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Doc No. 740124

11

MODEL

9 SERIES WELD HEAD

OPERATION MANUAL

7.0 ELECTRODE GEOMETRY & INSTALLATION

(cont’d.)

Use the formula below, along with your Rotor O.D. and Arc Gap to

establish the electrode length.

Fig. 11

Fig. 12

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Summary of Contents for M9 Series

Page 1: ...M9 SERIES WELD HEADS OPERATION MANUAL ...

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 14 9 0 Return to home rotor position adjustment 15 10 0 Cleaning maintenance 17 11 0 Storage 18 ...

Page 4: ...0 CABLE HOOK UP CAUTION Always turn the power supply off before making any cable connections The Model 9 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 requireme...

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: ...the other water cooled models 9 series heads In addition water cooling should always be used when doing high duty cycle work regardless of the tube wall thickness 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 t...

Page 7: ...ve auto calibration software In this case the weld head motor is manually calibrated by creating a weld program that should rotate the electrode 360 degrees ie 1 RPM for a total of 60 seconds 2 RPM for a total of 30 seconds 3 RPM for a total of 20 seconds etc Select a speed RPM and corresponding time close to or equal to the speed that you intend on welding at to achieve the most accurate calibrat...

Page 8: ...el 6 0 CLAMP INSERT GAS SEAL INSTALLATION Clamp inserts are designed for a specific tube or pipe size Select the appropriate clamp for the specific tube or pipe to be welded A set of clamps fits one side of the weld head Except for some special applications or when using a model 9E or 9ER type weld head two sets of clamps are required One set fits on each side of the head Note A set of clamp inser...

Page 9: ...lded Components such as elbows or other non straight or odd shaped parts will sometimes require repositioning of the gas seal to facilitate approximately a 1 16 1 6mm gap all around the part being welded This gap is used to allow arc gas to exit the weld head and to minimize gas seal burning The four mounting holes in the gas seal are large enough to allow the gas seal to be positioned as required...

Page 10: ...ions Most Model 9 series heads accommodate two electrode sizes Either 0 040 1 0mm and 1 16 1 6mm or 1 16 1 6mm and 3 32 2 3mm diameter The mounting holes in the rotor are approximately 180 degrees apart CAUTION Do not install an 0 040 electrode into the 1 16 electrode mounting hole or a 1 16 electrode into a 3 32 electrode mounting hole and never install more than one electrode 7 1 The electrode l...

Page 11: ... 5 776 146 71mm 9 4500 w elect extender 4 920 124 97mm 9 7500 10 440 265 18mm 9E 7500 9 375 238 12mm 9 7500 w elect extender 8 280 210 31mm Fig 8 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...

Page 12: ...No 740124 11 MODEL 9 SERIES WELD HEAD OPERATION MANUAL 7 0 ELECTRODE GEOMETRY INSTALLATION cont d Use the formula below along with your Rotor O D and Arc Gap to establish the electrode length Fig 11 Fig 12 ...

Page 13: ...prevent accidental dropping of the electrode into the weld head Loosen the electrode set screw See fig 13 Fig 13 Note Insure that the electrode mounting hole is free of foreign matter If required use isopropyl alcohol to clean the rotor Catch rinsate with a lint free cloth 7 5 Install the electrode from the rotor O D being sure to position the electrode flush with the rotor O D outside diameter Us...

Page 14: ...INSTALLATION cont d Fig 14 Install the electrode so the back end is flush with the rotor outside diameter Caution Do not leave any part of the electrode protruding past the rotor O D 7 6 Two spare electrode set screws may be found in the weld head cover See Fig 15 Fig 15 Model 9 2500 ...

Page 15: ...power supply to open the solenoid and set the flow rate on your flow meter at your gas source 8 2 Prepurge time and post purge time are also factors in minimizing weld oxidation and extending electrode life Refer to chart below for recommended arc gas flow rates and minimum recommended pre post purge times Note The chart below Fig 16 indicates the minimum recommended purge times Using longer purge...

Page 16: ...ed rotor will stop with both ends of the rotor flush or slightly recessed in the housing A rotor that needs adjustment will either stop with one side of the rotor protruding out from the housing or in a worst case the rotor does not stop at all after it returns to home in which case the power supply would have to be shut down before attempting any adjustment See fig 17 Fig 17 Should your Model 9 r...

Page 17: ...OSITION ADJUSTMENT cont d 9 3 1 For Models 9 2500 9 3500 9 4500 9 7500 and other heads in this series loosen both screws that hold the return to home limit switch bracket See fig 19 Fig 18 Models 9 750 9 1500 series weld heads Fig 19 Models 9 2500 9 3500 9 4500 9 7500 series weld heads ...

Page 18: ...LEANING AND MAINTENANCE All of the connectors at the end of the cable must be kept clean and free of grease oil dirt or other contaminants 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 w...

Page 19: ...ose internals Although you may 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 P...

Page 20: ... MANUAL 11 0 STORAGE Cont d CAUTION DO NOT USE AIR PRESSURE ABOVE 20 PSI 139 Kp 1 38 Bar 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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