Arc Machines 501 Operation Manual

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10500 Orbital Way

Pacoima, California 91331 U.S.A.

MODEL 501 POWER SUPPLY

OPERATION MANUAL

Document No. 740099

Rev. %

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Page 1 10500 Orbital Way Pacoima, California 91331 U.S.A. MODEL 501 POWER SUPPLY OPERATION MANUAL Document No. 740099 Rev. %...
Page 2 Tel.: 1- 818 896-9556 Fax: +49/2245 / 916868 Fax: 1-818 890-3724 sales@arcmachines.de sales@arcmachines.com UK OFFICE EUROPEAN OFFICE Arc Machines UK Limited Arc Machines, Inc. 10 Ashurst Court, London Road Chemin du Lavasson 2 Wheatley, Oxford OX331ER CH-1196 Gland England Switzerland Tel.: +44/1865/872121...
Page 3 The Model 501 uses AC current to preheat the wire. True values of current and voltage allow welding engineers to precisely calculate energy input in Joules per inch based on true RMS values.
Page 4: Table Of Contents
Table of Contents INTRODUCTION Applications Hot Wire Application with AMI Model 415 and M-2 SAFE OPERATION Safety Precautions M-501 Do’s and Don’ts Warnings MODEL 501 SPECIFICATIONS MODEL 501 POWER SUPPLY OPERATION & FUNCTIONS Hotwire Power Wire Feeder Supply System Configurations...
Page 5: Introduction
(See graph on page 2.) The Arc Machines, Inc. Hot Wire Power Supply Model 501 has controls for (heating wire) voltage. The standard mode of operation for 'RFXPHQW 1XPEHU &KDSWHU 3DJH ...
Page 6: Applications
Wire. )URP WKH $:6 :HOGLQJ +DQGERRN 1LQWK (G 2004 7Ke Model 501 is Constant AC Voltage (0 - 10 Volts true 506). The M501 implements advanced technology with significant competitive advantages. AC current is used to minimize magnetic interference (arc blow). The AC current of the M501 is far more precise and more sinusoidal than competitive machines, being very close to a true sine wave.
Page 7 $UF 0DFKLQHV ,QF 0RGHO +RWZLUH 3RZHU 6XSSO\ The Model 501 Hot Wire Power Supply can be used in combination with AMI’s Model 2 and Model 415 Power Supply for fast, high-quality, heavy-duty applications such as turbines. The photos show a demonstration of cladding at a trade show with the Model 2 with a hot wire torch.
Page 8: Hot Wire Application With
Hot Wire application with AMI Model 415 and Model 2 A versatile hot-wire welding automation system may be created by equipping an Arc Machines’ Model 2 with a Hot-Wire Torch with AVC and oscillation and optional video vision system and using an Arc Machine’s Model 415, GTAW 400 amp DCSP Power Supply as a controller.
Page 9 Read this manual carefully before operating welding and/or hot wire equipment. Although the Model 501 hot wire power supply has an open cir- cuit voltage of only 16 volts and so does not represent an extreme shock haz- ard by itself, exposed parts operating at very high temperatures represent a burn hazard.
Page 10 (200 to 240 VAC @ VERIFY 25 Amps) before plugging in the Model 501. 4. Do turn off equipment when not in use. 5. Do calibrate wire feed each time the Model 501 is connected. 'RFXPHQW 1XPEHU &KDSWHU 3DJH ...
Page 11 $UF 0DFKLQHV ,QF 0RGHO +RWZLUH 3RZHU 6XSSO\ 6. Do CHECK ALL CABLE AND QUICK DISCONNECT FITTINGS insure proper seating. 7. Do KEEP PROTECTIVE COVERS ON THE MOTOR CABLE when not in use. CONNECTORS 8. Do wear approved safety glasses with side shields. 9.
Page 12 (CFH) to GTAW torch GAS FLOW RATE beyond levels that could result in arc instability. 8. Don’t switch the Model 501 Power Supply ON and OFF rapidly with circuit breaker (CB-1). RF and EMI Emissions Arc Machines’ policy is to comply with the IEC and FCC regulation.
Page 13: Safety Precautions
Safety Precautions his section, concerning safe operating procedures for the Model 501 Hot Wire Power Supply, should be read and under- stood before proceeding to other sections of the training man- ual. It also contains precautions an warnings for the operation of welding equipment in general.
Page 14 $UF 0DFKLQHV ,QF 0RGHO +RWZLUH 3RZHU 6XSSO\ MODEL 501 WARNINGS Continued: : Welding can cause fires or explosions. Do not weld near ARNING flammable or explosive materials. Watch for fire. Have proper type of extinguisher in work area. WARNING: Welding Operators should wear non-flammable protective clothing, footwear and head gear.
Page 15 WARNING: Keep hands and fingers clear from moving parts such as fans, gears, rotors, and Rotation Mechanisms. The wire for the M-501 feeds at a high rate of speed and as it enters the puddle is at near melting temperature. Take care to avoid contact with the wire.
Page 16 $UF 0DFKLQHV ,QF 0RGHO +RWZLUH 3RZHU 6XSSO\ hapter 3. Specifications for the Model 501 Power Supply AMI Model 501 True RMS Hotwire Precision Power Supply Features Calibrated Precision Closed Loop Servo Output Control Constant Voltage (CV) True RMS mode-of-operation...
Page 17 Model 501 Remote Operator Pendant Model 501 Remote Operator Pendant An AMI Wirefeed head and wire feed torch may be used on the Model 2 in conjunction with the Model 501 Power Supply. 'RFXPHQW 1XPEHU &KDSWHU 3DJH ...
Page 18 GTAW torch is highly recom- mended. Wire Feeder. The Model 501 does not control the wire feeder, it only sup- plies the current to heat the wire. When the Model 501 is used as a stand- M-501 remote connector, connects to 501 Remote Programming Pendant.
Page 19 GTAW power supply is required. When the 501 is used in conjunction with the AMI Model 415 Power Supply, the wire feed speed is controlled by the Model 415.
Page 20 PENDANT Wire Feeder Set-Up of Model 501 Power Supply used in conjunction with an Arc Machines’ Model 415 GTAW power source. Wire feed and hot wire current controlled by Model 415. Operation of the Model 501 by an External Controller...
Page 21: Model 501 Specifications
$UF 0DFKLQHV ,QF 0RGHO +RWZLUH 3RZHU 6XSSO\ Hot wire remote connector pins Model 501 Hot Wire Remote Connector Pins Description 17 Sep. 2004 Pin # Signal Description Frame ground System enable input ( 5 – 24V ) Insulated from analog ground System enable input (5 –...
Page 22: Power Supply
(50 Hz or 60 Hz) will be audible near the weld puddle. After this is achieved, the wire feed speed can be increased and the Model 501 voltage 'RFXPHQW 1XPEHU &KDSWHU 3DJH ...
Page 23: Wire Feeder
For new installations, a similar “trial and error” procedure should be followed. Welding with the Model 501 is application-dependent and thus giving specif- ics for a particular welding procedure is not practical. However, in general the operator forms a puddle with the GTAW system and begins feeding wire.
Page 24: Welding
$UF 0DFKLQHV ,QF 0RGHO +RWZLUH 3RZHU 6XSSO\ hapter 6. Joint Preparation for Hot Wire GTA Welding reparation of the joint is a key to the success of automatic welding procedures. The advantages of hot wire technology can best be realized in downhand welding where the highest deposition rate can be achieved.
Page 25 $UF 0DFKLQHV ,QF 0RGHO +RWZLUH 3RZHU 6XSSO\ Hot Wire GTA welding of pipe is most efficient when the pipe can be rotated and the electrode remains in place. 'RFXPHQW 1XPEHU &KDSWHU 3DJH 5HY %...
Page 26 7. Assembly and Electrical Drawings The following documents are attached: 1. 501 Hotwire PS Basic Assembly Drawing 25E010101 2. 501 Hotwire PS Remote Pendant Assembly Drawing 25E010102 3. 501 Hotwire PS Wiring Diagram 47E010101 4. 501 Hotwire Remote Control Wiring Diagram 47E010102 5.
Page 27 $UF 0DFKLQHV ,QF 0RGHO +RWZLUH 3RZHU 6XSSO\ hapter 8. Icons and Symbols Table 1. Graphical Symbols Index Symbol Function, Key- Application Source word or Phrase Line To Signify a Power Line ANSI/NEMA or Cord Circuit Breaker To Signify a Circuit ANSI/NEMA Breaker in an Electrical Circuit...
Page 28 $UF 0DFKLQHV ,QF 0RGHO +RWZLUH 3RZHU 6XSSO\ Table 1. Graphical Symbols Index Dangerous Volt- To Signify Dangerous IEC 417 Voltage 5036A Read Operator’s To Signify that the Oper- Manual ator’s Manual Should be Read Torch Signifies a Welding or ANSI/NEMA Cutting Torch Gas Tungsten Arc...
Page 29 $UF 0DFKLQHV ,QF 0RGHO +RWZLUH 3RZHU 6XSSO\ Table 1. Graphical Symbols Index Pulse Signifies Pulse Function ANSI/NEMA or Control Sequence To Signify Advancing to ANSI/NEMA Advance the Next Sequence Event (Level) Sequence To Signify Returning to ANSI/NEMA Deadvance the Previous Sequence Event (Level) Air (Gas) Pres- To Signify Air (or Gas)
Page 30 $UF 0DFKLQHV ,QF 0RGHO +RWZLUH 3RZHU 6XSSO\ Table 1. Graphical Symbols Index To Signify the OFF State ANSI/NEMA of a Function Hand To Signify Manual ANSI/NEMA Control of a Function or Tool Disturbance (or To Signify a Disturbance ISO 7000-0228 change) in the Proper Run of a Procedure, or Fault Con-...
Page 31 $UF 0DFKLQHV ,QF 0RGHO +RWZLUH 3RZHU 6XSSO\ Table 1. Graphical Symbols Index Start Delay Time To Signify a Timed Delay ANSI/NEMA in Starting a Function Stop Delay Time To Signify a Timed Delay ANSI/NEMA in Stopping a Function Rotating Switch To Signify Increase or ANSI/NEMA Decrease of a Quantity...
Page 32 $UF 0DFKLQHV ,QF 0RGHO +RWZLUH 3RZHU 6XSSO\ Table 1. Graphical Symbols Index Wirefeed Start To Signify the Time after ANSI/NEMA/AMI Delay Sequence Start that Wire begins to Feed Wirefeed Stop To Signify the Amount of ANSI/NEMA/AMI Delay Time Time Programmed for Wire Stop Delay Wire Diameter To Signify the Diameter...
Page 33 Hotwire Power Supply Basic Assembly hot wire voltage Drawing - Page 2. hot-wire torch Hotwire Remote Control Assembly Drawing Input Power connector Remote Control Wiring Diagram input voltage 501 Hotwire Remote Control Assembly 'RFXPHQW 1R ,QGH[ 3DJH 5HY %...
Page 34 RMS metallurgy true sine wave Model 2 Model 415 GTAW power supply voltage Model 501 specifications open circuit voltage Modified ‘J’ Prep voltage feedback input multi-servo control M-501 remote connector Warnings Disconnect the input power...