Bad Start Check all Power and Ground connections.

Transcription

1 Bad Start Check all Power and Ground connections. 1. Check weld head power & ground connections to the adapter cable or pig-tail adapter. 2. Check power & ground connections at the power supply. 3. Check all power & ground connections at both ends of extension cable(s), if used. Note: When using the Model 96 weld head (or any other weld head that does not incorporate the ground through the weld head) check the connections at both ends of the external ground cable. Check electrode. 1. Verify that the correct electrode is properly installed. Refer to weld head operator manual for electrode installation, geometry and arc gap recommendations. 2. Check for electrode contamination. Replace if in doubt. Note: Although many types of tungsten electrodes are available, AMI recommends the use of 2% Ceriated tungsten electrodes only. AWS EWCe-2 (orange) or ISO CW20 & JIS Z YWCe-2 (gray). Check arc gas type, flow rate & pre-purge time. 1. Verify that the correct gas type is being used, and that the gas is not contaminated. Refer to weld head operator manual for gas type recommendations. If gas quality is in doubt, use an alternate gas source. Check pre-purge time & arc gas flow rate. Refer to weld head operator manual for recommended (minimum) pre-purge time and flow rates

2 Bad Start Check Input voltage. 1. Verify that input power is a dedicated line. Additional equipment on the same circuit can draw down the current, causing a Bad Start. 2. Check Voltage bar graph (bottom of screen 3. If voltage is shown on the bar graph, while the unit is idling (not in welding mode) there is an internal power supply fault which must be corrected by the AMI factory service department. Gas Fault Check all arc gas connections 1. Check arc gas input connection. (Left side of power supply) 2. Check arc gas output connection. (Right side of power supply) 3. Check all arc gas cable connections. Note: Chrome quick-disconnect fittings must be fully engaged and latched for gas to flow through the fitting. Use latch locking screw to prevent accidental disconnection. Check arc gas flow rate. 1. Minimum flow rate required is 7 CFH (3.3 LP) Refer to weld head operator manual for gas flow rate recommendations.

3 Printer fault Check paper, printer light, and or try printing another weld schedule file. 1. Verify that the printer has paper, and that the paper is properly installed. Refer to power supply operator manual for details. 2. If bad sectors are being printed, confirm that green light (on the printer) is lit. If it is blinking, the access door of the printer is not properly closed. 3. If problem persists, try printing another weld schedule. If this corrects the problem, the weld schedule that will not print properly is corrupted. Replace with a new program file. Unit Overheats Check ambient temperature. Confirm a maximum ambient temperature of 104F (40C). 1. Check to be sure the unit is properly ventilated. Remove any and all airflow obstructions. 2. If working outside in sunlight, move the unit to a shaded place, and allow the unit to cool for 15 minutes. 3. If steps 1 and/or 2 do not correct the UNIT OVERHEATS status, from the weld schedule home (start sequence) screen, press CALIBRATE.

4 Unit Overheats If blue screen displays I/O UNIT IS NOT CONNECTED, there is an internal power supply problem that must be corrected by the factory. Contact the AMI Service Department. Frozen Screen This may be caused by an incompatible weld schedule. If your weld schedule was created using M205 software version 1.1, and the machine was later upgraded to 1.3 or above, weld schedules created with software version 1.1 cannot be used with version 1.3 or above.

5 Frozen Screen When any key is pressed the screen freezes. 1. Turn off M205 Power Supply. 2. Connect a keyboard into the USB port. 3. Turn on M205 Power Supply, and wait for unit to boot up. 4. On key board Press CNTRL+ALT+DELETE 5. Windows task manager will appear, using keyboard arrows, scroll down to select M205.exe, press End Process in window. 6. A window will appear Task Manager Warning select Yes

6 Frozen Screen 7. On Microsoft main screen Select Start, Run 8. On command screen type C:\ then press enter.

7 Frozen Screen 9. Select all sch files and delete 10. Go back to Home screen, shut down, then Restart power supply.

8 Frozen Screen Disconnect AC power cord from power supply, and measure for appropriate voltage. Verify that voltage selector switch (behind the input connector panel) is set to match the voltage supplied. Refer to power supply operator manual for input voltage details. Check that both ends of AC power cable are fully connected 1. If proper voltage is present, contact AMI service department. Note: If CB1 circuit breaker (on/off switch) trips when raised to the ON position, there is an internal fault. DO NOT ATTEMPT TO OPERATE THE MACHINE! Disconnect power and contact the AMI service department. Weld head rotor will not rotate Check motor control connections at power supply, and at all cable junctions. 1. Motor control connectors must be clean and free of contaminants. Note: Be careful not to cross-thread the connectors threaded ring. Try an alternate weld head 2. If an alternate weld head is available, check it. If it rotates, there is no problem with the power supply. If it does not rotate, the problem may be associated with the power supply, the adapter cable or extension cable (if used). Check cables 3. If an adapter or extension cable is used, check for cable problems by connecting the weld head motor control connector directly to the power supply, (eliminating the adapter cable and extension cable if used). If this corrects the problem, there is a short in the adapter cable or extension cable. * If the fault persist contact AMI Customer Service.