Arc Machines 501 Manuel utilisateur
10500 Orbital Way
Pacoima, California 91331 U.S.A.
MODEL 501 POWER SUPPLY
OPERATION MANUAL
Document No. 740099
Rev. !
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HEADQUARTERS
Arc Machines, Inc.
10500 Orbital Way
Pacoima, CA 91331 U.S.A.
Tel.: 1- 818 896-9556
Fax: 1-818 890-3724
EUROPEAN OFFICE
Arc Machines, Inc.
Chemin du Lavasson 2
CH-1196 Gland
Switzerland
Tel.: +41 / 22 / 995.00.51
Fax: +41 / 22/ 995.00.59
GERMAN OFFICE
Arc Machines GmbH
Markelsbach 2
D-53804 Much, Germany
Tel.: +49/2245 / 91680
Fax: +49/2245 / 916868
UK OFFICE
Arc Machines UK Limited
10 Ashurst Court, London Road
Wheatley, Oxford OX331ER
England
Tel.: +44/1865/872121
Fax: +44/1865/876909
MODEL 501
POWER SUPPLY
Operation Manual
Arc Machines, Inc.
General Guidelines for Welding with the
AMI Model 501 Hotwire Power Supply
The Arc Machines, Inc. Model 501 Hotwire Power Supply was designed to
supply resistance-heated filler wire at near-melting temperatures to the weld
pool thereby increasing the arc energy available to melt the base metal. The
hot wire process increases the deposition rate and is usually run at higher
welding speeds than cold wire systems. When used with GTA welding sys-
tems, such as Arc Machines’ Model 415 Microprocessor-based power supply,
high-quality weld deposits characteristic of the gas tungsten arc process are
obtained.
The Model 501 uses AC current to preheat the wire. True values of current
and voltage allow welding engineers to precisely calculate energy input in
Joules per inch based on true RMS values.
The hot wire process is normally run in the flat welding position. Out-of-
position welding is possible, but may not provide the desired benefits.
Document Number: 740099
Effective Date: January, 2005
Table of Contents
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INTRODUCTION
Applications
Hot Wire Application with
AMI Model 415 and M-2
SAFE OPERATION
Safety Precautions
M-501 Do’s and Don’ts
Warnings
MODEL 501
SPECIFICATIONS
POWER SUPPLY
OPERATION & FUNCTIONS
Wire Feeder
System Configurations
WELDING
JOINT PREPARATION FOR
HOT WIRE WELDING
ELECTRICAL DRAWINGS
GRAPHICAL SYMBOLS
INDEX
INDEX
1
2
3
4
5
6
7
8
9
MODEL 501
Hotwire Power
Supply
OPERATION MANUAL
General Guidelines for
Welding with Hot Wire
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Chapter 1. Introduction
Filler metal in the form of wire is commonly added to welds in the GTA weld-
ing process, particularly when heavy wall thicknesses are being welded. A
wire feeder is used to deliver the wire to the weld pool and a power supply (or
controller) controls the rate of wire entry. The wire may be either cold (ambi-
ent temperature) or hot. Hot wire is normally fed into the trailing edge of the
pool while cold wire is fed into the leading edge. The hot wire GTAW (TIG)
welding process differs from the cold wire process in that the filler wire is
electrically pre-heated to near melting temperature before entering the weld
pool. This prevents the wire from chilling the weld pool and allows the filler
metal to flow out across the weld puddle resulting in a smooth, attractive
weld bead. Since nearly all of the full energy of the welding arc is available for
penetration, more wire can be deposited and fill rates are significantly higher
than with cold wire. (See graph on page 2.)
The Arc Machines, Inc. Hot Wire Power Supply Model 501 has controls for
(heating wire) voltage. The standard mode of operation for
Hot-wire set-up with GTAW torch and Model 2
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"#e Model 501 is Constant AC Voltage (0 - 10 Volts true$%&'). The M501
implements advanced technology with significant competitive advantages.
AC current is used to minimize magnetic interference (arc$blow). The AC
current of the M501 is far more precise and more sinusoidal than competitive
machines, being very close to a true sine wave. The ability to sense the hot
wire voltage at the tip of the wire feed tube, in addition to sensing the internal
voltage, provides an operational advantage because measuring the voltage at
the work is more accurate and not influenced by irrelevant factors such as cable
length, that can affect the internal reading. The accuracy of true RMS provided
by these measurements make it possible to duplicate production conditions from
one set-up to the next with excellent repeatability of process.
Applications
The Model 501 can be operated by an Arc Machines’, Model 415 Power
Supply, an external weld process controller or program, or can stand alone
and be operated from its own pendant. The hot wire GTAW process produces
a very clean weld with a very low incidence of porosity. The applications for
GTAW hot wire are those that require high-quality welds, but where faster
deposition rates than cold wire GTAW are desired. A conservative estimate of
deposition rates achievable with the M501 would be from 4 to 6 lbs per hour
to a maximum of about 8 lbs per hour. This makes it practical for overlays,
seam welds and other similar type welds in the 1G (downhand) welding
$
$
$
$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$Deposition rates for Gas Tungsten Arc
$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$Welding with Cold and Hot Steel Filler
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position. For example, hot wire GTAW would be suitable for welding high-
quality stainless steel tanks and vessels that are rotated during welding.
While it would be tempting to apply hot wire technology to true out-of-posi-
tion orbital welding, the significant increase in deposition that can be
achieved in downhand hot wire welding will not be seen in orbital applica-
tions. However, some benefit may be achieved in orbital applications at the
expense of greater complexity.
The GTAW process is metallurgically “simple” in
that the electrode is not consumed and filler
metals added to the weld may be precisely
designed to achieve a particular metallurgical
result. Thus, the hot wire GTAW process is
particularly applicable to 300 series stainless
steel as well as to engineered materials such as
duplex stainless steels, or high-nickel alloys,
where the metallurgical properties of the base
metal may be adversely affected by welding
unless high-quality welding procedures are
employed. The proper use of the GTAW process
with the addition of hot wire can optimize the
corrosion resistance and/or mechanical proper-
ties of the weldment and have a beneficial effect
on the material performance in service.
The Model 501 Hot Wire Power Supply can be used in combination with AMI’s Model 2 and
Model 415 Power Supply for fast, high-quality, heavy-duty applications such as turbines. The
photos show a demonstration of cladding at a trade show with the Model 2 with a hot wire
torch. Photo on the right is a close up of the torch.
Arc Machines Model 415 Windows!-
based Power Supply/Controller
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Hot Wire application with AMI Model 415 and Model 2
A versatile hot-wire welding automation system may be created by equipping
an Arc Machines’ Model 2 with a Hot-Wire Torch with AVC and oscillation and
optional video vision system and using an Arc Machine’s Model 415, GTAW
400 amp DCSP Power Supply as a controller.
The Model 415 is Windows!-based with built-in digital data acquisition and
multi-servo control capabilities. It is a very capable power supply that is easy
to operate. The heart of its flexibility is the emphasis on user-definability.
Almost all function ranges and modes can be defined by the user to exactly
match the unique Model 2 configuration being used. The closed-loop motor
servos and optional open-loop motor manipulator controls make these sys-
tems ideal for work-cell manufacturing environments.
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Chapter 2. Safe Operating Procedures
Safety Precautions for Model 501 Operation
Arc Welding Precautions
Arc Welding is potentially very hazardous unless safety precautions
are observed. Operators must receive adequate training before
being allowed to operate any type of welding equipment. Read this
manual carefully before operating welding and/or hot wire
equipment. Although the Model 501 hot wire power supply has an open cir-
cuit voltage of only 16 volts and so does not represent an extreme shock haz-
ard by itself, exposed parts operating at very high temperatures represent a
burn hazard. Operators must wear proper protective clothing including eye
protection when operating welding equipment. This chapter of the manual
explains and illustrates common dangers and precautions to take while oper-
ating welding equipment.
THE ELECTRODE SHOULD ALWAYS BE CONSIDERED A
POSSIBLE SHOCK HAZARD and touching it or internal
circuits could prove fatal.
This is especially true whenever the
system is:
• IN SEQUENCE
• READY TO WELD,
• IS WELDING,
• OR HAS JUST FINISHED
WELDING.
When replacing or adjusting the
electrode:
• Set power supply to “TEST”
mode Left arrow shows location of hot wire tube while right
arrow points to the electrode in a GTAW torch.
AVOID ALL CONTACT
WITH THE WELDING
WORK (GROUND) OR
ELECTRODE DURING ARC
START.
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HF Arc Start
Most AMI Power Supplies feature RF (radio frequency) Arc Starting. This is a
High/Voltage/High Frequency electrical transmission process. The GTAW pro-
cess requires electrical potential (high
voltage) to be present on the elec-
trode and on exposed internal termi-
nals during arc starting and during
welding.
ALL AMI Power Supplies contain a
“bleeder” circuit to ground any resid-
ual potential after welding or after an
aborted or bad “arc attempt”. How-
ever, these circuits take a few sec-
onds or could fail.
for Safe Use of Welding/ Hot Wire Equipment
Caution: Only experienced personnel familiar
with the operation and safe practice of welding
equipment should install or use this equipment.
DO’S
1. Do disconnect input power before servicing equipment.
2.Do properly install and ground this equipment.
3. Do VERIFY correct input voltage (200 to 240 VAC @
25 Amps) before plugging in the Model 501.
4. Do turn off equipment when not in use.
5. Do calibrate wire feed each time the Model 501 is
connected.
AMI Model 501 Hotwire Power Supply with cover
removed.
MODEL 501 DO’S AND DON’TS
Model 501 and RP
Table des matières
