AMI 415, Operation Manual, Page: 43 / 53

Model 415
Operation Manual
Document No. 740084
Revision N
38
5.10 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. If in doubt they should always be checked to
insure that they are calibrated. To check the Wire Feed calibration of a Weld Head perform the
following steps:
1. Insure that the weld head is connected per section III and the Weld Head manual. Wire Feed
calibration is done by feeding the wire and measuring actual speed. Before proceeding
CHECK THAT THE HEAD IS FREE TO FEED WIRE SAFELY
2. 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
3. A Wire Feed calibration schedule will always be run in TEST Mode and usually contains the
following:
Onelevel Functions
Prepurge 000 Level Advance Time 1.0
Upslope 00.0 Start Mode RF
Wirefeed Start Delay 00.0 Wirefeed Retract 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 be set for 60 seconds (1 minute). Pulse Mode should be OFF so only
one Wire Feed Speed is checked (primary). The Wire Feed Primary IPM on most weld
Heads should be set to 50 or 100 IPM or equivalent meters (or a rate closer to actual weld
schedules being used) . Insure that the Wire Mode switch is set to ON.
Note that no Start Delays or Stop Delays are used. It is very important for calibration that the
wire start feeding at the beginning of the of the Level 1 Time and stop at the end of
the Level 1 Time.
5. Create or recall from the LIBRARY the appropriate Weld Schedule and connect the Weld
Head to be calibrated. Insure that the system is SAFE to feed wire and that the System
Mode is in TEST.
6. Jog the wire until it is at the end of the nozzle but not protruding.
7. Press Sequence Start. Wire should feed for 60 seconds. When Sequence is over cut the
wire flush with the nozzle and measure. It should be whatever value was programmed. If it is
not adjust the Wire Feed Cal Potentiometer on the Weld Head. Repeat step 6 and 7 until the
wire is calibrated.