M9 SERIES WELD HEADS

OPERATION MANUAL
 MODEL 9 SERIES WELD HEAD
OPERATION MANUAL

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 expressed written permission of Arc Machines, Inc.

The information in this document has been carefully reviewed and is believed to be
accurate.

Information and instructions in this document are subject to change and Arc Machines,
Inc. reserves the right to change specifications 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 FLASH SYMBOL indicates that
there are potential electrical hazards. The use and display of these symbols make it the
OPERATOR’S RESPONSIBILITY TO INSURE THAT HE HAS READ AND/OR BEEN
MADE AWARE OF ALL OF THE SAFETY-RELATED ITEMS CONTAINED IN THESE
MANUALS.

Publication date : November, 2011

Copyright 2010 by Arc Machines, Inc.
All rights reserved

REV DCO # CHANGE DESCRIPTION DATE APR

A E6181 First Edition 4/1/11 BL

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 MODEL 9 SERIES WELD HEAD
OPERATION MANUAL

Table of Contents

Chapter Description Page

1.0 Introduction………………..…………………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

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1.0 INTRODUCTION
This manual covers basic set up and maintenance of the following model 9 and
model 9E series weld heads: 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. The operator
should have a working understanding of the power supply being used and should
understand this manual before operating the weld head.

2.0 UNPACKING
When unpacking the weld head use extreme caution in removing the plastic bag
covering the cable connectors. Tools such a knife of other sharp object can cut
the cables.

3.0 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 requirement
for an adapter. If an extension cable is used, it is connected between the power
supply and the adapter. After making connections, slide the rubber boots
together. See figures 1 - 4

Fig. 1
Connect the power and ground fittings by pulling the brass ring back and
inserting the male fitting into the female fitting, until it is fully seated. If it is not
fully seated, it will leak water or potentially come apart.

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3.0 CABLE HOOK UP (contd.)

Fig. 2
To connect the male to female (chrome) gas fittings, 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.

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3.0 CABLE HOOK UP (contd.)

Fig. 4
Slide the boots together securely to protect the connectors and fittings from dirt,
and to prevent the power and ground connectors from coming in contact with
each other.

4.0 WATER COOLING

Most Model 9 series heads are plumbed for water cooling, and are cooled via the
power supply’s (optional) cooling unit. Although water cooling is not required for
all applications, it should always be used when welding tube or pipe wall
thicknesses of 0.065” (1.6mm) or heavier in the Model 9-500C or 0.083” (2.1mm)
or heavier in all 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
the software. Refer to the power supply operation manual for specifics on auto
calibration.

5.1 Should the power supply indicate that the weld head requires
calibration adjustment, the calibration potentiometer can be accessed
through the screw driver slot on the side of the return-to-home switch
housing. See fig. 5. Follow the instructions on your power supply in
making adjustments to the potentiometer.

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5.0 ROTATION (SPEED) AUTO-CALIBRATION (Contd.)

Note: Some larger Model 9 series weld heads provide access to the
calibration potentiometer through an access hole in the side of the
housing, adjacent to the potentiometer. A nylon screw is used to plug
this access hole. Removed it to gain access to the calibration
potentiometer. Replace this screw when calibration is complete.

Fig. 5
Model 9-1500

5.2 ROTATION (SPEED) MANUAL CALIBRATION

Some power supplies do not have 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 calibration.

5.3 Calibration must be run in the “TEST” mode. Create a one level weld
schedule at your selected RPM. Amperage and pulse rate settings
may be set to any value, as during rotation calibration no arc will be
established. Set the rotation mode to “CONT” (continuous rotation).
Set rotation delay and downslope times to 0.0.

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5.0 ROTATION (SPEED) MANUAL CALIBRATION (Contd.)

5.4 Add one additional level with a duration of 5 or more seconds, with
the rotation mode set to “OFF”. This additional level (with rotation
off) will hold the electrode at its stopped position allowing the operator
to see if it traveled too far (traveling too fast) or not far enough
(traveling too slow).

5.5 Be sure the power supply is in the “TEST” mode, and run the program.
Should the electrode rotate too fast (traveling more than 360 degrees),
stopping beyond the home position, slow it down by turning the
potentiometer counter clockwise (CCW). Should the rotation be too
slow (traveling less than 360 degrees) stopping before it reaches a full
360 degrees, turn the potentiometer clockwise (CW). Continue this
procedure until the electrode stops after 360 degrees of travel.

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 inserts is made from one piece, and then split into two
halves. Each half is marked with matching alphanumeric characters.
Keeping matched sets together (on the same side of the weld head) will
result in the highest level of weld joint concentricity.

6.1 Before mounting the clamp insert into the head be sure both the clamp
and weld head clamp mounting groove are clean and free of dirt, oil or
other contaminants. The clamp mounting screw need only be lightly
snug. See fig. 6.

CAUTION
Use of the wrong size clamp, or clamping the head on the curved section of an
elbow or other irregular surface can result in damage to the clamp insert, weld
head clamp latch and/or hinge.

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6.0 CLAMP INSERT & GAS SEAL INSTALLATION (cont’d.)

Fig. 6

6.2 Model 9E and 9ER type heads use a clamp insert on one side, and a
gas seal on the other side of the head. The hole in the gas seal is
approximately 1/8” (3mm) larger than the diameter of the part to be
welded. 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.
Blank gas seals (without a hole in the center) are available for
custom applications. See fig. 7.

Fig. 7
Model 9ER-4500

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7.0 ELECTRODE GEOMETRY & INSTALLATION

CAUTION
To prevent the possibility of electrical shock, the power supply must be in the
“TEST” mode before proceeding with electrode installation or removal. Take
extreme care that fingers or foreign objects are clear of the rotor when jogging.

The recommended electrode type is 2% Ceriated. (AWS Spec. A5.12/A5.12M,

Orange tip). This type of electrode provides superior arc starting and longer life
than 2% Thoriated electrodes. Other types can also be used. Consult factory for
recommendations.

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 length ultimately determines the arc gap, and the arc
gap determines the arc voltage which affects the heat input into the
weld. Thus a consistent arc gap from weld to weld is essential for weld
repeatability.

In order to determine the correct electrode diameter, length and tip

diameter for a specific application, use the charts and formula below.

See figures 8, 9, 10, 11, and 12.

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7.0 ELECTRODE GEOMETRY & INSTALLATION (cont’d.)

Use this chart to determine the weld head Rotor O.D.

Model Rotor O.D.

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)
Fig. 8

Use this chart to establish an appropriate Arc Gap and Electrode Tip diameter

Tube/Pipe Wall Recommended Recommended Tip

Thickness Arc Gap 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) 0.030” (0.8mm)
0.091”-0.154” (2.3-3.9mm) 0.070”-0.090” (1.8-2.3mm) 0.040” (1.0mm)
Fig. 9

Use this chart to determine the electrode diameter.

Tube/Pipe Electrode
Wall thickness Diameter
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)
Fig. 10

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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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7.0 ELECTRODE GEOMETRY & INSTALLATION (cont’d.)

7.3 To change electrodes, using the “JOG” button on the power supply or
remote operators pendant, jog the rotor around until the electrode is
in the 12 O’clock position. See fig. 13.

7.4 Lay the weld head on its side to 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). Using the
correct electrode length, and installing it correctly will assure a correct
and repeatable arc gap. See fig. 14.

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7.0 ELECTRODE GEOMETRY & 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

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8.0 SHIELDING GAS

The type of shielding gas used has a profound effect on the character of the arc
and the depth of weld penetration. The most commonly used shielding gas and
backup (I.D. purge) gas used is Argon. Gas mixtures of 95% Argon/5% hydrogen
or 75% helium/25% argon are sometimes used to achieve deeper penetration.
Consult the factory for recommendations.

8.1 The Model 9 series weld heads work best when the arc gas is set to
the proper flow rate. Excessive flow rates can blow the arc, and flow
rates set too low can cause excessive weld oxidation (discoloration)
and electrode contamination. Use the Manual Purge button on the
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 times will extend the life of the
electrode and produce cleaner welds.

Recommended Recommended
Model Arc Gas Minimum Pre/Post
Flow Rate (CFH) purge times (seconds)
9-750 10-14 (21-29 LPM) 20
9-1500 15-25 (31-52 LPM) 20
9E-1500 25-35 (52-73 LPM) 20
9-2500 25-30 (52-63 LPM) 30
9E-2500 25-40 (52-84 LPM) 30
9-3500 25-30 (52-63 LPM) 30
9E-3500 30-45 (63-94 LPM) 30
9-4500 30-40 (63-84 LPM) 45
9E-4500 30-50 (63-105LPM) 45
9ER-4500 30-50 (63-105 LPM) 45
9-7500 30-40 (63-84 LPM) 60
9E-7500 40-60 (84-126 LPM) 60
Fig. 16

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8.0 SHIELDING GAS (cont’d.)

Note: If the system is being hooked up for the first time, or if it has been a
number of hours since it was last used, it’s a good idea to initiate the
Manual Purge button on the power supply to clear the lines of
oxygen for a few minutes before initiating a weld sequence.

9.0 RETURN-TO-HOME (ROTOR) POSITION ADJUSTMENT

The Model 9 series weld heads will return the rotor to the “home” (open) position
at the end of the weld program, after the post purge time has timed-out. A
properly adjusted 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 require return-to-home adjustment, follow these steps:

9.1 Be sure the power supply is either turned off or in the “TEST” mode.

9.2 Remove the screws holding the lower of the two access covers over
the return-to-home limit switch.

9.3 For Models 9-750 series and 9-1500 series heads, loosen the screw
on the left that holds the return-to-home limit switch bracket. See fig.
18.

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9.0 RETURN-TO-HOME (ROTOR) POSITION 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.)

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9.0 RETURN-TO-HOME (ROTOR) POSITION ADJUSTMENT (cont’d.)

9.4 Slide the limit switch bracket very slightly toward the rotor, (to stop the
rotor sooner) or very slightly away from the rotor (to stop the rotor
later) and re-tighten the limit switch mounting bracket screw(s).

9.5 Turn on the unit, and open a weld schedule.

9.6 Be sure the machine is in the “TEST” mode, and be sure the rotor is
safe to rotate. No tools or fingers in the way. Touch “START”, then
immediately touch “STOP”. The rotor should return to the “HOME”
position. Should the rotor not stop in the correct “HOME” position,
repeat steps 9.3 – 9.6.

9.7 Replace the access cover(s).

10.0 CLEANING 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, which should be cleaned on a regular basis.

10.1 Use isopropyl alcohol and Scotch Brite or steel wool to clean both
brass (male and female) power and ground connectors. Rinse off all
debris and dry before reconnecting.

10.2 After cleaning, use a small amount of o-ring lube, oil or grease on the
female (brass) connector o-ring to facilitate easier connecting.

10.3. Use a clean lint-free cloth and isopropyl alcohol to clean the rotor,
(black) rotor guide ring, weld head housing and view window.

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11.0 STORAGE
If the weld head has been used with water-cooling, and is to be stored for
more than 1 month, the residual water or water/coolant mix should be
purged from the hoses and weld head to minimize internal corrosion.

This is also important if the weld head is to be stored where the

temperature might fall below freezing, as trapped water can freeze and
damage weld head and/or hose 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-PB-06) to the disconnected “supply” line. See Fig. 20.

Fig. 20

11.2 Using a pressurized air source of maximum 20 PSI, (139 Kp)

(1.38 Bar) blow air into the fitting to force the water out of the cables
and weld head, and back into the cooling unit. See fig. 20.

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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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