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Model 415 
Operation Manual 

 

Document No. 740084 

 

Revision N 
 

10

     5. 

 Cerriated 

or 

Thoriated 

Electrodes with conventional grinds. 

 

 

   

6.  

Cable lengths up to 200 feet. 

     7. 

 Multiple 

arc 

strike 

attempts. 

 

2.9   

TORCH COOLING UNIT - Liquid cooled, forced air heat exchanger with coolant reservoir. 

 

 

 

1.  

Reservoir Capacity - 2.5 gallons (9.46 liters) 

 

 

2.  

Maximum Pressure - 60 PSI 

 

 

3.  

Flow - 0.3 GPM for 400 Ampere Torches. 

 

 

   

  0.2 GPM for 300 or less Ampere Torches 

 

 

4.  

Head - Up to 100 feet with 200 feet of cable.  

 

 

5.  

Duty Cycle - 100 % 

 

 

6.  

Distilled or Demineralized Water coolant, (see section 3.3 for use where freezing may occur).   

   7. 

 Replaceable 

coolant 

filter 

 

 

8.  

Pressure relief valve and by-pass built-in 

 
2.10  

GAS DISTRIBUTION SYSTEM 

 
 

 

1.  

Control - Electrical Solenoid valve. 

 

 

2.  

Pressure - Maximum 50 PSI 

 

 

3.  

Flow - 5 to 100 CFH 

 

Summary of Contents for 415

Page 1: ...MODEL 415 OPERATION MANUAL Document No 740084 Revision N ...

Page 2: ... symbols make it the OPERATOR S RESPONSIBILITY TO INSURE THAT HE HAS READ AND OR BEEN MADE AWARE OF ALL OF THE SAFETY RELATED ITEMS CONTAINED IN THIS MANUAL Publication date First Edition 1 July 1997 Copyright 1997 by Arc Machines Inc All rights reserved REV DCO CHANGE DESCRIPTION DATE APR A 3228 Revised pg iv 2 1 2 2 3 2 3 5 Sect 5 Add 3 11 1 27 99 GPE B 3304 Revised pages iv 2 1 2 2 3 5 5 10 thr...

Page 3: ...s 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 Please feel free to contact Arc Machines Service Department for documentation or information on how software updates affect this document ...

Page 4: ...tion and Cross seam Steering Servo 9 2 7 Timing Functions 9 2 8 Arc Starting 9 2 9 Torch Cooling Unit 10 SECTION III INSTALLATION 3 0 Installation General 11 3 1 Training 11 3 2 Inspection 11 3 3 Torch Cooling System Preparation 12 3 4 Primary Power Connection 13 3 5 Operators Pendant Connection 16 3 6 Inert Gas Connection 16 3 7 Weld Head Installation 16 3 8 Initial Turn On 17 SECTION IV SYSTEM F...

Page 5: ...Wire Feed Calibration 38 5 11 System Security 39 5 12 Project Data Recording 40 5 13 General Maintenance 40 5 14 System Fault Corrections 41 5 15 Re Shipping 42 5 16 Selecting and Creating Languages 43 5 17 Creating and Editing Weld Head Templates 45 5 18 CMOS Battery Replacement 47 LIST OF ILLUSTRATIONS NUMBER DESCRIPTION PAGE Figure 1 System Configuration 14 Figure 2 AC Power Set Up Transformer ...

Page 6: ...a acquisition The system can also be used as a manual welding power source using an optional manual torch with a variety of manual welding options such as a variable current foot controller with remote start stop switch NOTE In depth weld development instructions weld head set up maintenance and troubleshooting are contained in other manuals documents and training classes and are not included in t...

Page 7: ...may result in an EXPLOSION WARNING Welding produces high temperatures in both the welded components and the welding equipment Both can cause severe burns Do not touch recently welded components Avoid touching internal components of the welding system soon after use Avoid touching torch components and welding fixtures soon after welding WARNING The welding arc emits ultra violet UV radiation and th...

Page 8: ... for operating personnel to follow to insure minimum system down time due to improper operation and handling 1 To AVOID severe equipment damage VERIFY that the M 415 is connected to the correct Input AC power see section 3 4 2 Before operating check all fittings and connectors for proper seating and that all protective boots are in place If not properly seated or protected short circuits poor conn...

Page 9: ...sing radio frequency voltage In order to arc weld an electric arc must be created because of safety and economic concerns the no load voltage of arc power sources is kept as low as practical Thus a source of high voltage with a high safety factor must be utilized Radio Frequency voltage is the best method of meeting these criteria for many reasons quoted from CISPR B 63 2 RF REGULATION The FCC reg...

Page 10: ... be present on the electrode during arc starting and of course during the welding All AMI Power Supplies contain a bleeder circuit to ground any residual potential after welding or after an aborted or bad arc start attempt However these circuits take a few seconds to operate or COULD FAIL Do not depend on them to prevent electrical shock THE ELECTRODE SHOULD ALWAYS BE CONSIDERED A POSSIBLE SHOCK H...

Page 11: ...ation Rated MIN and MAX Outputs when current is pulsing 10 Symbol that output is Direct Current DC only 11 Rated No Load Output Voltage open circuit voltage is 61 volts 12 The M 415 is a 100 Duty Cycle for the rated outputs 9 15 Input Voltage type contains symbol for three 3 phase Alternating Current AC input at 50 or 60 Hz frequency 18 Nominal Input Voltage value is dependent on Transformer type ...

Page 12: ...ght polarity constant current DC regulation intended for GTAW welding only Minimum current Output all cases 5 Amperes DC Maximum current Output 400 Amperes DC continuous or peak pulse 4 CIRCUIT BREAKER Also used as ON OFF switch is a 60 Amp 3 phase Auto Trip with electrical Emergency Stop function available on the Power Supply Operators Pendant and from an Optional External Hard Wire Command 5 POW...

Page 13: ...it 35 VDC 6 Regulation Closed Loop position servo using arc voltage measured at the torch Intended for DC permanent magnet type motors only 7 Regulation Tolerance 1 of program value or 0 1 VDC whichever is greater Based on primary current only with no current pulsation Measurable accuracy with the current pulsing can be affected by the puddle growth and shrinkage 8 Regulation Response Variable and...

Page 14: ...on input steering commands from steering devices on Pendant and Display 2 7 TIMING FUNCTIONS 1 Purge Time Range pre and post 000 to 1000 seconds User can define minimum programmable time 2 Start Delay Time Range Travel Wire AVC 00 0 to 100 seconds in increments of 0 1 seconds 3 Stop Delay Time Range Travel Wire AVC 00 to 100 seconds 4 Upslope Time Range 00 0 to 100 seconds User can define minimum ...

Page 15: ...oir Capacity 2 5 gallons 9 46 liters 2 Maximum Pressure 60 PSI 3 Flow 0 3 GPM for 400 Ampere Torches 0 2 GPM for 300 or less Ampere Torches 4 Head Up to 100 feet with 200 feet of cable 5 Duty Cycle 100 6 Distilled or Demineralized Water coolant see section 3 3 for use where freezing may occur 7 Replaceable coolant filter 8 Pressure relief valve and by pass built in 2 10 GAS DISTRIBUTION SYSTEM 1 C...

Page 16: ...carefully in order to re use in case of a need to re ship the M 415 to another location 1 After unpacking inspect all items for obvious physical damage and loose parts If damage is evident contact a factory representative before using If water condensation is apparent dry the unit before using 2 All M 415 s are shipped with a variety of peripheral equipment such as gas hoses fittings manuals inclu...

Page 17: ... If antifreeze is required Arc Machines Inc recommends the use of a corrosion inhibitor and algaeside along with water or water mixture The present recommended water treatment is Optishield Plus manufactured by Opti Temp Corp and can be purchased from local welding supply Glycol mixtures can be purchased from Miller Electric for RF TIG applications available from local welding supply CAUTION It is...

Page 18: ...W stripe wire of the Cable is connected to Protective Earth Ground The other 3 wires red black and white or blue brown and black can be connected to phase A B and C in any order Remove the right side panel as directed in step 3 2 3 3 Perform the following steps to connect the input power 1 Set Up the Transformer taps for the input power The Main Transformer has a number of taps that must be connec...

Page 19: ...Model 415 Operation Manual Document No 740084 Revision N 14 ...

Page 20: ...INAL JUMPER SETTINGS 6 5 4 3 2 1 U1 12 11 10 9 8 7 V1 18 17 16 15 14 13 W1 575 VOLT TERMINAL JUMPER SETTINGS 6 5 4 3 2 1 U1 12 11 10 9 8 7 V1 18 17 16 15 14 13 W1 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...

Page 21: ...between 5 and 100 CFH on an appropriate gas supply 2 The Model 415 is supplied with a 15 foot Input Gas Hose with a standard 5 8 male NPS fitting on one end and a Bulkhead gas fitting on the other end 3 Connect the Input Gas Hose to the Flow meter NPS and to the BULKHEAD Input Gas Fitting at the rear of the Model 415 see Figure 1 Item 14 NOTE Automatic GTAW welding systems are very sensitive to ga...

Page 22: ...nnector 5 Connect the Service Adapter Cable weld head end to the Weld Head Service Cable gas coolant and electrode quick disconnects Be sure to install the Protective Boots on Fittings see Figure 3 Items 5 and 6 6 Connect the Ground Cable C Clamp to the pipe or object to be welded 7 Mount the Weld Head on the pipe or object to be welded Consult the Weld Head Operation Manual for details about Weld...

Page 23: ...nsformer terminal setup INTERNATIONAL TRANSFORMER TERMINAL JUMPER SET UP 200 VOLT TERMINAL JUMPER SETTINGS Document No 740084 Revision N 18 12 11 10 9 W1 8 7 6 5 V1 4 3 2 1 U1 220 VOLT TERMINAL JUMPER SETTINGS 12 11 10 9 W1 8 7 6 5 V1 4 3 2 1 U1 380 VOLT TERMINAL JUMPER SETTINGS 12 11 10 9 W1 8 7 6 5 V1 4 3 2 1 U1 415 VOLT TERMINAL JUMPER SETTINGS 12 11 10 9 W1 8 7 6 5 V1 4 3 2 1 U1 DOMESTIC USA T...

Page 24: ...Model 415 Operation Manual Document No 740084 Revision N 19 ...

Page 25: ...Model 415 Operation Manual Document No 740084 Revision N 20 ...

Page 26: ... and Excursion time is background EXT Will pulse from primary to background based on an external timing signal 6 LEVEL MODE AUTO Uses Level time to determine when to switch to the next level MANUAL Levels switch only from Pendant command manually made by operator POSITION Allows levels to advance based on weld head position in degrees or inches EXT Allows levels to advance based on an external inp...

Page 27: ...gas flows to the torch after Sequence Start and before arc start 2 START MODE Can be set to RF Start or Touch Start 3 TRAVEL MODE Determines which direction Clockwise or Counter Clockwise or OFF the Travel Servo will drive the motor when the Travel Servo is enabled 4 UPSLOPE Sets the time that the Current and the Oscillator will take to rise to Level I maximum values after arc start 5 TRAVEL START...

Page 28: ...Ground Fault Creates an ALL STOP condition if no ground return path is connected 6 AVC Mechanical Limit Creates a Sequence Stop if a weld head attempts to exceeds its AVC stroke User can disable function by weld head type 7 OSC Mechanical Limit Creates a Sequence Stop if a weld head attempts to exceed its Oscillator stroke User can disable function by weld head type 8 STUB OUT Detect Creates an AL...

Page 29: ... 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 2 MEMORY MEDIUMS The M 415 has a Built in 1 GB or greater hard drive 3 DATA BACK UP All information contained in the system hard drive...

Page 30: ...trode and the weld joint In TOUCH mode the AVC will perform a TOUCH START and initiate the arc can only be used with Weld Heads with an AVC function 3 EVENT 3 LEVEL 1 TIME START LEVEL UPSLOPE TRAVEL and WIRE START DELAY AVC START DELAY and OSC UPSLOPE When the arc is established the following functions all start at the same time 1 LEVEL 1 TIME When the arc is established all weld functions are con...

Page 31: ... arc is established depending on the weld schedule the current UPSLOPE OSC UPSLOPE and all START DELAYS Travel Wire AVC will be completed and all of the following functions will be in effect 1 LEVEL 1 TIME Will be counting towards 0 During its count all of the below functions will be occurring 2 LEVEL 1 PULSE MODE The PULSE MODE can be set in each LEVEL to work several different ways ON In the ON ...

Page 32: ...r the system is in Primary and the Wire Mode is set to ON 11 LEVEL 1 BACKGROUND WIRE After the Wire Start Delay is complete the Wire Feeder will feed at the Background Wire Feed value whenever the system is in Background and the Wire Mode is ON 12 LEVEL 1 AVC MODE The AVC can be set in each Level to work several different ways OFF Will prevent the AVC servo from operating CONT Allows the AVC to wo...

Page 33: ...MP value if pulsed and OSC AMPLITUDE will start to decrease towards 0 The time it takes to reach arc cutoff about 3 amp is called the DOWNSLOPE time and it is programmable 2 WIRE STOP DELAY TIMER At the end of the last Level the WIRE STOP DELAY time will start counting The WIRE will continue to feed until this time is complete When the wire quits feeding the wire will automatically retract go in r...

Page 34: ...Model 415 Operation Manual Document No 740084 Revision N 29 ...

Page 35: ...y must be connected Insure that all of these connections are per section 3 3 Plug in the AC power cable to the AC source Move the circuit breaker CB 1 to the ON position 4 After a few seconds the LOGO SCREEN will appear as shown in Figure 4 From this screen all system operations will begin NOTE If the input power is too low it is possible for the screens not to turn on or be scrambled If these con...

Page 36: ...y For AVC calibration the Weld Head must have the AVC function 400 Amp rating required 4 In place of the above mentioned weld heads or hand torch AMI makes an Optional External Current Shunt with or without a Variable Carbon Resistive Load call AMI Sales Dept for part number and availability 5 3 1 REQUIRED EQUIPMENT FOR WELD HEAD CALIBRATION 1 Dial Calipers 2 Tape Measure 5 4 MAIN REFERENCE VOLTAG...

Page 37: ...al measurements and for the external shunt option provided by AMI A weld schedule is required for the following calibrations The first time a calibration is done it will be necessary to CREATE a Calibration Weld Schedule Each section will outline all pertinent schedule elements need It is recommended that a single schedule be made with each calibration section programmed as a separate pass 1 Insur...

Page 38: ...asurements and any required adjustments are done Pulse Mode should be OFF so only the Primary Current Amps is checked The Primary Amps should be set to 200 for the Initial measurement Insure that the Travel Mode switch is set to OFF It is very important the calibration measurements are done quickly so not to melt the work piece A suggestion is to make the necessary connections to the PCB test poin...

Page 39: ... 1368246 01 shunt only or 1368248 01 shunt load bank kit Following voltages and tolerances assume that shunt is 1 amp mV at 0 1 2 Connect External Shunt into ground path cabling of weld head or load 3 DMM test leads must be connected only after Welding Current is established 4 Set the System Mode to WELD Press Sequence Start 5 Insert the DMM positive test lead into red test jack and the negative l...

Page 40: ... on the AVC OSC PCB P N 13D150313 01 located on the Servo PCB mounting plate in labeled slot B 0 1 Locate the AVC adjustment trim pot R 40 on the PCB diagram 4 DO NOT ADJUST TRIM POTS R 80 AND R 81 these are factory calibrated for use with special application weld heads or fixtures not discussed in this section R 40 R 80 R 81 DIAGRAM 4 4 To calibrate the AVC the user will need to have a Weld Sched...

Page 41: ... are factory presets that DO NOT REQUIRE FIELD CALIBRATION If you think someone has made adjustments to a factory preset trim pot call AMI Service Department for immediate support 5 8 WELD HEAD 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 ...

Page 42: ...e set for rotating weld heads programmed in RPM the time to rotate ONE REVOLUTION at the selected LEVEL 1 Primary Travel Speed For weld heads programmed in IPM such as a Model 15 the Level 1 Time needs to be set to give a measurable travel distance in inches or millimeters It is suggested to check calibration at a speed close to typical welding speeds being used and adjust the Level 1 time accordi...

Page 43: ...ct 0 0 Travel Start Delay 00 0 Travel Direction CCW Postpurge 000 Downslope 00 0 Wirefeed Stop Delay 00 Travel Stop Delay 00 Multilevel Functions Level Time 60 Pri Travel 0 0 Pri Amps 000 Travel Step CONT Pri Wirefeed 100 IPM Pulse Mode OFF NOTE Insure that all other programmable functions are not active or used during calibration INSURE THAT THE WELD TEST MODE IS IN TEST 4 Level 1 Time needs to b...

Page 44: ...mer 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 1 From the AMI Logo Screen Main Menu go to the File and select Log On A dialogue box titled User Logon will appear Enter the Logon name of ami lower case and the password of superuser also lower case Sel...

Page 45: ...CT DATA 5 13 GENERAL MAINTENANCE NOTE Calibration of the entire M 415 system is contained in the calibration section of the M 415 Maintenance Manual Weld Head Travel and Wire Feed Calibration is contained in steps 5 10 and 5 11 of this section WARNING Always disconnect the AC power cable from the line voltage before attempting any repairs to this welding power supply 1 AIR FILTERS The M 415 power ...

Page 46: ...ome type of blockage of air circulation fan failure or component failure within the Power Supply OR THE SYSTEM IS BEING OPERATED IN AN AMBIENT AIR TEMPERATURE BEYOND ITS RATED 110 DEGREES F This Fault should only occur during an actual weld sequence If it occurs when the machine is not welding then a serious internal problem exists In this case turn the Power Supply OFF and call an AMI service rep...

Page 47: ...n a BAD START occurs check the electrode connection and electrode condition first Also check to insure that CERRIATED electrodes are being used They have proven to be much more effective than THORIATED electrodes for RF transmission and longer life BAD STARTS can also be caused by not having the START LEVEL set properly RF starting problems can be very difficult to solve because of all the items t...

Page 48: ...g Software using the M 415 Display or for M 415 Remote Software using a PC 1 From the AMI Logo Screen main menu select Setup From the drop down menu select System A dialogue box titled M415 Power Supply System Setup will appear 2 Use the combo box located under Language to select the language file you wish to change to 3 Press OK A Message Box will appear noting that you need to exit the program a...

Page 49: ...lect Language File Transfer 2 A dialogue box titled Select Files to Copy and Press Open will appear The list box will show the language files that are available Select the language file that is not already in the program such as the one you just edited or created then select Open Another dialogue box will open titled Select Destination Folder In the list box next to Look in use the scroll key and ...

Page 50: ...welding select Typical Tube If almost everything about the weld head is unique then select Blank When done select OK A dialogue box called Weld Head Wizard the model number you entered will appear Setting up the Weld Head Wizard is now basically an Editing function At this point proceed to 5 18 2 3 for editing information 2 EDITING A WELD HEAD TEMPLATE 1 After using the correct Logon and Password ...

Page 51: ... and then select Manipulators Defs A tab box with 8 tabs one for each manipulator slot will appear Select the tab for the Manipulator to be activated then check the Used box This will activate the definition slots to define name program value for voltage and current limits Program as required and then select OK 5 Set Pendant 4 way arrow Button function On the pendant there is a 4 way arrow button ...

Page 52: ...bo box will appear showing all the multi level and single level functions in the order they appear on a weld schedule To change the order click and drag the function to the desired order of appearance Select Finished 5 18 CMOS Battery Replacement 1 Required Equipment 2 Phillips screw driver CR2032 battery Document 45D150143 2 Procedure Power off the M415 Power Supply Using the screwdriver remove t...

Page 53: ...therboard 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 ...

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