AMI M9 Series User manual

M9 SERIES WELD HEADS
OPERATION MANUAL

Doc No. 7401241
MODEL 9 SERIES WELD HEAD
OPERATION MANUAL
NOTICE
This document and the information contained herein is the property of Arc Machines,
Inc.. It is proprietary and submitted and received in confidence. It shall be used only for
the purpose for which it is submitted and shall not be copied in whole or in part without
the prior expressed written permission of Arc Machines, Inc.
The information in this document has been carefully reviewed and is believed to be
accurate.
Information and instructions in this document are subject to change and Arc Machines,
Inc. reserves the right to change specifications and data without notice.
WARNING
The nature of the GTAW process creates some POTENTIAL HAZARDS. In accordance
with international safety regulations the EXCLAMATION SYMBOL indicates that this
equipment is considered HAZARDOUS until an operator has been made aware of these
POTENTIAL HAZARDS by reading the appropriate Arc Machines, Inc. Power Supply
and/or Weld Head Operation Manual. The LIGHTNING FLASH SYMBOL indicates that
there are potential electrical hazards. The use and display of these symbols make it the
OPERATOR’S RESPONSIBILITY TO INSURE THAT HE HAS READ AND/OR BEEN
MADE AWARE OF ALL OF THE SAFETY-RELATED ITEMS CONTAINED IN THESE
MANUALS.
Publication date : November, 2011
Copyright 2010 by Arc Machines, Inc.
All rights reserved
REV DCO # CHANGE DESCRIPTION
DATE
APR
A E6181 First Edition 4/1/11 BL

Doc No. 7401242
MODEL 9 SERIES WELD HEAD
OPERATION MANUAL
Table of Contents
Chapter Description Page
1.0 Introduction………………..…………………3
2.0 Unpacking……………………………………3
3.0 Cable hook up……………………………… 3
4.0 Water Cooling………………………........... 5
5.0 Rotation (speed) Auto-Calibration……….. 5
5.2 Rotation (speed) Manual Calibration……. 6
6.0 Clamp Insert Installation………………… 7
7.0 Electrode Geometry & Installation…………9
8.0 Shielding Gas……………………………….14
9.0 Return-to-home (rotor) position
adjustment….. ……………………………. .15
10.0 Cleaning & maintenance…………………. 17
11.0 Storage…………………………………….. 18

Doc No. 7401243
MODEL 9 SERIES WELD HEAD
OPERATION MANUAL
1.0 INTRODUCTION
This manual covers basic set up and maintenance of the following model 9 and
model 9E series weld heads: 9-750, 9-1500, 9E-1500, 9-2500, 9E-2500, 9-3500,
9E-3500, 9-4500, 9E-4500, 9ER-4500, 9-7500 and 9E-7500. The operator
should have a working understanding of the power supply being used and should
understand this manual before operating the weld head.
2.0 UNPACKING
When unpacking the weld head use extreme caution in removing the plastic bag
covering the cable connectors. Tools such a knife of other sharp object can cut
the cables.
3.0 CABLE HOOK UP
CAUTION
Always turn the power supply off before making any cable connections.
The Model 9 series weld heads come supplied with an integral 10ft (3 m) cable.
This cable is NOT connected directly to the power supply. It must be mated to
the power supply via an adapter pig-tail or adapter cable. Extension cables may
also be used. The use of an extension cable does not eliminate the requirement
for an adapter. If an extension cable is used, it is connected between the power
supply and the adapter. After making connections, slide the rubber boots
together. See figures 1 - 4
Fig. 1
Connect the power and ground fittings by pulling the brass ring back and
inserting the male fitting into the female fitting, until it is fully seated. If it is not
fully seated, it will leak water or potentially come apart.

Doc No. 7401244
MODEL 9 SERIES WELD HEAD
OPERATION MANUAL
3.0 CABLE HOOK UP (contd.)
Fig. 2
To connect the male to female (chrome) gas fittings, unscrew the (4-40) socket
head screw to allow the latch to open far enough to fully seat the two fittings.
Lightly tighten this screw to prevent accidental disconnection of this fitting.
Fig. 3
Connect the motor control connector by aligning the key to the slot, and lightly
tightening the outer ring. Be careful not to cross-thread this ring.

Doc No. 7401245
MODEL 9 SERIES WELD HEAD
OPERATION MANUAL
3.0 CABLE HOOK UP (contd.)
Fig. 4
Slide the boots together securely to protect the connectors and fittings from dirt,
and to prevent the power and ground connectors from coming in contact with
each other.
4.0 WATER COOLING
Most Model 9 series heads are plumbed for water cooling, and are cooled via the
power supply’s (optional) cooling unit. Although water cooling is not required for
all applications, it should always be used when welding tube or pipe wall
thicknesses of 0.065” (1.6mm) or heavier in the Model 9-500C or 0.083” (2.1mm)
or heavier in all the other water-cooled models 9 series heads. In addition, water-
cooling should always be used when doing high-duty-cycle work, regardless of
the tube wall thickness. Consult the factory for recommendations.
5.0 ROTATION (SPEED) AUTO-CALIBRATION
Before welding, the electrode rotation motor in the weld head must be calibrated
to the power supply. Most power supplies include an auto calibration function in
the software. Refer to the power supply operation manual for specifics on auto
calibration.
5.1 Should the power supply indicate that the weld head requires
calibration adjustment, the calibration potentiometer can be accessed
through the screw driver slot on the side of the return-to-home switch
housing. See fig. 5. Follow the instructions on your power supply in
making adjustments to the potentiometer.

Doc No. 7401246
MODEL 9 SERIES WELD HEAD
OPERATION MANUAL
5.0 ROTATION (SPEED) AUTO-CALIBRATION (Contd.)
Note: Some larger Model 9 series weld heads provide access to the
calibration potentiometer through an access hole in the side of the
housing, adjacent to the potentiometer. A nylon screw is used to plug
this access hole. Removed it to gain access to the calibration
potentiometer. Replace this screw when calibration is complete.
Fig. 5
Model 9-1500
5.2 ROTATION (SPEED) MANUAL CALIBRATION
Some power supplies do not have auto calibration software. In this
case, the weld head motor is manually calibrated by creating a weld
program that should rotate the electrode 360 degrees. ie: 1 RPM for a
total of 60 seconds, 2 RPM for a total of 30 seconds, 3 RPM for
a total of 20 seconds, etc. Select a speed (RPM) and corresponding
time close to or equal to the speed that you intend on welding at to
achieve the most accurate calibration.
5.3 Calibration must be run in the “TEST” mode. Create a one level weld
schedule at your selected RPM. Amperage and pulse rate settings
may be set to any value, as during rotation calibration no arc will be
established. Set the rotation mode to “CONT” (continuous rotation).
Set rotation delay and downslope times to 0.0.

Doc No. 7401247
MODEL 9 SERIES WELD HEAD
OPERATION MANUAL
5.0 ROTATION (SPEED) MANUAL CALIBRATION (Contd.)
5.4 Add one additional level with a duration of 5 or more seconds, with
the rotation mode set to “OFF”. This additional level (with rotation
off) will hold the electrode at its stopped position allowing the operator
to see if it traveled too far (traveling too fast) or not far enough
(traveling too slow).
5.5 Be sure the power supply is in the “TEST” mode, and run the program.
Should the electrode rotate too fast (traveling more than 360 degrees),
stopping beyond the home position, slow it down by turning the
potentiometer counter clockwise (CCW). Should the rotation be too
slow (traveling less than 360 degrees) stopping before it reaches a full
360 degrees, turn the potentiometer clockwise (CW). Continue this
procedure until the electrode stops after 360 degrees of travel.
6.0 CLAMP INSERT & GAS SEAL INSTALLATION
Clamp inserts are designed for a specific tube or pipe size. Select the
appropriate clamp for the specific tube or pipe to be welded. A set of clamps fits
one side of the weld head. Except for some special applications, or when using a
model 9E or 9ER type weld head, two sets of clamps are required. One set fits
on each side of the head.
Note: A set of clamp inserts is made from one piece, and then split into two
halves. Each half is marked with matching alphanumeric characters.
Keeping matched sets together (on the same side of the weld head) will
result in the highest level of weld joint concentricity.
6.1 Before mounting the clamp insert into the head be sure both the clamp
and weld head clamp mounting groove are clean and free of dirt, oil or
other contaminants. The clamp mounting screw need only be lightly
snug. See fig. 6.
CAUTION
Use of the wrong size clamp, or clamping the head on the curved section of an
elbow or other irregular surface can result in damage to the clamp insert, weld
head clamp latch and/or hinge.

Doc No. 7401248
MODEL 9 SERIES WELD HEAD
OPERATION MANUAL
6.0 CLAMP INSERT & GAS SEAL INSTALLATION (cont’d.)
Fig. 6
6.2 Model 9E and 9ER type heads use a clamp insert on one side, and a
gas seal on the other side of the head. The hole in the gas seal is
approximately 1/8” (3mm) larger than the diameter of the part to be
welded. Components such as elbows or other non-straight or odd-
shaped parts will sometimes require repositioning of the gas seal to
facilitate approximately a 1/16” (1.6mm) gap all around the part being
welded. This gap is used to allow arc gas to exit the weld head and to
minimize gas seal burning. The four mounting holes in the gas seal
are large enough to allow the gas seal to be positioned as required.
Blank gas seals (without a hole in the center) are available for
custom applications. See fig. 7.
Fig. 7
Model 9ER-4500

Doc No. 7401249
MODEL 9 SERIES WELD HEAD
OPERATION MANUAL
7.0 ELECTRODE GEOMETRY & INSTALLATION
CAUTION
To prevent the possibility of electrical shock, the power supply must be in the
“TEST” mode before proceeding with electrode installation or removal. Take
extreme care that fingers or foreign objects are clear of the rotor when jogging.
The recommended electrode type is 2% Ceriated. (AWS Spec. A5.12/A5.12M,
Orange tip). This type of electrode provides superior arc starting and longer life
than 2% Thoriated electrodes. Other types can also be used. Consult factory for
recommendations.
Most Model 9 series heads accommodate two electrode sizes. Either 0.040”
(1.0mm) and 1/16” (1.6mm) or 1/16” (1.6mm) and 3/32” (2.3mm) diameter. The
mounting holes in the rotor are approximately 180 degrees apart.
CAUTION
Do not install an 0.040” electrode into the 1/16” electrode mounting hole, or a
1/16” electrode into a 3/32” electrode mounting hole, and never install more than
one electrode.
7.1 The electrode length ultimately determines the arc gap, and the arc
gap determines the arc voltage which affects the heat input into the
weld. Thus a consistent arc gap from weld to weld is essential for weld
repeatability.
In order to determine the correct electrode diameter, length and tip
diameter for a specific application, use the charts and formula below.
See figures 8, 9, 10, 11, and 12.