Model 217 WDR Tube Welding Power Supply Operator’s Manual Part No.
M O D E L 2 1 7 W D R O P E R A T O R ’ S M A N U A L INTRODUCTION T he Model 217 WDR is a power source and controller for automatic orbital tube welding. It is intended to be used only in conjunction with AMI and EXEL by AMI orbital tube welding heads and accessories. The Model 217 WDR power supply provides GTAW (Gas Tungsten Arc Welding) current with pulsation controls, high frequency arc starting, purge gas controls, weld head arc rotation and automatic timing functions.
M O D E L 2 1 7 W D R O P E R A T O R ’ S M A N U A L Table of Contents INTRODUCTION, NOTICE, Revision History ................................................................ i Table of Contents .......................................................................................................... ii 1.0 SAFETY PRECAUTIONS .................................................................................. 1 1.1 SHOCK HAZARD WARNING.........................................................................
M O D E L 2 1 7 W D R O P E R A T O R ’ S M A N U A L 8.0 8.1 8.2 MAINTENANCE AND TROUBLESHOOTING ................................................. 44 GENERAL MAINTENANCE ............................................................................ 44 TROUBLESHOOTING ..................................................................................... 45 AMI OFFICES ..................................................................................................
M O D E L 2 1 7 O P E R A T O R ’ S M A N U A L 1 Chapter 1.0 SAFETY PRECAUTIONS The Model 217 WDR is intended to be used only with AMI or EXEL by AMI weld heads for the purpose of GTAW welding of metal tube. The system is not to be used for any other purpose, specifically heating or cutting. 1.1 SHOCK HAZARD WARNING ICON KEY Warning WARNING Electrical Hazard The nature of the GTAW process creates POTENTIAL HAZARDS.
M O D E L 2 1 7 W D R O P E R A T O R ’ S M A N U A L The Model 217 WDR is intended to be used only with AMI and EXEL by AMI weld heads for the purpose of GTAW welding of metal tube or pipe. The system is not to be used for any other purpose, specifically heating or cutting. The Model 217 WDR is intended for typical GTAW shielding gases ONLY. NEVER CONNECT OXYGEN OR ACETYLENE to the Model 217 WDR or weld head.
M O D E L 2 1 7 W D R O P E R A T O R ’ S M A N U A L 1.2 WARNING LABEL DEFINITIONS The table below contains caution and warning labels for the operation of this equipment. Before operating this or any welding equipment users should be familiar with “ANSI-49.1 Safety in Welding and Cutting”. ELECTRIC SHOCK from welding electrode or wiring can kill. HIGH FREQUENCY RADIO WAVE can cause interference and sometimes even damage to nearby electronic equipment (such as computers) that are un-protected.
M O D E L 2 1 7 W D R O P E R A T O R ’ S M A N U A L WARNING: Exel factory training is essential for all Welding Operators and Maintenance Technicians who operate AMI or EXEL by 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.
M O D E L 2 1 7 W D R O P E R A T O R ’ S M A N U A L 1.3 SYSTEM SYMBOLS The following symbols are present on the Model 217 WDR: WARNING: Read this manual! This document contains information that could help prevent injury or damage to the equipment. AC main input, 115/230 volts AC, 50/60 Hz. On / Off switch (CB-1 main circuit breaker). Input for the arc shielding gas. An external regulator and flow indicator must be used. USB port.
M O D E L 2 1 7 W D R O P E R A T O R ’ S M A N U A L 2 Chapter 2.0 SPECIFICATIONS These specifications pertain to the Model 217 WDR power supply only. For weld heads, refer to the specification sheet of each particular model. For non-AMI supplied equipment such as gas tanks and regulators, refer to the original manufacturer’s documentation. The Model 217 WDR is a mobile system that is intended to be hand carried.
M O D E L 2 1 7 W D R O P E R A T O R ’ S M A N U A L OUPUT POWER DETAIL Straight polarity, constant current DC regulation intended for GTAW welding only. Static characteristic of all power supplies is flat. 5 to 100 amperes DC using 100 to120 VAC input (15 Ampere service). 5 to 150 amperes DC using 200 to 240 VAC input (30 Ampere service). CIRCUIT BREAKER – ON/OFF, two pole, 30 Ampere at 250 VAC. DUTY CYCLE – determined by the AC input voltage and the required output current.
M O D E L 2 1 7 W D R O P E R A T O R ’ S M A N U A L 2.4 PROGRAMMABLE AND OPERATIONAL FUNCTIONS SINGLE ENTRY PARAMETERS AND FUNCTIONS FUNCTION RANGE WELD TYPE (PULSED, NON-PULSED, STEP, TACK, S^3) SELECTABLE NUMBER OF LEVELS 1 - 99 LEVELS START CURRENT 5 - 150 AMPS PREPURGE 10 - 1000 SECONDS POSTPURGE 10 - 1000 SECONDS TRAVEL START DELAY 0.
M O D E L 2 1 7 W D R O P E R A T O R ’ S M A N U A L MULTI-LEVEL PARAMETERS AND FUNCTIONS (con’t) BACKGROUND SPEED (RPM) 0.0 RPM TO WELD HEAD MAX.** BACKGROUND SURFACE SPEED CALCULATED AVERAGE SPEED CALCULATED * For S^3 schedules the PRIMARY AMPS parameter is replaced by START AMPS and END AMPS parameters. ** TRAVEL parameters are in 0.01 RPM increments.
M O D E L 2 1 7 W D R O P E R A T O R ’ S M A N U A L 3 Chapter 3.0 START-UP 3.1 REQUIRED PERIPHERALS 1. An orbital weld head is required to weld with the Model 217 WDR. Shown below is the EXEL by AMI RDR-05 Rotor Driver and an AMI Model 9-750 orbital weld head. 2. An A.C. power cord rated for 600 VAC service (below left) and gas purge lines are provided to connect power and inert gas to the power supply. Note: A.C. input power cords are shipped WITHOUT an attached utility plug.
M O D E L 2 1 7 W D R O P E R A T O R ’ S M A N U A L 3.2 OPTIONAL PERIPHERALS All AMI power supplies have their own respective optional remote pendant. This gives the operator remote welding functions of the Model 217 WDR power supply itself. The optional cooling unit is recommended for high production or heavy walled (.109”-.154”) welding applications.
M O D E L 2 1 7 W D R O P E R A T O R ’ S M A N U A L 3.3 POWER SUPPLY CONNECTION 1. Below is a view of the input and output sides of the Model 217 WDR Power Supply with all connectors visible. Connect the A.C. power cord into a utility power source ranging from 115/230 volts, 50/60 hertz single phase. CB-1 Ethernet port Input A.C. 2. Connect Argon (or mixed gas) from an external source to the Model 217 WDR ARC GAS INPUT connector (I.D.
M O D E L 2 1 7 W D R O P E R A T O R ’ S M A N U A L 3.4 POWER-UP Flip ON the main power switch (CB-1). Once the computer boots up the MAIN SCREEN will appear on the touch screen. The Main Screen allows the operator to CREATE new weld schedules, access the LIBRARY, OPEN LAST weld schedule that was used, select certain SETUP features, display information ABOUT Arc Machines, Inc., and properly SHUT DOWN the power supply.
M O D E L 2 1 7 W D R O P E R A T O R ’ S M A N U A L 4 Chapter 4.0 LIBRARY AND MEMORY Touch the LIBRARY pad on the MAIN SCREEN and the Library will appear. The operator can select and LOAD a weld schedule (selected to weld), DELETE weld schedules, and COPY weld schedules to/from an external memory device. LIBRARY These modes are enabled and displayed only when a memory storage device is connected to the Model 217 WDR’s USB port(s).
M O D E L 2 1 7 W D R O P E R A T O R ’ S M A N U A L 4.1 LOADING A WELD SCHEDULE FROM THE MODEL 217 WDR LIBRARY 1. Flip the main power switch (CB-1) of the Model 217 WDR to the ON position. 2. Once the computer boots up touch LIBRARY on the MAIN SCREEN. 3. Peruse the LIBRARY, touch the desired weld schedule on the screen, it will become highlighted. 4. Touch LOAD SCHEDULE. 5. The selected weld schedule will be loaded and the Weld Screen will appear. (Next page).
M O D E L 2 1 7 W D R O P E R A T O R ’ S M A N U A L WELD SCREEN From the Weld Screen the operator has access to all power supply, welding and weld head functions at a touch of the weld screen: START: Starts the Weld sequence. (Pre purge, arc start, weld sequence, post purge, rotor returns home, finish weld). STOP: Terminates weld sequence. (Arc off/rotation stops, post purge, rotor returns home, finish). TEST: Starts Test Run sequence.
M O D E L 2 1 7 W D R O P E R A T O R ’ S M A N U A L POWER ADJUST: This value establishes the min/max % adjustment that the operator can make to the welding current. On the Weld screen the operator can then adjust the welding current up or down in 0.1% increments to this value.
M O D E L 2 1 7 W D R O P E R A T O R ’ S M A N U A L 4.2 COPYING WELD SCHEDULES FROM THE MODEL 217 WDR LIBRARY TO AN EXTERNAL MEMORY DEVICE 1. Open LIBRARY. Insert the external memory device into the Model 217 WDR USB port. 2. Select (highlight) one weld schedule to be copied to the external memory device. 3.Touch COPY TO EXTERNAL MEMORY to copy that one weld schedule, or touch COPY ALL TO EXTERNAL MEMORY if you want the entire Model 217 WDR library copied to the external memory device.
M O D E L 2 1 7 W D R O P E R A T O R ’ S M A N U A L 4. The screen below will be displayed to verify if one weld schedule was copied successfully to the external memory device. 5. OR the screen below will be displayed to verify if the entire Model 217 WDR library has been copied successfully to the external memory device.
M O D E L 2 1 7 W D R O P E R A T O R ’ S M A N U A L 6. Touch OK to clear verification screen. Touch EXTERNAL MEMORY display. 7. Verify that the weld schedule or schedules have been copied to the external memory device. 8. Remove external memory device.
M O D E L 2 1 7 W D R O P E R A T O R ’ S M A N U A L 4.3 COPYING WELD SCHEDULES FROM AN EXTERNAL MEMORY DEVICE TO THE MODEL 217 WDR LIBRARY 1. Open LIBRARY. Insert external memory device in the Model 217 WDR USB port. 2. Touch EXTERNAL MEMORY to open and display external memory device library. 3. Select (highlight) one weld schedule to be copied to the Model 217 WDR library. 4.
M O D E L 2 1 7 W D R O P E R A T O R ’ S M A N U A L 5. The screen below will be displayed to verify if one weld schedule was copied successfully to the Model 217 WDR library. 6. OR the screen below will be displayed to verify if the entire external memory library has been copied successfully to the Model 217 WDR library. ALL SCHEDULES COPIED TO M217.
M O D E L 2 1 7 W D R O P E R A T O R ’ S M A N U A L 7. Touch OK to clear verification screen. Touch M217 WDR display. 8. Verify that the weld schedule or schedules have been copied to the Model 217 WDR library. 9. Remove external memory device.
M O D E L 2 1 7 W D R O P E R A T O R ’ S M A N U A L 5 Chapter 5.0 CREATING WELD SCHEDULES 5.1 CREATING A MANUAL 4 LEVEL WELD SCHEDULE 1. From the MAIN SCREEN touch the CREATE SCHEDULE pad and the create schedule menu will be displayed. Select MANUAL SCHEDULE. 2. Page 1 of the SCHEDULE SCREEN will be displayed. Select and enter all required MATERIAL, WELD HEAD and ELECTRODE parameters using the numerical key pad.
M O D E L 2 1 7 W D R O P E R A T O R ’ S M A N U A L 3. Press Page 2. Select and enter all required LEVELS, PURGE and MOTOR parameters. You may also enter any SPECIAL NOTES that you may have. 4. Press Page 3. Select and enter all required WELDING parameters for all 4 levels. 5. Press SAVE.
M O D E L 2 1 7 W D R O P E R A T O R ’ S M A N U A L 6. The SCHEDULE NAME screen will be displayed. The default schedule name is based on the tube O.D., wall thickness and material you entered when creating this weld schedule. You may save it as is or use the keypad to assign your own personal weld schedule name. Press SAVE when finished. 7. Pressing SAVE will store all data in the library under the SCHEDULE NAME you selected and the WELD SCREEN will be displayed with the schedule name on top. 8.
M O D E L 2 1 7 W D R O P E R A T O R ’ S M A N U A L 5.2 CREATING AN AUTOMATIC 4 LEVEL WELD SCHEDULE 1. From the MAIN SCREEN touch the CREATE SCHEDULE pad and the create schedule menu will be displayed. Select AUTO SCHEDULE. 2. The AUTO SCHEDULE screen will be displayed. Select and enter all required O.D., WALL, MATERIAL and WELD HEAD parameters using the numerical key pad. 3. Press the AUTO PULSED pad.
M O D E L 2 1 7 W D R O P E R A T O R ’ S M A N U A L 4. The AUTO SCHEDULE NAME screen will be displayed. The default schedule name is based on the tube O.D., wall thickness and material you entered when creating this weld schedule. You may save it as is or use the keypad to assign your own personal weld schedule name. Press SAVE when finished. 5. Pressing SAVE will store all data in the library under the SCHEDULE NAME you selected and the WELD SCREEN will be displayed with the schedule name on top. 6.
M O D E L 2 1 7 W D R O P E R A T O R ’ S M A N U A L 5.3 CREATING AN AUTO STEP WELD SCHEDULE 1. From the MAIN SCREEN touch the CREATE SCHEDULE pad and the create schedule menu will be displayed. Select AUTO SCHEDULE. 2. The AUTO SCHEDULE screen will be displayed. Select and enter all required O.D., WALL, MATERIAL and WELD HEAD parameters using the numerical key pad. 3. Press the AUTO STEP pad.
M O D E L 2 1 7 W D R O P E R A T O R ’ S M A N U A L 4. The AUTO SCHEDULE NAME screen will be displayed. The default schedule name is based on the tube O.D., wall thickness and material you entered when creating this weld schedule. You may save it as is or use the keypad to assign your own personal weld schedule name. Press SAVE when finished. 5. Pressing SAVE will store all data in the library under the SCHEDULE NAME you selected and the WELD SCREEN will be displayed with the schedule name on top. 6.
M O D E L 2 1 7 W D R O P E R A T O R ’ S M A N U A L 5.4 CREATING AN AUTO TACK WELD SCHEDULE 1. From the MAIN SCREEN touch the CREATE SCHEDULE pad and the create schedule menu will be displayed. Select AUTO SCHEDULE. 2. The AUTO SCHEDULE screen will be displayed. Select and enter all required O.D., WALL, MATERIAL and WELD HEAD parameters using the numerical key pad. 3. Press the AUTO TACK pad.
M O D E L 2 1 7 W D R O P E R A T O R ’ S M A N U A L 4. The TACK PARAMETERS screen will be displayed. You can select the amount of PENETRATION PERCENTAGE (0% to 126%) desired, the NUMBER OF TACKS (1 to 40) desired, and the TACKING PATTERN – SEQUENTIAL (consecutive) or BALANCED (180 degrees opposite each other) desired. Press O.K. when set. 5. The AUTO SCHEDULE NAME screen will be displayed. The default schedule name is based on the tube O.D.
M O D E L 2 1 7 W D R O P E R A T O R ’ S M A N U A L 6. Pressing SAVE will store all data in the library under the SCHEDULE NAME you selected and the WELD SCREEN will be displayed with the schedule name on top. 6. The Model 217 WDR is now loaded with the weld schedule and is in STANDBY mode, ready to tack. 5.5 CREATING AN AUTO S^3 (S cubed) WELD SCHEDULE 1. From the MAIN SCREEN touch the CREATE SCHEDULE pad and the create schedule menu will be displayed. Select AUTO SCHEDULE. 2.
M O D E L 2 1 7 W D R O P E R A T O R ’ S M A N U A L 3. Press the AUTO PULSED S^3 pad. 4. The AUTO SCHEDULE NAME screen will be displayed. The default schedule name is based on the tube O.D., wall thickness and material you entered when creating this weld schedule. You may save it as is or use the keypad to assign your own personal weld schedule name. Press SAVE when finished. 5.
M O D E L 2 1 7 W D R O P E R A T O R ’ S M A N U A L 6. The Model 217 WDR is now loaded with the weld schedule and is in STANDBY mode, ready to weld. 7. Below is an example of an S^3 (pronounced S cubed) weld, it is named for the three S’s defining the weld (Single Slope, Single pass). It is a linear reduction of current from a START AMPS to an END AMPS with a LOW AMP PULSATION for an AVERAGE AMP OUTPUT.
M O D E L 2 1 7 W D R O P E R A T O R ’ S M A N U A L 6 Chapter 6.0 SETUP 6.1 PROGRAMMING BASIC SETUP FEATURES 1. From the MAIN SCREEN touch the SETUP pad. 2. The SETUP screen will be displayed. 3. From the SETUP screen is where the internal CLOCK (local time and year) is set, the libraries UNITS OF MEASURE (English or Metric) is selected, and the current override POWER ADJUST minimum and maximum limits are set.
M O D E L 2 1 7 W D R O P E R A T O R ’ S M A N U A L 6.2 PROGRAMMING THE LANGUAGE FEATURES 1. The LANUAGE pad displays the current languages available to use in the language library: 2. Select CHINESE, FRENCH, GERMAN, JAPANESE, SPANISH or ENGLISH. 3. The ADD LANGUAGE pad displays the language menu: 4.
M O D E L 2 1 7 W D R O P E R A T O R ’ S M A N U A L 6.3 PROGRAMMING THE PASSWORD FEATURES The CHANGE PROGRAMMER PASSWORD and CHANGE SECURITY PASSWORD pads allow management/supervisors to set passwords so as to minimize or limit operator access to certain screens and operational features of the Model 217. This will determine what the operator can do, cannot do, or is limited in doing with the Model 217.
M O D E L 2 1 7 W D R O P E R A T O R ’ S M A N U A L 7 Chapter 7.0 ALARMS AND FAULTS 7.1 PROGRAMMING ALARM SETTINGS ALARM SETTINGS are only accessible using a 5 digit “1-Day Programmer Password”, which is only available by calling AMI Technical Support (In USA 818-896-9556). 1. From the MAIN SCREEN touch the SETUP pad. The SETUP SCREEN will be displayed. Touch the CHANGE PROGRAMMER PASSWORD pad and the password screen will appear. 2. Enter and confirm the 5 digit 1-Day Programmer Password.
M O D E L 2 1 7 W D R O P E R A T O R ’ S M A N U A L 6. Wait 10 seconds, flip CB-1 to the ON position, wait for computer to boot up. 7. Once boot up is complete, the MAIN SCREEN will be displayed. On the MAIN SCREEN touch the SETUP pad. 8. The MAIN SCREEN will prompt you for the PROGRAMMER PASSWORD. 9. ENTER the 5 digit 1-Day Programmer Password. 10. The ALARM SETTINGS will be displayed on SETUP SCREEN.
M O D E L 2 1 7 W D R O P E R A T O R ’ S M A N U A L 7.2 ALARM SETTINGS LOW PRESSURE: The lowest allowable pressure desired for the purge inlet of the power supply. Low Pressure value should be set to 0.0. Inadequate flow will trigger a flow alarm on the touch screen. HIGH PRESSURE: The highest allowable pressure desired for the purge inlet of the power supply. The maximum value for this field is 50.0 psi. Over pressure will trigger a flow alarm on the touch screen.
M O D E L 2 1 7 W D R O P E R A T O R ’ S M A N U A L 2. The message below left will appear if arc voltage goes above the set value. The message below right will appear if arc voltage goes below the set value. VOLTAGE IS ABOVE RECOMMENDED VALUE VOLTAGE IS BELOW RECOMMENDED VALUE OK OK 3. The message below left will appear if the gas fails to flow to the weld head. The message below right will appear if the input gas pressure is below minimum requirement.
M O D E L 2 1 7 W D R O P E R A T O R ’ S M A N U A L 7.5 PROPER SHUTDOWN OF THE MODEL 217 WDR 1. Touch HOME from whatever screen you are on to return to the MAIN SCREEN. 2. Touch SHUT DOWN. 3. The screen above will appear to CONFIRM SHUT DOWN. Touch SHUT DOWN. 4. The MAIN SCREEN will reappear for approximately 5 seconds before screen turns BLACK (computer turns OFF). 5. Flip the MAIN POWER SWITCH (CB-1) to the OFF position.
M O D E L 2 1 7 W D R O P E R A T O R ’ S M A N U A L 8 Chapter 8.0 MAINTENANCE AND TROUBLESHOOTING Always disconnect the AC power cable from the line voltage before attempting to work on this welding power supply. There are no user serviceable components located inside the Model 217 WDR. Do not open the unit in an attempt to repair it. Contact Arc Machines, Inc. if the unit is malfunctioning, or suspected of being broken. As such, no wiring diagram or internal circuit drawing is provided. 8.
M O D E L 2 1 7 W D R O P E R A T O R ’ S M A N U A L Always keep the protective boots and dust caps on all connectors and fittings until cables are ready to install. A major cause of downtime in any automatic welding system is improper care and use of cables. Take extreme care to avoid dropping the power supply or the weld heads. Always disconnect the power input cable from the junction box or wallplug before cleaning the unit.
M O D E L 2 1 7 W D R O P E R A T O R ’ S M A N U A L This fault should only occur during an actual weld sequence. If it occurs when the machine is not welding then a serious internal problem exists. In this case turn the Power Supply OFF and call an Arc Machines Service representative. If it occurs during welding, check for blockage of the air intakes and exhaust on the sides of the machine. 2. GAS - This fault will only occur at the beginning of or during a weld sequence.
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