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AMI 415 Operation Manual

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MODEL 415
OPERATION MANUAL
Document No. 740084
Revision N

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  • Page 1 MODEL 415 OPERATION MANUAL Document No. 740084 Revision N...
  • Page 2 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.
  • Page 3 Model 415 Operation Manual 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.
  • Page 4 Model 415 Operation Manual TABLE OF CONTENTS SECTION DESCRIPTION PAGE SECTION I INTRODUCTION Introduction Safety Precautions Operational Precautions RF and EMI emissions Shock Hazard Warning SECTION II SPECIFICATIONS Electrical Physical Construction Current Output Arc Voltage and Arc Voltage Control Servo...

  • Page 5: Table Of Contents

    Model 415 Operation Manual TABLE OF CONTENTS SECTION DESCRIPTION PAGE SECTION V OPERATION Introduction Initial Power-On Power Supply Calibration Introduction Required Equipment For Calibration Main Reference Voltage Calibration Position Feedback Voltage Calibration Current Calibration Arc Voltage Calibration Weld Head Travel Calibration Introduction Weld Head Travel Calibration 5.10...
  • Page 6 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).
  • Page 7 Model 415 Operation Manual 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.
  • Page 8 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.
  • Page 9 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 .
  • Page 10 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. SHOCK HAZARD WARNING As already stated in this manual “High Voltage”...
  • Page 11 (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.
  • Page 12 POWER CABLE -25 foot (7.6 m) Neoprene jacketed harmonized CE approved 4 conductor 8 AWG (10mm²) cordage, rated voltage: 500V. STANDARDS - The M-415 is designed and maintained to meet all applicable IEC and ISO standards as well as all applicable EC Directives.
  • Page 13 Model 415 Operation Manual 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.
  • Page 14 Motor Output Voltage Limit - 35 VDC 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.
  • Page 15 Model 415 Operation Manual Cerriated or Thoriated Electrodes with conventional grinds. Cable lengths up to 200 feet. Multiple arc strike attempts. TORCH COOLING UNIT - Liquid cooled, forced air heat exchanger with coolant reservoir. Reservoir Capacity - 2.5 gallons (9.46 liters) Maximum Pressure - 60 PSI Flow - 0.3 GPM for 400 Ampere Torches.
  • Page 16 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. After unpacking, inspect all items for obvious physical damage and loose parts. If damage is evident, contact a factory representative before using.
  • Page 17 Cable Jacket. 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. RP Pendant Extension Cable, 50 foot (15.2 meters) (see Figure 1 Item 6).
  • Page 18 (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).

  • Page 19: Figure 1 System Configuration

    Model 415 Operation Manual Document No. 740084 Revision N...

  • Page 20: Figure 2 Ac Power Set Up (Transformer Jumpers - International)

    FIGURE 2 .NOTE During the first production run of M-415s there were two (2) types of transformers offered by AMI. Later production runs were replaced by a single Universal type. If your Power supply was manufactured before January 1999 it may be configured differently than the above figure.
  • Page 21 Operation Manual OPERATORS PENDANT CONNECTION The Model 415 is supplied (standard) to operate Weld Heads and the Pendant up to 70 feet (21 meters) from the Power Supply Cabinet. The Pendant includes a built in 20 foot (7 meters) connection cable and attaches to a 50 foot (15.2 meters) standard Pendant Extension cable. For ease of operation the Pendant can be connected directly to the Power Supply without the use of the 50 foot (15.2 meters) Extension Cable.
  • Page 22 Ground (work) Cable, 50 feet (15.2 meter)- (see Figure 1, Item 9) Items 1 and 2 are always connected to the 10 foot (3 meter) Cable attached to all AMI Weld Heads. This allows for standard operation of Weld Head up to 50 feet (15.2 meters) from the Power Supply Cabinet.

  • Page 23: Figure 2A

    NOTE During the first production run of M-415s there were two (2) types of transformers offered by AMI. If your Power Supply was manufactured before January 1999 the below figure may be used for Transformer terminal setup.

  • Page 24: Figure 3 Cable Connections

    Model 415 Operation Manual Document No. 740084 Revision N...

  • Page 25: Figure 4 Status Screen/Initial Turn-On

    Model 415 Operation Manual Document No. 740084 Revision N...
  • Page 26 SECTION IV - SYSTEM FUNCTIONS INTRODUCTION The M-415 is intended for use with AMI orbital welding heads and has functions designed for these weld heads. This section describes what these functions are and may, where needed for clarification, indicate how they are commonly (but not always) used.
  • Page 27 Model 415 Operation Manual 16. BACKGROUND AVC - Sets the Arc Voltage value in each level during the BACKGROUND PULSE time. 17. AVC MODE CONTINUOUS - Regulates the Arc Voltage to the Primary AVC value during primary and regulates the arc voltage to the Background AVC value during the background pulse.
  • Page 28 Torch Gas Flow - An analog flow sensor provides a signal equal to the Flow rate (CFH) and the M-415 displays this flow rate and compares it against a program value and creates an Sequence Stop condition if it is not correct during a weld and prevents sequence if not correct during Pre-purge.
  • Page 29 33. EMERGENCY STOP - Electronically turns the main breaker on the M-415 OFF. OTHER SYSTEM FEATURES PRINTING - The M-415 can be connected to any Windows 95 compatible parallel port printer and hard copies of all weld schedules can be made. An auto print feature can be set up to allow the system to automatically print a copy of the Weld Parameters used (including overrides) after each sequence.
  • Page 30 LEVEL 1. If the TIMER MODE is in AUTO the LEVEL 1 Timer will start to count and the M-415 will stay in LEVEL 1 until this time is complete. If the TIMER MODE is set to MANUAL or POSITION or EXT the system will still be in LEVEL 1 but the timer will not...
  • Page 31 Model 415 Operation Manual TRAVEL START DELAY - Rotation of the arc should not occur in most cases, until full penetration of the weld has been achieved. When the arc is established the TRAVEL START DELAY time will begin to count. When this programmable period of time is complete the weld head will start to rotate the arc.
  • Page 32 Model 415 Operation Manual OFF = Will prevent rotation from occurring. CONT = Runs the travel at the PRIMARY-RPM speed only, regardless of PULSE MODE. STEP = Will pulse the travel between the PRIMARY-RPM and BACKGROUND-RPM speed. If the TRAVEL MODE is in STEP but the PULSE MODE is in OFF then only PRIMARY will occur (without pulsing there are no background functions).
  • Page 33 Model 415 Operation Manual 17. LEVEL 1 IN DWELL TIME - The amount of time the oscillator will stay at the IN position before EXCURSION to the OUT position. LEVEL 1 OUT DWELL TIME - The amount of time the oscillator will stay at the OUT position before EXCURSION to the IN position.

  • Page 34: Figure 5 Sequence Timing Chart

    Model 415 Operation Manual Document No. 740084 Revision N...

  • Page 35: Introduction

    It is very important to insure, before operating, that the operators have INSTALLED the M-415 per section 3 and that they have a good understanding of functions from section 4. Function explanations are not covered in this section.

  • Page 36: Required Equipment For Calibration

    MAIN REFERENCE VOLTAGE CALIBRATION NOTE To access internal PCBs remove the rear top cover of the M-415 Power Supply. This can be achieved by removing of the two (2) rear eyebolts and four (4) Phillips screws located at the sides of the panel.

  • Page 37: Position Feedback Voltage Calibration

    Manual. (Tip: Use a copper block as a work piece.) 2. To calibrate Current the user will need to have a Weld Schedule in the Library for the M-415 and applicable Weld Head, (Pass 1). If using the optional AMI Carbon Load or Hand Torch Welding voltage must be maintained between 9 and 15 volts (approximately 1/8th inch Arc Gap).
  • Page 38 *Maximum torch value of 300 amps – use 300 amps here. Step 5.6-6-9 value would then be 3.75 VDC +/- 0.037 VDC. Level Time will be in the Manual Mode requiring the operator to Sequence stop the M-415 after measurements and any required adjustments are done. Pulse Mode should be OFF so only the Primary Current Amps is checked.
  • Page 39 Model 415 Operation Manual Set the System Mode to WELD. Press Sequence Start. The DMM should read 5.000 VDC  0.010 VDC. If out of tolerance call AMI Service for “DAC” calibration instructions. Press SEQ. STOP key to end Welding Sequence.

  • Page 40: Arc Voltage Calibration

    R-80 & R-81 DIAGRAM 4 To calibrate the AVC the user will need to have a Weld Schedule in the Library for the M-415 and applicable Weld Head, (Pass 2). The AVC calibration schedule will be run in the WELD Mode and will contain the following:...

  • Page 41: Weld Head Travel Calibration Introduction

    The following general weld head calibration procedure depends on a fully calibrated M-415 Power Supply. Once a weld head’s Wire Feed and Travel Tachometers are calibrated to a M-415 it can be moved from one M-415 to another M-415 without needing to be re-calibrated. However, if any motor assembly components are repaired, replaced or calibrated to a different Model Power Supply (M- 227, M-215) they must be re-calibrated.

  • Page 42: Weld Head Travel Calibration

    Model 415 Operation Manual To manually calibrate the user will need to have a Weld Schedule in the Library programmed in accordance to the Calibration Procedure contained in the operation manual for the particular Weld Head being used. WELD HEAD TRAVEL CALIBRATION...

  • Page 43: Weld Head Wire Feed Calibration

    WELD HEAD WIRE FEED CALIBRATION NOTE Once a weld head has had its Wire Feed and Travel Tachometers calibrated to an M-415 it can be moved from one M-415 to another M-415 without needing to be re-calibrated. However, if the motor assemblies have been repaired, replaced or calibrated to a different Model Power Supply (M-227, M-215) they may need to be re-calibrated.

  • Page 44: System Security

    Schedule information. CHANGING/EDITING/ADDING LOGON and PASSWORDS NOTE The M-415 is shipped defaulted to the Supervisor level of security and logging in is not required. It is recommended to create a new programmer Logon at once and delete AMI superuser. The following steps are for initial set up upon installation. Once the Superuser Logon and password have been changed these steps will not work as written.

  • Page 45: Project Data Recording

    Always disconnect the AC power cable from the line voltage before attempting any repairs to this welding power supply. AIR FILTERS - The M-415 power supply has two (2) foam air filters behind a single screen in the front of the power supply. Inspect these air filters regularly. To inspect, remove the two captive screws at the top of the screen and tilt the screen forward to expose the filters.

  • Page 46: System Fault Corrections

    The following is a general description of the cause of each type of fault and some recommendations for correction. TEMP - The M-415 has internal temperature probes. If the Power Supply exceeds maximum operating temperature a fault occurs. This can occur only if there is some type of blockage...

  • Page 47: Re-Shipping

    , Check the weld procedure and the arc gap required for the weld. BAD START - If for any reason the M-415 cannot achieve a stable Arc at the end of PREPURGE the system will display this statement.

  • Page 48: Selecting And Creating Languages

    SELECTING AND CREATING LANGUAGES - CUSTOMIZING SCREEN/FUNCTION NAMES Some of the text that appears on the M-415 display is derived from Windows but most of the text seen is contained in the M-415 Operating (or Remote) Software. This software also contains a program called "Language Translation".
  • Page 49 Model 415 Operation Manual 4. A List Box will appear that contains every individual line of text contained in the M-415 software. Use the scroll bar to move up and down and find the text you wish to edit. (if your creating a new language just start at the first line). Using the mouse, double click (left key) on the line to be edited.

  • Page 50: Creating And Editing Weld Head Templates

    Model 415 Operation Manual You will now be able to follow the steps of 5.17.1 (Selecting a Language) to select the new language. Do not forget that after you have done that you must exit the program and re-start in order for the new language file be in effect.
  • Page 51 "Create New Servo" box will appear and you will need to fill in the: 1. Servo Name 2. Servo Slot – There are a possible 8 servo positions in the M-415 (AO,A1,B0,B1,C0,C1,D0,D1). Enter the position being added. 3. Servo Function – This box will set the basic servo to a Position type, velocity type, jog only type, etc.

  • Page 52: Cmos Battery Replacement

    Model 415 Operation Manual Preferences can also be used to change the order that they appear on the screen. To set preferences select "Edit" and then select "Preferences". A combo box with the functions that can be changed will appear. Highlight the function to be changed and select "Edit"...

  • Page 53: Figure 7 Cmos Battery Location On Sbc84710 Motherboard

    Model 415 Operation Manual CR2032 Battery Figure 7 SBC84710 Motherboard Replace the battery Replace the front and rear top covers Referencing document 45D150143, power on the M415 and enter the BIOS settings to reconfigure the motherboard. When the boot up is complete verify that the M415 is fully functional It is recommended to replace this battery annually Document No.

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