AMI 205 User manual

Part No. 740108
Revision J
Model 205 Tube Welding Power Supply
Operator’s Manual

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INTRODUCTION
he Model 205 is a power source and controller for automatic orbital tube welding. It is
intended to be used only in conjunction with AMI or EXEL orbital tube weldheads.
The Model 205 power supply provides GTAW (Gas Tungsten Arc Welding) current
with pulsation controls, high frequency arc starting, purge gas controls, weldhead arc
rotation and automatic timing functions. Users need only to supply input AC power, a
regulated gas source with flow meter andthe appropriate weldhead.
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
express written permission of Arc Machines, Inc. The information in this document has
been carefully reviewed and is believed to be accurate. However, no responsibility is
assumed for inaccuracies.
Information and instructions in this document are subject to change and Arc Machines, Inc.
reserves the right to change specifications and data without notice.
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Revision History
Rev ECO No. Change Description Date Appr.
A N/A Initial release 3/10/09 B.F.
B 5355 Update sections 2.0, 3.0, 4.0, 5.0 & 6.0; delete Glossary 5/14/09 B.F.
C 5411 Update section 4.10.9 Performing a Weld 07/06/09 B.F.
D 5447 CE changes 12/30/09 D.C.
E 5713 Correct table in Section 6.1.2 with correct weight 06/16/10 D.C.
F 5817 Incorporate S/W v1.5, corrections for CE changes, add
power grounded to section 2.0, update obsolete data 12/08/10
D.C.
G 6346 Incorporate M21 W/H information, add changes to Run
screen, add Associated Data look-up tables, add
information on system initiate 0.5 second delay, add
information on +1%/-1% buttons, update UK address.
06/15/12 D.C.
H 6518 Section 6.2, changed picture of Remote Pendant (pg51) 3/20/13 BL
J 6646 Add Weld Data Recording functionality and update
applicable screens 2/25/14 W.O.

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Tab e of Contents
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ab e of ContentsTab e of Contents
Tab e of Contents
INTRODUCTION....................................................................................................i
NOTICE..............................................................................................................i
Revision History............................................................................................ii
Table of Contents.........................................................................................iii
1.0 SAFETY PRECAUTIONS......................................................................1
1.1 SHOCK HAZARD WARNING................................................................1
1.2 WARNING LABEL DEFINITIONS.........................................................3
2.0 SPECIFICATIONS.................................................................................5
2.1 ELECTRICAL ........................................................................................5
2.2 ELECTICAL SERVICE GUIDE..............................................................6
2.3 PHYSICAL DIMENSIONS .....................................................................6
2.4 PROGRAMMABLE AND OPERATIONAL FUNCTIONS......................7
3.0 INITIAL SETUP......................................................................................8
3.1 SYSTEM SYMBOLS..............................................................................8
3.2 INSPECTION.......................................................................................10
3.3 POWER CONNECTION.......................................................................11
3.4 WELDING GAS CONNECTIONS........................................................11
3.5 MODEL 205 TO M8 / M9 WELDHEAD HOOK UP..............................12
3.6 MODEL 205 TO EXEL ROTOR DRIVER HOOK UP...........................16
3.7 MODEL 205 TO M21 WELDHEAD HOOK UP....................................17
4.0 OPERATION........................................................................................18
4.1 SYSTEM FUNCTIONS.........................................................................18
4.2 INITIAL POWER ON............................................................................20
4.3 SET-UP FUNCTIONS..........................................................................21
4.4 OPENING THE LAST WELD SCHEDULE..........................................25
4.5 SELECTING A WELD SCHEDULE FROM THE LIBRARY ................25
4.6 MODIFY A WELD SCHEDULE ...........................................................26
4.7 COPY A WELD SCHEDULE ...............................................................30
4.8 CREATE A WELD SCHEDULE...........................................................33
4.9 WELDHEAD CALIBRATION...............................................................35
4.10 PERFORMING A WELD.....................................................................36
4.11 WELD DATA RECORDING................................................................40
5.0 MAINTENANCE AND TROUBLE-SHOOTING ...................................43
6.0 OPTIONS.............................................................................................52

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Electrical
Hazard
1.0 SAFETY PRECAUTIONS
The Model 205 is intended to be used only with AMI or EXEL weldheads for the purpose of
GTAW welding of metal tube. The system is not to be used for any other purpose, specifically
heating or cutting.
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. 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 ENSURE
THAT HE HAS READ AND/OR BEEN MADE AWARE OF ALL OF THE SAFETY-RELATED
ITEMS CONTAINED IN THIS MANUAL.
1.1 SHOCK HAZARD WARNING
HIGH VOLTAGEis presenton exposedinternal terminals. The ELECTRODE (tungsten /
weldhead rotor) isalso an EXPOSED TERMINAL and by its naturethe GTAW process requires
electrical potential to be present on the electrode during arc starting and during welding.
Chapter
1
I C O N K E Y
Warning

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All AMI Power Supplies contain a “bleeder” circuit to ground any residual potential
after welding or after an aborted or bad arc start attempt. These circuits take a few seconds
to operate or could fail.
The electrode should always be considered a possible shock hazard. This is
especially true when the system is in “weld sequence”, ready to weld, is welding or has just
finished welding. Equipment/component failure, system abuse or improper maintenance
could result in electrical potential at the weldhead even when not in “weld sequence”.
The users/operators of this equipment must take all precautions necessary to avoid
contact with the ELECTRODE at “ALL TIMES”. The only exception is when actually
replacing or adjusting the electrode and this should be done WITH THE POWER TURNED
OFF.
If performed with the power “ON” the system must be in “TEST” mode out of weld
sequence and the USER MUST OBSERVE COMMON SAFETY PRACTICES such as
grounding the electrode to ensure discharge before actually touching it.
Most AMI Power Supplies feature High Frequency (HF) Arc Starting. This is a High
Voltage/High Frequency electrical transmission process. To eliminate any HF shock
possibility “AVOID ALL CONTACT” with the Welding WORK (ground), the ELECTRODE or
the WELDHEAD during arc start.
Remember, there is a possible shock hazard in all welding power supplies at
ALL times.

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1.2 WARNING LABEL DEFINITIONS
The table below contains caution and warning labels for the operation of this equipment. Before
operating this or any welding equipment users should be familiar with ANSI-49.1 Safety in
Welding and Cutting.
ELECTRIC SHOCK from welding electrode or wiring can kill.
HIGH FREQUENCY RADIO WAVES can cause interference and
sometimes even damage to nearby electronic equipment (such
as computers) that are un-protected.
MAGNETIC FIELDS can affect implanted medical devices.
Wearers of pacemakers should keep away until consulting their
doctor.
Welding can cause FIRE OR EXPLOSIONS. Do not weld near
FLAMMABLE or EXPLOSIVE MATERIALS. Have the proper
type of extinguisher in the work area.
WEAR NON-FLAMMABLE protective clothing, footwear and
head gear at all times.
HOT PARTS can cause severe burns. Do not touch recently
welded components. Avoid touching torch components and
welding fixtures soon after welding.
ARC RAYS can burn the eyes and skin. The welding arc emits
ultra-violet (UV) radiation and the molten weld gives off infra-red.
Both can burn eyes and skin if unprotected. Suitable eye and skin
protection must be worn.
BUILD UP OF GAS can injure or kill. Weld materials can emit
toxic fumes during welding. WELD ONLY IN AREAS WITH
ADEQUATE VENTILATION.
FUMES AND GASES can be hazardous. Welding produces
fumes and gases. Breathing these fumes and gases can be
hazardous to your health. DO NOT weld in enclosed areas
without proper ventilation or respirators.

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MOVING PARTS - Keep hands and fingers clear of fans,
gears, rotors, wire feed, rotation and AVC mechanisms
WARNING: AMI factory training is essential for all Welding
Operators and Maintenance Technicians who operate AMI
equipment.
WELDING WIRE and ELECTRODES are sharp and can cause
injury.
MOVING PARTS may cause crush or pinch points.
WARNING: Disconnect the input power to the machine before
opening or servicing. Discharge all circuits that store high
voltage such as capacitor packs. Only AUTHORIZED and
QUALIFIED service personnel should open this equipment.

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2.0 SPECIFICATIONS
These specifications pertain the to Model 205 power supply only. For weldheads, refer to the
specification sheet of each particular model. For non-AMI supplied equipment such as gas
tanks and regulators, refer to the original manufacturer’s documentation.
The Model 205 is a mobile system that is intended be hand carried. The supporting equipment
such as weldheads, water coolers, gas regulators, remote controls and extension cables can
also be hand carried. Items such as gas tanks and welding fixtures should be moved with
appropriate equipment and safety precautions. Gas tanks should be securely anchored to
prevent toppling over.
2.1 ELECTRICAL
INPUT POWER DETAIL
The Model 205 can operate on the following Auto Adjusting for Single Phase AC input:
Input Power
Single-Phase
AC
Rated Welding
Output
Welding
Amperage
Range
Max OCV
DC (Up)
Rated Peak
Starting
Voltage (Up)
Amperes Input
At Rated Load
Output, 50/60Hz,
Single-Phase
KVA
@
Duty
Cycle
KW
115 Volts TIG
100A @ 14.0
Volts DC, 100%
Duty Cycle 5 - 150A
90V
12-16 15 KV 18.4 2.1 2.1
20A 150A @ 16.0
Volts DC, 30%
Duty Cycle 5 - 150A
90V
12-16 15 KV 28 3.4 3.1
230 Volts TIG
100A @ 14.0
Volts DC, 100%
Duty Cycle 5 - 150A
90V
12-16 15 KV 8.3 2 1.9
20A 150A @ 16.0
Volts DC, 30%
Duty Cycle 5 - 150A
90V
12-16 15 KV 14.2 3.2 3.1
Input power must be grounded.
Chapter
2

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OUTPUT POWER
Straight polarity, constant current DC regulation intended for GTAW welding only. Static
characteristic of all power supplies is flat.
5 to 150 amperes DC using 100 to 120 VAC input.
5 to 150 amperes DC using 200 to 240 VAC input.
CIRCUIT BREAKER – ON/OFF, two pole, 20 Ampere at 250 VAC.
DUTY CYCLE – determined by the AC input voltage and the required output current. The
Model 205 system has an internal thermal sensor that will limit operation should the
temperature exceed the safe operating parameters.
2.2 ELECTICAL SERVICE GUIDE
FUNCTION RANGE
INPUT VOLTAGE 115/230
INPUT AMPERES AT RATED OUTPUT 13.1
MAX RECOMMENDED STD FUSE RATING IN AMPERES
•CIRCUIT BREAKER, TIME DELAY
•NORMAL OPERATING
15
20
MIN INPUT CONDUCTOR SIZE IN AWG 14
MAX RECOMMENDED INPUT CONDUCTOR
LENGTH IN FEET (METERS) 91 (28)
MIN GROUNDING CONDUCTOR SIZE IN AWG 14
2.3 PHYSICAL DIMENSIONS
POWER SUPPLY HEIGHT 18” (457mm)
POWER SUPPLY WIDTH 19” (483mm)
POWER SUPPLY DEPTH 14” (356mm)
POWER SUPPLY WEIGHT 51 lbs (22 kg)