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AMI M9 Series Operation Manual

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M9 SERIES WELD HEADS
OPERATION MANUAL

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  • Page 1 M9 SERIES WELD HEADS OPERATION MANUAL...
  • Page 2 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.

  • Page 3: Table Of Contents

    MODEL 9 SERIES WELD HEAD OPERATION MANUAL Table of Contents Chapter Description Page Introduction………………..…………………3 Unpacking……………………………………3 Cable hook up……………………………… 3 Water Cooling………………………... 5 Rotation (speed) Auto-Calibration……….. 5 Rotation (speed) Manual Calibration……. 6 Clamp Insert Installation………………… Electrode Geometry & Installation…………9 Shielding Gas……………………………….14 Return-to-home (rotor) position adjustment…..

  • Page 4: Introduction

    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.
  • Page 5 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.

  • Page 6: Water Cooling

    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.

  • Page 7: Rotation (Speed) Manual Calibration

    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.

  • Page 8: Clamp Insert Installation

    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).
  • Page 9 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”...

  • Page 10: Electrode Geometry & Installation

    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.
  • Page 11 MODEL 9 SERIES WELD HEAD OPERATION MANUAL 7.0 ELECTRODE GEOMETRY & INSTALLATION (cont’d.) Use this chart to determine the weld head Rotor O.D. Model Rotor O.D. 9-750 2.00” (50.8mm) 9-1500 3.187” (80.9mm) 9E-1500 2.687” (68.25mm) 9-1500 w/elect. extender 2.031” (51.6mm) 9-2500 4.380”...
  • Page 12 MODEL 9 SERIES WELD HEAD OPERATION MANUAL 7.0 ELECTRODE GEOMETRY & INSTALLATION (cont’d.) Use the formula below, along with your Rotor O.D. and Arc Gap to establish the electrode length. Fig. 11 Fig. 12 Doc No. 740124...
  • Page 13 MODEL 9 SERIES WELD HEAD OPERATION MANUAL 7.0 ELECTRODE GEOMETRY & INSTALLATION (cont’d.) 7.3 To change electrodes, using the “JOG” button on the power supply or remote operators pendant, jog the rotor around until the electrode is in the 12 O’clock position. See fig. 13. 7.4 Lay the weld head on its side to prevent accidental dropping of the electrode into the weld head.
  • Page 14 MODEL 9 SERIES WELD HEAD OPERATION MANUAL 7.0 ELECTRODE GEOMETRY & INSTALLATION (cont’d.) Fig. 14 Install the electrode so the back end is flush with the rotor outside diameter. Caution Do not leave any part of the electrode protruding past the rotor O.D. 7.6 Two spare electrode set screws may be found in the weld head cover.

  • Page 15: Shielding Gas

    MODEL 9 SERIES WELD HEAD OPERATION MANUAL 8.0 SHIELDING GAS The type of shielding gas used has a profound effect on the character of the arc and the depth of weld penetration. The most commonly used shielding gas and backup (I.D. purge) gas used is Argon. Gas mixtures of 95% Argon/5% hydrogen or 75% helium/25% argon are sometimes used to achieve deeper penetration.

  • Page 16: Return-To-Home (Rotor) Position Adjustment

    MODEL 9 SERIES WELD HEAD OPERATION MANUAL 8.0 SHIELDING GAS (cont’d.) Note: If the system is being hooked up for the first time, or if it has been a number of hours since it was last used, it’s a good idea to initiate the Manual Purge button on the power supply to clear the lines of oxygen for a few minutes before initiating a weld sequence.
  • Page 17 MODEL 9 SERIES WELD HEAD OPERATION MANUAL 9.0 RETURN-TO-HOME (ROTOR) POSITION ADJUSTMENT (cont’d.) 9.3.1 For Models 9-2500, 9-3500, 9-4500, 9-7500 and other heads in this series, loosen both screws that hold the return-to-home limit switch bracket. See fig.19. Fig. 18 (Models 9-750 &...

  • Page 18: Cleaning & Maintenance

    MODEL 9 SERIES WELD HEAD OPERATION MANUAL 9.0 RETURN-TO-HOME (ROTOR) POSITION ADJUSTMENT (cont’d.) 9.4 Slide the limit switch bracket very slightly toward the rotor, (to stop the rotor sooner) or very slightly away from the rotor (to stop the rotor later) and re-tighten the limit switch mounting bracket screw(s).

  • Page 19: Storage

    MODEL 9 SERIES WELD HEAD OPERATION MANUAL 11.0 STORAGE If the weld head has been used with water-cooling, and is to be stored for more than 1 month, the residual water or water/coolant mix should be purged from the hoses and weld head to minimize internal corrosion. This is also important if the weld head is to be stored where the temperature might fall below freezing, as trapped water can freeze and damage weld head and/or hose internals.
  • Page 20 MODEL 9 SERIES WELD HEAD OPERATION MANUAL 11.0 STORAGE (Cont’d.) CAUTION, DO NOT USE AIR PRESSURE ABOVE 20 PSI (139 Kp) (1.38 Bar) 11.2 Attach the dust cap to the electrical connector, and store the weld head in a clean, dust-free area. 11.3 Store the head with the clamp housing latches un-latched.

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