Ami 415 User manual

MODEL 415

OPERATION MANUAL

Document No. 740084

Revision N

Model 415

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 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.

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 THIS 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 THIS MANUAL.

Publication date : First Edition - 1 July 1997

REV DCO # CHANGE DESCRIPTION DATE APR

A 3228 Revised pg. iv,2.1,2.2,3.2,3.5,Sect. 5 Add 3.11 1/27/99 GPE

B 3304 Revised pages iv, 2.1, 2.2, 3.5, 5.10 thru 5.20 4/20/99 GPE

C 3518 Revised Sec 5.6, corrected sec # error, added sec

5.18, 5.19, 5.20 updated Index page numbers 12/07/99 GPE

D 3548 Revised pages i, 2.1, 2.2 2/08/00 GPE

E 3632 Revised pages 3.2 and 3.3 5/18/00 GPE

F 3749 Revised page 2.5 Removed algaecide requirement 10/17/00 GPE

G 3779 Revised pages 5.1 to 5.11, Cal clarification 11/28/00 GPE

H 3829 Revised pages 5.1 to 5.8. change volt tolerance 03/15/01 LEC II

J 5229 Replace floppy drive with USB, update Section 3.3,

Remove Section 5.18, 5.19, 5.20 12/10/08 BF

K 5097 Correct Terminal Jumper Settings on page 3.5 12/18/08 BF

L 5450 Correct typo’s per BPMI-RS-P-02745, Update Input

Power Detail Section 2.0 9/29/09 BF

M 6245 Removed description of Neutral Overload (4.4.6) 2/7/12 SM

N 6412 Add CMOS battery replacement procedure section

5.18, reformat pagination 11/05/12 DC

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Model 415

Operation Manual

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EFFECTIVITY

Features and operation of the Model 415 are derived mostly from SOFTWARE. This document is

based on the latest STANDARD version of SOFTWARE at the time of last revision (see revision

page).

Some deviations in actual operation, from this document, are possible depending on the software

version of a particular machine. Please feel free to contact Arc Machines Service Department for

documentation or information on how software updates affect this document.

Model 415

Operation Manual

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iii

TABLE OF CONTENTS

SECTION DESCRIPTION PAGE

SECTION I INTRODUCTION

1.0 Introduction 1

1.1 Safety Precautions 1

1.2 Operational Precautions 3

1.3 RF and EMI emissions 4

1.4 Shock Hazard Warning 5

SECTION II SPECIFICATIONS

2.0 Electrical 6

2.1 Physical Construction 7

2.2 Current Output 8

2.3 Arc Voltage and Arc Voltage Control Servo 8

2.4 Travel Servo 8

2.5 Wire Feed Servo 8

2.6 Torch Oscillation and Cross-seam Steering Servo 9

2.7 Timing Functions 9

2.8 Arc Starting 9

2.9 Torch Cooling Unit 10

SECTION III INSTALLATION

3.0 Installation, General 11

3.1 Training 11

3.2 Inspection 11

3.3 Torch Cooling System Preparation 12

3.4 Primary Power Connection 13

3.5 Operators Pendant Connection 16

3.6 Inert Gas Connection 16

3.7 Weld Head Installation 16

3.8 Initial Turn On 17

SECTION IV SYSTEM FUNCTIONS

4.0 Introduction 21

4.1 Multi-Level Functions and Modes 21

4.2 Single Level Functions and Modes 22

4.3 Miscellaneous Non-Programmable Functions 22

4.4 Sensors and Faults 23

4.5 Pendant Controls 23

4.6 Other System Features 24

4.7 Weld Sequence 25

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Operation Manual

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TABLE OF CONTENTS

SECTION DESCRIPTION PAGE

SECTION V OPERATION

5.0 Introduction 30

5.1 Initial Power-On 30

5.2 Power Supply Calibration Introduction 30

5.3 Required Equipment For Calibration 31

5.4 Main Reference Voltage Calibration 31

5.5 Position Feedback Voltage Calibration 32

5.6 Current Calibration 32

5.7 Arc Voltage Calibration 35

5.8 Weld Head Travel Calibration Introduction 36

5.9 Weld Head Travel Calibration 37

5.10 Weld Head Wire Feed Calibration 38

5.11 System Security 39

5.12 Project Data Recording 40

5.13 General Maintenance 40

5.14 System Fault Corrections 41

5.15 Re-Shipping 42

5.16 Selecting and Creating Languages 43

5.17 Creating and Editing Weld Head Templates 45

5.18 CMOS Battery Replacement 47

LIST OF ILLUSTRATIONS

NUMBER DESCRIPTION PAGE

Figure 1 System Configuration 14

Figure 2 AC Power Set Up (Transformer jumpers - International) 15

Figure 2A AC Power Set Up (Transformer jumpers - Domestic) 18

Figure 3 Cable Connections 19

Figure 4 Status Screen/Initial Turn-On 20

Figure 5 Sequence Timing Chart 29

Figure 6 CMOS battery location on EP811 motherboard 47

Figure 7 CMOS battery location on SBC84710 motherboard 48

Model 415

Operation Manual

SECTION I - INTRODUCTION

1.0 INTRODUCTION

This manual is intended to assist users of this equipment in set-up and basic operation. Automated

welding requires a good deal of operator expertise which also requires AMI supplied, hands-on

training. THIS MANUAL IS NOT INTENDED AS A SUBSTITUTE FOR THAT TRAINING.

The Model 415 (M-415) welding power supply is part of a complete welding system intended for the

welding of tubes, pipes and fittings (see figure 1). The complete system consists of the M-415

power supply, adapter cable, gas lines and a variety of different AMI Welding Heads or Torch Fixture

devices (Heads and Fixtures are sold separately).

The standard version of the M-415 power supply provides GTAW current with pulsation controls,

high frequency arc starting, purge gas controls, weld head arc rotation, cold wire feed, Arc Voltage

Control, Torch Weave/Steering (Oscillation) and automatic timing functions. The M-415 includes an

Operators Pendant and comes ready to weld. Users need only to supply input AC power,

regulated gas source with flow meter and the appropriate weld head or manual torch.

The M-415 family of options also includes PC or Laptop operation for Remote Welding and a

variety of quality assurance options such as project and function data acquisition.

The system can also be used as a manual welding power source using an optional manual torch

with a variety of manual welding options such as a variable current foot controller with remote

start/stop switch.

NOTE

In-depth weld development instructions, weld head set-up, maintenance and troubleshooting are

contained in other manuals, documents and training classes and are not included in this manual.

Contact your AMI representative for more information about these items.

1.1 SAFETY PRECAUTIONS

This section contains cautions and warnings concerning the operation of this equipment and

welding equipment in general. However, in addition to reading this manual and before

operating this or any welding equipment, users should reference and be familiar with “ANSI-

49.1 Safety in Welding and Cutting”. This standard is published by the American National

Standards Institute and the American Welding Society.

WARNING: Touching energized electrical parts can cause fatal

shocks and burns. When in weld sequence the electrode and work

are electrically energized. Incorrectly installed or improperly

grounded equipment is a hazard.

WARNING: This equipment is authorized to use a type of arc starter

that produces a High Frequency Radio Wave (sometimes called HF

and/or RF Starting). It can cause interference and sometimes even

damage to nearby electronic equipment (such as computers) that

are un-protected or poorly protected against such interference.

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WARNING: Magnetic Fields from High Currents can affect

pacemakers. PACEMAKER WEARERS KEEP AWAY UNTIL

CONSULTING YOUR DOCTOR.

WARNING: Disconnect the input power to the machine before

opening or servicing. Discharge all circuits that store high voltage

such as capacitor packs. Only QUALIFIED service personnel should

open this equipment.

WARNING: Welding can cause fires or explosions. Do not weld

near FLAMMABLE or EXPLOSIVE MATERIALS. Watch for fire.

Have the proper type of extinguisher in your work area.

WARNING: Welding Operators should wear non-flammable

protective clothing, footwear and head gear.

WARNING: Never weld on sealed containers or pipes. This may

result in an EXPLOSION.

WARNING: Welding produces high temperatures in both the

welded components and the welding equipment. Both can cause

severe burns. Do not touch recently welded components. Avoid

touching internal components of the welding system soon after use.

Avoid touching torch components and welding fixtures soon after

welding.

WARNING: The welding arc emits ultra-violet (UV) radiation and the

molten weld gives off infra-red (IR). Both can burn eyes and skin if

unprotected. Suitable eye and skin protection must be worn.

WARNING: Weld materials can emit toxic fumes during welding.

WELD ONLY IN AREAS WITH ADEQUATE VENTILATION.

WARNING: Most GTAW gases like Argon are non-toxic, however,

Argon is heavier than air and will displace the normal atmosphere in

enclosed areas. DO NOT WELD IN ENCLOSED AREAS WITH

OUT PROPER VENTILATION OR RESPIRATORS.

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Operation Manual

WARNING: AMI factory training is essential for all Welding

Operators and Maintenance Technicians who operate AMI

equipment.

WARNING: Before operating, storing or handling, always make sure

that the M-415, M-415 Pendant, weld heads and cables are not

exposed to rain or standing water. SYSTEM COMPONENTS ARE

NOT WEATHER-PROOF.

WARNING: Keep hands and fingers clear from moving parts such

as fans, gears rotors, Wire Feed, Rotation and AVC Mechanisms.

WARNING: The M-415 Power Supply is not intended for pipe thawing or heating in any

form.

WARNING: The M-415 Power Supply weighs in excess of 700 lb. (317.5 kg). Be sure to

follow your local, OSHA, international and employer guidelines for proper methods of handling and

re-locating this equipment.

1.2 OPERATIONAL PRECAUTIONS

The following is a check list for operating personnel to follow to insure minimum system down-time

due to improper operation and handling:

1. To AVOID severe equipment damage VERIFY that the M-415 is connected to the correct

Input AC power (see section 3.4).

2. Before operating, check all fittings and connectors for proper seating and that all protective

boots are in place. If not properly seated or protected, short circuits, poor connections or

inert gas leaks could occur.

3. The M-415 is intended for typical GTAW gases ONLY. NEVER CONNECT OXYGEN OR

ACETYLENE TO THE M-415.

4. Before operating, insure that all cables are routed or protected in such a way that they will

not be subject to heat, equipment and/or personnel traffic. Insure that the cables DO NOT

come in contact with HOT PIPE.

5. When storing or handling cables, always keep the protective boots and dust caps on all

connectors and fittings until ready to install. A major cause of downtime in any automatic

welding system is improper care and use of cables.

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6. Before operating, insure that the M-415 has adequate air flow. Do not restrict the intakes or

exhaust vents of the power supply.

7. Before operating, always insure that there is bare metal contact between the weld head

components which connect to GROUND (clamp inserts, etc.) and the tube or pipe to be

welded.

8. When storing or handling weld heads, always keep them in the protective containers they are

shipped in, or optional carrying case, until ready to install.

9. When operating, storing or handling, insure that the system is protected against dirt, dust,

etc. NEVER GRIND NEAR AN EXPOSED WELD HEAD OR THE M-415.

10. Do not use acid, corrosives, liquid “Easy Out” or any liquid substance on the M-415 or any

AMI weld head. When cleaning, use only a light solution of Isopropyl alcohol on a soft cloth .

11. When handling, take extreme care to avoid dropping the M-415, weld heads, cables or any

accessories.

12. Do not attempt to move tube end into position using the weld head as a lever.

13. Do not add any lubrication like graphite, oil or grease to the weld heads or power supply

unless it is specified in the operation or maintenance manual for that equipment.

1.3 RF AND EMI EMISSIONS

1. WHY RF?

“It has long been recognized that in the practice of welding and cutting, there are

circumstances where it is required to assist the process using radio frequency voltage. In

order to arc weld an electric arc must be created, because of safety and economic concerns,

the no load voltage of arc power sources is kept as low as practical. Thus, a source of high

voltage with a high safety factor must be utilized. Radio Frequency voltage is the best

method of meeting these criteria for many reasons” (quoted from CISPR/B/63).

2. RF REGULATION

The FCC regulates the RF emission limitations for welding equipment by the use of an IEC

(international) regulation created by the Special Committee on Radio Interference (known

as CISPR) subcommittee B. The regulation of record is: CISPR/B/63

“CODE OF PRACTICE FOR THE USE OF WELDING AND CUTTING POWER SOURCES

UTILIZING RADIO FREQUENCY VOLTAGE FOR STARTING OR STABILIZING THE

ARC.”

The regulation states that due to the variety of work requirements and conditions it is

virtually impossible to establish fixed, normalized and predictable tests and test setups for

RF limits that would actually mean something. Instead of limits they state the following:

“The manufacturer must design and produce equipment that is functional but at the same

time, design this equipment to keep electromagnetic radiation at a minimum.”

“The user has the responsibility to install and use the power source per the instructions of

the manufacturer. Through this practice, it is reasonable to assume that the probability of

electromagnetic disturbances will be significantly reduced. However, if some electromagnetic

disturbances are felt, then it is the responsibility of the USER of the equipment to resolve

the situation.”

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3. RF PROTECTION

AMI policy is to comply with the IEC (and thus FCC) regulations. Our design rules and

procedures include testing and observing this area. We can assure our customers that

every effort has been made to reduce RF emissions to the absolute minimum from our power

sources.

However, this does not mean that a user will not have occasional problems with RF

interference with other equipment due to the use of our equipment. This is the nature of RF

starting.

Most RF noise interference problems are going to be either set-up related or caused by poor

or no filtering on the behalf of the equipment that is being disrupted. Most interference

problems are easily correctable but each one must be looked at on a “case by case basis.”

4. EMI SUPPRESSION

The M-415 is equipped with a heavy-duty Pi-Network filter, connected to the input power

line, to prevent propagation of EMI either into or out of the M-415. The all-metal enclosures

and internal shields prevent radiated EMI.

1.4 SHOCK HAZARD WARNING

As already stated in this manual “High Voltage” is present on exposed internal terminals. The

ELECTRODE (tungsten) and tube weld head rotors (M-8, M-9) are also an “exposed terminal” and

by its nature the GTAW process requires electrical potential to be present on the electrode during

arc starting and of course during the welding.

All AMI Power Supplies contain a “bleeder” circuit to ground any residual potential after welding or

after an aborted or bad “arc start” attempt. However, these circuits take a few seconds to operate

or COULD FAIL. Do not depend on them to prevent electrical shock.

“THE ELECTRODE SHOULD ALWAYS BE CONSIDERED A POSSIBLE SHOCK HAZARD”.

This is especially true when ever the system is in “weld sequence” ready to weld, is welding, or

has just finished welding. However, equipment/component failure, system abuse, or improper

maintenance could result in electrical potential at the weld head “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

insure discharge before actually touching it. REMEMBER, there is a “POSSIBLE” shock hazard in

all welding power supplies at “ALL” times.

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 WELD HEAD during arc

start.

Model 415

Operation Manual

SECTION II - SPECIFICATION

The following contains only general specifications about the M-415 Power Supply. More detailed

information is available in AMI Specification No. 415.

2.0 ELECTRICAL

1. RATING PLATE DEFINITIONS

1) Company: Country:

ARC MACHINES, INC.USA

3) Model:

Model 415

S/N: DATE:

8) Process:

10) Type:

23) Shock Rating:

6) Standards:

NEMA EW1 IEC 974-1

9) Output:

Minimum Maximum

5A / 5V 400A / 30V

11) No-load Voltage:

U0= 61V

12) Duty Cycle:

X = 100% ALL RATED OUTPUTS

15) Input:

3~ 50/60 HZ

18) Voltage:

U1= 200V

U1= 240V

U1= 400V

U1= 440V

U1= 480V

U1= 575V

19) Input Current:

I1max = 49A I1eff = 49A

I1max = 44A I1eff = 44A

I1max = 25A I1eff = 25A

I1max = 20A I1eff = 20A

21) Rating:

IP21

22) Rating:

G.T.A.W.

1) - Manufacturer and Country of Origin.

3) - Model Number Rating Plate applies to.

4) - Serial Number and Date of Manufacture.

6) - International and USA Standards that the equipment meets.

8) - Weld Process symbol for GTAW welding.

9) - Rated MIN and MAX Outputs at Continuous Current with no pulsation.

Rated MIN and MAX Outputs when current is pulsing.

10) - Symbol that output is Direct Current (DC) only.

11) - Rated No Load Output Voltage (open circuit voltage) is 61 volts.

12) - The M-415 is a 100 % Duty Cycle for the rated outputs (9).

15) - Input Voltage type contains symbol for three (3) phase Alternating

Current (AC) input at 50 or 60 Hz frequency.

18) - Nominal Input Voltage value is dependent on Transformer type.

M-415s manufactured before January 1999 are listed as: Domestic, or International.

After January 1999 the Universal transformer was released for use in all countries.

19) - Rated maximum current required from the AC supply. Given for both

I1maximum (I1max) and I1effective (I1eff). Plate shown above is for the Universal

transformer. Consult the rating plate on your Power Supply for actual number.

21) - International Protection (IP) rating. The M-415 is rated IP21 which includes protection

against a limited amount of exposure to rain (does not make it weather proof or

intended for all weather usage).

22)- The M-415 is rated as class I. No symbol is used for class I equipment.

23)- “S” Symbol indicates a welding power source which is suitable for an environment with an

increased electric shock hazard.

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2. INPUT POWER, DETAIL - The M-415 can have 1 of 3 operating ranges:

Voltage Phase - Freq. Max Input Current

Required Transformer Type Model 415

Main Circuit Breaker

200 VAC 3 - 50/60 Hz 50 amperes Service Universal 60 Ampere-600 VAC

240 VAC 3 - 50/60 Hz 45 amperes Service 60 Ampere-600 VAC

400 VAC 3 - 50/60 Hz 25 amperes Service 60 Ampere-600 VAC

440 VAC 3 - 50/60 Hz 25 amperes Service 60 Ampere-600 VAC

480 VAC 3 - 50/60 Hz 20 amperes Service 60 Ampere-600 VAC

575 VAC 3 - 50/60 Hz 20 amperes Service 60 Ampere-600 VAC

FOR POWER SUPPLIES MADE BEFORE JANUARY 1999

200 VAC 3 - 50/60 Hz 60 amperes Service International 60 Ampere-415 VAC

220 VAC 3 - 50/60 Hz 60 amperes Service 60 Ampere-415 VAC

380 VAC 3 - 50/60 Hz 40 amperes Service 60 Ampere-415 VAC

415 VAC 3 - 50/60 Hz 40 amperes Service 60 Ampere-415 VAC

FOR POWER SUPPLIES MADE BEFORE JANUARY 1999

230 VAC 3 - 50/60 Hz 50 amperes Service Domestic USA 50 Ampere-600 VAC

240 VAC 3 - 50/60 Hz 40 amperes Service 50 Ampere-600 VAC

440 VAC 3 - 50/60 Hz 40 amperes Service 50 Ampere-600 VAC

480 VAC 3 - 50/60 Hz 40 amperes Service 50 Ampere-600 VAC

3. OUTPUT POWER - Straight polarity, constant current DC regulation intended for GTAW

welding only.

Minimum current Output all cases .................... = 5 Amperes DC

Maximum current Output ................................. = 400 Amperes DC continuous or peak pulse

4. CIRCUIT BREAKER – Also used as ON/OFF switch, is a 60 Amp 3 phase Auto-Trip, with

electrical Emergency Stop function available on the Power Supply, Operators Pendant and

from an Optional External Hard Wire Command.

5. POWER CABLE -25 foot (7.6 m) Neoprene jacketed harmonized CE approved 4 conductor 8

AWG (10mm²) cordage, rated voltage: 500V.

6. STANDARDS - The M-415 is designed and maintained to meet all applicable IEC and ISO

standards as well as all applicable EC Directives.

7. RATED CONDITIONS - The system will meet or exceed the functional ranges and

tolerances stated, provided that the following conditions exist:

1. Input Voltage does not deviate greater than +/- 10% from normal voltage.

2. Ambient operating temperature range is between 0 degree C (32° F) and 40° C (105° F)

3. Arc Voltage at the power supply terminals is equal to or less than 30 volts.

4. All electrical performance is based on maximum weld head distance of 200 feet (61 m)

from the M-415

2.1 PHYSICAL CONSTRUCTION

1. Cabinet material - aluminum and steel

2. Dimensions (basic Power Supply):

Height: 39 inches (990.6 mm)

Width: 26 inches (660.4 mm)

Depth: 36 inches (914.4 mm)

3. Weight: Less than 700 lb. (317.5 kg) depending on configuration

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2.2 CURRENT OUTPUT NOTE

The following specifications will, in many cases, reference “User Defined”. User defined means

that the user can set up the actual programmable ranges and functionality of any given function.

For specification purposes this means that no actual function range can be given. Where

applicable only an absolute maximum or minimum are given.

1. Range - 5 to 400 Amperes programmable. Programmable increments can be user

defined in units of 1 or 0.1 amperes.

2. Type - Continuous or pulsed output DC Straight Polarity for GTAW (TIG) welding only.

3. Regulation - Constant Current closed loop servo using second generation high frequency

(60 KHz) series switching regulation.

4. Regulation Response - Response time for correction of current deviation is less than 500

microseconds. Pulsed mode rise time from background current to primary is 1.2 ampere

per microsecond.

5. Regulation Tolerance - +/- 0.5% of programmed setting or +/- 1.0 ampere whichever is

greater.

2.3 ARC VOLTAGE and ARC VOLTAGE CONTROLLER SERVO

1. Open Circuit Output Voltage - 61 VDC

2. Maximum Output Voltage under load - 30 volts (measured at power supply, not at torch)

3. Arc Voltage Controller Range - (measured at the torch)

Minimum - 5 VDC

Maximum - 25 VDC

Actual programmable range is user defined.

4. AVC Motor Output Current Limit - User defined by weld head type in increments of

0.1 Amperes up to a maximum motor drive current limit of 4.0 Amperes.

5. AVC Motor Output Voltage Limit - 35 VDC

6. Regulation - Closed Loop position servo using arc voltage measured at the torch. Intended

for DC permanent magnet type motors only.

7. Regulation Tolerance - +/- 1% of program value or 0.1 VDC, whichever is greater.

Based on primary current only with no current pulsation. Measurable accuracy with the

current pulsing can be affected by the puddle growth and shrinkage.

8. Regulation Response - Variable and programmable.

9. Jogs - Motor servo provides for UP and DOWN motor jogs. Jog speeds are adjustable.

2.4 TRAVEL (torch rotation) SERVO

1. Range - Programmable range is User defined by weld head type. Unit of measure (IPM or

RPM) and increments is user defined by weld head type.

2. Regulation - Closed loop velocity servo using, as standard, analog tachometer feedback

of 0 to 5 VDC. Can be set up to regulate using digital tachometer or digital encoder

feedback. Intended for DC permanent magnet type motors only.

3. Motor Output Current Limit - User defined by weld head type in increments of

0.1 Amperes up to a maximum motor drive current limit of 4.0 Amperes.

4. Motor Output Voltage Limit - 35 VDC

5. Regulation Tolerance - +/- 1% of program value or +/- 0.1 IPM or RPM whichever is

greater. Based on maximum range being at least 10 IPM or RPM.

6. Jogs - Motor servo provides for bi-directional (CW and CCW) motor jogs. Jog speeds are

adjustable.

2.5 WIRE FEED SERVO

1. Range - Programmable range is User defined by weld head type. Unit of measure (IPM or

mm/min) also user defined by weld head type.

2. Regulation - Closed loop velocity servo using, as standard, analog tachometer feedback

of 0 to 5 VDC. Can be set up to regulate using digital tachometer or digital encoder

feedback. Intended for DC permanent magnet type motors only.

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3. Motor Output Current Limit - User defined by weld head type in increments of

0.1 Amperes up to a maximum motor drive current limit of 4.0 Amperes.

4. Motor Output Voltage Limit - 35 VDC

5. Regulation Tolerance - +/- 2% of program value or +/- 1 inch, whichever is

greater. Based on maximum range being at least 100 IPM.

6. Jogs - Motor servo provides for bi-directional (FEED and RETRACT) motor jogs. Jog

speeds are Adjustable.

2.6 TORCH OSCILLATION and CROSS-SEAM STEERING SERVO

1. Range - User Defined by weld head type as to maximum programmable amplitude.

2. Regulation - Closed loop position servo using +/- 5 VDC feedback voltage for

position information. Feedback device varies with weld head model. Intended for DC

permanent magnet type motors only.

3. Motor Output Current Limit - User defined by weld head type in increments of

0.1 Amperes up to a maximum motor drive current limit of 4.0 Amperes.

4. Motor Output Voltage Limit - 35 VDC

5. Regulation Tolerance - +/- 1% of program value or 0.010 inches, whichever is greater.

Based solely on M-415 servo specification. Actual response speed and tolerance

performance can vary depending on the dynamic loads on the weld head. Consult the

weld head specification for each weld head tolerance.

6. Jogs - No jogs are provided. Oscillator is continually seeking desired position. Position

is based on input (steering) commands from steering devices (on Pendant and Display).

2.7 TIMING FUNCTIONS

1. Purge Time Range (pre and post) -

000 to 1000 seconds. User can define minimum programmable time.

2. Start Delay Time Range (Travel, Wire, AVC) -

00.0 to 100 seconds in increments of 0.1 seconds.

3. Stop Delay Time Range (Travel, Wire, AVC) -

00 to 100 seconds.

4. Upslope Time Range -

00.0 to 100 seconds. User can define minimum programmable time

5. Downslope Time Range -

00 to 100 seconds. In increments of 1 second

6. Weld Level Time Range (up to 99 levels) -

0000 to 10000 seconds.

7. Pulse Timing Range (Primary/Background) -

0.00 to 100 seconds in increments of 0.01 seconds.

8. Oscillator Timing Range (Dwells and Excursion) -

0.00 to 100 seconds in increments of 0.01 seconds.

9. Primary WF pulse delay -

0.00 to 100 seconds in increments of 0.01 seconds.

10. Timing Resolution -

+/- 0.01 seconds (all timing functions)

2.8 ARC STARTING

1. Starting Methods - Touch or RF (radio frequency)

2. Touch Start provides a smooth, consistent and tungsten inclusion free start with any weld

head that has an AVC. Touch and Retract speeds are user defined. User can set up for

single start attempt or multiple start attempt.

3. RF Starting provides a method of arc starting without the electrode touching the weld

surface. System is designed for best performance under the following conditions:

1. Minimum first level primary current - 5 Amperes (in Argon only)

2. Gases - Argon, 95/5 Argon/Hydrogen, Helium or Helium/Argon Mixes.

3. 1 atmosphere pressure. Consult factory for operation in pressure chambers.

4. Maximum arc gap - 0.156 inch (4 mm)

Model 415

Operation Manual

Document No. 740084

Revision N

5. Cerriated or Thoriated Electrodes with conventional grinds.

6. Cable lengths up to 200 feet.

7. Multiple arc strike attempts.

2.9 TORCH COOLING UNIT - Liquid cooled, forced air heat exchanger with coolant reservoir.

1. Reservoir Capacity - 2.5 gallons (9.46 liters)

2. Maximum Pressure - 60 PSI

3. Flow - 0.3 GPM for 400 Ampere Torches.

0.2 GPM for 300 or less Ampere Torches

4. Head - Up to 100 feet with 200 feet of cable.

5. Duty Cycle - 100 %

6. Distilled or Demineralized Water coolant, (see section 3.3 for use where freezing may occur).

7. Replaceable coolant filter

8. Pressure relief valve and by-pass built-in

2.10 GAS DISTRIBUTION SYSTEM

1. Control - Electrical Solenoid valve.

2. Pressure - Maximum 50 PSI

3. Flow - 5 to 100 CFH

Model 415

Operation Manual

Document No. 740084

Revision N

SECTION III - INSTALLATION

3.0 INSTALLATION, GENERAL

The Model 415 Power Supply is designed to provide reliable and repeatable performance within its

specified limits. The Model 415 is also, by its nature, something that must be relocated from time to

time and be installed, by the user, without Factory Service being required. Because of this,

assurance that the Model 415 is working within its specified limits is a “user” responsibility and it

begins with INSTALLATION.

This Section of the Operation Manual provides the requirements and procedures for the proper

installation and initial turn on of the Model 415.

3.1 TRAINING

The Model 415 is designed to be as easy as possible to install and operate. The instruction of this

manual should, in most cases, supply the user with the information needed for Installation and

Operation. However, automatic welding systems can be complicated and Arc Machines, Inc.

“STRESSES” the need for complete FACTORY training involving Installation, Operation,

Programming and Maintenance.

This manual does not attempt to cover all possible problems, deviations or usage of the Model

415. In this Manual, where these items might occur, a general instruction is given to consult a

Factory Representative.

3.2 INSPECTION NOTE

The M-415 is shipped new, in a re-usable and factory approved shipping container. This container

should be retained and stored carefully in order to re-use in case of a need to re-ship the M-415 to

another location.

1. After unpacking, inspect all items for obvious physical damage and loose parts. If damage is

evident, contact a factory representative before using. If water condensation is apparent, dry

the unit before using.

2. All M-415’s are shipped with a variety of peripheral equipment such as gas hoses, fittings,

manuals (including this one) and electrical drawings. An exact list of these items is included

with each power supply shipment. This manual will reference some of those items, so before

beginning installation, these items should be located and be available.

3. Inspect the Power Supply Cabinet (See Figure 1, Item 1)

1. Perform an exterior visual inspection looking for obvious physical problems such as

broken connectors, dents or loose components.

2. There are two Connect Panels on the left side of the Cabinet. These are the Electrical

- I/O Connect Panel (left side upper) and the Weld Head Connect Panel (left side rear).

Insure that all Protective Dust Covers and Retaining Chains are installed on all electrical

multi-pin Connectors (See Figure 1, Item 2).

3. Remove both the left and right hand SIDE PANEL Retaining Screws and remove the

SIDE PANELS (see Figure 1, Item 3, 13). Leave the SIDE PANELS off until the end of

Section Step 3.4.

4. Visually inspect the interior for obvious physical problems such as loose components,

dangling wires, foreign (loose) objects, excessive dirt or any standing water,

condensation or moisture.

5. Note the location of the main transformer and tap setting Terminal Strip (See Figure 1,

Item 4). This will be set up in Section 3.4.

Model 415

Operation Manual

4. Operator Pendant (see Figure 1, Item 5)

1. For the remainder of this manual this will be called the RP Pendant or just Pendant.

2. Perform a visual inspection to insure no obvious shipping damage has occurred.

Check Pendant cable for Protective Connector Covers, tight strain relief and no

frays or tears in the Cable Jacket.

5. Cables

There are five Standard Cables included with the Model 415. Check each of the following

Cables for Protective Covers, proper strain relief and obvious frays or tears.

1. RP Pendant Extension Cable, 50 foot (15.2 meters) (see Figure 1 Item 6).

2. Weld Head Adapter Control Cable, 40 foot (12.2 meters) (see Figure 1 Item 7).

3. Weld Head Adapter Service Cable, 40 foot (12.2 meters) (see Figure 1 Item 8).

4. Ground cable with “C” Clamp, 50 foot (15.2 meters) (see Figure 1, Item 9).

5. Input Power Cable, 25 foot (7.6 meters) (see Figure 1, Item 10).

6. Weld Head (see figure 1, Item 11)

1. Inspect the Weld Head or Heads for obvious physical damage. The Model 415 can

operate all AMI Weld Heads. The user will find detailed Weld Head Installation and

Inspection information in the Operation Manual for each specific Weld Head.

3.3 TORCH COOLANT SYSTEM PREPARATION

The Model 415 power source is air cooled. However, almost all AMI Torches require liquid

cooling. The Coolant System provides coolant for Weld Heads equipped with liquid cooled

Torches. The liquid coolant should be a combination of pure de-mineralized, de-ionized or distilled

water and pure Ethylene glycol.

If antifreeze is required Arc Machines, Inc. recommends the use of a corrosion inhibitor and

algaeside along with water or water mixture. The present recommended water treatment is

Optishield Plus manufactured by Opti-Temp Corp. and can be purchased from local welding

supply. Glycol mixtures can be purchased from Miller Electric for RF TIG applications,

available from local welding supply

. CAUTION

It is extremely important to insure proper operation of the Coolant System. The coolant system

will operate, for a few weeks or months, with plain tap water as the coolant. After some length of

operating in this condition the Coolant System will begin to have problems with bacteria growth,

contaminates, poor connections, hoses and pump flow. For the Coolant System to continue to

meet the demands of the System Specification it must “BEGIN” operations per this procedure.

The following is for initial preparation of the Coolant System after shipment from the FACTORY.

1. The Coolant System reservoir has a capacity of 2.5 gallons (9.46 liters). This reservoir is

located on the lower left side of the Power Supply. The left side panel should already be

removed (step 3.2.2.2), if not remove the left side panel to access the coolant system.

2. Remove the coolant fill spout cap (Figure 1, Item 12) and add 2.5 gallons of coolant solution

or distilled water. NEVER USE TAP WATER IN THE COOLANT SYSTEM.

Before Operating be sure to re-install the left side panel (Figure 1, Item 13)..

NOTE

For operation and storage in areas subject to freezing temperatures, use 1.75 gallons of

distilled water mixed with 0.75 gallons of pure Ethylene Glycol for a total of 2.5 gallons of

coolant.

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Model 415

Operation Manual

CAUTION

If antifreeze needs to be added, use only pure Ethylene Glycol. Commercial antifreezes

(such as Prestone) contain dyes and additives that are harmful to the Coolant System.

DO NOT over-fill the Coolant Reservoir.

When using glycol or coolant additives the optional UV sterilization unit must be disabled by

unplugging input power.

3.4 PRIMARY POWER CONNECTION

WARNING

Do not connect the M-415 power supply to any AC power other than the ones listed on the

rating plate and on the transformer (see section 2).

The Model 415 is supplied with a 25 foot (7.6 meter), 4 wire Power Cable. One end of this Cable is

pre-wired inside the Power Supply, the other end is pigtailed and an appropriate connector or switch

box (user supplied) must be wired to this end (see Figure 1, Item 10 for Cable location).

NOTE

The Model 415 is not phase sensitive, when wiring the user must only insure that the GREEN or

GREEN with YELLOW stripe wire of the Cable is connected to Protective Earth Ground. The other 3

wires (red, black and white, or blue, brown, and black) can be connected to phase A, B and C in any

order.

Remove the right side panel as directed in step 3.2.3.3. Perform the following steps to connect the

input power:

1. Set Up the Transformer taps for the input power. The Main Transformer has a number of

taps that must be connected via jumpers to set it for the correct input power. Refer to

Figure 2 and set the jumpers for the power to be used.

CAUTION

Do not touch or relocate Input Power Terminal Strip jumpers with Power Cable connected

to an AC source. BE SURE NO POWER IS PRESENT ON THE POWER CABLE.

2. Wire an appropriate connector or switch box to the pigtailed end of the Cable. DO NOT

PLUG IN OR TURN ON SWITCH BOX.

3. Verify again that the jumpers are correctly set and reinstall the SIDE PANEL

.NOTE

THE MODEL 415 CAN NOW HAVE INPUT POWER APPLIED AND CAN BE TURNED ON.

HOWEVER IT IS RECOMMENDED THAT THE PENDANT, GAS AND WELD HEAD

INSTALLATION BE COMPLETED BEFORE TURNING ON POWER. INITIAL POWER ON IS

DISCUSSED IN STEP 3.8.

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Model 415

Operation Manual

Document No. 740084

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Model 415

Operation Manual

INTERNATIONAL TRANSFORMER TERMINAL JUMPER SET UP

200 VOLT TERMINAL JUMPER SETTINGS

6 5 4 3 2

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240 VOLT TERMINAL JUMPER SETTINGS