Tracking System Manual, providing
cross slide and control and pendant placement. The
Dual Interface Control orientation is shown in Figure
1 - Dual Pendant System Diagram. The Figure 2 -
Dual Interface Control Mounting Dimensions shows a
dimensional drawing of the Dual Interface Control
used to mount the assembly to a fixture or other
suitable surface.
WARNING
For your own safety and to ensure proper
operation of this equipment, read this
manual and all operating precautions before
operating the equipment. Also read and un-
derstand the PTST Seam Tracking System
Manual for your safety and for proper in-
stallation and setup.
a) Read this entire Operator's Manual
prior to operation of the Jetline Seam
Tracker System.
17
DUAL INTERFACE CONTROL
b) Be sure that adequate eye protection
and ventilation is provided in the
vicinity of the welding area.
Be sure that all insulators and protective
covers on the torch and torch lead connections
are in place.
DURING OPERATION
Keep fingers, hands, etc. away from the
cross-slides during operation of the seam
tracker.
DURING MECHANICAL ADJUST-
MENTS
Ensure that the AC power is disconnected
from the control unit to prevent possible
shock when adjusting the control unit, and
accidental operation of moving parts being ad-
justed.
DURING ELECTRICAL ADJUSTMENTS
Do not disconnect connectors or remove
circuit boards when the power is con-
nected at the control unit.
DUAL INTERFACE CONTROL
INITIAL SET-UP INSTRUCTIONS
DIP SWITCH SETTINGS
There are three DIP switches on the Dual Pendant
Interface Board assembly and are labeled S1, S2 and
S3. The S1 DIP Switch, Arc Release Select, affects
both Seam Tracking Systems (A and B). DIP Switch,
S2, affects system A and DIP Switch, S3, affects Sys-
tem B turning on or off the Vertical and Horizontal
Disable feature. Figure 3 - Dual Interface Control
Board Layout is a drawing showing these DIP
Switches and their positions on the Dual Pendant
Interface Board Assembly.
ARC RELEASE SELECT
When the Arc Release Select DIP Switch is set in the
Manual position, the operator must press the Arc
Release pushbutton on the Dual Interface Control to
allow the welding process to begin. This is required
after the seam tracking systems have found the weld
seam and are awaiting the operators final say to begin
the welding process. The systems will not continue
until the operator has pressed the Arc Release
pushbutton.
When the Arc Release Select DIP Switch is set in the
Auto (Automatic) position, the systems don't require
any additional input from the operator to begin the
welding process. As soon as both seam tracking sys-
tems have found the weld seam, the systems will start
the Weld / Enable Timer and energize the K1 relay of
each system.
VERTICAL DISABLE SELECT
The left position of the DIP Switches S2 and S3, se-
lects the Vertical Disable feature. If the DIP Switch
position is pressed to the On position, the Vertical
Disable feature will be turned on. In this case, verti-
cal tracking will be disabled once the welding process
has begun.
On the other hand, if the DIP Switch position is
pressed to the Off position, the Vertical Disable fea-
ture will be turned off, allowing vertical tracking dur-
ing the welding process.
HORIZONTAL DISABLE SELECT
The right position of the DIP Switches S2 and S3, se-
lects the Horizontal Disable feature. If the DIP
Switch position is pressed to the On position, the Hor-
izontal Disable feature will be turned on. In this case,
horizontal tracking will be disabled once the welding
process has begun.
On the other hand, if the DIP Switch position is
pressed to the Off position, the Horizontal Disable
feature will be turned off, allowing horizontal tracking
during the welding process.
18
INSTALLATION
USER INTERFACE
A connector on the Dual Pendant Interface Board has
been provided to allow customers to connect the Dual
Pendant to other components of the welding system.
The interface connector, J8, is available to the user to
connect other control equipment. A customer sup-
plied cable is required. The cable should be twisted
pair, shielded cable to provide the best immunity to
noise. The shielding should only be attached to the
connecting component and should not make contact to
the Dual Interface Control enclosure or chassis com-
ponents.
The connect provides the following inputs:
• Start
• Process Stop
• Cutoff
The drawing in Figure 7 - Remote Interface Sche-
matic illustrates the typical wiring of components to
this connector. Substitute the switches with the com-
ponents outputs, i.e., PLC's relay output, limited
switches, etc.
Two cables are supplied with the system to assist in
interfacing the seam tracker system with other equip-
ment such as welding power sources, wire feeder con-
trollers, carriages, Programmable Logic Controllers
(PLC's), etc.
PRELIMINARY CHECKOUT PROCEDURE
It is strongly advised to follow the PTST Preliminary
Checkout Procedure and the PTST Checkout
Procedure described in the 9660 Series Seam
Tracking System Manual before continuing to prevent
equipment damage and/or personal injury.
As a initial setting recommendation, set both of the S2
and S3 DIP Switch positions to the Off position. In
addition, select Manual for the Arc Release Select
DIP Switch, S1. These settings give a balance of au-
tomatic and manual control of the system, leaning to-
ward a safer system. Starting the process
automatically to find the weld seam, but requiring op-
erator input to begin the welding process, provides a
good balance.
Once the system is tested for proper operation, select-
ing other features is appropriate and more beneficial.
Troubleshooting the system later may be required and
knowing a baseline initial setting can prove useful in
solving the problem.
INSTALLATION DUAL INTERFACE CONTROL

FIGURE 2 - DUAL INTERFACE CONTROL MOUNTING DIMENSIONS

19
DUAL INTERFACE CONTROL INSTALLATION

20
MAINTENANCE DUAL INTERFACE CONTROL

MAINTENANCE formed on the assembly is to be sure the enclosure is

MAINTENANCE REQUIREMENTS
Maintenance required by the Dual Interface Control is
minimal. The best preventive maintenance to be pre-
closed tightly. This prevents dust, dirt and other con-
taminants from entering and fouling the circuit board
inside.
Additional maintenance to be preformed is periodic
cleaning of the front panel and the switches.

21
DUAL INTERFACE CONTROL MAINTENANCE

22
DRAWING AND PARTS LISTS DUAL INTERFACE CONTROL

DRAWING AND PARTS LISTS

FIGURE 3 - DUAL INTERFACE CONTROL BOARD LAYOUT

23
DUAL INTERFACE CONTROL DRAWING AND PARTS LISTS

FIGURE 4 - DUAL PENDANT EXPLODED VIEW

24
DRAWING AND PARTS LISTS DUAL INTERFACE CONTROL

TABLE 1 - DUAL INTERFACE CONTROL PARTS LIST

ITEM # QPA UM PART NUMBER DESCRIPTION

1 1.000 EA ??? DUAL PENDANT ASSY ENCLOSURE
2 2.000 EA ??? DUAL PENDANT FACEPLATE
3 1.000 EA 0600-0363 DUAL PENDANT INTERFACE BD ASSY
4 2.000 EA 9660-100-2 SEAM TRACKER PENDANT FACEPLATE
5 4.000 EA 2062-0081 SWITCH PB 10 AMP BLACK
6 2.000 EA 1116-0352 SWITCH SIDETRACK
7 1.000 EA 1116-0400 SW MUSHROOM STOP ST PENDANT
8 1.000 EA 2060-0055 SWITCH, TOGGLE, DPST
9 2.000 EA 2066-0112 SW, JOY STICK, 9 POS SNGL POLE
10 2.000 EA 1116-0387 SWITCH AUTO/MAN
11 3.000 EA 941000-103 LAMP LENS TRANSLUCENT YELL SM
12 2.000 EA 941000-101 LAMP LENS TRANSLUCENT RED SM
13 1.000 EA 1114-1332 ST PENDANT ASSY, 10 FT. (NOT SHOWN)
14 1.000 EA 1114-1332-20 ST PENDANT ASSY, 20FT (NOT SHOWN)
15 5.000 EA 941000-200 LAMP HOLDER LH73/1
16 2.000 EA 2040-0552 CONN STRAIN RELIEF/CBL .50 HUB
17 .620 IN 933001-004 SHRINK TUBING 1/8" (NOT SHOWN)
18 5.000 EA 941000-011 LAMP 387
19 20.000 EA 970021-304 SCR 6-32X.38 HSBC SBZ
20 8.000 EA 970021-404 SCR 8-32X.38 HSBC SBZ
21 2.000 EA 979001-001 CABLE TIE .75 BUNDLE DIA (NOT SHOWN)
22 1.000 EA 940002-008 HOLE PLUG .875" DIA MTG HOLE

25
DUAL INTERFACE CONTROL DRAWING AND PARTS LISTS

26
TROUBLESHOOTING
TROUBLESHOOTING
Troubleshooting of the Dual Interface Control is also
minimal, due to the assembly's simplicity. A sche-
matic of the Dual Interface Control, Figure 5 - Dual
Interface Control Schematic, and of the Pendand
27
DUAL INTERFACE CONTROL
Cable Assembly, Figure 6 - Pendant Cable Schematic,
are provided to assist in troubleshooting the assembly.
Also refer to the Troubleshooting Section in the 9660
Series Seam Tracking System Manual for additional
information.
DUAL INTERFACE CONTROL TROUBLESHOOTING

28
SCHEMATICS AND BLOCK DIAGRAMS DUAL INTERFACE CONTROL

SCHEMATICS AND BLOCK DIAGRAMS

FIGURE 5 - DUAL INTERFACE CONTROL SCHEMATIC

29
DUAL INTERFACE CONTROL SCHEMATICS AND BLOCK DIAGRAMS

FIGURE 6 - PENDANT CABLE SCHEMATIC

30
SCHEMATICS AND BLOCK DIAGRAMS DUAL INTERFACE CONTROL

FIGURE 7 - REMOTE INTERFACE SCHEMATIC

31
DUAL INTERFACE CONTROL SCHEMATICS AND BLOCK DIAGRAMS

32
 DUAL INTERFACE CONTROL

held · · · · · · · · · · · xi Precautions · · · · · · · · · ix
INDEX Horizontal Disable · · · · · 15,18 Preliminary · · · · · · · · · 18
Procedure · · · · · · · · · 18
A I process · · · · · · · · 13,15,18
accidental · · · · · · · · · 17 Process Stop · · · · · · · 15,18
IC · · · · · ·
ix- x · · · · ·
adequate · · · · · · · · x- xi,17 Programmable Logic Controllers xi,13,18
indication. · · · · 13 · · · · ·
anti-jam · · · · · · · · · · 15 pushbutton · · · · · · · 13,15,18
Input · · · · · 13,15 · · · · ·
Arc Release · · · · · · · 15,18 Installation · · · · 17 · · · · ·
Auto · · · · · · · · · · · 18 insulated · · · · · · · · · · ix R
Automatic · · · · · · · · · 18 Interface · · · · · · 13,15,18,31 relay · · · · · · · · · 13,15,18
AVC · · · · · · · · · · · 16 Remote · · · · · · · · 13,15,31
J requirements · · · · · · · · 13
B J8· · · · · · · · · · · 15,18
rocker · · · · · · · · · · 13
barrel · · · · · · · · · · · x rod · · · · · · · · · · · · x
joystick · · · · · · · · · · 13
Button · · · · · · · · · · 15
K S
C K1 · · · · · · · · · · 15,18
S1 · · · · · · · · · · 15,18
Cable · · · · ·
13,15,27 · · · S2 · · · · · · · · · · · 18
carriage · · · · · · · · · · xi S3 · · · · · · · · · · · 18
Checkout · · · · · · · · · 18
L Safety
connectors · · · · · · · · 13,17 lamps · · · · · · · · · · 13 Information · · · · · · · ix
Contacts · · · · · · · · · 13 location · · · · · · · · · · 13 Seam Tracking System Manual · 17,27
Control · · · · · · · · · · xi lug · · · · · · · · · · · · x service · · · · · · · · · · ix
control lines · · · · · · · · 15 shield · · · · · · · · · · x- xi
Cross · · · · · · · · · · 17 M shielded cable · · · · · · · · 18
cross-slide · · · · · · · · · 17 maintained · · · · · · · · · ix Slide · · · · · · · · · · · 17
current· · · · · · · · · · x- xi Maintenance · · · · · · · · 21 source · · · · · · · · · · · x
Cutoff · · · · · · · · · 15,18 MAN · · · · · · · · · · · ix Start · · · · · · · · · 13,15,18
Cycle Lamp · · · · · · · · 15 manual · · · · · · ix,15,17- 18,27 suitable · · · · · · · · · · 17
Mechanical · · · · · · · · · 17 switch · · · · · · · 13,15,18,21
D momentary · · · · · · · · · x Synchronized · · · · · · · · 13
multi-pass · · · · · · · · 15- 16 System A · · · · · · · · · 15
DIP · · · · · · · · · · 15,18 System B · · · · · · · · · 18
Disable · · · · · · · · · 15,18 Multi-System Operation and Wiring · 15
System Selector Switch · · · · · 15
Dual Interface Control · · 14- 15,18,24
duration · · · · · · · · · · xi N T
dust · · · · · · · · · · · x null · · · · · · · · · · · 15
Null Input · · · · · · · · · 15 tactile · · · · · · · · · · 16
E torch · · · · · · · · · ix- xi,17
travel · · · · · · · · · · · x
Emergency Stop · · · · · · · 15 O Troubleshooting · · · · · · · 27
end-of-weld· · · · · · · · · 15 Off · · · · · · ·
· 18 · · · twisted pair · · · · · · · · · 18
Exploded · · · · · · · · · 24 ON · · · · · · ·
· 17 · · ·
Operation · · · · · · · · 15- 17 U
F output · · · · · · · · · · · xi
Output · · · · · · · · · · 13 User Interface · · · · · · · · 18
faulty · · · · · · · · · · · ix
Field · · · · · · · · · · · xi Overlap Mode · · · · · · · · 15
V
G P Vertical Disable · · · · · · 15,18
panels · · · · · · · · · · xi vicinity · · · · · · · · · · 17
ground · · · · · · · · · ix- xi
PE · · · · · · · · · · · ix- xi
W
H pendant · · · · · · · · 13,15,17
PLC · · · · · · · · · 13,15,18 Weld/Enable · · · · · · · · 15
Hardware · · · · · · · · · 13 welding process · · · · · · 15,18
Wiring · · · · · · · · · 13,15

33
DUAL INTERFACE CONTROL

34
Jetline Engineering, 15 Goodyear Street, Irvine, California 92618
Telephone: 949-951-1515 Fax: 949-951-9237 Fax
Dual Interface Control Manual, Rev. x December 2006
Web site: www.jetline.com
www.cyclomatic.com

E-Mail: sales@jetline.com
service@jetline.com