AMI 205 Operator'S Manual Download

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Part No. 740108
Revision J

Model 205 Tube Welding Power Supply

Operator’s Manual

Summary of Contents for 205

Page 1: ...Part No 740108 Revision J Model 205 Tube Welding Power Supply Operator s Manual ...

Page 2: ... source with flow meter and the appropriate weldhead NOTICE This document and the information contained herein is the property of Arc Machines Inc It is proprietary and submitted and received in confidence It shall be used only for the purpose for which it is submitted and shall not be copied in whole or in part without the prior express written permission of Arc Machines Inc The information in th...

Page 3: ...ection 6 1 2 with correct weight 06 16 10 D C F 5817 Incorporate S W v1 5 corrections for CE changes add power grounded to section 2 0 update obsolete data 12 08 10 D C G 6346 Incorporate M21 W H information add changes to Run screen add Associated Data look up tables add information on system initiate 0 5 second delay add information on 1 1 buttons update UK address 06 15 12 D C H 6518 Section 6 ...

Page 4: ...L SETUP 8 3 1 SYSTEM SYMBOLS 8 3 2 INSPECTION 10 3 3 POWER CONNECTION 11 3 4 WELDING GAS CONNECTIONS 11 3 5 MODEL 205 TO M8 M9 WELDHEAD HOOK UP 12 3 6 MODEL 205 TO EXEL ROTOR DRIVER HOOK UP 16 3 7 MODEL 205 TO M21 WELDHEAD HOOK UP 17 4 0 OPERATION 18 4 1 SYSTEM FUNCTIONS 18 4 2 INITIAL POWER ON 20 4 3 SET UP FUNCTIONS 21 4 4 OPENING THE LAST WELD SCHEDULE 25 4 5 SELECTING A WELD SCHEDULE FROM THE ...

Page 5: ...L indicates that this equipment is considered HAZARDOUS The LIGHTNING FLASH SYMBOL indicates that there are potential electrical hazards The use and display of these symbols make it the OPERATOR S RESPONSIBILITY TO ENSURE THAT HE HAS READ AND OR BEEN MADE AWARE OF ALL OF THE SAFETY RELATED ITEMS CONTAINED IN THIS MANUAL 1 1 SHOCKHAZARDWARNING HIGH VOLTAGE is present on exposed internal terminals T...

Page 6: ...erators of this equipment must take all precautions necessary to avoid contact with the ELECTRODE at ALL TIMES The only exception is when actually replacing or adjusting the electrode and this should be done WITH THE POWER TURNED OFF If performed with the power ON the system must be in TEST mode out of weld sequence and the USER MUST OBSERVE COMMON SAFETY PRACTICES such as grounding the electrode ...

Page 7: ...ld near FLAMMABLE or EXPLOSIVE MATERIALS Have the proper type of extinguisher in the work area WEAR NON FLAMMABLE protective clothing footwear and head gear at all times HOT PARTS can cause severe burns Do not touch recently welded components Avoid touching torch components and welding fixtures soon after welding ARC RAYS can burn the eyes and skin The welding arc emits ultra violet UV radiation a...

Page 8: ...all Welding Operators and Maintenance Technicians who operate AMI equipment WELDING WIRE and ELECTRODES are sharp and can cause injury MOVING PARTS may cause crush or pinch points WARNING Disconnect the input power to the machine before opening or servicing Discharge all circuits that store high voltage such as capacitor packs Only AUTHORIZED and QUALIFIED service personnel should open this equipm...

Page 9: ...e moved with appropriate equipment and safety precautions Gas tanks should be securely anchored to prevent toppling over 2 1 ELECTRICAL INPUT POWER DETAIL The Model 205 can operate on the following Auto Adjusting for Single Phase AC input Input Power Single Phase AC Rated Welding Output Welding Amperage Range Max OCV DC Up Rated Peak Starting Voltage Up Amperes Input At Rated Load Output 50 60Hz S...

Page 10: ...ut current The Model 205 system has an internal thermal sensor that will limit operation should the temperature exceed the safe operating parameters 2 2 ELECTICALSERVICEGUIDE FUNCTION RANGE INPUT VOLTAGE 115 230 INPUT AMPERES AT RATED OUTPUT 13 1 MAX RECOMMENDED STD FUSE RATING IN AMPERES CIRCUIT BREAKER TIME DELAY NORMAL OPERATING 15 20 MIN INPUT CONDUCTOR SIZE IN AWG 14 MAX RECOMMENDED INPUT CON...

Page 11: ...rammed at each level to change value during a given weld sequence FUNCTION RANGE LEVEL POSITION 0 9999 degrees LEVEL DEGREES 0 9999 degrees SLOPE DEGREES 0 9999 degrees TIME 0 1 999 9 seconds SLOPE TIME 0 0 999 9 seconds PRIMARY AMPS 5 0 150 0 amps BACKGROUND AMPS 5 0 150 0 amps PRIMARY TRAVEL As defined by Weldhead BACKGROUND TRAVEL As defined by Weldhead PRIMARY PULSE 0 01 9 99 seconds BACKGROUN...

Page 12: ...EMSYMBOLS The following symbols are present on the Model 205 version 13B050100 02 Revision NC and up WARNING Read this manual This document contains information that could help prevent injury or damage to the equipment 115 230 VAC INPUT AC mains input 100 240 volts AC 50 60 Hz ON OFF On Off switch circuit breaker ARC GAS INPUT input for the arc shielding gas An external regulator and flow indicato...

Page 13: ... ELECTRODE weldhead ground and electrode connections ARC GAS OUTPUT output for the arc shielding gas connection WELDHEAD CONTROL weldhead motor control Intended for AMI and EXEL weldheads only The optional water cooler M205 CW is marked with the following symbols WATER RETURN cooling water input WATER OUT cooling water output Cooling liquid tank fill opening ...

Page 14: ...or connections or inert gas leaks could occur Ensure that all cables are routed and protected in such a way that they will not be subject to heat or equipment personnel traffic Ensure that the cables DO NOT come in contact with HOT PIPE For operation the Model 205 must be placed on a flat level surface capable of supporting the weight of the unit cables and any other options The Model 205 can be m...

Page 15: ... circuit conductor Neutral Black Ungrounded circuit conductor Line 2 Ensure that the circuit breaker is in the down or OFF position 3 Connect the AC line connector to the power cord Do not connect the Model 205 to the AC power source until all installation steps are complete 3 4 WELDINGGASCONNECTIONS The Model 205 is intended for typical GTAW gases ONLY NEVER CONNECT OXYGEN OR ACETYLENE TO THE MOD...

Page 16: ...iquid cooled weldheads connect to the Model 205 via a short pig tail or via an adapter cable If needed an extension cable can be used The extension cable connects to the Model 205 then to the weldhead for non liquid cooled weldheads or to the adapter cable for liquid cooled weldheads Pig tail Connections 1 Connect the ground and electrode brass quick disconnect fittings on the pig tail to the mati...

Page 17: ...on the adapter cable to the mating fittings on the weldhead Pull the knurled ring on the female fitting back and fully insert the male fitting These connectors are fully seated when the ring will spring back to its original position Slide the rubber boots together and secure them in place being careful not to dislodge the connectors Male boots should cover the connection first The boots protect th...

Page 18: ...he lock screw on the male connectors 6 Attach the weldhead control male connector on the adapter cable to the WELDHEAD CONTROL connector on the Model 205 Note the positioning keyway and NEVER FORCE or use tools on the cable connectors Hand tighten the connecting ring being careful not to cross thread the ring 7 Insert the male gas quick disconnect fitting on the adapter cable to the mating ARC GAS...

Page 19: ...M O D E L 2 0 5 O P E R A T O R S M A N U A L 15 15 15 15 Fig 2 Hookups for Liquid Cooled Weldheads ...

Page 20: ...il fully locked 2 Attach the weldhead control male connector on the rotor driver to the WELDHEAD CONTROL connector on the Model 205 Note the positioning keyway and NEVER FORCE or use tools on the cable connectors Hand tighten the connecting ring being careful not to cross thread the ring 3 Insert the male gas quick disconnect fitting on the rotor driver to the mating ARC GAS OUTPUT connector on th...

Page 21: ... A L 17 17 17 17 3 7 MODEL205TOM21WELDHEADHOOKUP Always turn the power supply off before making any cable or connection changes to the power supply Note Note for hook up of the M21 weldhead see the Model 21 Weldhead Operation Manual P N 740122 ...

Page 22: ...ent 4 1 SYSTEMFUNCTIONS The Model 205 is intended for use with AMI or EXEL orbital welding heads and has functions designed for these weldheads This section describes what these functions are and may where needed for clarification indicate how they are commonly but not always used LIBRARY The heart of the Model 205 is its MEMORY The values of each parameter for a given weld are only programmed one...

Page 23: ...ting both the PRIMARY and BACKGROUND PULSE timers FAULT STATUS The system monitors arc gas flow arc volts and power supply temperature If any of these functions fall outside certain limits the system will alert the operator and weld schedule will be halted See Section 5 3 GAS FUNCTIONS As stated the Model 205 is intended for the GTAW process This process requires a welding gas usually inert for op...

Page 24: ... AC power cable to the AC source and to the 115 230 VAC INPUT connector on the Model 205 Move the circuit breaker to the ON position 3 If the Model 205 CW is installed connect the AC cord to 110 or 220 VAC single phase power Set the ON OFF switch to the ON position Note The Model 205 CW contains a flow sensor The green lamp indicates that there is sufficient flow If this lamp goes out either the w...

Page 25: ...creen press SETUP 2 From the SETUP screen select each Date and Time field to be changed Enter the new date and time data on the 10 key pad then press ENTER When all data has been entered press the SET DATE TIME button to set the new date and time PASSWORD SETTING The Model 205 can be set up to require a password entry to use the machine Your unit is shipped to you with no password requirement 1 OP...

Page 26: ...ess YES on the Shut Windows screen Wait for the screen to go blank before turning off the circuit breaker TO DELETE OR CHANGE A PASSWORD 1 From the HOME screen press SETUP 2 From the ENTER PASSWORD screen enter the Programmer password 3 You may now select which password to delete or change by pressing CHANGE OPERATOR PASSWORD CHANGE SUPERVISOR PASSWORD or CHANGE PROGRAMMER PASSWORD and follow the ...

Page 27: ...uire more letters than others To fit additional characters into all fields the font style and or size may need to be changed 1 From the HOME screen press SETUP 2 From the SETUP screen press ADD LANGUAGE 3 Select the language to be changed 4 Press CHANGE FONT 5 Select a different Font Style and or Size and press OK 6 Press SAVE to overwrite this language or enter a new name in the LANGUAGE NAME tex...

Page 28: ...he SETUP screen press ADD LANGUAGE 4 From the ADD LANGUAGE screen press ADD LANGUAGE FROM EXT MEMORY 5 When the Windows Open screen displays select the language file in the external memory to be added lgv file 6 Press OK When adding a language from external memory the language MUST be formatted for the Model 205 software otherwise the screens will be corrupted when this language is selected ...

Page 29: ...are stored in the library 1 From the HOME screen press OPEN LAST 4 5 4 5 4 5 4 5 SELECTINGAWELDSCHEDULEFROMTHELIBRARY SELECTINGAWELDSCHEDULEFROMTHELIBRARY SELECTINGAWELDSCHEDULEFROMTHELIBRARY SELECTINGAWELDSCHEDULEFROMTHELIBRARY Skip to Step 4 8 if no weld schedules are stored in the library 1 From the HOME screen press LIBRARY 2 Weld schedules will be listed from newest to oldest Select a weld sc...

Page 30: ...dules by DIAMETER WALL or MATERIAL Select one or more of these categories from the 3 drop down lists select the weld schedule then press LOAD 4 6 MODIFYAWELDSCHEDULE Skip to Step 4 8 if no weld schedules are stored in the library 1 From the HOME screen press OPEN LAST to modify the last weld schedule loaded or LIBRARY to select and load a weld schedule from the Library ...

Page 31: ...27 27 27 27 2 From the RUN screen press SCHEDULE 3 The first parameters displayed are the SINGLE ENTRY parameters The MULTI LEVEL parameters and ASSOCIATED DATA parameters are accessed by using the NEXT button on each screen Single Entry Parameters ...

Page 32: ...28 28 28 Multi Level Parameters Associated Data Parameters 4 Select each field to be modified and enter the text or value via the on screen alpha numeric keyboard or 10 key pad then press the RETURN or ENTER key The changes will automatically be saved ...

Page 33: ...0 TC04 0626 02 0 500 0 563 0 040 TC04 0563 02 RTU 008 1 814 0 035 0 125 0 809 0 040 TC04 0809 02 0 250 0 746 0 040 TC04 0746 02 0 375 0 685 0 040 TC04 0685 02 0 500 0 622 0 040 TC04 0622 02 0 625 0 560 0 040 TC04 0560 02 RTU 016SL 2 628 0 040 0 500 1 024 0 062 TC06 1024 02 0 750 0 899 0 062 TC06 0899 02 1 000 0 772 0 062 TC06 0772 02 RTU 032 3 75 0 045 0 500 1 580 0 062 TC06 1580 02 0 750 1 456 0 ...

Page 34: ...all weld schedules stored in the Model 205 Library and save them to a USB Memory stick or copy one or all weld schedules on a USB memory stick and save them to the Model 205 Library Copy a weld schedule in the Model 205 Library 1 From the HOME screen press LIBRARY then select the weld schedule to be copied 2 Press COPY Enter a new schedule name and press either SAVE or RETURN The new schedule will...

Page 35: ...3 From LIBRARY press VIEW USB Copy one or all weld schedules in the Model205 Library and save to a USB memory stick 1 Insert a USB memory stick into the USB port on the Model 205 2 From the HOME screen press LIBRARY 3 Select a weld schedule to be copied and press COPY 4 For copying one weld schedule to a USB stick press COPY TO USB For copying ALL weld schedules to a USB stick press COPY ALL TO US...

Page 36: ...es from a USB memory stick to the Model 205 Library 1 Insert a USB memory stick into the USB port on the Model 205 2 From the HOME screen press LIBRARY then press VIEW USB 3 Select the weld schedule to be copied and press COPY TO M205 If copying all weld schedules press COPY ALL TO M205 ...

Page 37: ...edule NAME 3 Enter the DIAMETER WALL and MATERIAL 4 Press the WELDHEAD MODEL field and select the weldhead that you will be using Note Use the ENTER key on the displayed 10 key pad or the RETURN key on the displayed keyboard to SAVE each entry before making an entry into the next field Note The Name Diameter Wall and Material will be displayed in the Library The Diameter Wall and Weldhead Model wi...

Page 38: ...se of the weld rather than stepping it down via multiple levels This ramping is programmed by selecting a starting amps START AMPS a background amps and an ending amps END AMPS Over the course of the weld the amps will ramp down to the value programmed into END AMPS while pulsing between the ramping down starting amps value and the background amps value Auto Continuous Travel this version of autom...

Page 39: ...g sequence sequential or balanced 4 9 4 9 4 9 4 9 WELDHEAD WELDHEAD WELDHEAD WELDHEAD CALIBRATION CALIBRATION CALIBRATION CALIBRATION Any time a different weldhead or weld schedule is selected the weldhead must be calibrated to that weldhead and schedule 1 Load the weld schedule from the Library When the RUN screen opens press CALIBRATE 2 Check to be sure that it is safe to run the weldhead rotati...

Page 40: ... the weldhead per Section 3 5 and the specification sheet for the weldhead 2 From the HOME screen press the LIBRARY key select a weld schedule and press LOAD or use the OPEN LAST key to access the last schedule used 3 Before performing the weld calibrate the weldhead to the schedule being used per Section 4 9 This is required when a different schedule and or weldhead is used 4 Install the correct ...

Page 41: ... TEST font on the button turns yellow to indicate which mode the system is set to 7 When you are ready to start welding press the WELD TEST button to put the power supply in WELD mode 8 Press START to initiate the weld The center of the RUN screen displays a count down of each weld sequence Note For M21 weldheads refer to theModel21WeldheadOperationManual on how to initiate and stop a weld sequenc...

Page 42: ...p up to the programmed Level 1 PRIMARY AMPS value When an UPSLOPE is not programmed the arc will be initiated at the Level 1 PRIMARY AMPS value Once the arc is established and PULSE MODE programmed to ON the weld current will pulse between the PRIMARY and BACKGROUND amp values The amount of time it remains at these values is determined by the PRIMARY and BACKGROUND PULSE times In most cases rotati...

Page 43: ...PE at the end of the last level over the course of the programmed DOWNSLOPE time both primary and background amps will ramp down while continuing to pulse until the arc is extinguished EVENT 6 POSTPURGE once the arc is extinguished the POSTPURGE time begins counting down During this time the arc gas continues to flow into the weldhead EVENT 7 RETURN TO HOME at the end of the POSTPURGE the gas will...

Page 44: ...een 2 Enter data in each of the fields Note Power Supply Model Number Power Supply Serial Number and Weldhead Model Number are already stored in the system so these fields are automatically filled Note The ONLY required field is Weld ID and it must be unique If a non unique value is entered Weld Camino de las Estrellas ID that has already been used an error message will be displayed 3 Press WDR EN...

Page 45: ...tton turns yellow if Weld Data Recording is enabled AND Weld Test is set to Weld 3 Press START to start the weld sequence and the Weld Data Recording Note The font on the WDR button turns red while the weld data is being recorded Export Weld Data Record 1 Insert a USB memory stick into the USB port on the Model 205 2 Press WDR to return to the Weld Data Recording screen ...

Page 46: ...led when BOTH the Source and Destination fields are filled The Destination will normally be the D drive which is the USB memory stick 5 Repeat steps 3 and 4 to export additional WDR files 6 Remove the USB memory stick and load on a PC to view print the weld data record s Note The exported weld data record s will be in csv format and can be opened in Microsoft Excelor Notepad ...

Page 47: ...a coating of dirt and dust Do not use shop air to blow dust particles away from the panels since it is usually too wet Use a vacuum cleaner with a soft brush Where a vacuum brush cannot reach use a clean soft paint brush and then vacuum INPUT OUTPUT PANEL CONNECTIONS periodic inspection of the Model 205 panel as well as electrode gas water return quick disconnects on all cables should be performed...

Page 48: ... extreme care to avoid dropping the power supply or the weldheads Always disconnect the power input cable from the junction box or wall plug before cleaning DO NOT USE acid corrosives or any liquid substance on the Model 205 or any AMI weldhead When cleaning use only a light solution of isopropyl alcohol on a soft cloth DO NOT ADD lubrication such as graphite oil or grease to the weldhead or power...

Page 49: ...rols and their relationships All personnel must be aware of the location of hazardous voltage carrying conductors terminals heat sinks etc and must employ safety precautions when working with the Model 205 EQUIPMENT REQUIRED Digital Multimeter DMM minimum 4 digit readout The meter must have floating inputs not connected to line or chassis ground with a minimum of 1 mega ohm input impedance Battery...

Page 50: ...and insert a tube pipe or copper rod that can withstand 150 amps of continuous current with no rotation If these items are not available then use a Hand Torch on a large plate with the torch fixed so it cannot change the gap during calibration 2 Connect the shunt between the ground connection on the power supply and the ground connection on the weldhead or manual torch Current is always measured a...

Page 51: ...M O D E L 2 0 5 O P E R A T O R S M A N U A L 47 47 47 47 3 From the HOME screen press SETUP 4 From the SETUP screen press ADVANCED ...

Page 52: ... Digital Multimeter to read the 200 mVDC scale 7 Prepare to insert the test probes into the red and black terminals on the shunt Any testing or recording instruments connected to any points in the machine or to the welding head may be exposed to extremely high transient voltage at the time the arc starter operates ENSURE THAT ALL TEST EQUIPMENT IS DISCONNECTED DURING ARC START Make sure that when ...

Page 53: ...the arc is established connect the black and red test probes from the DMM to the shunt Fig 3 9 The weld schedule will remain at each Command level for 15 seconds and advance through all 10 Commands During this process make note of the DMM mV reading at each Command 10 At the conclusion of the weld sequence enter each of the DMM readings into the SHUNT column 11 Press HOME to return to the HOME scr...

Page 54: ...TEMPERATURE the Model 205 has an internal temperature sensor thermal switch If the Power Supply internal temperature rises above the safe limit a TEMPERATURE fault occurs This can only occur if there is some type of blockage of air circulation fan failure component failure within the Power Supply or that the system is being operated in ambient air temperatures above or below its rating of 0 C 32 F...

Page 55: ... to blow out and create a hole BAD START if for any reason the Model 205 cannot establish a stable arc at the end of Prepurge the system will display a BAD START fault There can be several reasons for this to occur The most common are poor ground or electrode connections contaminated gas or a contaminated electrode Another common cause of a BAD START is too short of a Prepurge time This is especia...

Page 56: ...e options have their own manuals and these are not discussed in this section Always turn the power supply OFF before making any cable or connection changes to the Model 205 power supply 6 1 COOLING UNIT Model 205 CW SPECIFICATIONS AC INPUT POWER 90 260 VAC 1 Phase 4 amps max COOLANT CAPACITY 0 75 gallons 2 8 liters CIRCULATION 0 5 GPM 2 8 LPM Chapter 6 ...

Page 57: ... CLEAN DISTILLED or DE IONIZED water DO NOT USE automotive antifreeze or STOP LEAK type antifreeze 2 Before mounting the Model 205 CW Cooling Unit to the Model 205 remove the fill cap and add the coolant mixture Replace the fill cap 3 Place the Model 205 onto the Model 205 CW Cooling Unit and close the latches on each end 4 For connections to the weldhead see Section 3 5 5 The Model 205 CW contain...

Page 58: ...MOTE connector on the Model 205 Note the positioning keyway and NEVER FORCE or use tools on the cable connectors Hand tighten the connecting ring being careful not to cross thread the ring Note The EXEL RDR 005 rotor driver contains a built in remote pendant which is fully functional with the Model 205 Note The remote pendant cannot be connected if an M21 weldhead is being used Note For additional...

Page 59: ...M O D E L 2 0 5 O P E R A T O R S M A N U A L 55 55 55 55 ...

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