Tracing Systems

I.B.
495-100
SERVICE
MANUAL
HL-90
TRACING
SYSTEMS
Copyright 1995, 1996, 1997
NORTHROP GRUMMAN - CANADA, LTD.
The information contained herein, which is now the property of Northrop Grumman -
Canada, Ltd., must be maintained in confidence. No portion of this publication may
be reproduced or used without the express permission of Northrop Grumman -
Canada, Ltd.
Manufactured and sold under one or more of the following patents:
Canada U.S.A. U.K. Japan France Italy Australia Switzerland
917,773 3,704,372 1,292,507 756,804 2,066,165 916,825 450,468 531,395

930,795 3,727,120 1,384,253 844,232 2,213,543
930,838 3,725,761 1,445,253 2,461,298
950,553 3,860,862 2,008,343
972,446 3,883,735 1,578,514
1,005,540 4,197,453 2,054,198
1,005,548 4,128,297
1,077,755 4,160,158
1,082,333 4,146,801
4,195,265
and pending applications in Canada, U.S.A., U.K., Germany, Japan, and Italy.
SEPTEMBER 1997
Manual Number I.B. 495-100

Rev. G
iii
Read, Understand and Follow These
IMPORTANT SAFETY INSTRUCTIONS
Before Operation Or Service
1. Please read ALL these instructions before 7. Unplug this product from the power source
operating the equipment. and refer servicing to qualified service
personnel, under these conditions:
2. Do not locate this equipment where moisture
could cause a shock hazard. a. When the power cord is damaged or
frayed.
3. Operate this equipment only using the type of b. If the product has been exposed to
power source specified. The equipment must rain, water, or other liquid.
be grounded by using a properly installed 3- c. If the product does not operate
wire cable that is terminated either by a 3-pin normally when the operating
grounding type power plug, or by connection instructions are followed. Adjust only
to a properly grounded distribution box. It is those controls that are covered by
hazardous to defeat the purpose of this the operating instructions, since
grounding. improper adjustment of other controls
may result in damage and will often
4. Locate the power cord where it cannot be require extensive work by a qualified
walked on. Be sure that nothing heavy technician to restore the product to
enough to deform or damage the cord is normal operation.
allowed to rest on it. d. If the unit has been damaged.
e. If the product exhibits a distinct
5. In general, extension cords should not be change in performance, indicating a
used. Where their use cannot be avoided, be need for service.
sure that the cord is rated to carry the
required current, and that the current capacity 8. This equipment should not be used for
of the power outlet is not exceeded. purposes, other than its intended and
designed use.
6. Do not attempt to service this product
yourself, as opening or removing covers may
expose you to dangerous voltage points or
other risks. Refer all servicing to qualified
personnel.
iv
IMPORTANT SERVICING
INFORMATION
CAUTION WARNING
The subassemblies listed by serial VOLTAGES EMPLOYED IN THE

number on the reverse on the test EQUIPMENT ARE SUFFICIENTLY HIGH TO
tracing, shipped with each equipment, ENDANGER HUMAN LIFE. THIS
comprise a complete system. To avoid EQUIPMENT SHOULD BE SERVICED BY
the need for realignment after QUALIFIED SERVICE TECHNICIANS.
installation, ensure that the serial
numbers os listed are kept together as
one system. To avoid damage to this equipment, turn the
unit OFF and remove AC input source power
Every effort has been made to ensure to the equipment before disconnecting cables
that this service manual contains the or removing circuit cards.
latest product information. Changes may
be made from time to time, however, to
improve product performance. CHECK
THE BACK OF THE MANUAL for
coloured Technical Bulletins of Errata
Sheets that describe these changes. If it
is noted that a component value in the
equipment differs from that shown in the
corresponding schematic diagram,
record the actual value in this manual so
that the same value can be used for
replacement, if required, when servicing
that particular assembly.
ESD PRECAUTIONS
Proper Electrostatic Discharge (ESD)

procedures must be followed at all times
when servicing one of these products.
Wear a properly grounded wrist strap
when handling any circuit card. All circuit
cards and assemblies must be handled
in electrostatic protective containers
when in transit or when handled by non-
grounded personnel.
v
File No.
LR27781
The equipment described in this manual is

manufactured to CSA-approved standards.
Any changes made to this equipment may void

CSA approval.
The equipment described in this manual meets the

requirements of the low voltage directive
73/23/EEC and EMC requirements of 89/336/EEC.
Any changes made to this equipment may void this

compliance.
vi
NORTHROP GRUMMAN Table of Contents
TABLE OF CONTENTS
CHAPTER 1 GENERAL DESCRIPTION
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Principle of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
CHAPTER 2 DETAILED DESCRIPTION
Tracer Unit Sub-assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1

Chassis Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Power Supplies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Plus and Minus 20 VDC Supplies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Regulated Plus and Minus 12 VDC Supplies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
Scanner Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
Control Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
Tracing Circuit Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
Sensor Signal Processing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
Sine Reference Signal Processing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
Drive Amplifier Circuits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
Cutting Oxygen Solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7
On-Pattern Light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7
Indicator/Flood Lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7
Circuit Card Connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7
Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8
Low Speed Corner Enhancement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8
High Speed Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9
Corner Slowdown Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10
CNC Interface Circuits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12
12V Encoder Option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12
CHAPTER 3 INSTALLATION
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Mechanical Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Tracer Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Drive Units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
Electrical Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
Tracer Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
Drive Units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7
Direction of Motor Rotation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7
Motor Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7
CHAPTER 4 OPERATING INSTRUCTIONS
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Tracing Mode (Oxy-Fuel) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
HL-90 Tracing Systems Service Manual Rev G vii

NORTHROP GRUMMAN Table of Contents
Tracing Mode (Plasma) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6

Stripping Mode (Oxy-Fuel) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6
CHAPTER 5 OPERATING FEATURES
Lead . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
Kerf . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
Patterns . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
Guidelines for Patterns . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
Corner Compensation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5
Low Contrast and Shopworn Patterns . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6
Pattern Nesting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6
Command Marks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7
CHAPTER 6 ALIGNMENT & TROUBLESHOOTING
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
Shielding the Scanner Assembly Photo-Transistor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
Power Supply Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
Signal Level Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
Zero-Signal Offset Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
Linear Speed Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
Line Frequency Change Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4
Converting from 50 Hz to 60 Hz Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4
Converting from 60 Hz to 50 Hz Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4
Low Speed Range Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5
High Speed Stability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5
Slowdown Circuit Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5
Measuring And Recalibrating True Linear Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6
Changing the Lead . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7
Re-Zeroing Kerf . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9
Periodic Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9
Scanner Sub-assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9
Tracer Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9
Drive Units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-10
Replacing Flood Lamps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-10
Replacing Indicator Lamps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-11
Ordering Replacement Lamps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-12
Troubleshooting Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-12
viii HL-90 Tracing Systems Service Manual Rev G

NORTHROP GRUMMAN List of Figures
LIST OF FIGURES
2-1 Cable Assembly 415B905H01 Installed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2

2-2 Command Mark for Corner Slowdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10
3-1 Tracer Unit Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2

3-2 Typical Gearbox Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
3-3 Typical Drive Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
3-4 Tracer Unit Electrical Connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
4-1 HL-90 Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
5-1 Kerf Offset Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1

5-2 Determining Direction of Kerf Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
5-3 Minimum Line Separation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5
5-4 Corner Compensation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5
5-5 Pattern Nesting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6
5-6 Command Mark for Corner Slowdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7
6-1 Tracer Unit Assembly, Opened View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2

6-2 Speed Measurement Test Line . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6
6-3 Mirror & Magnet Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8
6-4 Location of Flood and Indicator Lamps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-10
6-5 Component Location on the Chassis Board CCA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-12
6-6 Component Location on Tracing Circuit CCA 3925D27G01 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-24
HL-90 Tracing Systems Service Manual Rev G ix

NORTHROP GRUMMAN List of Tables
LIST OF TABLES
1-1 HL-90 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
2-1 Chassis Board Test Points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2

2-2 Chassis Board Connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
2-3 Primary Power Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
2-4 DC Voltage Distribution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
2-5 Circuit Card Connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7
4-1 HL-90 Control Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
5-1 Pattern Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
6-1 Flood Lamps and Spotlight - Part Numbers and description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-12
6-2 Troubleshooting Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-13
6-3 Adjustments and Test Points on the Tracing Circuit CCA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-23
x HL-90 Tracing Systems Service Manual Rev G

NORTHROP GRUMMAN About This Manual
ABOUT THIS MANUAL
This service manual consists of six Chapter 6: ALIGNMENT & TROUBLE-

standard Chapters for all HL-90 products, SHOOTING. This section
followed by a custom Parts List and where covers all essential
applicable, an Addendum, as follows: maintenance procedures,
operating and speed
Chapter 1: GENERAL adjustments, power supply
DESCRIPTION. checks and line frequency
Describes the principle of change procedures.
operation of the Linatrol
HL-90 Co-ordinate Drive
Tracing System, including Supplement: PARTS LIST. This is a
specifications. complete listing, on an
assembly basis, of
Chapter 2: DETAILED replaceable parts for the
DESCRIPTION. Provides particular HL-90 model you
functional and circuit have selected. The
descriptions of the Tracing information found in this
System assemblies and section will be of value
subassemblies. when ordering either
spares or replacement
Chapter 3: INSTALLATION. Covers parts.
the mechanical and
electrical installation
procedures and the motor Addendum: Where applicable, this manual
checkout procedure. contains an Addendum
covering any differences from
Chapter 4: OPERATING the standard configuration.
INSTRUCTIONS. The
HL-90 Front Panel controls
are described and
operating instructions are
given for the two tracing
modes (PLASMA and
OXY-FUEL) and the
Stripping mode.
Chapter 5: OPERATING FEATURES.

This section covers the
special features of the
HL-90 system, Lead
Tracing, Kerf
compensation and Pattern
Tracing capabilities.
HL-90 Tracing Systems Service Manual Rev G xi

NORTHROP GRUMMAN General Description
GENERAL DESCRIPTION 1
INTRODUCTION
The HL-90 Linatrol Co-ordinate Drive Tracing System automatically controls the motion of a cutting tool by
following a line or silhouette pattern. It is intended for use on small cutting machines.
System features include automatic line acquisition, tool off-pattern interlock and a four-position direction switch
for manual operation. The system consists of a Tracing Unit containing:
! the Scanner
! the Electronics and Controls
! two Drive Units.
A view of the HL-90 Drive Tracing System is shown in Figure 1-1.
PRINCIPLE OF OPERATION
The scanner is an opto-electronic device using a circular scan system to trace either line or silhouette patterns.
The scan motor is a synchronous ac motor, operating at 1800 rpm on a 60 Hz primary power supply (or 1500 rpm
on a 50 Hz supply). Attached to the motor shaft is a mirror and magnet assembly. The magnet associated with a
fixed coil generates a sinusoidal reference signal. The mirror reflects an image of the fixed photo-sensor through a
focussing lens on to the pattern surface. The mirror is inclined at a small angle with reference to the optical axis
and the image of the photo-sensor therefore traces a circular path about the pattern line.
The photo-sensor signal is obtained when the image of the sensor crosses the pattern line. It is processed along
with the sine reference signal on the Tracing Circuit card to produce two vector signals that describe the direction
of tracer motion required to follow the pattern line. These signals are amplified and supplied to the two
Drive Units, thereby producing machine motion along the pattern line.
The controls which are wired directly to the Tracing Circuit card provide for speed adjustment, tracing or
stripping operations and a four-direction manual traversing control. A green LED indicates pattern acquisition
when illuminated.
HL 90 Tracing Systems Service Manual Rev G 1-1

General Description NORTHROP GRUMMAN
The radius of the scanned circular path is known as the lead. A general purpose 3 mm lead is fitted on most
models as standard equipment. Other leads are available, to suit specific requirements and operating conditions.
SPECIFICATIONS
POWER ! 100 Vac +10%/-15%, 50/60 Hz, or

! 115 Vac +10%/-15%, 50/60 Hz, or
! 230 Vac +10%/-15%, 50/60 Hz,
Selectable by internal connections to the transformer, factory preset to the
voltage specified by the customer.
TRACING SPEED ! 100 mm/min to 3000 mm/min;

this depends on the options used with the system and the machine characteristics.
PATTERNS ! Line width or silhouette (0.5 mm, minimum);

refer to Chapter 5.
LEAD ! Standard: 3 mm, fixed;

other leads are available upon request.
FOCUS ! A 6-mm depth of field allows variations in tracing table height of ±3 mm, while
still maintaining tracing accuracy.
ENVIRONMENT ! Operating temperature from 0EC to +50EC.

! Storage temperature from -18EC to +65EC.
! Humidity to 95% RH (non-condensing).
! It is recommended that this equipment be used in controlled indoor environment.
! Meets requirements for IP54 protection.
Table 1-1 HL-90 Specifications
WARNING
The Linatrol equipment is designed to operate from a three-wire,

grounded power source.
Failure to provide the correct power source and grounding connections,

as detailed in the installation instructions, may result in conditions
hazardous to the operator and/or service personnel.
OPTIONS
These options are available for use with the HL-90 Linatrol Co-ordinate Drive Tracing System:
1. Increased power for high-speed applications, up to 3000 mm/min.
2. Corner enhancement to improve low speed operation.
1-2 HL-90 Tracing Systems Service Manual Rev G

NORTHROP GRUMMAN General Description
3. Command mark actuated corner slowdown to reduce speed and allow the system to negotiate sharp
corners while travelling at high speed.
4. CNC interface.
Figure 1-1 HL-90 Drive Tracing System
HL 90 Tracing Systems Service Manual Rev G 1-3

NORTHROP GRUMMAN Detailed Description
DETAILED DESCRIPTION 2
TRACER UNIT SUB-ASSEMBLY
The Tracer Unit Subassembly consists of the following components:

! Chassis-mounted transformer T1
! Power switch S5
! Primary fuse F1
! Cutting oxygen solenoid connector J5
! X-drive connector J6 and Y-drive connector J7 (as well as connector J9 or P9 for CNC interfacing, if
fitted for CNC operation)
! Chassis Board circuit card assembly (CCA).
The unit is equipped with a latching power relay K3, which de-energizes, should input power fail. The unit must
be reset before operation can resume.
Chassis Board
ASSEMBLY SCHEMATIC
3916D27G01 3924D55
3916D27G02 3924D71
The Chassis Board CCA is mounted in the Tracer Unit Subassembly, on the back wall of the enclosure. The card
is connected to other parts of the HL-90 by means of ‘Fast On’ terminals and connectors. The
transformer secondary input to the card is via connector J12, pins 1 and 2.
The transformer output is rectified by rectifier bridge CR1 and filtered by capacitor C1 to produce +20 Vdc, and
by capacitor C2 to produce -20 Vdc. Voltage regulator U1 is used to produce a regulated +12 Vdc source for the
flood lamps and indicator light. If the unit is fitted for CNC operation (via connector J8), capacitors C3 and C6
are installed for stability.
On the 3916D27G01 card, transistor Q1 is used to turn on the flood lights; relay K2 performs the same function
on the 3916D27G02 card.
Solid-state relay K1 is used to switch on the cutting oxygen solenoid. Capacitor C3 is used as a phase-
shift capacitor for powering the scanner motor.
HL-90Tracing Systems Service Manual Rev G 2-1

Detailed Description NORTHROP GRUMMAN
Test points and connectors provided on the Chassis Board are listed in Tables 2-1 and 2-2 respectively.
Test Points Connector Connecting To

+20V J3 Scanner Assembly
-20V J8 CNC Option
+12V J12 Transformer
Secondary
GND J13 Tracing Circuit CCA
Table 2-1 Chassis Board Test Points Table 2-2 Chassis Board Connectors
‘Fast On’ connection points E4 to E18 (refer to Figure 6-5) make it possible to configure the unit to operate from
different input voltages and to provide different voltages to operate the cutting oxygen solenoid; E3 is ground.
Cable Assembly 415B905H01 is required to connect J13 on the Chassis Board CCA to J1 on the Tracing
Circuit CCA. The cable should be installed as shown in Figure 2-1. Ensure that there are no twists in the cable
and that pin 1 of J13 connects to pin 1 of J1. The cable connectors have a black dot on each end. These dots
should be adjacent to a black mark on the mating connectors on the Chassis Board and the Tracer Circuit when
the cable is correctly installed.
Figure 2-1 Cable Assembly 415B905H01 Installed
Power Supplies
When the appropriate transformer is fitted, the HL-90 system will operate from any of the single phase grounded
AC power sources listed in Table 2-3.
LINE VOLTAGE LINE FREQUENCY

230 50 Hz or 60 Hz
115 50 Hz or 60 Hz
100 50 Hz or 60 Hz
Table 2-3 Primary Power Requirements

Line frequency is factory selected to order. Adjustments necessary when changing from operation at one
frequency to operation at another are detailed in Chapter 6, Alignment & Troubleshooting.
Power is supplied through primary fuse F1 and POWER ON/OFF switch S5 to the primary of transformer T1.
The scanner motor power is supplied from the 115V winding on the primary of T1. The cutting oxygen
solenoid power is supplied through solid state relay K1 on the Chassis Board CCA. The voltage to the solenoid
can be either 24 Vac, 100 Vac, 115 Vac or 220 Vac, depending on the application.
PLUS AND MINUS 20 VDC SUPPLIES
The output from the secondary of T1, leads 4 (green) and 6 (green), is rectified by bridge rectifier CR1; the positive
side of the bridge is filtered by C1 and the negative side by C2, to provide +20 Vdc and -20 Vdc outputs. The
centre tapped secondary of T1, lead 5 (white and green), connects to chassis ground. Table 2-4 shows the
dc voltage distribution.
VOLTAGE USED FOR
Tracer Unit Subassembly:
+12V Regulated Supply (U1) to flood and

spot lamps in the Lighting & Sensing
+20 Volts Assembly.
Tracing Circuit Assembly:
U8, U22, and +12V Regulated Supply

(U26).
Tracing Circuit Assembly:

-20 Volts
U8, U22, and -12V Regulated Supply
(U27).
Table 2-4 DC Voltage Distribution
The +20 Vdc output is supplied to regulator U26 on the Tracing Circuit CCA via J1-5, to a CNC (if fitted) via J8-3,
and to regulator U1 on the Chassis Board CCA. The +12 Vdc output of U1 is fed via J3-1 to the series-parallel
combination of flood lamps (DS1, DS2) and spot lamp (DS3) in the Lighting And Sensing Assembly. It is
returned to chassis ground (E2) from the parallel DS1, DS2 lamps via J3-2 and FET light switch Q1 (or relay K2).
Q1 is switched ON and OFF (or K2 is operated) from the Tracing Circuit Assembly via J2-1 and J3-3. Spot lamp
DS3 is returned to chassis ground via J3-4.
The -20 Vdc output is supplied to regulator U27 on the Tracing Circuit CCA via J1-6. The +20 Vdc and-20 Vdc
outputs go to U8 and U22 on the Circuit Board Assembly and to the collectors of their associated transistors Q3,
Q4, Q5 and Q6.
REGULATED PLUS AND MINUS 12 VDC SUPPLIES

Regulated outputs, U26-3 and U27-3 provide +12 Vdc and -12 Vdc to the remaining integrated circuits and
associated components on the Tracing Circuit CCA. The +12 Vdc and -12 Vdc supply voltages can be measured
at test points TP1 and TP2 respectively.
SCANNER ASSEMBLY
The scanner assembly generates signals which, when processed, drive motors that enable a machine to accurately
follow a pattern. A circular scan device is used to detect the pattern and generate a sine-wave reference signal.
The scanner rotates at 1800 rpm when operated with a 60 Hz power supply and at 1500 rpm when a 50 Hz supply
is used. The scanner includes a magnet which rotates between AC generator coils to generate a sine-wave
reference signal. The output of the generator coils appears between P2-3 (GND) and P2-6; connecting to the
tracing circuits at J2-3 and J2-6, respectively.
Flood lamps illuminate the pattern to be traced. A lens is used to focus an image of the pattern line, in the plane
of photo-sensor Q1, via a mirror mounted at the lower end of the scanner. When the scanner intercepts a black
pattern line, the mirror reflects an image of the fixed photo-sensor on to the pattern line. While the image of the
sensor covers the line, a reduced light condition exists and the sensor output current decreases. When the image of
the sensor moves off the line, as a result of the circular scan motion, the current is restored to its original value.
The sensor output is therefore a series of pulses at a repetition rate of twice the scanner rpm.
When tracing a line pattern, two pulses are produced, one corresponding to the forward direction of the scan, the
other to the trailing side of the scan. The latter pulse is referred to as the `back scan' signal. When tracing a
silhouette pattern, only one pulse per revolution is produced, the duration of which is approximately one half of
the scan time.
The flood lamps which are mounted on the underside of the Tracer Unit illuminate a broad area. To effectively
locate the Tracer at any point on the pattern (e.g. at a required starting point), a spot light illuminates a small area
centred on the optical axis of the scanner. The appropriate light source is turned on automatically when the
desired operating mode is selected on the STRIP/TRACE/START switch.
CONTROL ASSEMBLY
The controls are mounted on the front surface of the Tracer unit enclosure, except the POWER ON/OFF switch
which is mounted, together with fuse F1, on the left hand side.
The six front panel controls are:

! SPEED
! DIRECTION
! DRIVE (ON/OFF)
! MODE
! CUT OXY (MANUAL/OFF/AUTO).
! POWER
An ‘ON PATT’ (On Pattern) LED is provided to indicate when the tracer is following a pattern.
TRACING CIRCUIT ASSEMBLY

The following description applies to all groups of Tracing Circuit CCA 3925D27 used in systems with serial
numbers of 10,000 and greater.
All signal processing circuits are located on this circuit card (refer to Chapter 7 for schematics). The
sine generator output is used as a reference signal in the Sample And Hold circuits, and to generate timing signals
that gate sample pulses through the control logic circuits. In the Tracing mode, sample pulses are derived from the
sensor signal originating in the scanner; in the Stripping mode, the reference signal itself is used to originate the

sample pulses. This ensures that the tracing speeds, under all modes of operation, are compatible.
Sensor Signal Processing

The sensor output goes to Buffer Amplifier U23A, via choke L1, and is ac-coupled to pre-amplifier U24B. The
dc level of the pre-amplifier input is clamped by U23B so that U24B output is a series of positive pulses which
correspond to the scanned crossings of the pattern line being traced. A peak detector circuit, U24A, measures the
pre-amplifier output observed at TP5 and adjusted by gain control R21 until the output begins to limit
(approximately 10.5 Vdc).
To eliminate the ‘back scan’ pulses, monostable U25 is triggered by the first pulse received upon acquisition of a
pattern. The output of U25A is the Inhibit Pulse which is adjusted by R30 to 28 msec on a 60 Hz supply (on a
50 Hz supply the Inhibit Pulse is 34 msec). Since U25A is connected in a configuration which cannot be re-
triggered, the duration of the inhibit pulse blocks the `back scan' signal, permitting the next forward pulse to trigger
the Inhibit Pulse again.
As long as a pattern is being scanned, the Q output (TP6) of the Inhibit Pulse Generator is a train of pulses at a
30 Hz rate. Note that here, and in the following description, references to 30 Hz are in conjunction with a 60 Hz
supply; a system using a 50 Hz supply has a corresponding reference of 25 Hz.
Monostable U20A, the On Pattern pulse generator, is timed to produce an output pulse with a duration of
approximately five rotations of the scanner. Connected to be re-triggerable, the Q output is a continuous logic 1
(or high) as long as a pattern is being scanned. The output high from U20A drives the on pattern circuit, Q2 and
DS1 (ON PATT); the Q output is used in mode-switching functions.
The output of U25A-6 is used to trigger the X-sample pulse at monostable U21B; the Y-sample pulse is generated
by U21A. U20B-9 delays the Y-sample pulse from the X-sample pulse by 90E (8.33 msec for a 60 Hz supply;
10 msec for a 50 Hz supply).
The X-sample and Y-sample pulses are applied to Sample and Hold devices U11 (X-channel) and U18 (Y-channel)
which produce the speed vector voltages necessary to follow the pattern.
Sine Reference Signal Processing

The Sine Generator output signal is a sinusoidal waveform, with peak negative voltage occurring as the scanner
crosses the -Y axis of the machine. The signal is amplified by U13A with the gain adjusted by R41 to produce an
output at TP3 of 15 volts peak-to-peak (5.3 Vrms).

A proportion of this signal is determined by the setting of the SPEED control potentiometer R40 and, if fitted, the
LO/HI range switch or possible operation of the Slowdown circuit. This composite signal is sampled in the
Sample and Hold circuits U11 and U18 to generate the speed signals that drive the X- and Y-Axis Drives,
respectively.
For the Strip Mode implementation, amplifier U13B squares and inverts the sine wave reference signal. The
positive-going edge of this signal is used to generate an approximate 90E delay (U5A). The negative-going edge of
the 90E delay triggers U5B which produces a 6 µsec pulse used to sample the peak of the sine wave
speed signal input to U14A.
The output of U14A is used in the Strip and Start modes as the X and Y speed vector voltages. The polarity of the
voltages is determined by the setting of Direction Switch S1.
For Strip/Trace operation, analog switches U10A and U10B select either the manual-steer vector voltages or the
trace-speed vector voltages for the Y and X channels respectively. The switch from Strip to Trace is made only if
S2 is in the Start position and a pattern is detected. Should the pattern be ‘lost’, the Strip vector voltages are
selected. Since S2 is in the Trace position, the voltages are zero and no motion takes place.
Analog switches U26A and U26B connect the sampling capacitor of the X-channel Sample and Hold IC, to the
vector speed signal output in the Strip or Start mode. This ensures that when the switch to the trace-
speed vector signal occurs, the speed vector at that instant is the same as the strip-speed vector voltage.
Drive Amplifier Circuits

This description applies to the X channel; the Y channel is identical (with the exception of component identities).
Analog switch U10A selects either the Strip speed signal voltage or the Trace speed signal voltage. This signal, or
one from a CNC at J15-6, is the input to the servo-amplifier.
The servo-amplifier consists of operational amplifier U8 and a driver stage consisting of transistors Q3 and Q4.
Potentiometer R50 is used to adjust the servo-amplifier offset to zero. Motor speed for a given speed signal input
is adjusted by R65 which determines the scale factor of the tacho feedback summed with the speed input signal.
Capacitor C40, resistor R49 and the network consisting of R53 and C28 determine the amplifier
frequency response characteristics and ensure amplifier stability.
The current output of U8 is limited by the value of R59. The output to the motor is provided by Q3 and Q4.
Motor drive current is limited by CR34 and CR35 for positive output voltages, and by CR36 and CR37 for
negative output voltages. When Q3 conducts, the maximum supplied current occurs when the voltage drop across
CR34 and CR35 equals the base-emitter drop in Q3 and the voltage drop across R67. Any further increase in the
voltage across R67 biases Q3 to reduce the current flow. Current limiting when Q4 conducts is achieved in a
similar manner. Current limit is set to a nominal value of 1.5 amperes for G04 and G06 circuit cards, and to
1.0 ampere for G01 circuit cards.
Connections to the Drive Motor and Tachometer are made through XM and XT fast-on connectors.
Motor return current and tachometer ground connections are made at the E2 (chassis ground) terminal.
Cutting Oxygen Solenoid

Cutting oxygen solenoid control is provided by means of a solid-state relay, located on the Chassis Board CCA.
This relay is controlled by transistor Q1 which is turned ON when:
1. The Cut Oxygen selector (S3) is set to MAN, or

2. The Cut Oxygen selector (S3) is set to AUTO, and the pattern is being traced, or
3. The Cut Oxygen selector (S3) is set to AUTO, and the STRIP/TRACE/ START switch (S2) is in the
START position.
On-Pattern Light
The ON Pattern light (DS1) illuminates when a pattern is acquired. The light is controlled by transistor Q2.
Indicator/Flood Lights
The selection of Indicator light or Flood light is controlled by the signal at J2-1. A logic 0 at J2-1 in STRIP mode
selects the Indicator light. Selection of TRACE or START results in a logic 1 at J2-1, turning ON the Flood lights.
Circuit Card Connectors

The connectors for the circuit card functions are listed in Table 2-5.
CONNECTOR FUNCTION
J1 Input power and cutting oxygen control
J2 Tracing signals
J10 Torch Height Control Enable or On Pattern
J14 Connections to tracer control
J15 CNC Connection
J16 Connection to tracer control
Table 2-5 Circuit Card Connectors

OPTIONS
The four optional circuits available with the system are:
! Low Speed Corner Enhancement - Tracing Circuit CCA 3925D27G04 or G06.

! High Speed operation - Tracing Circuit CCA 3925D27G04 or G06.
! Corner Slowdown - Tracing Circuit CCA 3925D27G06.
! CNC Interface - can be supplied with all Tracing Circuit CCA,
3925D27G01, G04 or G06.
The part number of the standard Tracing Circuit CCA (without any options) is 3925D27G01.
Low Speed Corner Enhancement
These circuits introduce a delay in the Tracer response to changes in direction of travel. The path followed by the
Tracer can be made to more accurately reproduce small radii pattern corners by selecting the delay required to
compensate for lead-induced under-cutting of corners. Ideally, Tracer response should be inversely proportional
to the speed at which the Tracer is travelling.
In this system the delay is in the form of three fixed increments over the Low Speed range of 0 to 600 mm/min
(0 to 24 IPM). Speeds from 0 to 230 mm/min (0 to 9 IPM) require the longest delay, while a lesser delay is
required at speeds from 230 to 500 mm/min (9 to 20 IPM). The shortest delay is used at speeds from
500 to 600 mm/min (20 to 24 IPM).
Response variation is achieved by increasing/decreasing the capacitance of the sampling capacitor used in the
Sample and Hold circuit. As a sample pulse is applied to U14-8, the X-axis Sample and Hold IC, capacitor C15 is
charged to the voltage level at U14-3.
These sample pulses are too short to completely charge C15 during a single sample pulse. The source that supplies
the charge current has a finite output impedance and therefore there is an exponential charging rate of C15, with an
RC time constant during each sample pulse period.
This system is designed so that maximum speed on the Low range is 600 mm/min, regardless of the maximum
speed on the High range. A ratio can be determined that will relate maximum speeds of these ranges. The
maximum speed in the High range can be set at any value between 1000 and 3000 mm/min, depending on the
application. The Low range speed adjustment (R122) should be set to the peak-to-peak sine wave voltage
measured at TP12, corresponding to the High/Low ratio. Adjustment of this potentiometer defines the
High/Low ratio.
The root-mean-square (rms) voltage, at maximum speed, is 5.3V (15V peak-to-peak) and the amplitude of this
signal, measured at the wiper of R40 (Speed Control), is monitored at TP12. For a system with a 3000 mm/min
maximum speed, R122 should be adjusted such that, when the speed control is set to Low range maximum, TP12
indicates 1.03 Vrms (3.0 Vp-p).
The calculation is: 600 mm/min

VTP12 = 5.3 Vrms X
3000 mm/min
= 1.06 Vrms
= 3.0 Vp-p
Tracer speed setting must be determined in order to allow switching extra capacitors in/out of the
Sample and Hold circuit. This is accomplished by means of a circuit consisting of U28 (two halves of which form
a rectifier and filter) and U32. The sine wave at U32-1 is rectified so that the output, observed at TP13, is positive

only and filtered by the combination of R98 and C64, C65 to remove ripple. The output, observed at TP13, is a
DC voltage proportional to the amplitude of the sine wave, the gain of which can be adjusted at R86, part of the
U32 circuit. The gain adjustment is set so that at maximum speed on the Low range and the voltage at TP13 is
5.0 Vdc.
The filtering circuit uses a long time constant so the voltage, measured at TP13, lags changes in speed
control setting by several seconds. The two halves of U29 form comparators for the voltage observed at TP13 and
a fixed reference voltage, taken from divider network R89, R90 and R91. The resistance values used in this
network have been chosen so that the comparators will switch at speeds of 230 and 500 mm/min.
When the voltage observed at TP13 is less than the reference voltage input, the comparator output will be
approximately 5 Vdc (considered to be a logic 1 level). A logic 0 will be generated by the comparators when the
voltage at TP13 is greater than the reference voltage.
The outputs from these comparators are used to drive analog switches U30 and U31. The action of these two
switches will cause extra capacitors to be brought into, or taken out of the Sample and Hold circuit. The extra
capacitors are connected in parallel with C14 and C15 respectively, for X and Y channels.
Setting the HI/LO switch to the low speed range connects capacitors C98 and C101 in parallel with C14 and C15,
respectively.
When the speed control is set between 500 and 600 mm/min, capacitors C73 through C77 are connected, through
R105 and the action of analog switch U30, to X1. This charges capacitors (C73 to C77) to the voltage level found
on capacitors C14 and C98. This eliminates transients in speed output when capacitors C73 and C74 are switched
into the circuit in parallel with C14 and C98. At speeds of less than 230 mm/min, capacitors C75, C76 and C77
are also switched in parallel with C14 and C98.
Adjusting the voltage at TP13 higher than 5.0 Vdc, with the speed control at maximum on the low speed range,
lowers the switching points at which the time constant of the Sample and Hold circuit is charged. For example, if
the voltage at TP13 is set to 6.0 Vdc, switching occurs at 430 mm/min and at 190 mm/min, resulting in less
overshoot on corners, at speeds of between 430 to 500 mm/min and 190 to 230 mm/min.
High Speed Operation

Increased machine stability, sometimes required in systems operating at high speeds is accomplished by the two
shunts fitted between terminals 1-4 and 2-3 of both W1 and W2. Connecting one of these shunts between
terminals 1-2 on W1 and W2 will increase machine stability. When further stability is required; connect the other
shunt between terminals 3-4 of W1 and W2. Increasing machine stability may produce additional corner overshoot
which can be reduced or eliminated through the use of the Corner Slowdown Option.
Since High Speed operation usually involves the use of a Plasma system, additional filtering to improve immunity
to Plasma noise is provided by L1 on the Tracing Circuit card.
Corner Slowdown Circuit

The slowdown circuit operates by detecting the presence of command marks, or an edge pattern such as that
shown in Figure 2-2. When a command mark is detected the tracer is made to slow down to a speed adjustable to
any rate above 1/3 of maximum speed. The slowdown feature is enabled when:
! The circuit is enabled, and

! While in pattern acquisition mode.
! A Command Mark is being scanned.

Figure 2-2 Command Mark for Corner Slowdown
The signal from the scanner (from U23-1) is amplified by U33. Signal gain is adjusted by R114 so that when the
scanner is over an edge pattern (Command Mark), the signal at TP14 is saturated (full amplitude) for the duration
of the signal from the Command Mark.
2 - 10 HL-90 Tracing Systems Service Manual Rev G

The signal at TP15 is the peak detected signal, suitable for monitoring with a dc voltmeter. R114 is adjusted
clockwise (CW) until further adjustment causes little increase in voltage reading at TP15. Using an oscilloscope to
view the waveforms at TP14 is the preferred method of gain adjustment.
When the signal from U21-6 (scan signal, delayed by 90 electrical degrees) is applied at U35-2 and the logic 1
generated by the scanning of a Command Mark is applied at U35-1, the condition of U35-9 is governed by the
state of U35-8.
The signals on U34-1 and U34-15 are at logic 0, as a result of this counter being reset. A logic 1 clock signal is
applied to U34-3 causing the counter to increment to 1. The output of U34-1 becomes a logic 1. On the next scan
of the Command Mark the counter is incremented to 2 and the outputs of U34-1 and U34-15 are reset to
logic 0 and 1, respectively. As a third scan of the Command Mark is completed, the counter increments to 3 and
the U34-1 output is set to logic 0; the output state of U34-15 does not change. As the three count is reached,
U35-8 is set to logic 0, inhibiting the clocking signal to the counter.
The logic 0 at U36-3 causes the output, measured at TP16, to become a logic 1 which will open the switches in
analog gate U38. Opening these switches inserts R120 in series with the speed control, resulting in a drop in the
Tracer speed.
As the Tracer moves off a Command Mark and on to a line portion of the pattern, the first scan of the line portion
results in a logic 0, 90 electrical degrees after the leading edge of the scan pulse, at TP14. This produces a logic 1 at
U36-12 which, together with the logic 1 of the 90 degree delayed pulse, produces a logic 0 at U35-3. Since U35-4
and U35-5 were previously a logic 1, a logic 0 at U35-3 results in a logic 1 at U35-6, resetting counter U34.
As U34 is reset to zero, U36-3 becomes a logic 1 causing the switches in U38 to close and short-out the
slowdown resistor, R120. With R120 effectively taken out of the circuit, normal speed is resumed and the 3-input
NAND gate is enabled by the output at U35-9. The active NAND gate output enables the counter so that
clocking can occur when a Command Mark is again scanned.
Circuits are included to ensure that the Command Mark feature does not function when the speed range switch is
in the LO position, slowdown is disabled, or the STRIP mode is selected. The selection of LO Speed or
Slowdown Disabled results in a logic 0 at U35-4, which causes a logic 1 at U35-6 to reset the counter.
Selection of the STRIP mode produces a logic 0 at U35-5 which results in resetting the counter, inhibiting
slowdown.
Setting the mode switch to START when the high range is selected, enables the Slowdown feature, causing a
logic 1 at U35-11, 12 and 13. This results in a logic 0 at TP16, causing Slowdown to result.
As a means of enabling/disabling the automatic height control of a Plasma system, an output is produced. This is
available at connector J10, on the circuit card. Relay K2 operates contacts that are connected to J10. The relay is
energized whenever slowdown is in effect, either through sensing of a Command Mark, in the START mode, or
when the tracer is stationary in the TRACE mode. When the HL-90 is used in conjunction with a Picopath
CNC, moving shunt W7 accross pins 3 & 4 makes it possible to ‘Teach Trace’ and tracing automatically stops
when the pattern has been traced.
HL-90Tracing Systems Service Manual Rev G 2 - 11

CNC Interface Circuits

The HL-90 can be supplied, or retro-fitted, with an interface cable that will enable it to operate with a CNC. The
CNC Interface Cable Harness Assembly, suitable for use with various versions of the Picopath CNC, can be
installed by simple plug-in connections to the Tracing Circuit CCA (3925D27G01, G04, or G06) and to the
Chassis Board Assembly (3916D27G01 or G02). No soldering or unsoldering is required. Installation instructions
provided with this optional purchase provide all the information required.
Alternatively, a CNC Interface Harness Assembly (6D21182G01) can be installed by a plug-in connection to the
Tracing Circuit CCA and Chassis Board Assembly to permit operation with a Picopath or Hybrid D11 CNC.
12V ENCODER OPTION

When the HL-90 System is supplied (or retrofitted) with a CNC Interface, drive units incorporating
optical incremental encoders can be supplied.
Contact Northrop Grumman-Canada, Ltd. for further information.

NORTHROP GRUMMAN Installation
INSTALLATION 3
GENERAL
Three units make up the standard HL-90 system:
! a Tracer Unit, and

! two Drive Units.
Unpack the units carefully and visually inspect for transit damage. Verify that the parts supplied match the parts
ordered.
NOTE
To avoid the need to re-align the system after installation, ensure that
serial numbers of the sub-assemblies match those listed on the back of
the test tracing, shipped with each system.
MECHANICAL INSTALLATION
General
In most applications the Tracer Unit is mounted above the tracing table on the Torch Carriage, which moves with the
cutting torches in both axes. Accurate tracing is obtained by ensuring that the Tracer Unit is level and at the correct
height, with reference to the scribed line (HEIGHT SET MARK) on the Scanner Assembly.
One Drive Unit is mounted so that it will drive the machine in the X-axis (Transverse axis) and the second Drive Unit
is mounted to drive the machine in the Y-axis (Longitudinal axis).
Tracer Unit
Three holes, slotted vertically, enable the unit to be bolted securely to its mount, while permitting some adjustment
of the head height and levelling.
The instructions required to install the HL-90 Tracer Unit are:
1. Insert one screw into the lower mounting hole, on the mounting plate, located on the machine.
HL-90 Tracing Systems Service Manual Rev G 3-1

Installation NORTHROP GRUMMAN
2. Rest the Tracer Unit on this screw and then put the remaining screws through the slotted holes on the
Tracer and into the machine mounting plate.
3. Adjust the height of the Tracer Unit so that the set mark on the head is set 38 mm (1-1/2 inches)
above the pattern table. Tighten all mounting screws securely.
4. Check the height at several places on the tracing table to ensure that height variations do not exceed 3 mm
from minimum to maximum. Variations in excess of 3 mm will result in an out of focus condition, which
can result in unreliable operation.
Figure 3-1 Tracer Unit Installation

Drive Units
GENERAL
Before installing drives, make sure the machine moves freely and that the machine rails, in both axes, are clean and
free of obstructions.
Mount the gearbox with the pivot point on the pitch line (see Figure 3-2).
Mount the gearbox so that pressure on the output shaft is toward the centre of the gearbox.
Figure 3-2 Typical Gearbox Mounitng
NOTE
The Drive Units can be interchanged to either the X or Y axis without

causing damage. Once a unit is selected though, it must be identified
for future reference.
Use only the minimum pressure required to keep the rack and pinion meshed (2.5 kg/5 lb, nominal), to reduce the
sideload on the gearbox output shaft.
The pinion size used should be the smallest possible, to produce minimum free motion at the machine (backlash).
This will also produce the maximum thrust at the machine. The recommended range is 12mm (0.5 inch) to 18mm
(0.7 inch) diameter.

Figure 3-3 Typical Drive Assembly

ELECTRICAL INSTALLATION
WARNING
The equipment described in this manual is designed to operate from a

three-wire, grounded power source.
Failure to provide the correct power source and grounding connections,

as detailed in these instructions, may result in conditions hazardous to
the operator and/or service personnel.
The supplier of the cutting machine must install an approved Emergency

Off switch which must be readily accessible and is to remove power from
the HL-90 when the switch is operated.
Tracer Unit
Electrical installation of the Tracer Unit involves connecting the input power and three cables to the connectors on
top of the unit, as illustrated in Figure 3-4.
Figure 3-4 Tracer Unit Electrical Connectors

These connections include:
1. The Cutting OxygenSolenoid cable mates with connector J5, located just behind the power input
receptacle. J5 is a seven-pin connector with the following pin assignments:
J5 SIGNAL COMMENTS
PIN NUMBER NAME
1 Line
4 Neutral
2 Ground Long pin supplied in connector
kit must be used for this location
3 Not Used
5 Height Control Only used if
Corner Slowdown
is fitted
6 Height Control
7 Height Control
NOTES - Contacts 5 and 7 from the Height Control Relay K2 are closed to disable height
control; contacts 6 and 7 are open to enable height control.
2. The X-axis Drive Unit, via the ‘D’ cable, mates with the connector located to the left of the Cutting
Oxygen Solenoid cable connector. The shield grounding terminal must be installed under one of the
mounting screws of the connector.
3. The Y-axis Drive Unit, via the ‘E’ cable, mates with the connector located to the left of the Power Input
receptacle. The shield grounding terminal must be installed under one of the mounting screws of the
connector.
4. The equipment must be operated from a three-wire, grounded power source. The power cable is connected
in the equipment as follows:
! the BLACK wire is LINE,

! the WHITE wire is NEUTRAL, and
! the GREEN or GREEN/YELLOW wire is GROUND.
NOTE
Ensure that the power plug is connected to

match that of the illustration at right.

5. The gearboxes of the Drive Unit must be connected via a low impedance path to the PE of machine
installation. This is done by connecting a wire from the terminal screw marked on the motor
mounting plate of the gearbox to the machine frame. Ensure that the part of the machine frame used for
this connection is connected to the PE of the installation. The resistance between the ground screw and
the PE should be sufficiently low as to meet safety requirements.
Drive Units
If the direction of rotation of the drive motors results in machine motion which does not agree with the direction
selected on the DIRECTION switch, follow the procedure outlined below. Do not change the orientation of the
DIRECTION knob.
DIRECTION OF MOTOR ROTATION
Perform the following to reverse the rotation of either the X- or Y-axis motor.
1. Isolate the system from the AC supply.
CAUTION
When opening the Door Assembly, do not permit the door to open
more than 90° or damage to the wiring may result.
2. Unlock the door for access to the interior of the Tracing Unit assembly.
3. Pull off the ‘fast-on’ type connection, identified as ‘XM’ on the top left corner of the circuit card, and
exchange with the other X motor lead connected to the ground connection on the chassis of the unit;
similarly, interchange the X tacho leads.
4. The motor drive wires are red and black; the tachometer wires are green and white.
MOTOR SPEED
For maximum machine speed, the recommended motor rpm is 2050 to 3000 (depending on pinion size and gearbox
ratio).
Motor speeds of the X and Y motors are adjusted by R65 and R66, respectively, on the circuit card; clockwise (CW)
rotation will increase motor speed.

NORTHROP GRUMMAN Operating Instructions
OPERATING INSTRUCTIONS 4
GENERAL
The operating controls for this system are mounted on the hinged door of the tracing unit.
The control functions are described in Table 4-l. The equipment Operating Instructions follow this table.
Controls
The front panel controls (see Table 4-l) select these functions:
l. Machine SPEED.
2. Machine DIRECTION (4-way).
3. DRIVE (ON/OFF).
4. DRIVE Speed Range (HI/LO).
5. Mode (STRIP/TRACE/START).
6. CUT OXY (MAN/OFF/AUTO).
The POWER (ON/OFF) switch is located at the left side of the unit.
OPERATION
The tracer may be operated in either the Tracing mode, using a pattern, or the Stripping mode for manual cutting.
Tracing Mode (Oxy-Fuel)
1. Turn the POWER, DRIVE and CUT OXY off.
2. Fix a pattern on the tracing table.

Operating Instructions NORTHROP GRUMMAN
Figure 4-1 HL-90 Controls
4-2 HL-90 Tracing Systems Service Manual Rev

G
SYMBOL/
SWITCH
FUNCTION POSITION DESCRIPTION
SPEED
(Variable Enables the speed of the tracer to be set from 0 to
Control) maximum.
DIRECTION Used for the stripping mode and to enter and leave
(4-position a pattern in the tracing mode.
rotary)
DRIVE Connects the speed signals to the input of the drive

(2-position amplifiers.
toggle)
Removes the speed signals from the drive

amplifiers.
If installed, this switch selects the high speed range

of from 0 to maximum.
If installed, this switch selects the low speed range

of from 0 to 600 mm/min.
Table 4-1 HL-90 Control Functions

SYMBOL/
SWITCH
MODE
(3-position Tracer moves in the direction set on the
toggle) DIRECTION switch at the speed set on the SPEED
dial.
The tracer will follow the pattern until the switch is

(Centre position) moved to the STRIP position. The tracer will then
move in the direction set on the DIRECTION switch
and, with the CUT OXY switch set to AUTO, the
cutting oxygen will automatically shut off.
Momentary contact position. The tracer will travel in

the direction set on the DIRECTION switch until a
pattern is intercepted and the ON PATT light is lit.
When the switch is released, it will return to the
TRACE position.
CUT OXY
(3-position
toggle) Maintains the cutting oxygen while the tracer is off
(Centre position) pattern for chain cutting, or in the STRIP mode.
Cutting oxygen is off.
Cutting oxygen is on as long as the

STRIP/TRACE/START switch is in the START
position or the tracer is on pattern. If the tracer
goes off pattern, the cutting oxygen will switch off.
POWER Momentary Up position - power is applied to the

(3-position equipment.
toggle)
Mid position - normal operating position, power ON
or OFF.
Momentary Down position - shuts off power to the

equipment.
Table 4-1 HL-90 Control Functions (Cont'd)
4-4 HL-90 Tracing Systems Service Manual Rev

G
SYMBOL/SWITCH
SLOWDOWN The Corner Slowdown feature is enabled when the

ENABLED shunt is placed over the two left pins of S6 (located
at centre left of the circuit card).
SLOWDOWN The Corner Slowdown feature is disabled when the

DISABLED shunt is placed over the two right pins of S6
(located at centre left of the circuit card).
KERF The kerf can be set over a range of 0 to 3 mm

(1/8th inch). Before attempting kerf adjustment,
LOOSEN the KERF LOCK SCREW and rotate the
scanner assembly for the required amount; RE-
TIGHTEN after the kerf adjustment is made.
NOTE
See chapter 5, page 1, for

detailed information on kerf
compensation.
Table 4-1 HL-90 Control Functions (Cont'd)
3. Move the POWER switch to the Up position. The floodlights will come on or the Position Indicator
will light. Power should remain on when the switch is released to its mid position.
4. Set the MODE to STRIP and select the required speed range.
5. Turn the DRIVE to ON and steer the machine to the desired starting position, using the DIRECTION
switch and SPEED control.
6. Turn the DRIVE to OFF and the MODE switch to TRACE when the desired position is reached.
7. Place the CUT OXY switch in the AUTO position (see Table 4-1, CUT OXY, for chain cutting).
8. Set the SPEED control to the desired cutting speed.
9. Set the DIRECTION control for the desired pattern entry direction.
10. Adjust the torches to preheat the plate.

11. When the plate is ready, set the DRIVE to ON and hold the MODE switch in the START position.
Cutting oxygen will come on and the tracer will approach the pattern. When the pattern is acquired and
the ON PATT light comes on, release the MODE switch.
12. Turn the DIRECTION switch so that at the end of the cut the tracer can be made to leave the pattern
away from the work.
13. At the end of the cut, place the MODE switch to STRIP. The Tracer will leave the pattern and the
cutting oxygen will automatically shut off.
14. Turn the DRIVE to OFF.
If the Tracer is equipped with the Low Speed Enhancement feature, or designed for High Speed operation, the HI
range must be selected for speeds greater than 600 mm/min.
Tracing Mode (Plasma)
Operation depends on the type of Plasma Unit used and its interface to the Tracer.
Stripping Mode (Oxy-Fuel)
1. Turn POWER, DRIVE and OXY to OFF.
2. Turn the power ON.
3. Set the MODE to STRIP and select the required speed range.
4. Turn the DRIVE to ON and steer the machine to the desired starting position, using the DIRECTION
switch and SPEED control.
5. Turn the DRIVE to OFF when the starting position is reached.
6. Set the SPEED control to the desired cutting speed.
7. Set the DIRECTION control to the desired cutting direction.
8. Adjust the torches to preheat the work.
9. When the work is ready, turn the CUT OXY switch to MAN.
10. Turn the DRIVE switch to ON.
11. When the cut is complete, turn the CUT OXY and DRIVE switches to OFF.

NORTHROP GRUMMAN Operating Features
OPERATING FEATURES 5
LEAD
The mirror in the tracing head is tilted and off centre to enable it to scan a circular path. It therefore scans the
pattern ahead of its position by a distance, or ‘look-ahead’, known as the lead. In the case of the HL-90, it is 3 mm
(1/8th inch). Optional leads of 1 and 1.5 mm are available upon request.
KERF
To compensate for the width of cut, or kerf, adjustment is provided which is continuously variable between
zero to 3 mm (with standard 3 mm Kerf-Lead modules). Kerf compensation is adjusted by turning the
Scanner Assembly inside the Tracing Unit (see Figure 5-1). The Kerf Lock Screw must be loosened before making
the adjustment.
Figure 5-1 Kerf Offset Adjustment
To adjust for the required compensation the kerf width is set on the kerf scale. For example, if the kerf is 2.0 mm,
the scale should be adjusted so that the black ‘2' (on the white section of the scale) is directly below the
scribe mark. The tracer path is offset by half the kerf setting. When `0' on the scale is set below the scribe mark,
there is no kerf compensation.

Operating Features NORTHROP GRUMMAN
Figure 5-2 Determining Direction of Kerf Adjustment

PATTERNS
Patterns may be black lines or silhouettes drawn on white paper, or a cutout of white paper or card (referred to as a
`white silhouette') laid on a black table top, as shown in Figure 5-2 (c).
The quality of the pattern has a considerable influence on the accuracy and reliability of the tracer. Patterns can be
drawn so that material wastage is reduced and the efficiency of cutting operations improved. For accurate corner
cuts, compensation for the lead/speed characteristics of the tracer may be made by adjusting the corners on the
pattern.
Guidelines for Patterns
Factors, associated with patterns, that influence the tracing operation include:
1. Contrast between line and background.
2. Cleanliness of the pattern.
3. Width of the line in line-drawn patterns.
4. Type of material on which the patterns are drawn.
5. Type of material used to draw the patterns.
To produce patterns that provide the best results, the following guidelines are recommended.
Table 5-1 lists some of the materials used in producing patterns.
TYPE OF MATERIAL REMARKS
COMMERCIAL Use India ink or firmly drawn pencil (H or HB). Ideal material for
PATTERN PAPER durability, dimensional stability and contrast.
BRISTOL BOARD Excellent contrast. Liable to absorb moisture.

(Buff or White)
ART BOARD Similar to Bristol board, but more durable. Thickness may require re-
(Buff or White) focussing.
HEAVYWEIGHT Similar to Bristol board. Generally most popular for ‘one-off’ patterns.
BOND PAPER
‘MYLAR’ Excellent dimensional stability. Durable white backing sheet required.

Tendency to curl requires a means to maintain uniform contact with
backing sheet/tracing table to prevent an out-of-focus condition.
‘DIAZO’ Reflect infra-red. Requires special lens on tracing unit. Easily

TRANSPARENCIES scratched. Good dimensional stability.
Table 5-1 Pattern Materials

TYPE OF MATERIAL REMARKS
PHOTOGRAPHIC Not recommended.

NEGATIVES
TRACING PAPER White backing sheet required. Changes size with moisture (not
recommended).
FELT PENS Some felt-tipped pens reflect infra-red. May require a special lens on
the tracing head.
‘PLEXIGLASS’ If used as a protective cover (and to keep patterns flat), it is susceptible

to pitting from cutting splatter. It should be used with caution.
Table 5-1 Pattern Materials (Cont'd)
1. The edge of the line should be drawn accurately, since it is the edge of the pattern that will be traced.
2. A red pen or pencil should be used for drawing construction lines or notes; the tracer will not detect
red.
3. For optimum performance, lines should be drawn in black India ink, with a minimum width of 0.7 mm
(1/32nd inch), on a white or buff background; however, ‘H’ or ‘HB’ grade pencil- drawn lines with a
minimum width of 0.5 mm (1/64th inch) provide acceptable results.
4. If pencils are used, the lines should be dense and free from breaks. Repeatedly going over a line tends
to polish the surface, causing it to behave like a mirror; this should be avoided.
5. Some materials appear black to the human eye but are seen differently by the tracer; these materials
should be avoided (see Table 5-1).
6. Paper or card stock used for patterns should be of a type that is not affected by moisture. Some types
readily absorb moisture and may, consequently, change size (see Table 5-1).
7. Patterns should be kept as clean as possible and free from grit marks or smudges, especially near the
tracer's path.
8. The minimum distance between adjacent lines on the pattern should not be less than the lead, i.e. 3 mm
(1/8th inch); see Figure 5-3.

Figure 5-3 Minimum Line Separation
Corner Compensation
Tracing head lead may be compensated for on the pattern in applications that require accurate corner cuts at lower
speeds.
Figures 5-4 (a) and 5-4 (b) illustrate the technique for outside and inside corners. The lead-speed correction factor
is obtained on a trial and error basis since it is affected by the physical characteristics of the cutting machine. The
lower the cutting speed the greater the correction factor. This is typically equal to the lead or scan radius used.
Low Contrast and Shopworn Patterns
Figure 5-4 Corner Compensation

Adjustments may be made if lighter pencil-drawn patterns need to be traced (i.e. patterns that provide a lower
contrast than firmly-drawn ‘H’ or ‘HB’ grade pencils). Refer to Signal Level Set-Up in Chapter 6, Alignment &
Troubleshooting.
NOTE
An overall dirty pattern reduces the reflected light and hence, the signal
output; dirty marks may generate false signals. It is important to
maintain patterns in as clean a condition as possible.
Pattern Nesting
When cutting several parts from the same plate, it may be more economical and more efficient to group or nest
them on one pattern.
Similar or dissimilar pieces may be nested together. Figure 5-5 shows simplified arrangements; more complex
shapes may be treated in the same manner. Chain cutting of groups of unconnected patterns
(e.g. white silhouettes) may be performed if the cutting oxygen is operated with the ‘CUT OXY’ switch (S3) set in
the ‘MAN’ position.
Figure 5-5 Pattern Nesting

Command Marks
Command marks are placed on a pattern to initiate the automatic corner slowdown operation. The use of
command marks is only possible when the Corner Slowdown Option circuits are installed in the system.
Command marks are detected at 90E after line interception. When drawing Command marks, the dimensional
information given in Figure 5-6 should be closely followed, noting these points:
1. When a Command mark is used, the leading edge of the mark should represent the desired point of
slowdown and include allowances for 3 scan revolutions (120 msec for 50 Hz operation or 100 msec for
60 Hz operation) and machine-dependent deceleration time.
2. The width of the Command mark (dimension ‘a’ in Figure 5-6) should be at least 1½ times the lead
used, without any gap between it and the pattern line.
3. There should be little or no difference in contrast between the Command marks and the pattern lines.
4. Kerf compensation cannot be adjusted at the scanner assembly when Command marks are used.
Kerf allowances can be incorporated into the pattern.
Figure 5-6 Command Mark for Corner Slowdown

NORTHROP GRUMMAN Alignment & Troubleshooting
ALIGNMENT & TROUBLESHOOTING 6

WARNING
Setting the Power Switch to OFF does not remove power from
the equipment. Disconnect the power source from the unit before
opening for servicing.
GENERAL
As an aid to performing alignment, the procedure has been subdivided into a logical sequence as follows:
! Power Supply Checks

! Signal Level Set-up
! Zero-Signal Offset Adjustments
! Linear Speed Adjustments
! Line Frequency Change
P Converts from 50 to 60 Hz
P Converts from 60 to 50 Hz
! Low Speed Range Adjustment
! High Speed Stability
! Slowdown Circuit Calibration
! Measuring and Recalibrating True Linear Speed
Where applicable, references have been made to troubleshooting information presented in Table 6-2. Examples of
how these references will appear are `refer to Troubleshooting Guide, Step (number)'. In each case refer to
Table 6-2.
Shielding the Scanner Assembly Photo-transistors
The cast aluminum housing of the installed Scanner Assembly is a lattice-structure type (see Figure 6-1) and the
internal photo-transistor and lens can be seen through the open slots.
It is necessary to shield the photo transistor from ambient light when the door of the Tracer Unit Assembly is
opened for servicing. This can be done by wrapping a piece of paper around the scanner housing so that it is
shielded from the ambient light (a piece of cloth will serve equally well).
Failure to follow this procedure may result in the sensor circuit producing false signals, making it impossible to
calibrate the system properly or for the system to trace a pattern.

Alignment & Troubleshooting NORTHROP GRUMMAN
’D’ CABLE CONNECTOR

CUTTING OXYGEN
SOLENOID CONNECTOR
’E’ CABLE CONNECTOR
POWER UNIT RECEPTACLE

TRACING UNIT
SUBASSEMBLY
PHOTO TRASISTOR
AND LENS
CHASSIS BOARD ASSEMBLY
SCANNER ASSEMBLY
CONTROL
ASSEMBLY
Figure 6-1 Tracer Unit Assembly, Opened View
Power Supply Checks
1. Switch the power ON. If the system does not respond, refer to Troubleshooting Guide, Step 1.
2. Set the DRIVE switch to ON, the SPEED control to 5 and the STRIP/TRACE/START switch to
STRIP.
3. The following measurements must be made while the machine is moving. Refer to
Troubleshooting Guide, Steps 2 and 3.
(a) Chassis Board CCA measurements: +20 Vdc ±3V at the +20V TP (Test Point).
-20 Vdc ±3V at the -20V TP.
+12 Vdc ±0.6V at the +12V TP.
(b) Tracing Circuit card measurements: +12 Vdc ±0.6V at TP1.

-12 Vdc ±0.6V at TP2.

Signal Level Setup
1. Position a typical shop pattern under the Scanner Assembly.
2. Set the tracer controls to acquire the pattern and once the pattern is acquired, set the DRIVE switch to
OFF. Refer to Troubleshooting Guide, Step 4.
Observe the voltage at TP5 and adjust R21 on the circuit card CW until the output shows no further
increase (between 9.5 and 11.5 Vdc). Turn R21 CCW until the voltage decreases by approximately 0.1V
from the maximum reading, then turn it CW 1/10th of a turn.
Typical symptoms of decreasing signal level after the equipment has been in service for some time are
erratic acquisition of a pattern or tracer reversal on pattern.
Zero-Signal Offset Adjustments
1. Measure the voltage at TP3 on the circuit card. Adjust R41 for 5.3 Vac ±0.1V on a digital voltmeter
(15 Vp-p ±0.3V) and then switch the power OFF. Refer to Troubleshooting Guide, Step 5.
2. Disconnect the scanner motor connector P4/J4. Switch the power ON and measure the voltage at TP3
on the circuit card. Adjust R73 until the voltage level at TP3 reaches 0 Vdc ±5 mV.
3. Measure the voltage at terminal XM on the circuit card and adjust R50 for 0 Vdc ±50 mV. Measure the
voltage at terminal YM on the circuit card and adjust R52 for 0 Vdc ±50 mV.
4. Switch the power OFF and re-connect the Scanner motor connector P4/J4. Switch the power ON.
Linear Speed Adjustments
1. Set the DRIVE switch to ON, select the HI drive range and set the SPEED control to 10 on dial.
2. Measure the actual speed of travel in the X axis and adjust R65 on the circuit card until the linear speed
agrees with the specified maximum speed. Refer to Troubleshooting Guide, Steps 5, 6, 7 and 8.
3. Measure the actual speed of travel in the Y axis and adjust R66 on the circuit card until the linear speed
agrees with the specified maximum speed. Refer to Troubleshooting Guide, Steps 9, 10, 11 and 12.

Line Frequency Change Adjustments
The Linatrol HL-90 equipment can operate on either 50 Hz or 60 Hz line frequencies. The following procedures
must be followed when changing the frequency of operation.
CONVERTING FROM 50 Hz TO 60 Hz SUPPLY
1. Measure the voltage at TP3 on the circuit card using a digital voltmeter. Adjust R41 for 5.3 Vac ±0.1V
(15 Vp-p ±0.3V).
2. With the Tracer Unit set to trace on Test Pattern 205P773 (located at the end of this manual), adjust
R30 for a positive-going pulse of 28 msec ±1 msec duration at TP6 and R35 for a negative-going pulse
of 8.33 msec ±0.15 msec duration at TP7 (an oscilloscope is required).
NOTE
Resistors R30 and R35 have been sealed with Glyptol cement. Break
the seal to adjust and reseal after adjustment. Change the ‘50 Hz’
marking on the circuit card to read ‘60 Hz’.
3. Perform steps 3 and 4 from the Zero-Signal Offset Adjustment procedure.
4. Set the DRIVE switch to OFF.
CONVERTING FROM 60 Hz TO 50 Hz SUPPLY
1. Using a digital voltmeter, measure the voltage at TP3 on the circuit card. Adjust R41 for 5.3 Vac ±0.1V
(15 Vp-p ±0.3V).
2. With the Tracer Unit set to trace on Test Pattern 205P773 (located at the end of this manual), adjust
R30 for a positive-going pulse of 34 msec ±1 msec at TP6, and R35 for a negative-going pulse of
10.0 msec ±0.15 msec at TP7 (an oscilloscope is required).
NOTE
Resistors R30 and R35 have been sealed with Glyptol cement. Break
the seal to adjust and reseal after adjustment. Change the ‘60 Hz’
marking on the circuit card to read ‘50 Hz’.
3. Perform steps 3 and 4 from the Zero-Signal Offset Adjustment procedure.
4. Set the DRIVE switch to the OFF position.

Low Speed Range Adjustment (Dual Range Equipment Only)
1. With the SPEED control set to 10 and the LO DRIVE RANGE selected, adjust R122 to obtain a
linear speed of 600 mm/min (24 IPM).
2. If the Tracer is equipped with the Low Speed Enhancement circuit, adjust R86 for 5.0 Vdc ±0.1V at
TP13, with the SPEED control set to 10 and the LO DRIVE RANGE selected. Wait several seconds
for the voltage at TP13 to stabilize after adjusting R86.
3. Operation at high speeds on the low-speed range may result in excessive overshoot on sharp corners. If
overshoot occurs, repeat step 2 above, setting the voltage at TP13 to 6.0 Vdc ±0.1V. Corner
compensation can be increased by adjusting R86 until a 4.0 Vdc ±0.1V level is measured at TP13.
High Speed Stability (High Speed Systems Only)
1. If the machine exhibits instability during high speed operation, check that shunts are installed connecting
pins 1 and 2 and connecting pins 3 and 4 of W1 and of W2. Ensure that the gearbox mounting and
spring pressure do not permit free motion of the machine. If instability persists, the machine is not suitable
for high speed operation.
2. If the machine exhibits excessive overshoot during high speed operation, remove the shunt connecting
pins 1 and 2 of W1 and W2. If the machine becomes unstable, return the shunt connecting pins 1 and 2
to W1 and W2; otherwise proceed to step 3.
3. If the machine is stable and further reduction in overshoot is required, remove the shunt connecting pins 3
and 4 of W1 and of W2. Install a shunt connecting pins 1 and 2 of W1 and W2. If the machine becomes
unstable, remove the shunt connecting pins 1 and 2 and place it across pins 3 and 4 of W1 and W2;
otherwise proceed to step 4.
4. If the machine is stable and further reduction in overshoot is required, remove the shunt connecting pins 1
and 2 of W1 and W2. If the machine is unstable, install a shunt connecting pins 1 and 2 of W1 and W2.
Slowdown Circuit Calibration (If Command Mark Option Installed)
1. To enable the command circuit, install a shunt across the left/centre pins of Jumper S6 (below U36 on the
Tracing Circuit CCA). Install the shunt across the centre/right pins to disable the circuit.
2. Using Pattern 206P969 (located at the end of this manual), operate the Tracer over a Command Mark and
stop the Tracer.
3. Observe the signal at TP15 with a digital voltmeter and adjust R114 cw until the point at which an increase
in R114 does not result in a change in the voltage at TP15. Or, using an oscilloscope, observe the signal
at TP14 and adjust R114 to obtain a saturated signal for the duration of time that the Command Mark is
scanned. Do not increase the gain settings past the point where the signal is clipped. Noise from dirt on
patterns may cause improper operation of the circuit.
4. Verify correct operation of this circuit by tracing Pattern 206P969.
5. Using a typical pattern, adjust R120 to obtain a speed during slowdown operation which results in
optimum corner tracing at the maximum operating speed,. Maximum counter-clockwise (ccw) adjustment
results in a slowdown speed which is approximately 1/3 of the dial speed.

Measuring and Recalibrating True Linear Speed
The 0 to 10 calibration on the SPEED potentiometer should represent speeds from zero to the
maximum rated speed of the machine. A setting of `5' will therefore represent 50% of maximum speed.
The following example is for a machine with a maximum speed of 1000 mm/min (40 IPM). To measure the actual
speed:
1. Remove the cap from the SPEED control knob; it can be lifted out with your fingers.
2. Loosen the collet-locking nut and remove the knob on the control shaft.
3. Trace a test line, drawn in the X-axis direction, 500 mm long (see Figure 6-2).
Figure 6-2 Speed Measurement Test Line
4. Starting from the fully CCW position, slowly rotate the control until the X drive begins to turn, then
back the control off until the drive just stops.
5. Replace the knob on the control shaft to set the index mark over the scale `0' and tighten the nut.
6. Repeat step 4 and check that the drive stops at `0', readjust if necessary. Then reinsert the cap in the
control knob.
7. Set the SPEED control to `10' and record the time taken to traverse the 500 mm test line. At
1000 mm per minute this should be 30 seconds.
8. While tracing the test line measure the output voltage at terminal XT on the circuit card.
9. Calculate the calibrated speed voltage (VCAL) as follows, assuming the measured tacho voltage at
terminal XT is 5 volts and the time taken to travel 500 mm is 27 seconds:
27 seconds
VCAL = X 5 volts
30 seconds
= 4.5 volts
10. Retrace the test line and adjust R65 for a tacho output of 4.5 volts at terminal XT. Verify that the tracer
takes 30 seconds to travel 500 mm.

The Y axis is calibrated in a similar manner, with the 500 mm test line drawn in the Y-axis direction. The Y-drive
tacho output voltage is measured at terminal YT and adjusted by R66.
In this example, the machine was rated at 1000 mm (40 inches) per minute. If the machine is rated at
2000 mm (80 inches) per minute, the measured test line becomes 1000 mm (40 inches) long, and so forth.
Changing the Lead
The following instructions describe the steps required to replace a Standard (3 mm lead) Mirror &
Magnet Assembly, part number 1904C26G01, with either a 1 mm lead Mirror & Magnet Assembly, 1904C26G02
(identified by the number `1' on the face of the assembly on which the mirror is located), or a 1.5 mm lead
Mirror & Magnet Assembly, 1904C26G03 (identified by the number `1.5' on the face of the assembly on which the
mirror is located).
If either the 1 mm lead mirror or the 1.5 mm lead mirror is used, both kerf and system tracing speed are affected.
! The use of kerf is not possible. If required it should be included in the pattern.
! The maximum tracing speed of the system is limited, as follows:
MIRROR MAXIMUM TRACING SPEED
1 mm lead 1000 mm per minute

1.5 mm lead 1500 mm per minute
The Lead may be changed by the following procedure:
1. Switch the mains power OFF and disconnect the scanner motor connector J4/P4. This is a three-
contact connector, one half of which is part of the scanner motor assembly.
2. Loosen the kerf locking screw and rotate the scanner assembly (as would be required to adjust the kerf)
so that the two screws used to mount the scanner motor can be removed. A short screwdriver is
required.
3. Remove the scanner motor and mirror & magnet assembly.
4. Remove the mirror & magnet assembly by undoing the two set screws that secure it to the motor shaft.
5. Install the new mirror & magnet assembly, positioning it on the shaft so that its end is located
approximately 7.5 mm from the face of the boss on the motor end plate. Refer to Figure 6-3.

Figure 6-3 Mirror & Magnet Assembly
6. Replace the Motor Assembly and secure it in place using the four mounting screws removed in Step 2.
7. Reconnect connector J4/P4 and set the kerf scale to the zero position.
On systems using Tracing Circuit card part number 3925D27G04 or 3925D27G06, the Low Speed
Corner Adjustment feature (which is intended to work with a 3 mm lead mirror) must be disabled when a 1 mm or
1.5 mm lead mirror is used.
To disable the Low Speed Enhancement circuit:
! Note the position of the adjustment screw on potentiometer R86 on the Tracing Circuit card. If a
3 mm lead mirror is reinstalled, R86 must be returned to this position.
! Adjust R86 to the maximum clockwise (cw) position.
The `Corner Slowdown' feature on systems using Tracing Circuit card 3925D27G06 must also be disabled. To do
this place the two-pin shunt across the two right hand pins of three-pin header S6 which is located on the
Tracing Circuit card.
For speeds up to 300 mm per minute, the LOW speed range can be used (`5' on the dial on the LOW
speed range). For speeds greater than 300 mm per minute, use the HI speed range.
NOTE
When the Lead is changed, it may be necessary to re-zero the Kerf.

See ‘Re-Zeroing Kerf’ instructions.

Re-Zeroing Kerf
The procedure for checking and, if necessary, correcting calibration of the kerf is:
1. Attach a ball point pen (or similar scribing device) to the Tracer Unit to scribe a drawing next to the
test pattern being traced.
2. Set the Kerf Control to zero.
3. Trace the 0.5 mm wide line inside the circle of Test Pattern 205P773. The path recorded by the pen will
result in a single line. If necessary adjust the kerf. This is the new zero kerf position. Kerf should not
be adjusted when a 1 mm or 1.5 mm lead mirror is used.
PERIODIC MAINTENANCE
General
Perform periodic maintenance (as described below) at three-month intervals, or more frequently where conditions
require.
Component locations on the Lighting & Sensing Unit (part number 1904C30G01) and Lighting & Sensing Board
(part number 415B803GO1) are shown in Figure 6-4. Component locations on the Chassis Board CCA
(part numbers 3916D27G01 and 3916D27G02) are shown in Figure 6-5, and component locations on the
appropriate Tracing Circuit cards (part numbers 3925D27G01, 3925D27G04 and 3925D27G06) are shown in
Figures 6-6 through 6-8, respectively.
Scanner Sub-assembly
1. Check the flood lamps and wipe them with a soft cloth on a regular basis.
2. Replace the lamps once a year. Darkened flood lamps give reduced light output which affects tracing
performance.
3. Check and wipe the flood lamp reflector with a damp, clean, soft cloth.
Tracer Unit
1. Check if any relays or control switches are loose or worn.
2. Ensure that internal plugs and connectors are properly seated.
Drive Units
The motors are lubricated and sealed and do not require additional lubrication.
1. Check for excessive gear backlash and if necessary, replace the gearbox or drive unit.
2. Routine cleaning of the rails and wheel surfaces will prevent a buildup of slag which can lead to drag on
the drives.

Replacing Flood Lamps
The flood lamps, located at the bottom of the Lighting & Sensing Unit in the Scanner Assembly are held in place
by clips that are also the electrical contacts. See Figure 6-4.
To replace the flood lamps (DS1 and DS2):
1. Remove the Scanner Assembly or move the unit clear of the table.
2. Loosen the clip screws.
3. Rotate the clips and remove the lamps.
4. Install new lamps.
5. Position the clips and tighten the screws.
6. Replace the Scanner Assembly at the optimum height.
7. Rotate the flood lamps to eliminate shadow (if present) caused by a seam in the glass.
Figure 6-4 Flood Lamps and Spotlight
Replacing Indicator Lamps
The Lighting & Sensing Unit Assembly produces a small, well defined indicator spot that can be positioned in the
centre of the scanned area.
All Lighting & Sensing Units, part number 1904C30G01, with Serial Number 2392 and up, are new assemblies.
They contain a new Lighting & Sensing Board Assembly, part number 415B803G01. The new Lighting &
Sensing Units replace older assemblies (with Serial Numbers below 2392).

The new circuit card assembly (CCA) 415B803G01 is identical to the previous version except for indicator
lamp DS3, which is held in place by two clips instead of a socket mounted on two posts. The lamp now used for
DS3 is the same type as those used for the flood lamps (see Table 6-1).
A metal mask with a narrow slit is used to obtain a small indicator spot. The mask is held in place by the two
screws used to mount the CCA on the plastic moulding.
Figure 6-4 shows the location of components on Lighting & Sensing CCA 415B803G01.
To replace the indicator lamp (DS3):
1. Remove the two retaining screws from the Lighting & Sensing Unit Assembly.
2. Lower the unit while feeding the attached cable through the slot in the side of the Scanner Assembly.
Cut the plastic cable-tie securing the cable to the Scanner Assembly and disconnect the
motor ground connection by removing the motor mounting screw in one corner of the motor.
Disconnect the Scanner-to-Chassis Board cable connectors, if necessary.
3. Pry the indicator lamp straight up from the clips using a small screwdriver to push one end of the lamp
out of the clip. Remove the lamp; do not force the clips sideways.
Install a new lamp by resting it on the clips and pushing straight down until the lamp snaps into place.
4. Replace the Lighting & Sensing Unit Assembly. Replace the motor ground connection and the
mounting screw in one corner of the motor. Carefully feed the cable back through the slot in the side of
the Scanner Assembly. Excess cabling inside the housing may block light and prevent tracing. Replace
the two retaining screws used to mount the Lighting & Sensing Unit Assembly.
5. Check spotlight centering with the tracer positioned at the correct height above the pattern. Trace a
pattern, with zero kerf, stopping the tracer while it is moving in the X and Y axes and noting the
position of the indicator spot in relation to the pattern.
The position of the spot along the X axis can be altered by moving the slotted mask under the indicator lamp; two
screws secure the mask. The position of the spot along the Y axis can be altered by rotating the indicator lamp
between the clips. The lamp filament is offset from the centre.
Replace the plastic cable tie securing the cable to the Scanner Assembly and if necessary, the Scanner-to-
Chassis Board cable.
HL-90 Tracing Systems Service Manual Rev G 6 - 11

Ordering Replacement Lamps
The part number and description of the flood lamps, DS1 and DS2, and the Spotlight, DS3, used on the
Lighting & Sensing CCA, are given in Table 6-1.
CIRCUIT DESCRIPTION PART NUMBER

DESIGNATION
DS1 and DS2 Flood Lamp, Stanley K7486A1L01
A3472C12V5W10X37
DS3 Spotlight, Stanley K7486A1L01
A3472C12V5W10X37
Table 6-1 Flood Lamps and Spotlight - Part Number and Description
Figure 6-5 Component Location on the Chassis Board CCA
Troubleshooting Information
A step-by-step Troubleshooting Guide and Adjustment Procedures are included in Tables 6-2 and 6-3.
The component layouts for the Tracing Circuit CCA's are shown in Figures 6-6, 6-7 and 6-8. A set of schematics
is included in the attached parts supplement for this HL-90 configuration.

FAULT
STEP SYMPTOM CHECK LOCATION ACTION
1-1 No response Power Input Top of Check connection to correct

from the Cable Tracer. mains supply.
system; no
motion or
lights. The
Scan Motor
does not run.
1-2 F1, Left side of Check fuse; replace if defective.

Mains Fuse. Tracer Unit.
1-3 S5, Left side of Measure line voltage at the input

Mains Switch. Tracer Unit. to the switch; it should be within
+10%, -15% of the ac input
rating shown on the rating
nameplate on the lower left side
of the Tracer Unit. If the output
of the switch is not the same,
replace the switch. Latching
power relay K3 must operate.
2-1 No response T1 Power P12 on the Measure the voltage between

from the Transformer Chassis P12-1 and P12-2; it should be 30
system except output. Board Vac ±3V at nominal input. If
the Scan Assembly. high, recheck the mains voltage;
Motor runs. if low, replace the transformer. If
normal, check CR1; replace, if
defective.
2-2 +20 Vdc Chassis Measure the voltage between

Test Point. Board the Test Point and GND; it
Assembly. should be +20 Vdc ±3V. If low,
disconnect P1 from the CCA.
If the voltage is now correct, the

CCA is defective; repair or
replace it. If the voltage remains
low, U1 or the lamp circuit is
defective; refer to Step 3 for fault
finding. If the voltage is still low,
check rectifier CR1 and
capacitor C1 and replace the
defective part.
Table 6-2 Troubleshooting Guide

FAULT
2-3 -20 Vdc Chassis Measure the voltage between

Test Point. Board the Test Point and GND. It
Assembly. should be -20 Vdc ±3V. If low,
disconnect P1 from the CCA.
If the voltage is now correct, the

CCA is defective. Repair or
replace it. If the voltage is still
low, check rectifier CR1 and
capacitor C2 and replace the
defective part.
2-4 TP1, Circuit Card Measure the voltage at TP1. It

+12 Vdc. Assembly. should be +12 Vdc ±0.6V.
Repair or replace the CCA, if

defective.
TP2, Circuit Card Measure the voltage at TP2. It

-12 Vdc. Assembly. should be -12 Vdc ±0.6V.
Repair or replace the CCA, if

defective.
3-1 No lights; U1, U1 on the Measure the voltage at the +12V

Tracer moves. Lamp Chassis Test Point. It should be
Regulator. Board +12 Vdc ±0.6V.
Assembly.
If the voltage is incorrect,
disconnect P3 from the scanner
assembly.
If the voltage is still incorrect,

replace U1.
If the voltage is correct, the

fault is in the scanner assembly.
Table 6-2 Troubleshooting Guide (Cont'd)

FAULT
3-2 Flood Lights. Bottom, Check the flood lights DS1 and
Lighting & DS2 for continuity (J3-1 and
Sensing J3-2).
Assembly.
Replace if defective (see
Figure 6-4).
3-3 Spot light. Inside, Check the spot light DS3 for
Lighting & continuity (J3-2 and J3-4).
Sensing
Assembly. Replace if defective (see
Figure 6-4).
3-4 Flood lights Flood Switch Q1 on the Set the STRIP/TRACE/START

ON, very dim. Circuit. Chassis switch (S2) to the trace position.
Board, or K2 Measure the voltage at J3-2; it
on the should be 1.5 Vdc ±0.6V.
Chassis
Board.
4-1 The ON PATT a. Verify that the flood lights

light does not are ON.
come on, and b. Verify that the lights and
the tracer reflecting surfaces are clean.
does not c. Check that the Head height
follow a is 38 mm from the reference
pattern. line to the pattern.
d. Verify that the pattern
meets the requirements of
the tracer (refer to
Chapter 5).
4-2 TP5, Sensor Circuit Card Measure the output signal on

Signal. Assembly. TP5. With the tracer over a
pattern, the voltage should be
10.5 Vdc ±1.0V; if incorrect,
readjust per Table 6-2, Step B. If
adjustment does not correct the
fault, check that:
4-3 a. The scan motor is running.

b. The correct voltage is applied
to the photo sensor; it should
be +12 Vdc ±0.6V at P2-7 and
-7 Vdc ±1.2V at P2-4.

FAULT
4-4 Photo Sensor P2-2. Over a pattern, the output should

Output. be pulses, minimum 100 mV.
An oscilloscope is required to
make this measurement.
The dc level at this point should

be approximately 0 volts.
If the voltage is close to either

+12 Vdc or -7 Vdc, replace the
photo sensor. If the photo
sensor pulse is within spec., the
circuit card is defective. Repair
or replace it.
5-1 Machine will Set the STRIP/TRACE/START

not drive in the switch (S2) to STRIP, the speed
X axis. control to maximum and the
drive switch to the +X (right)
direction.
5-2 TP10, +X Circuit Card Measure the speed signal; it

Speed Signal. Assembly. should be +7.5 Vdc ±0.3V. If the
voltage is out of spec., complete
Step 6 in this guide. If no voltage
is measured, recheck the power
supplies, Step 2 in this guide.
Proceed if the power supplies
are OK.
5-3 TP3, Sine Circuit Card Measure the sine signal. It

Ref. Signal. Assembly. should be 5.3 Vac ±0.2V. If the
Step 6 in this guide. If no voltage
is measured, check the sine
generator output from the
scanner assembly at J2-6. If a
voltage is not present, repair or
replace the scanner assembly. If
the signal at TP3 is OK, proceed.

FAULT
5-4 Terminal Xm Circuit Card Measure the speed signal. It

Motor Output. Assembly. should be approximately 10 Vdc.
If the output is approximately
-3 Vdc, disconnect the motor
leads. If the voltage is
unchanged, repair or replace the
circuit card assembly. If the
voltage increases to
approximately -20 Vdc, repair or
replace the Drive Unit. If the
output is zero volts, replace the
circuit card.
5-5 Repeat Steps 5-1 to 5-5 with the

direction switch in the -X (left)
position; voltages at TP10 and
Terminal Xm should be similar,
but with positive
polarity.
6-1 Machine Set the STRIP/TRACE/START

drives in the X switch (S2) to STRIP, the speed
axis; the control to maximum, the drive
speed is switch to ON and the direction
controllable, switch to +X (right).
but not at the
set speed.
6-2 TP10, +X Circuit Card Measure the speed signal. It

Speed Signal. Assembly. should be +7.5 Vdc ±0.15V.
If the voltage is out of spec.,

recheck the power supplies, as
in Step 2 of this guide. If the
power supplies are OK, proceed.
6-3 TP3, Sine Ref. Circuit Card Measure the speed signal. It
Signal. Assembly. should be 5.3 Vac ±0.1V. If the
Steps C1 and C2 in this guide.

FAULT
If the voltage cannot be

adjusted to within spec., check
the sine generator output from
the scanner assembly at J2-6; it
should be approximately 3 Vac
(0.5 to 5 Vac). If this voltage is
out of spec., repair or replace
the scanner assembly. If the
voltage is OK, repair or replace
the circuit card assembly.
6-4 Motor Speed, If all voltages are OK, check the

+X Direction. motor speed; refer to Linear
Speed Adjustments, Steps 1
and 2. If the speed is still
incorrect, proceed.
6-5 Terminal Xm Circuit Card Measure the output voltage; it

Motor Output. Assembly. should be -5 Vdc to -8 Vdc.
6-6 Terminal Xt Measure the output voltage; it

Tacho Output. should be +4 Vdc to +6 Vdc.
If this voltage is incorrect, the

fault can be in either the CCA or
the drive unit assembly.
Interchange the X and Y motors

by switching the Xm and Xt
leads with the Ym and Yt leads;
repeat Step 6-4.
If the Y motor, driven by the X

amplifier, runs at the correct
speed, the X drive assembly is
defective. If the fault transfers
to the Y motor speed, the CCA
is defective. Repair or replace
the defective assembly.

FAULT
6-7 Motor Speed, If the fault occurs only in the

-X Direction. -X direction, repeat Steps 6-1
through 6-6 with the direction
switch in the -X (left) direction.
The voltage at TP10 should be
+8.5 Vdc, Term Xm +5 Vdc to
+8 Vdc, and Term Xt -4 Vdc to
-6 Vdc.

drives in the X switch to STRIP, the direction
axis but there switch to +X (right), the SPEED
is no speed control to 0, the drive switch to
control. OFF and the power switch to
ON.
If the drive motor immediately

runs at high speed, the circuit
card assembly is defective.
Repair or replace.
If the drive motor does not run,

set the DRIVE switch to ON and
increase the SPEED control
setting to 1. If the motor runs at
high speed and stops when the
SPEED control is returned to
zero, the fault is an open tacho.
Replace the drive unit.
If the motor continues to run at

high speed, the drive unit is
miswired, i.e. either motor leads
or tacho leads are reversed.
Refer to Chapter 4, Motor
Rotation.

drives in the X switch to STRIP, the direction
axis but the switch to +X (right), the SPEED
speed is control to 0, the drive switch to
irregular. OFF and the power
switch to ON.

FAULT
8-2 TP10, +X Circuit Card Monitor the voltage at TP10; it

Speed Signal. Assembly. should be 3.75 Vdc ±0.15V and
remain constant.
8-3 TP3, Sine Circuit Card If the voltage varies, measure

Ref. Signal. Assembly. the sine reference; it should be
5.3 Vac ±0.2V and remain
constant.
If the reference voltage varies,

repair or replace the scanner
assembly.
If the reference voltage is

constant, repair or replace the
circuit card assembly.
8-4 R68, Current Circuit Card Measure the voltage across R68.
Limit Resistor. Assembly. With a resistance of 1.0 ohm,
the meter reading in volts is
equivalent to the motor current in
amperes (R68 = 0.68 ohm in the
high speed version, current = 1.4
times the voltage reading). The
current is limited to a maximum
of approximately 1 ampere
(1.4 amperes for the high speed
versions). Under normal
operation, the motor should
require less than 0.5 ampere
and the voltage across R68
should be 0.5 Vdc, or less. If the
voltage is high, i.e. 0.8 Vdc to
1.1 Vdc, a fault in either the drive
unit or the machine wheels and
bearings is indicated.
Decouple the motor from the

machine to determine the
location of the fault. Repair or
replace the faulty components.

FAULT
8-5 R67, Current Circuit Card Repeat Step 8-4 with the
Limit Resistor. Assembly. direction switch in the -X (left)
position and measure the
voltage across R67.
9-1 Machine will Perform Steps 5-1 to 5-5, but in

not drive in the the Y axis. Measure the Speed
Y axis. Signal at TP11, the Sine
Reference at TP3 and the Motor
Output at terminal Ym.
10-1 Machine Perform Steps 6-1 to 6-7, in the

drives in the Y Y axis. Measure the Speed
axis; the Signal at TP11, the Sine
speed is Reference at TP3, the Motor
controllable, Output at terminal Ym and the
but not at the Tacho Output at terminal
set speed. Yt.
11-1 Machine Perform Step 7-1, in the Y axis.

drives in the Y
axis but there
is no speed
control.
12-1 Machine Perform Steps 8-1 to 8-5, in the

drives in the Y Y axis. Measure the Speed
axis but the Signal at TP11, the Sine
speed is Reference at TP3, the +Y
irregular. current limiting across R69 and
the -Y current across R70.
13-1 Machine Power FET Located on Replace Q1 or K2.

operates, but Q1, or Relay the Chassis
the flood K2. Board
lamps can not Assembly.
be turned off.

FAULT
13-2 Tracer will not Signal Gain Circuit Card Adjust the Gain. Refer to
slowdown over TP14, TP15. Assembly. Slowdown Circuit Calibration,
Command Step 3.
Marks.
Signal at Circuit Card The voltage must be +5V when

TP16. Assembly. the Tracer is over a Command
Mark.
If the voltage is not +5V, the

circuit card is defective.
13-3 Corner Signal at Circuit Card The voltage at TP13 must be

Compensation TP13. Assembly. +5 Vdc when on the LO range
is incorrect. and SPEED control at 1-. Adjust
R86; refer to Low Speed Range
Adjustment, Steps 1 through 3.
If this voltage is correct, the

circuit card is defective.

TEST OUTPUT
POINT SIGNAL TYPICAL VOLTAGES ADJUSTMENT
TP1 +12V Supply +12 Vdc ±0.6V N/A
TP2 -12V Supply -12 Vdc ±0.6V N/A
TP3 Sine Output 15 Vp-p ±0.3V (5.3 Vac ±0.1V) R41 (Gain),
R73 (Offset)
TP4 Sensor Signal 0V to +12V pulse R21
TP5 Scan Signal 10.0V ±0.5V R21
TP6 Inhibit Pulse 0V to +12V pulse (27 or 34 msec) R30
TP7 90E +12V to 0V pulse (8 to 10 msec) R35
U21B-10 Sample Pulse 0V to +12V pulse (5 to 7 µsec) --
U21A-6 Sample Pulse 0V to +12V pulse (5 to 7 µsec) --
TP10 `X' Speed Between +7.5 Vdc and -7.5 Vdc R40
R73 (Offset)
TP11 `Y' Speed Between +7.5 Vdc and -7.5 Vdc R40
R73 (Offset)
XM `X' Drive 0 Vdc ±50 mV R50 (Offset)
XT `X' Tacho Between +6 Vdc and -6 Vdc maximum R65 (Speed)
YM `Y' Drive 0 Vdc ±50 mV R52 (Offset)
YT `Y' Tacho Between +6 Vdc and -6 Vdc maximum R66 (Speed)
TP12 Speed Between +7.5 Vdc and -7.5 Vdc R40, R122, R120
TP13 Speed Ref. 0.0 to +5.0 Vdc R86
TP14 Scan Signal 0V to +12V pulse R114
TP15 Peak Detected 0V to +12V R114

Scan Signal
TP16 Slowdown Signal +5V
Table 6-3 Adjustments and Test Points on the Tracing Circuit CCA

Figure 6-6 Component Location on Tracing Circuit CCA 3925D27G01
NOTE
Not all Tracing Circuit CCA illustrated in this chapter may be used in
your system. Please refer to Parts List to determine which Component
Location figure is applicable.

NOTE
Not all Tracing Circuit CCA illustrated in this chapter may be used in your
system. Please refer to Parts List to determine which Component Location
figure is applicable.

NOTE
Not all Tracing Circuit CCA illustrated in this chapter may be used in
your system. Please refer to Parts List to determine which Component
Location figure is applicable.

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What patents are associated with the product?

What patents are associated with the product?

I.B.

NORTHROP GRUMMAN - CANADA, LTD.

Manufactured and sold under one or more of the following patents:

Canada U.S.A. U.K. Japan France Italy Australia Switzerland

917,773 3,704,372 1,292,507 756,804 2,066,165 916,825 450,468 531,395

Manual Number I.B. 495-100

The subassemblies listed by serial VOLTAGES EMPLOYED IN THE

Proper Electrostatic Discharge (ESD)

The equipment described in this manual is

Any changes made to this equipment may void

The equipment described in this manual meets the

Any changes made to this equipment may void this

CHAPTER 1 GENERAL DESCRIPTION

CHAPTER 2 DETAILED DESCRIPTION

Tracer Unit Sub-assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1

HL-90 Tracing Systems Service Manual Rev G vii

Tracing Mode (Plasma) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6

CHAPTER 5 OPERATING FEATURES

CHAPTER 6 ALIGNMENT & TROUBLESHOOTING

viii HL-90 Tracing Systems Service Manual Rev G

2-1 Cable Assembly 415B905H01 Installed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2

3-1 Tracer Unit Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2

4-1 HL-90 Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2

5-1 Kerf Offset Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1

6-1 Tracer Unit Assembly, Opened View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2

HL-90 Tracing Systems Service Manual Rev G ix

1-1 HL-90 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

2-1 Chassis Board Test Points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2

4-1 HL-90 Control Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3

5-1 Pattern Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3

x HL-90 Tracing Systems Service Manual Rev G

ABOUT THIS MANUAL

This service manual consists of six Chapter 6: ALIGNMENT & TROUBLE-

Chapter 5: OPERATING FEATURES.

HL-90 Tracing Systems Service Manual Rev G xi

A view of the HL-90 Drive Tracing System is shown in Figure 1-1.

HL 90 Tracing Systems Service Manual Rev G 1-1

POWER ! 100 Vac +10%/-15%, 50/60 Hz, or

TRACING SPEED ! 100 mm/min to 3000 mm/min;

PATTERNS ! Line width or silhouette (0.5 mm, minimum);

LEAD ! Standard: 3 mm, fixed;

ENVIRONMENT ! Operating temperature from 0EC to +50EC.

Table 1-1 HL-90 Specifications

The Linatrol equipment is designed to operate from a three-wire,

Failure to provide the correct power source and grounding connections,

1. Increased power for high-speed applications, up to 3000 mm/min.

2. Corner enhancement to improve low speed operation.

1-2 HL-90 Tracing Systems Service Manual Rev G

Figure 1-1 HL-90 Drive Tracing System

HL 90 Tracing Systems Service Manual Rev G 1-3

The Tracer Unit Subassembly consists of the following components:

HL-90Tracing Systems Service Manual Rev G 2-1

Test Points Connector Connecting To

Figure 2-1 Cable Assembly 415B905H01 Installed

LINE VOLTAGE LINE FREQUENCY