AMI 21 User manual

Model 21 Weld Head
Operation Manual
Part No.740122
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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 : 4-15- 2011
Copyright 2011 by Arc Machines, Inc.
All rights reserved
Revision History
Revision ECO No. Change Description Date Appr.
- N/A Initial release 4/15/11 PP
A 6052 Updated select text and images 7/7/11 PP

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Table o Contents
Table o ContentsTable o Contents
Table o Contents
1.0 INTRODUCTION................................................................................................1
1.1 SHOCK HAZARD WARNING............................................................................ 1
2.0 SPECIFICATION ...............................................................................................2
2.1 TUBE SIZES - STANDARD...............................................................................2
2.2 CURRENT - MAXIMUM..................................................................................... 2
2.3 DUTY CYCLE MODEL 21-500 ..........................................................................2
2.4 DUTY CYCLE MODEL 21-1000 ........................................................................2
2.5 CLAMP DIMENSIONS....................................................................................... 3
3.0 INSTALLATION INSTRUCTIONS .....................................................................4
3.1 CONTROLLER CONNECTIONS.......................................................................4
4.0 OPERATION INSTRUCTIONS ..........................................................................7
4.1 WELDHEAD USER INTERFACE ......................................................................8
4.1.1 DISPLAY LEGEND............................................................................................ 8
4.2 STARTUP PROCEDURE ..................................................................................9
4.3 SET ALIGNMENT PROCEDURE ......................................................................9
4.4 OPERATION PROCEDURE ............................................................................10
5.0 MAINTENENCE INSTRUCTIONS ...................................................................11
5.1 ELECTRODE REPLACEMENT PROCEDURE ...............................................11
5.2 COLLET CHANGE PROCEDURE ..................................................................12
5.3 ROTOR AND PARTS REPLACEMENT ..........................................................13
5.4 STARTUP PRELIMINARY CHECKLIST .........................................................14
5.5 OPERATION PRELIMINARY CHECKLIST.....................................................14
5.6 ELECTRODE LENGTH FORMULA ................................................................15
5.7 ELECTRODE LENGTH CHART...................................................................... 15
6.0 TROUBLESHOOTING..................................................................................... 16
6.1 MEANDERING WELD .....................................................................................16
6.2 MISALIGNMENT .............................................................................................16
6.3 INCORRECT ROTOR HOME POSITION ........................................................17
7.0 MAINTENANCE...............................................................................................18
7.1 CLEANING AND MAINTENANCE ..................................................................18

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1.0 INTRODUCTION
The Model 21 is a weld head for automatic orbital tube welding. This manual covers basic
set up and maintenance of the Model 21-500 & Model 21-1000. The operator should have a
working understanding of the power supply being used and should understand this manual
before operating the weld head.
1.1 SHOCK HAZARD WARNING
WARNING: ELECTRIC SHOCK CAN KILL
Significant D.C. voltage is present after removal of input power
•Electrical parts may retain electrical charge
•Shut down the Orbital Weld Head System before unplugging the input cord
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2.0 SPECIFICATION
2.1 TUBE SIZES - STANDARD
21-500 – Standard 1/4”, 3/8”, and 1/2” collets with optional 1/8” and custom
sized collets
21-1000 – Standard 1/4", 3/8”, 1/2", 3/4", and 1” collets with optional custom
sizes
2.2 CURRENT - MAXIMUM
21-500 – 60 Amps
21-1000 – 100 Amps
2.3 DUTY CYCLE MODEL 21-500
40 welds/hour @ 30 Amps
30 welds/hour @ 40 Amps
20 welds/hour @ 60 Amps
2.4 DUTY CYCLE MODEL 21-1000
40 welds/hour @ 30 Amps
30 welds/hour @ 60 Amps
20 welds/hour @ 100 Amps
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2.5 CLAMP DIMENSIONS
Dimensions 21-500 21-1000
A 0.63 1.10
B 0.63 1.10
B open 1.27 2.00
C 0.48 1.40
D electrode 0.25 0.70

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3.0 INSTALLATION INSTRUCTIONS
3.1 CONTROLLER CONNECTIONS
1. From a regulated air/argon source, connect a ¼” - 50 psi hose into the receptacle
fitting, labeled “CDA” [Clean Dry Air]. This fitting is a compression type and only
requires the bare ended hose to be pushed in. Ref Figure 1.
2. From the welding power supply, connect an Argon hose from the “Arc Gas
Output” fitting to the “Argon” receptacle. This fitting is a compression type and
only requires the bare ended hose to be pushed in. Ref Figure 1.
3. Insert the “Ground” and “Electrode” connectors into their respective receptacles
on the welding power supply. Twist to lock. Ref Figure 2.
4. Connect the 10-pin round connector to “Weldhead Control” on the power supply.
Ref Figure 2.
5. Connect the 25-pin semi-rectangular connector to “Auxiliary” on the power supply.
Ref Figure 2.
6. Connect the weldhead to the end of the Controller cable. The shape of the
mating ends and the pin location indicate connection orientation. Ref Figure 3.
7. If needed, plug the foot pedal cable into the foot pedal plug (B1 & B2 Modes).
Ref Figure 4.
8. Connect the cord from the 24VDC transformer to the chrome receptacle (Does
not apply to M207). Ref Figure 1.
9. Push end of Controller cable into bottom of weldhead. Push together until the two
latches click into closed position and securely hold the weldhead. Ref Figure 5.
Note
The 120AC/24DC transformer is only required if the welding power source does not
supply 24VDC.
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Figure 1
Figure 2
Figure 3
Argon from power supply Air from 50 psi source
24VDC supply
Ground
Electrode
Weldhead
Auxiliary

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Figure 4
Figure 5
Push Controller cable into weldhead (left) until latches “click” closed (right).
Foot Pedal
Connection

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4.0 OPERATION INSTRUCTIONS
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