AMI 21 Operation Manual

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Model 21 Weld Head

Operation Manual

Part No.740122

Revision A

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Page 1 Model 21 Weld Head Operation Manual Part No.740122 Revision A...
Page 2 M O D E L O P E R A T I O N M A N U A L NOTICE This document and the information contained herein is the property of Arc Machines, Inc... It is proprietary and submitted and received in confidence.
Page 3: Table Of Contents
INTRODUCTION....................1 SHOCK HAZARD WARNING................1 SPECIFICATION ....................2 TUBE SIZES - STANDARD................2 CURRENT - MAXIMUM ..................2 DUTY CYCLE MODEL 21-500 ................2 DUTY CYCLE MODEL 21-1000 ................ 2 CLAMP DIMENSIONS..................3 INSTALLATION INSTRUCTIONS ..............4 CONTROLLER CONNECTIONS............... 4 OPERATION INSTRUCTIONS ................
Page 4: Introduction
Chapter 1.0 INTRODUCTION The Model 21 is a weld head for automatic orbital tube welding. This manual covers basic set up and maintenance of the Model 21-500 & Model 21-1000. 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: Specification
M A N U A L 2.0 SPECIFICATION 2.1 TUBE SIZES - STANDARD 21-500 – Standard 1/4”, 3/8”, and 1/2” collets with optional 1/8” and custom sized collets 21-1000 – Standard 1/4", 3/8”, 1/2", 3/4", and 1” collets with optional custom sizes 2.2 CURRENT - MAXIMUM...
Page 6: Clamp Dimensions
M O D E L O P E R A T I O N M A N U A L 2.5 CLAMP DIMENSIONS Dimensions 21-500 21-1000 0.63 1.10 0.63 1.10 B open 1.27 2.00 0.48 1.40 D electrode 0.25 0.70...
Page 7: Installation Instructions
M O D E L Chapter O P E R A T I O N M A N U A L 3.0 INSTALLATION INSTRUCTIONS 3.1 CONTROLLER CONNECTIONS 1. From a regulated air/argon source, connect a ¼” - 50 psi hose into the receptacle fitting, labeled “CDA”...
Page 8 M O D E L O P E R A T I O N M A N U A L Argon from power supply Air from 50 psi source 24VDC supply Figure 1 Ground Electrode Weldhead Auxiliary Figure 2 Figure 3 5 5 5 5...
Page 9 M O D E L O P E R A T I O N M A N U A L Foot Pedal Connection Figure 4 Figure 5 Push Controller cable into weldhead (left) until latches “click” closed (right). 6 6 6 6...
Page 10: Operation Instructions
M O D E L Chapter O P E R A T I O N M A N U A L 4.0 OPERATION INSTRUCTIONS 7 7 7 7...
Page 11: Weldhead User Interface
M O D E L O P E R A T I O N M A N U A L 4.1 WELDHEAD USER INTERFACE 1. ON/OFF – Used to power on/off the weld head independent of the interface box when changing heads. 2.
Page 12: Startup Procedure
M O D E L O P E R A T I O N M A N U A L 4.2 STARTUP PROCEDURE STARTUP PROCEDURE STARTUP PROCEDURE STARTUP PROCEDURE 1. Make power supply and weldhead connections as described in Section 3.0. Turn on power switch on controller and weldhead.
Page 13: Operation Procedure
M O D E L O P E R A T I O N M A N U A L Image above left, shows jaws open ready to receive sample tube to insure collets are seated within the jaws. Image above right, shows tube being removed from jaws after verifying collets are seated.
Page 14: Maintenence Instructions
M O D E L Chapter O P E R A T I O N M A N U A L 5.0 MAINTENENCE INSTRUCTIONS 5.1 ELECTRODE ELECTRODE ELECTRODE ELECTRODE REPLACEMENT PROCEDURE REPLACEMENT PROCEDURE REPLACEMENT PROCEDURE REPLACEMENT PROCEDURE 1. Set power supply to TEST mode. 2.
Page 15: Collet Change Procedure
M O D E L O P E R A T I O N M A N U A L 5.2 COLLET C COLLET CHANGE PROCEDURE HANGE PROCEDURE COLLET C COLLET C HANGE PROCEDURE HANGE PROCEDURE 1. Turn off power to the Controller. 2.
Page 16: Rotor And Parts Replacement
M O D E L O P E R A T I O N M A N U A L 5.3 ROTOR AND PARTS REPLACEMENT ROTOR AND PARTS REPLACEMENT ROTOR AND PARTS REPLACEMENT ROTOR AND PARTS REPLACEMENT 1. With the jaws in the open position turn off the power to the Controller. 2.
Page 17: Startup Preliminary Checklist
M O D E L O P E R A T I O N M A N U A L 5.4 STARTUP PRELIMINARY CHECKLIST STARTUP PRELIMINARY CHECKLIST STARTUP PRELIMINARY CHECKLIST STARTUP PRELIMINARY CHECKLIST Interface purge is connected to Arc Gas Output Controller is plugged in (Does not apply to 207) Foot pedal is connected (F Mode Only) Remote pendent is connected (Optional)
Page 18: Electrode Length Formula
ELECTRODE ELECTRODE ELECTRODE LENGTH FORMULA LENGTH FORMULA LENGTH FORMULA LENGTH FORMULA X = .954 for 21-500 X = 1.716 for 21-1000 Y = Tube OD Z = Wall Thickness Formula for calculating Electrode Length = ((X-Y)/2) - ((Z/2) +. 01) = ((Rotor Diameter-Tube OD)/2) - ((Wall/2) +.
Page 19: Troubleshooting
M O D E L Chapter O P E R A T I O N M A N U A L 6.0 TROUBLESHOOTING TROUBLESHOOTING TROUBLESHOOTING TROUBLESHOOTING 6.1 MEANDERING WELD Welds beads that are not straight can usually be attributed to one of four things: 1.
Page 20: Incorrect Rotor Home Position
M O D E L O P E R A T I O N M A N U A L 8. If misalignment is in another axis or is not corrected by the above, the collets/jaws may be damaged. Figures 1 & 2 MISALIGNMENT 6.3 INCORRECT ROTOR HOME POSITION If the rotor is not stopping in the correct home position the center pin will not operate.
Page 21: Maintenance
M O D E L Chapter O P E R A T I O N M A N U A L 7.0 MAINTENANCE Always disconnect the AC power cable from the line voltage before attempting to work on this welding power supply. There are no user serviceable components located inside the M21 weld heads.
Page 22 Tel: +41 22 995 00 51 England Fax: +41 22 995 00 59 Tel: +44 1327 312787 sales@arcmachines.ch Fax: +44 1327 315034 sales@arcmachines.co.uk SERVICE DEPARTMENT AMI Applied Solutions Group AMI Applied Solutions Group AMI Applied Solutions AMI Applied Solutions Group Group Arc Machines, Inc 13509 South Point Blvd., Ste 190...