AMI 415, Operation Manual, Page: 47 / 53

Model 415
Operation Manual
Document No. 740084
Revision N
42
4. SENSOR 1, 2, - These faults must be turned on and set up by the user. Contact whoever set
them up.
5. STUB OUT - This fault will only occur when an arc is present and will no longer exist when
the arc goes out. If the arc voltage gets to low or the electrode should touch the weld puddle
then a fault will occur. It creates an ALL STOP but does not operate the “return to home”
function after Postpurge.
The operator should check to see if the electrode is stuck to the tube being welded. Clear
the obstruction and jog the rotor to open position, remove the tube and replace the electrode
and then press the C key to clear the fault.
Check the required tungsten length and arc gap required for the weld. Something
caused the arc gap to get too small in the first place.
6. HIGH VOLTS - If the arc voltage gets too high during a weld sequence this fault will occur. It
usually occurs if a hole should be made in the weld and the arc can extend over to the opposite
side of the weld , Check the weld procedure and the arc gap required for the weld.
7. BAD START - If for any reason the M-415 cannot achieve a stable Arc at the end
of PREPURGE the system will display this statement.
There can be several reasons for this to occur. The most common are poor cable,
ground and electrode connections, bad gas, bad tungsten, dirty tungsten, etc.
The RF is transmitted from the M-415 to the electrode, if anything creates
resistance or an alternate path for the RF the start can be weak.
When 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 that
can cause problems. If continued RF problems occur call the AMI Service Dept.
for help in finding the problem .
8. ILLEGAL OPERATION – From time to time the Windows Operating system has been known to
perform an "illegal Operation" which will essentially freeze the processor and prevent any type
of operator input or control. Every effort has been made to eliminate as many of these as
possible. However, it is still possible for an "illegal Operation" to occur. If it does the system, if
in Sequence, will automatically create a downslope and display the "illegal
Operation" dialogue box.
If not in weld sequence just the dialogue box will appear. If this occurs the user must turn the
power supply off and then on again to re-boot the system.
5.15 RE-SHIPPING
CAUTION
DRAIN COOLANT from POWER SUPPLY AND ALL HOSES BEFORE SHIPPING.
1. The Coolant Tank on the Model 415 Power Supply is not designed as a shipping container.
If the machine is tipped or oscillated coolant liquid may be released into the power supply
workings, damaging internal components.
2. The Coolant in hoses may freeze causing tubing to split during transportation.
CAUTION
Used Coolant is considered a hazardous waste. Dispose of used coolant and or materials used to
clean up coolant spills or leaks in a manner approved by your local governmental regulations.