AMI M9 Series - User Manual

M9 SERIES WELD HEADS
OPERATION MANUAL

Summary

Introduction

Unpacking

Cable Hook Up

Water Cooling

Rotation (Speed) Calibration

Calibration Potentiometer Access

How to access and use the calibration potentiometer for adjustment.

Rotation (Speed) Manual Calibration

Procedure for manual calibration when auto-calibration software is unavailable.

Calibration Test Mode

Setting up the weld schedule and test mode for manual calibration.

Rotation OFF Level

Adding a level with rotation off to check electrode travel limits.

Adjusting Rotation Speed

How to adjust rotation speed using the potentiometer based on travel results.

Clamp Insert Installation

Clamp and Groove Cleaning

Ensuring the clamp and weld head groove are clean before installation.

Model 9 E;9 ER Gas Seal

Specifics for Model 9E/9ER heads regarding gas seal installation and gap adjustment.

Electrode Geometry & Installation

Electrode Type Recommendation

Recommends 2% Ceriated electrodes for superior arc starting and life.

Electrode Size Accommodation

Details the two electrode sizes accommodated by Model 9 series heads.

CAUTION: Incorrect Electrode Installation

Warning against installing incorrect electrode sizes or multiple electrodes.

Arc Gap and Repeatability

Explains how electrode length determines arc gap, impacting weld repeatability.

Electrode Diameter Charts

Charts to determine appropriate electrode diameter based on tube/pipe wall thickness.

Electrode Changing Procedure

Steps for changing electrodes, including jogging the rotor to the 12 o'clock position.

Electrode Installation Preparation

Laying the head on its side and loosening the electrode set screw before installation.

Electrode Seating and Gap

Installing the electrode flush with the rotor O.D. for a correct and repeatable arc gap.

CAUTION: Protruding Electrode

Warning against leaving any part of the electrode protruding past the rotor O.D.

Spare Electrode Set Screws

Locating spare electrode set screws found in the weld head cover.

Shielding Gas

Arc Gas Flow Rate

Importance of correct arc gas flow rate to prevent arc blow or oxidation.

Pre;Post Purge Times

Factors in minimizing oxidation and extending electrode life, with recommended times.

Return-to-Home (Rotor) Position Adjustment

Power Supply Mode

Ensuring the power supply is off or in "TEST" mode before adjustment.

Access Cover Removal

Removing access covers to reach the return-to-home limit switch.

Limit Switch Bracket Adjustment

Loosening screws on the limit switch bracket for adjustment.

Specific Model Adjustments

Specific instructions for adjusting limit switch brackets on different model series.

Sliding Limit Switch Bracket

Sliding the bracket slightly to adjust rotor stopping position (sooner or later).

Unit Power Up

Turning on the unit and opening a weld schedule after adjustment.

Testing Home Position

Testing the rotor return to home position using the "START" and "STOP" commands.

Replacing Access Covers

Reinstalling the access covers after completing the adjustment.

Cleaning and Maintenance

Connector Cleaning

Cleaning brass connectors with isopropyl alcohol and Scotch Brite/steel wool.

O-ring Lubrication

Applying o-ring lube to the female connector's o-ring for easier connection.

Rotor and Housing Cleaning

Cleaning the rotor, guide ring, housing, and window with lint-free cloth and alcohol.

Storage

Draining Coolant

Procedure for draining coolant using a specific fitting and air pressure.

CAUTION: Air Pressure Limit

Warning against using air pressure above 20 PSI for purging.

Dust Cap and Storage Area

Attaching the dust cap and storing the weld head in a clean, dust-free area.

Clamp Housing Latches

Storing the head with the clamp housing latches unlatched.

Overview

1. Function Description
2. Important Technical Specifications
3. Usage Features
4. Maintenance Features

The provided document is an operation manual for the AMI (Arc Machines, Inc.) M9 Series Weld Heads. This manual covers the basic setup and maintenance of various models within the 9 and 9E series, including 9-750, 9-1500, 9E-1500, 9-2500, 9E-2500, 9-3500, 9E-3500, 9-4500, 9E-4500, 9ER-4500, 9-7500, and 9E-7500.

Function Description:

The AMI M9 Series Weld Heads are designed for orbital GTAW (Gas Tungsten Arc Welding) processes, specifically for welding tubes and pipes. These weld heads facilitate precise and repeatable welds by controlling the rotation of an electrode around the workpiece. The system integrates with a power supply, which manages parameters such as rotation speed, amperage, and purge times. The weld heads are designed to accommodate various tube and pipe sizes through the use of interchangeable clamp inserts and gas seals.

Important Technical Specifications:

• Models Covered: 9-750, 9-1500, 9E-1500, 9-2500, 9E-2500, 9-3500, 9E-3500, 9-4500, 9E-4500, 9ER-4500, 9-7500, 9E-7500.
• Cable Length: Integral 10ft (3m) cable, requiring an adapter pig-tail or adapter cable for connection to the power supply. Extension cables can also be used.
• Water Cooling: Most models are plumbed for water cooling, which is recommended for welding tube or pipe wall thicknesses of 0.065" (1.6mm) or heavier in Model 9-500C, and 0.083" (2.1mm) or heavier in other water-cooled models. It is also recommended for high-duty-cycle work.
• Electrode Types: Recommended electrode type is 2% Ceriated (AWS Spec. A5.12/A5.12M, Orange tip) for superior arc starting and longer life. Other types can be used.
• Electrode Sizes: Most models 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.
• Shielding Gas: Argon is the most commonly used shielding gas. Gas mixtures like 95% Argon/5% hydrogen or 75% helium/25% argon can be used for deeper penetration.
• Recommended Arc Gas Flow Rates (CFH / LPM) and Minimum Pre/Post Purge Times (seconds):
  • 9-750: 10-14 CFH (21-29 LPM), 20 seconds
  • 9-1500: 15-25 CFH (31-52 LPM), 20 seconds
  • 9E-1500: 25-35 CFH (52-73 LPM), 20 seconds
  • 9-2500: 25-30 CFH (52-63 LPM), 30 seconds
  • 9E-2500: 25-40 CFH (52-84 LPM), 30 seconds
  • 9-3500: 25-30 CFH (52-63 LPM), 30 seconds
  • 9E-3500: 30-45 CFH (63-94 LPM), 30 seconds
  • 9-4500: 30-40 CFH (63-84 LPM), 45 seconds
  • 9E-4500: 30-50 CFH (63-105 LPM), 45 seconds
  • 9ER-4500: 30-50 CFH (63-105 LPM), 45 seconds
  • 9-7500: 30-40 CFH (63-84 LPM), 60 seconds
  • 9E-7500: 40-60 CFH (84-126 LPM), 60 seconds
• Rotor O.D. (Outer Diameter) for various models:
  • 9-750: 2.00" (50.8mm)
  • 9-1500: 3.187" (80.9mm)
  • 9E-1500: 2.687" (68.25mm)
  • 9-1500 w/elect. extender: 2.031” (51.6mm)
  • 9-2500: 4.380" (111.25mm)
  • 9E-2500: 4.280" (108.71mm)
  • 9-2500 w/elect. extender: 3.156" (80.16mm)
  • 9-3500: 5.380" (136.65mm)
  • 9E-3500: 5.310" (134.87mm)
  • 9-3500 w/elect. extender: 4.031" (102.38mm)
  • 9-4500: 6.875" (174.62mm)
  • 9E-4500: 6.280" (159.51mm)
  • 9ER-4500: 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)
• Recommended Arc Gap and Electrode Tip Diameter based on Tube/Pipe Wall Thickness:
  • 0.020”-0.035" (.5–1.0mm): Arc Gap 0.020”-0.030” (0.5-0.8mm), Tip Diameter 0.010”-0.20” (.25-.50mm)
  • 0.035"-0.085" (1.0-2.1mm): Arc Gap 0.050"-0.070" (1.3-1.8mm), Tip Diameter 0.030” (0.8mm)
  • 0.091"-0.154” (2.3-3.9mm): Arc Gap 0.070"-0.090" (1.8-2.3mm), Tip Diameter 0.040” (1.0mm)
• Electrode Diameter based on Tube/Pipe Wall Thickness:
  • 0.020” – 0.035” (.50 – 1.0mm): 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)

Usage Features:

• Cable Hook Up: Requires careful connection of power, ground, and motor control fittings. Rubber boots slide together to protect connectors.
• Rotation (Speed) Calibration: The electrode rotation motor must be calibrated to the power supply. This can be done via an auto-calibration function in the power supply software or manually. Manual calibration involves creating a weld program in "TEST" mode to rotate the electrode 360 degrees at a selected RPM and adjusting a potentiometer until the electrode stops after 360 degrees of travel.
• Clamp Insert & Gas Seal Installation: Clamp inserts are specific to tube/pipe size. Matched sets of clamp halves (marked with alphanumeric characters) ensure weld joint concentricity. Model 9E and 9ER heads use a clamp insert on one side and a gas seal on the other, with the gas seal hole approximately 1/8" (3mm) larger than the part diameter to allow arc gas exit and minimize burning.
• Electrode Geometry & Installation: The electrode length, arc gap, and tip diameter are crucial for consistent heat input and weld repeatability. Operators must select the correct electrode diameter, length, and tip diameter based on charts and formulas provided in the manual. Electrodes are installed by jogging the rotor to the 12 o'clock position, loosening a set screw, and inserting the electrode flush with the rotor O.D.
• Shielding Gas Control: Proper arc gas flow rate is essential to prevent arc blow, excessive weld oxidation, and electrode contamination. Prepurge and post purge times are also critical for minimizing oxidation and extending electrode life.
• Return-to-Home (Rotor) Position Adjustment: The rotor automatically returns to an "open" or "home" position after a weld program. If the rotor does not stop correctly (flush or slightly recessed in the housing), a limit switch bracket adjustment is required.

Maintenance Features:

• Cleaning and Maintenance:
  • All cable connectors must be kept clean and free of grease, oil, dirt, or other contaminants.
  • Brass power and ground connectors should be cleaned with isopropyl alcohol and Scotch Brite or steel wool, then rinsed and dried.
  • After cleaning brass connectors, a small amount of O-ring lube, oil, or grease should be applied to the female (brass) connector O-ring for easier connection.
  • The rotor, black rotor guide ring, weld head housing, and view window should be cleaned regularly with a clean lint-free cloth and isopropyl alcohol to remove soot buildup.
• Storage:
  • If the weld head has been water-cooled and will be stored for more than one month, residual water or coolant mix must be purged from the hoses and weld head to prevent internal corrosion.
  • Purging is also critical if the weld head will be stored in freezing temperatures to prevent damage from trapped water.
  • Purging involves using an Arc Machines, Inc. fitting (part number 294-PB-06) and a pressurized air source (maximum 20 PSI / 139 Kp / 1.38 Bar) to blow air through the supply line, forcing water out of the cables and weld head back into the cooling unit.
  • When storing, attach the dust cap to the electrical connector and store the weld head in a clean, dust-free area with the clamp housing latches un-latched.

AMI M9 Series Specifications

General

Brand	AMI
Model	M9 Series
Category	Analytical Instruments
Language	English