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Doc No. 740123

4

MODEL 8 SERIES WELD HEAD

OPERATION MANUAL

3.0 CABLE HOOK UP

(Contd.)

Fig. 2
To connect the male to female (chrome) gas fittings, unscrew the (4-40) socket
head screw to allow the latch to open far enough to fully seat the two fittings.
Lightly tighten this screw to prevent accidental disconnection of this fitting.

Fig. 3
Connect the motor control connector by aligning the key to the slot, and lightly
tightening the outer ring. Be careful not to cross-thread this ring.

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Summary of Contents for M8 Series

Page 1: ...OPERATION MANUAL M8 SERIES WELD HEADS ...

Page 2: ...tions and data without notice WARNING The nature of the GTAW process creates some POTENTIAL HAZARDS In accordance with international safety regulations the EXCLAMATION SYMBOL indicates that this equipment is considered HAZARDOUS until an operator has been made aware of these POTENTIAL HAZARDS by reading the appropriate Arc Machines Inc Power Supply and or Weld Head Operation Manual The LIGHTNING F...

Page 3: ...3 2 0 Unpacking 3 3 0 Cable hook up 3 4 0 Water Cooling 5 5 0 Rotation speed Auto Calibration 5 5 2 Rotation speed Manual Calibration 6 6 0 Clamp Insert Installation 7 7 0 Electrode Geometry Installation 9 8 0 Shielding Gas 13 9 0 Return to home rotor position adjustment 14 10 0 Cleaning maintenance 16 11 0 Storage 17 ...

Page 4: ...making any cable connections The Model 8 series weld heads come supplied with an integral 10ft 3 m cable This cable is NOT connected directly to the power supply It must be mated to the power supply via an adapter pig tail or adapter cable Extension cables may also be used The use of an extension cable does not eliminate the requirement for an adapter If an extension cable is used it is connected ...

Page 5: ...s unscrew the 4 40 socket head screw to allow the latch to open far enough to fully seat the two fittings Lightly tighten this screw to prevent accidental disconnection of this fitting Fig 3 Connect the motor control connector by aligning the key to the slot and lightly tightening the outer ring Be careful not to cross thread this ring ...

Page 6: ...avier or when doing high duty cycle work Consult the factory for recommendations 5 0 ROTATION SPEED AUTO CALIBRATION Before welding the electrode rotation motor in the weld head must be calibrated to the power supply Most power supplies include an auto calibration function in the software Refer to the power supply operation manual for specifics on auto calibration 5 1 Should the power supply indic...

Page 7: ...and corresponding time close to or equal to the speed that you intend on welding at to achieve the most accurate calibration 5 3 The power supply must be in the TEST mode Create a one level weld schedule at your selected RPM Amperage and pulse rate settings may be set to any value as during rotation calibration no arc will be established Set rotation mode to CONT continuous rotation Set rotation d...

Page 8: ...to be welded A set of clamps fits one side of the weld head Except for some special applications or when using the Model 8 with a gas seal on one side and a clamp on the other two sets of clamps are required One set fits on each side of the head CAUTION Use of the wrong size clamp or clamping the head on the curved section of an elbow or other irregular surface can result in damage to the clamp in...

Page 9: ...s practical by manual tack welding the two components together first and mounting a gas seal on the side of the weld head where this fitting is to be positioned The hole in the gas seal is designed to be approximately 1 8 3mm larger than the diameter of the fitting being welded to allow shielding gas to escape Before welding the gas seal must be positioned around the fitting so the 1 16 gap betwee...

Page 10: ...electrodes The mounting holes in the rotor are approximately 180 degrees apart CAUTION Do not install a 1 16 electrode into the 3 32 electrode mounting hole and never install more than one electrode 7 1 The ceramic heat shield installed in the rotor is to be used in either the 1 16 or 3 32 electrode position If it is mounted in the wrong location remove the two button head screws that hold the hea...

Page 11: ... 7 Use this chart to establish an appropriate Arc Gap and Electrode Tip diameter Tube Pipe Wall Thickness Recommended Arc Gap Recommended Tip Diameter 0 020 0 035 5 1 0mm 0 020 0 030 0 5 0 8mm 0 010 0 20 25 50mm 0 035 0 085 1 0 2 1mm 0 050 0 070 1 3 1 8mm 0 030 0 8mm 0 091 0 154 2 3 3 9mm 0 070 0 090 1 8 2 3mm 0 040 1 0mm Fig 8 Use the formula below along with your Rotor O D and Arc Gap to establi...

Page 12: ...0 040 or 1 16 1 0 or 1 6mm 0 049 0 083 1 2 2 1mm 1 16 1 6mm 0 091 0 154 2 3 3 9mm 3 32 2 3mm Fig 10 Fig 11 7 3 Using the JOG button on the power supply or remote operators pendant jog the rotor around until the electrode or electrode mounting hole is in the 12 o clock position See fig 12 7 4 Lay the weld head on its side to prevent accidental dropping of the electrode into the weld head Loosen the...

Page 13: ...er in order for the electrode to be properly seated against the electrode stop roll pin 7 3 Install the electrode from the rotor I D as shown in fig 13 Tighten the electrode set screw when the electrode is fully seated against the electrode stop roll pin If the electrode is not fully seated against this pin the arc gap between the electrode and the tube will be incorrect Fig 13 ...

Page 14: ...commonly used shielding gas and backup I D purge gas used is Argon Gas mixtures of 95 Argon 5 Hydrogen or 75 Helium 25 Argon are sometimes used to achieve deeper penetration Consult the factory for recommendations 8 1 The Model 8 series weld heads work best when the arc gas is set to the proper flow rate Excessive flow rates can blow the arc and flow rates set too low can cause excessive weld oxid...

Page 15: ...he system is being hooked up for the first time or if it has been a number of hours since it was last used it s a good idea to initiate the manual purge button on the power supply to clear the lines of oxygen for a few minutes before initiating a weld sequence 9 0 RETURN TO HOME ROTOR POSITION ADJUSTMENT The Model 8 series weld heads will return the rotor to the home open position at the end of th...

Page 16: ...s 9 1 Be sure the power supply is either turned off or in the TEST mode 9 2 Remove the access plate See fig 17 9 3 Loosen the screw that holds the bracket attached to the return to home limit switch See fig 17 9 4 Slide the limit switch bracket slightly toward the rotor to stop the rotor sooner or slightly away from the rotor to stop the rotor later and re tighten the bracket screw Fig 17 ...

Page 17: ...ts Keep the cap on the electrical multi pin connector when not in use From time to time depending on the cleanliness of the tube pipe being welded the type and quality of the arc gas and the number of welds done the rotor and weld head housing will build up soot which should be cleaned on a regular basis 10 1 Use isopropyl alcohol and Scotch Brite or steel wool to clean the both brass male and fem...

Page 18: ... not be storing the adapter and or extension cables leave them hooked up to the weld head when purging out the water 11 1 To drain the coolant from the weld head and cables use Arc Machines Inc fitting part number 294 PB 06 Unplug the water supply line from the cooling unit leaving the water return line connected to the cooling unit and attach the female fitting 294 PB 06 to the disconnected suppl...

Page 19: ...L 8 SERIES WELD HEAD OPERATION MANUAL 11 0 STORAGE cont d 11 2 Attach the dust cap to the electrical connector and store the weld head in a clean dust free area 11 3 Store the head with the clamp housing latches un latched ...

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