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AMI 217P Operator's Manual

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Model 217P Tube Welding Power Supply
Operator's Manual
Part No. 740141
Revision B

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Summary of Contents for AMI 217P

  • Page 1 Model 217P Tube Welding Power Supply Operator’s Manual Part No. 740141 Revision B...
  • Page 2 M A N U A L INTRODUCTION he Model 217P is a power source and controller for automatic orbital tube welding. It is intended to be used in conjunction with AMI and EXEL by AMI orbital tube welding heads and accessories. The Model 217P power supply provides GTAW (Gas Tungsten Arc Welding) current with pulsation controls, high frequency arc starting, purge gas controls, weld head arc rotation and automatic timing functions.

  • Page 3: Table Of Contents

    MODEL 217P TO 217P-CW WATER COOLER HOOK UP ......13   4.0 LIBRARY AND MEMORY ..................16     LOADING A WELD SCHEDULE FROM THE MODEL 217P LIBRARY ..17   5.0 CREATING WELD SCHEDULES ................27   CREATING A MANUAL 4 LEVEL WELD SCHEDULE ........27  ...

  • Page 4: Safety Precautions

    Chapter 1.0 SAFETY PRECAUTIONS The Model 217P is intended to be used with AMI or EXEL by AMI weld heads for the purpose of GTAW welding of metal tube. The system is not to be used for any other purpose, specifically heating or cutting.
  • Page 5 USER MUST OBSERVE COMMON SAFETY PRACTICES such as grounding the electrode to ensure discharge before touching it. 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”...

  • Page 6: Warning Label Definitions

    M O D E L 2 1 7 P O P E R A T O R ’ S M A N U A L 1.2 WARNING LABEL DEFINITIONS The table below contains caution and warning labels for the operation of this equipment. Before operating this or any welding equipment users should be familiar with “ANSI-49.1 Safety in Welding and Cutting”.
  • Page 7 O P E R A T O R ’ S M A N U A L WARNING: Exel factory training is essential for all Welding Operators and Maintenance Technicians who operate AMI or EXEL by AMI equipment. WELDING WIRE and ELECTRODES are sharp and can cause injury.

  • Page 8: System Symbols

    Ethernet port. For networking capability. Devices should not be left plugged in while welding. Remote control connection. Weld head electrode and ground connections. Output for the arc shielding gas connection. Weld head control. Intended for AMI and EXEL by AMI weld heads.

  • Page 9: Specifications

    The Model 217P is a mobile system that is intended to be hand carried. The supporting equipment such as weld heads, water coolers, gas regulators, remote controls and extension cables can also be hand carried.
  • Page 10 CIRCUIT BREAKER – ON/OFF, two pole, 30 Ampere at 250 VAC. DUTY CYCLE – determined by the AC input voltage and the required output current. The Model 217P system has an internal thermal sensor that will limit operation should the temperature exceed the safe operating parameters.

  • Page 11: Physical Dimensions

    M O D E L 2 1 7 P O P E R A T O R ’ S M A N U A L 2.3 PHYSICAL DIMENSIONS POWER SUPPLY HEIGHT 18” (457mm) POWER SUPPLY WIDTH 19” (483mm) POWER SUPPLY DEPTH 14.8”...
  • Page 12 M O D E L 2 1 7 P O P E R A T O R ’ S M A N U A L MULTI-LEVEL PARAMETERS AND FUNCTIONS The following parameters and functions can be programmed in each level to change value during a weld sequence.

  • Page 13: Start-Up

    Chapter 3.0 START-UP 3.1 REQUIRED PERIPHERALS 1. An orbital weld head is required to weld with the Model 217P. Shown below is the EXEL by AMI RDR-05 Rotor Driver (below left) and an AMI Model 9-750 orbital weld head. 2. An A.C. power cord rated for 600 VAC service (below left) and gas purge lines are provided to connect power and inert gas to the power supply.

  • Page 14: Optional Peripherals

    All AMI power supplies have their own respective optional remote pendant. This gives the operator remote welding functions of the Model 217P power supply itself. The optional cooling unit is recommended for high production or heavy walled (.109”-.154”) welding applications.

  • Page 15: Power Supply Connection

    M A N U A L 3.3 POWER SUPPLY CONNECTION 1. Below is a view of the input and output sides of the Model 217P Power Supply with all connectors visible. Connect the A.C. power cord into a utility power source ranging from 115/230 volts, 50/60 hertz single phase.

  • Page 16: Model 217P To 217P-Cw Water Cooler Hook Up

    217P. Liquid-cooled weldheads connect to the Model 217P / 217P-CW via a short pig-tail or adapter cable. If needed an extension cable can be used. The extension cable connects to the Model 217P and Model 217P-CW cooler on one end, then to the liquid-cooled weldhead on the other.
  • Page 17 WATER OUT and WATER RETURN connectors on the Model 217P-CW. These connectors are interchangeable so either connector may be connected to either mating fitting. To prevent accidental disconnection after making the connection, finger-tighten the lock screw on the male connectors.

  • Page 18: Main Screen

    SHUT DOWN the power supply. MAIN SCREEN Touch LIBRARY pad to open the Model 217P’s internal library which can store over 1,000 complete weld schedules. Each schedule having up to 99 individual levels allowing for precise manipulation of weld parameters to achieve optimum results based upon your...

  • Page 19: Library And Memory

    COPY weld schedules to/from an external memory device. These modes are enabled and displayed only when a memory storage device is connected to the Model 217P’s USB port(s). The Model 217P’s Library shows the weld schedules available and displays them by: ...

  • Page 20: Loading A Weld Schedule From The Model 217P Library

    4.1 LOADING A WELD SCHEDULE FROM THE MODEL 217P LIBRARY 1. Flip the main power switch (CB-1) of the Model 217P to the ON position. 2. Once the computer boots up touch LIBRARY on the MAIN SCREEN. 3. Peruse the LIBRARY, touch the desired weld schedule on the screen, it will become...
  • Page 21 M O D E L 2 1 7 P O P E R A T O R ’ S M A N U A L 4. Touch LOAD SCHEDULE. Note Double clicking the desired (highlighted) weld schedule will also cause the weld schedule to load.
  • Page 22 M O D E L 2 1 7 P O P E R A T O R ’ S M A N U A L 5. The selected weld schedule will be loaded and the Weld Screen will appear. WELD SCREEN From the Weld Screen the operator has access to all power supply, welding and weld head functions at a touch of the weld screen: START: Starts the Weld sequence.
  • Page 23 M O D E L 2 1 7 P O P E R A T O R ’ S M A N U A L PRINT SCHEDULE: Provides printout of entire weld schedule parameters. CALIBRATE: If weld heads differ when changing weld schedules, provides automatic weld head calibration to power supply.
  • Page 24 4.2 COPYING WELD SCHEDULES FROM THE MODEL 217P LIBRARY TO AN EXTERNAL MEMORY DEVICE 1. Open LIBRARY. Insert the external memory device into the Model 217P USB port. 2. Select (highlight) one weld schedule to be copied to the external memory device.
  • Page 25 COPY ALL TO EXTERNAL MEMORY if you want the entire Model 217P library copied to the external memory device. Note Should the weld schedule(s) you are trying to copy from the Model 217P library already exist in the external memory device the following screen be displayed (Next Page): 4.
  • Page 26 O P E R A T O R ’ S M A N U A L 5. OR the screen below will be displayed to verify if the entire Model 217P library has been copied successfully to the external memory device.
  • Page 27 MEMORY DEVICE TO THE MODEL 217P LIBRARY 1. Open LIBRARY. Insert external memory device in the Model 217P USB port. 2. Touch EXTERNAL MEMORY to open and display external memory device library. 3. Select (highlight) one weld schedule to be copied to the Model 217P library.
  • Page 28 O P E R A T O R ’ S M A N U A L 4. Touch COPY TO M217P to copy that one weld schedule, or touch COPY ALL TO M217P if you want the entire external memory library copied to the Model 217P library. Note...
  • Page 29 Model 217P library. 7. Touch OK to clear verification screen. Touch M217P display. 8. Verify that the weld schedule or schedules have been copied to the Model 217P library. 9. Remove external memory device.

  • Page 30: Creating Weld Schedules

    M O D E L 2 1 7 P O P E R A T O R ’ S M A N U A L Chapter 5.0 CREATING WELD SCHEDULES 5.1 CREATING A MANUAL 4 LEVEL WELD SCHEDULE 1. From the MAIN SCREEN touch the CREATE SCHEDULE pad and the create schedule menu will be displayed.
  • Page 31 M O D E L 2 1 7 P O P E R A T O R ’ S M A N U A L 3. Press Page 2. Select and enter all required LEVELS, PURGE and MOTOR parameters. You may also enter any SPECIAL NOTES that you may have. 4.
  • Page 32 7. Pressing SAVE will store all data in the library under the SCHEDULE NAME you selected and the WELD SCREEN will be displayed with the schedule name on top. 8. The Model 217P is now loaded with the weld schedule and is in STANDBY mode, ready to weld.

  • Page 33: Creating An Automatic 4 Level Weld Schedule

    M O D E L 2 1 7 P O P E R A T O R ’ S M A N U A L 5.2 CREATING AN AUTOMATIC 4 LEVEL WELD SCHEDULE 1. From the MAIN SCREEN touch the CREATE SCHEDULE pad and the create schedule menu will be displayed.
  • Page 34 5. Pressing SAVE will store all data in the library under the SCHEDULE NAME you selected and the WELD SCREEN will be displayed with the schedule name on top. 6. The Model 217P is now loaded with the weld schedule and is in STANDBY mode, ready to weld.

  • Page 35: Creating An Auto Step Weld Schedule

    M O D E L 2 1 7 P O P E R A T O R ’ S M A N U A L 5.3 CREATING AN AUTO STEP WELD SCHEDULE 1. From the MAIN SCREEN touch the CREATE SCHEDULE pad and the create schedule menu will be displayed.
  • Page 36 M O D E L 2 1 7 P O P E R A T O R ’ S M A N U A L 3. Press the AUTO STEP pad. 4. The AUTO SCHEDULE NAME screen will be displayed. The default schedule name is based on the tube O.D., wall thickness and material you entered when creating this weld schedule.

  • Page 37: Creating An Auto Tack Weld Schedule

    M O D E L 2 1 7 P O P E R A T O R ’ S M A N U A L 6. The Model 217P is now loaded with the weld schedule and is in STANDBY mode, ready to weld.
  • Page 38 M O D E L 2 1 7 P O P E R A T O R ’ S M A N U A L 3. Press the AUTO TACK pad. 4. The TACK PARAMETERS screen will be displayed. You can select the amount of PENETRATION PERCENTAGE (0% to 126%) desired, the NUMBER OF TACKS (1 to 40) desired, and the TACKING PATTERN –...
  • Page 39 6. Pressing SAVE will store all data in the library under the SCHEDULE NAME you selected and the WELD SCREEN will be displayed with the schedule name on top. 6. The Model 217P is now loaded with the weld schedule and is in STANDBY mode, ready to tack.

  • Page 40: Creating An Auto S^3 (S Cubed) Weld Schedule

    M O D E L 2 1 7 P O P E R A T O R ’ S M A N U A L 5.5 CREATING AN AUTO S^3 (S cubed) WELD SCHEDULE 1. From the MAIN SCREEN touch the CREATE SCHEDULE pad and the create schedule menu will be displayed.
  • Page 41 M O D E L 2 1 7 P O P E R A T O R ’ S M A N U A L 3. Press the AUTO PULSED S^3 pad. 4. The AUTO SCHEDULE NAME screen will be displayed. The default schedule name is based on the tube O.D., wall thickness and material you entered when creating this weld schedule.
  • Page 42 M O D E L 2 1 7 P O P E R A T O R ’ S M A N U A L 6. The Model 217P is now loaded with the weld schedule and is in STANDBY mode, ready to weld.

  • Page 43: Setup

    M O D E L 2 1 7 P O P E R A T O R ’ S M A N U A L Chapter 6.0 SETUP 6.1 PROGRAMMING BASIC SETUP FEATURES 1. From the MAIN SCREEN touch the SETUP pad. 2.
  • Page 44 M O D E L 2 1 7 P O P E R A T O R ’ S M A N U A L 3. From the SETUP screen is where the internal CLOCK (local time and year) is set, the libraries UNITS OF MEASURE (English or Metric) is selected, and the current override POWER ADJUST minimum and maximum limits are set.
  • Page 45 Model 217P. This will determine what the operator can do, cannot do, or is limited in doing with the Model 217P. ! NOTE !
  • Page 46 M O D E L 2 1 7 P O P E R A T O R ’ S M A N U A L 3. CONFIRM new password (re-enter same numbers) and press ENTER. 4. NEW PASSWORD IS SET will appear on screen if password is set properly. 5.

  • Page 47: Alarms And Faults

    ALARM SETTINGS are only accessible using a 5 digit “1-Day Programmer Password”, which is only available by calling AMI Technical Support (In USA 818-896-9556). 1. From the MAIN SCREEN touch the SETUP pad. The SETUP SCREEN will be displayed. Touch the CHANGE PROGRAMMER PASSWORD pad and the password screen will appear.
  • Page 48 M O D E L 2 1 7 P O P E R A T O R ’ S M A N U A L 6. Wait 10 seconds, flip CB-1 to the ON position, wait for computer to boot up. 7.

  • Page 49: Alarm Settings

    M O D E L 2 1 7 P O P E R A T O R ’ S M A N U A L 7.2 ALARM SETTINGS LOW PRESSURE: The lowest allowable pressure desired for the purge inlet of the power supply.

  • Page 50: Printing

    M O D E L 2 1 7 P O P E R A T O R ’ S M A N U A L 2. The message below left will appear if arc voltage goes above the set value. The message below right will appear if arc voltage goes below the set value.

  • Page 51: Proper Shutdown Of The Model 217P

    O P E R A T O R ’ S M A N U A L 7.5 PROPER SHUTDOWN OF THE MODEL 217P 1. Touch HOME from whatever screen you are on to return to the MAIN SCREEN. 2. Touch SHUT DOWN.

  • Page 52: Maintenance And Troubleshooting

    There are no user serviceable components located inside the Model 217P. Do not open the unit in an attempt to repair it. Contact Arc Machines, Inc. if the unit is malfunctioning, or suspected of being broken.

  • Page 53: Troubleshooting

    8.2 TROUBLESHOOTING The Model 217P has the ability to monitor certain functions. If they are not working correctly a system fault will alert the operator to the problem.
  • Page 54 I.D. gas pressure, causing the weld to blow out from the I.D. and creating a hole. 5. BAD START - If for any reason the Model 217P cannot establish a stable arc (at the end of PREPURGE) the system will display a BAD START fault. There can be several reasons for this to occur.

  • Page 55: Options

    M A N U A L 9.0 OPTIONS The following are installation and operation instructions for Model 217P options. Some options have their own manuals and these are not discussed in this section. Always turn the power supply OFF before making any cable or connection changes to the Model 217P power supply.
  • Page 56 DO NOT USE automotive antifreeze or STOP-LEAK type antifreeze 2. Before mounting the Model 217P-CW Cooling Unit to the Model 217P remove the fill and add the coolant mixture. Replace the fill cap. 3. Place the Model 217P power supply onto the Model 217P--CW Cooling Unit and close the latches on each end.
  • Page 57 M O D E L 2 1 7 P O P E R A T O R ’ S M A N U A L 10500 Orbital Way Pacoima, CA 91331 USA Tel: 1-818-896-9556 Fax: 1-818-890-3724 sales@arcmachines.com...

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