10500 Orbital Way

Pacoima, California 91331 U.S.A.

MODEL 501 POWER SUPPLY

OPERATION MANUAL

Document No. 740099

Rev. !
 HEADQUARTERS GERMAN OFFICE
Arc Machines, Inc. Arc Machines GmbH
10500 Orbital Way Markelsbach 2
Pacoima, CA 91331 U.S.A. D-53804 Much, Germany
Tel.: 1- 818 896-9556 Tel.: +49/2245 / 91680
Fax: 1-818 890-3724 Fax: +49/2245 / 916868
sales@arcmachines.com sales@arcmachines.de

EUROPEAN OFFICE UK OFFICE

Arc Machines, Inc. Arc Machines UK Limited
Chemin du Lavasson 2 10 Ashurst Court, London Road
CH-1196 Gland Wheatley, Oxford OX331ER
Switzerland England
Tel.: +41 / 22 / 995.00.51 Tel.: +44/1865/872121
Fax: +41 / 22/ 995.00.59 Fax: +44/1865/876909
sales@arcmachines.ch sales@arcmachines.co.uk

!"#$%&'()*$%+&,)-.//00
1&23)4
 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
1 INTRODUCTION
Applications
Hot Wire Application with
AMI Model 415 and M-2

2 SAFE OPERATION
Safety Precautions
M-501 Do’s and Don’ts
Warnings

3 MODEL 501
SPECIFICATIONS

MODEL 501 POWER SUPPLY

4 OPERATION & FUNCTIONS
Hotwire Power Wire Feeder
Supply System Configurations

5 WELDING

OPERATION MANUAL
6 JOINT PREPARATION FOR
HOT WIRE WELDING

7 ELECTRICAL DRAWINGS
General Guidelines for
Welding with Hot Wire GRAPHICAL SYMBOLS
8
INDEX

9 INDEX

!"#$%&'()*"3)-.//00
1&23)4
!"#$%&#'()*+,$-)#.$%/0*1$234$5/67("*$8/7*"$9:;;1<$

Chapter 1. Introduction

Hot-wire set-up with GTAW torch and Model 2

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

=/#:>*)6$?:>@*"$AB33CC$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$D'&;6*"$4.$8&E*$4.
F*G.$H
!"#$%&#'()*+,$-)#.$%/0*1$234$5/67("*$8/7*"$9:;;1<$

$
$
$
$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$Deposition rates for Gas Tungsten Arc
$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$Welding with Cold and Hot Steel Filler
$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$Wire. 5,"%)(6&)789)8&:;<'=)>?';+""@A)
)))))))))))))))))))))))))))))))))))))))*<'(6)B;3A)2004

"#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

=/#:>*)6$?:>@*"$AB33CC$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$D'&;6*"$4.$8&E*$I.
F*G.$H66
!"#$%&#'()*+,$-)#.$%/0*1$234$5/67("*$8/7*"$9:;;1<$

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.

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. Arc Machines Model 415 Windows!-
based Power Supply/Controller

=/#:>*)6$?:>@*"$AB33CC$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$D'&;6*"$4.$8&E*$J.
F*G.$H
!"#$%&#'()*+,$-)#.$%/0*1$234$5/67("*$8/7*"$9:;;1<$

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.

=/#:>*)6$?:>@*"$AB33CC$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$D'&;6*"$4.$8&E*$B.
F*G.$H
!"#$%&#'()*+,$-)#.$%/0*1$234$5/67("*$8/7*"$9:;;1<$

Chapter 2. Safe Operating Procedures

Safety Precautions for Model 501 Operation
AVOID ALL CONTACT
WITH THE WELDING
WORK (GROUND) OR
ELECTRODE DURING ARC
START.

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.
=/#:>*)6$?:>@*"$AB33CC$$$$$$$$$$$$$$$$$$$$$$$$$$$$D'&;6*"$I.$8&E*$4.
F*G.$H
!"#$%&#'()*+,$-)#.$%/0*1$234$5/67("*$8/7*"$9:;;1<$

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.

AMI Model 501 Hotwire Power Supply with cover

removed.

MODEL 501 DO’S AND DON’TS

for Safe Use of Welding/ Hot Wire Equipment

Model 501 and RP

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.

=/#:>*)6$?:>@*"$AB33CC$$$$$$$$$$$$$$$$$$$$$$$$$$$$D'&;6*"$I.$8&E*$I.
F*G.$H
!"#$%&#'()*+,$-)#.$%/0*1$234$5/67("*$8/7*"$9:;;1<$

6. Do CHECK ALL CABLE AND QUICK-DISCONNECT FITTINGS to

insure proper seating.

7. Do KEEP PROTECTIVE COVERS ON THE MOTOR CABLE

CONNECTORS when not in use.

8. Do wear approved safety glasses with side shields.

9. Do use protective screens or barriers to protect from

flash and glare. The intense light associated with arc
welding can cause damage to the retina of the eye, while
infrared radiation may damage to the cornea and result
in the formation of cataracts.

Invisible ultraviolet light (UV) from the arc can cause

"arc eye" or "welder's flash" after even a brief
exposure (less than one minute). The symptoms of arc
eye usually occur many hours after exposure to UV light,
and include a feeling of sand or grit in the eye,
blurred vision, intense pain, tearing, burning, and
headache.

The arc can reflect off surrounding materials and burn

co-workers who work nearby. About half of welder's flash
injuries occur in co-workers who are not welding. Welders
and cutters who continually work around ultra violet
radiation without proper protection can suffer permanent
eye damage.

10. Do wear welding goggles or suitable eye protection

when working around a welding arc.

Exposure to ultraviolet light can also cause skin burns

similar to sunburn, and increase the welder's risk of skin
cancer.

11. Do wear gloves and protective clothing to prevent

burns from hot surfaces and from UV exposure.

12. Do keep your head out of welding fumes. Do not

breathe fumes.

13. Do use a respirator if ventilation is not good.

14. Do read Material Safety Data Sheets (MSDS) and the

manufacturer’s instructions for metals, consumables,
solvents etc.

=/#:>*)6$?:>@*"$AB33CC$$$$$$$$$$$$$$$$$$$$$$$$$$$$D'&;6*"$I.$8&E*$J.
F*G.$H
!"#$%&#'()*+,$-)#.$%/0*1$234$5/67("*$8/7*"$9:;;1<$

15. Do protect gas cylinders and secure them firmly them in

upright position. A damaged cylinder can explode and fly
through the air like a guided missile.

16. Do USE PIPE STANDS, CLAMPS, ALIGNMENT TOOLS,

etc. to hold weld components in position for welding.
Tack welding of components with a manual torch prior to
welding may be necessary in some applications.

MODEL 501 DON’TS

1. Don’t watch the arc. The light can cause blindness.

2. Don’t attempt to weld without a secure BARE METAL WORK

(GROUND) CONNECTION when using the Model 501.

3. Don’t attempt to weld without PROPER FACING AND

CLEANING OF THE MATERIAL to be welded.

4. Don’t route the cables where they will be SUBJECT TO

DAMAGE from traffic or equipment.

5. Don’t C$:: on cables. This will result in DAMAGE TO THE

EQUIPMENT.

6. Don’t add oil or grease to the wire feed mechanism.

7. Don’t increase GAS FLOW RATE (CFH) to GTAW torch

beyond levels that could result in arc instability.

8. Don’t switch the Model 501 Power Supply ON and OFF

rapidly with circuit breaker (CB-1).

RF and EMI Emissions

Arc Machines’ policy is to comply with the IEC and FCC
regulation. Every effort has been made to reduce RF emissions
from our power supplies to the absolute minimum. (See Model
415 Operation Manual P/N 740095 for more information.)

=/#:>*)6$?:>@*"$AB33CC$$$$$$$$$$$$$$$$$$$$$$$$$$$$D'&;6*"$I.$8&E*$B.
F*G.$H
!"#$%&#'()*+,$-)#.$%/0*1$234$5/67("*$8/7*"$9:;;1<$

Model 501 Hot Wire Power Supply

W71*D*E9F
Safety Precautions
This section, concerning safe operating procedures for the
Model 501 Hot Wire Power Supply, should be read and under-
stood before proceeding to other sections of the training man-
ual. It also contains precautions an warnings for the operation of
welding equipment in general. In addition, users should refer-
ence and become familiar with “ANSI-49.1 Safety in Welding and
Cutting” published by the American National Standards Institute.

WARNING: Touching energized electrical parts can cause fatal

shocks and burns. When in weld sequence the electrode and work
are electrically energized. Incorrectly installed or improperly
grounded equipment is a hazard.

WARNING: This equipment is authorized to use a type of arc starter

that produces a High Frequency Radio Wave (sometimes called
HF and/or RF Starting). It can cause interference and sometimes
even damage to nearby electronic equipment (such as computers)
that are unprotected or poorly protected against such interference.

WARNING: Magnetic fields from High Currents can affect pace-

makers. PACEMAKER WEARERS KEEP AWAY UNTIL CONSULTING YOUR
DOCTOR.

WARNING: Disconnect the input power to the machine before

opening or servicing. Discharge all circuits that store high voltage
such as capacitor packs. Only QUALIFIED service personnel should
open this equipment.

=/#:>*)6$?:>@*"$AB33CC$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$D'&;6*"$I.$8&E*$2.
F*G.$H
!"#$%&#'()*+,$-)#.$%/0*1$234$5/67("*$8/7*"$9:;;1<$

MODEL 501 WARNINGS Continued:

WARNING: Welding can cause fires or explosions. Do not weld near

flammable or explosive materials. Watch for fire. Have proper type
of extinguisher in work area.

WARNING: Welding Operators should wear non-flammable

protective clothing, footwear and head gear.

WARNING: Never weld on sealed containers or pipes. This may

result in an EXPLOSION.

WARNING: Welding produces high temperatures in both the

welded components and the welding equipment. Both can cause
severe burns. Do not touch recently welded components. Avoid
touching internal components of the welding system soon after use.
Avoid touching torch components and welding fixtures soon after
welding.
WARNING: The welding arc emits ultra-violet (UV) radiation and the
molten weld gives off infra-red. Both can burn eyes and skin if
unprotected. Suitable eye and skin protection must be worn.

WARNING: Weld materials can emit toxic fumes during welding.

HEXAVALENT CHROMIUM, which is given off when stainless steel is
welded, causes lung cancer in humans. See Semi F79-0703
Appendix- HEXAVALENT CHROMIUM ALERT. WELD ONLY IN
AREAS WITH ADEQUATE VENTILATION.

=/#:>*)6$?:>@*"$AB33CC$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$D'&;6*"$I.$8&E*$K.
F*G.$H
!"#$%&#'()*+,$-)#.$%/0*1$234$5/67("*$8/7*"$9:;;1<$

MODEL 501 WARNINGS Continued:

WARNING: Most GTAW gases like argon are non-toxic, however,

argon is heavier than air and will displace the normal atmosphere in
enclosed areas. DO NOT WELD IN ENCLOSED AREAS WITH-
OUT PROPER VENTILATION OR RESPIRATORS.

WARNING: AMI factory training is essential for all Welding Opera-

tors and Maintenance Technicians who operate AMI equipment.
Consult factory for dates of training classes and other training
information.

WARNING: Some systems, such as the M-501 Power Supply are

intended solely for indoor use and must be kept dry. Before operat-
ing, storing, or handling, always make sure that the M-501, M-501-
Operator Pendant, weld heads and cables are not exposed to rain
or standing water. SYSTEM COMPONENTS ARE NOT WATER
PROOF.
WARNING: Keep hands and fingers clear from moving parts such
as fans, gears, rotors, and Rotation Mechanisms.

The wire for the M-501 feeds at a high rate of speed and as it
enters the puddle is at near melting temperature. Take care to avoid
contact with the wire. Keep eyes protected.

=/#:>*)6$?:>@*"$AB33CC$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$D'&;6*"$I.$8&E*$A.
F*G.$H
!"#$%&#'()*+,$-)#.$%/0*1$234$5/67("*$8/7*"$9:;;1<$

Chapter 3. Specifications for the Model 501 Power

Supply
AMI Model 501
True RMS Hotwire Precision Power Supply
Features
" Calibrated Precision Closed Loop Servo Output Control
" Constant Voltage (CV) True RMS mode-of-operation
" Constant Current (CC) True RMS mode-of-operation
" Voltage Feedback Sensing at the wire feed tip or internal to
the power supply
" True RMS instrumentation Outputs (Amps and Volts)
" Optional Manual Remote Programming Pendant
" Control input for connection to an external
controller/programmer

Basic Specifications
Input: 200 to 240 VAC 25 AMPS
1Ø
Output: CC Mode 250 Amps true +/- 3% maximum
RMS AC
CV Mode 0-10 Volts true +/- 3% maximum
RMS AC
Open Circuit Voltage: 16 VAC
Loop Response: 1.2 Seconds
Duty Cycle: 100%

Weight: 135 lbs (61.5 kg)

Dimensions: 23 x 19 x 9.5 inches (585 x 485 x 240
mm)

Remote Control Interface (External Controller)

Voltage/Current CC Mode: 0.025 Volts/Amp input (2.50 VDC = 250 A RMS AC
Level: Output)
CV Mode: 0.100 Volts/Volt input (1.00 VDC = 10 V RMS AC
Output)
All Control Inputs: 0.5 M! Input Impedance

Power Supply Enable: Contact “closed” or input 5-24 volt VAC/VDC, 7- 40 mA

Mode of Operation CC Mode: Contact “closed” or input 5-24 VAC/VDC, 7- 40 mA

Select: CV Mode: Contact “open” or input <5 VAC/VDC, 7- 40 mA

Data Collection Amperage Monitor 2.50 VDC = 250 A True RMS Output
Signals:
Voltage Monitor 1.00 VDC = 10 V True RMS Output
Common Ground, 2 mA Load Maximum

=/#:>*)6$?:>@*"$AB33CC$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$D'&;6*"$J.$8&E*$4.
F*G.$H
!"#$%&#'()*+,$-)#.$%/0*1$234$5/67("*$8/7*"$9:;;1<$

Model 501 Remote Operator Pendant

Model 501 Remote Operator Pendant

An AMI Wirefeed head and wire feed torch may be used on the Model 2
in conjunction with the Model 501 Power Supply.

=/#:>*)6$?:>@*"$AB33CC$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$D'&;6*"$J.$8&E*$I.
F*G.$H
!"#$%&#'()*+,$-)#.$%/0*1$234$5/67("*$8/7*"$9:;;1<$

Chapter 4. Model 501 Power Supply Operation and

Function

The Model 501 Hot Wire Power supply can be used as a stand-alone unit with
its own operator pendant, it can be operated by an Arc Machines Model 415
GTAW Power Supply, or by an external weld process controller or program-
mer. The cable connections will depend on how the system is configured. A
special cable and servo for the M-415 are available by special order and may
be required for operation of the hot wire system by the Model 415. The servo
can be installed on site by a qualified electrician. A weld head definition for
the GTAW head being used with the 501 must reside in the Model 415.

Water Cooling. Due to the high amperage typically used with hot
wire applications, water cooling of the GTAW torch is highly recom-
mended.

Wire Feeder. The Model 501 does not control the wire feeder, it only sup-
plies the current to heat the wire. When the Model 501 is used as a stand-
M-501 remote connector,
connects to 501 Remote
Programming Pendant. If M-415
is used this connects a cable to
the 415 and the 415 controls
the 501. A weld head definition
including the hot wire torch is
required.

Circuit Breaker (ON/OFF)

Input Power connector

Connector for an external

enable signal such as from
a Jetline# controller.

Hot Wire AC Current

Connectors

Connector to external
A
voltage sensor. Requires
sense and ground wires. V

=/#:>*)6$?:>@*"$AB33CC$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$D'&;6*"$B.$8&E*$4.
F*G.$H
!"#$%&#'()*+,$-)#.$%/0*1$234$5/67("*$8/7*"$9:;;1<$

alone unit, a separate external wire feed controller, or a component of the

GTAW power supply is required. When the 501 is used in conjunction with the
AMI Model 415 Power Supply, the wire feed speed is controlled by the Model
415.

Possible System Configurations using the Model 501 Hotwire

Power Supply.
The Model 501 is flexible and can be configured in a variety of ways
depending on customer application and requirements. Some examples are
given here. Consult factory for any special cable requirements.

Model 501 used as a Stand-Alone Unit

Controller

Set-Up of Model 501 as a stand-alone unit controlled by the 501 Remote Programming
Pendant. The GTAW power supply and wire feed with controller are separate systems.

=/#:>*)6$?:>@*"$AB33CC$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$D'&;6*"$B.$8&E*$I.
F*G.$H
!"#$%&#'()*+,$-)#.$%/0*1$234$5/67("*$8/7*"$9:;;1<$

Model 501 used with an AMI Model 415

415
REMOTE
PENDANT

Wire
Feeder

Set-Up of Model 501 Power Supply used in conjunction with an Arc Machines’ Model 415
GTAW power source. Wire feed and hot wire current controlled by Model 415.

Operation of the Model 501 by an External Controller

External
Controller Wire Feeder

S2

Operation of the Model 501 Hot Wire Power Supply by an External Controller. The
controller plugs in to the “remote operation” bypass switch, S2. The controller con-
trols the Model 501 hot wire current, a separate wire feeder, and the GTAW power
supply.

=/#:>*)6$?:>@*"$AB33CC$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$D'&;6*"$B.$8&E*$J.
F*G.$H
!"#$%&#'()*+,$-)#.$%/0*1$234$5/67("*$8/7*"$9:;;1<$

Hot wire remote connector pins

Model 501

Hot Wire Remote Connector Pins Description 17 Sep. 2004

Pin # Signal Description

A Frame ground
B System enable input ( 5 – 24V ) Insulated from analog ground
C NC
D System enable input (5 – 24V ) Insulated from analog ground
E +10 V reference output Insulated from analog ground
F + 5V meter Power output Not insulated from analog ground
G Voltage meter signal Not insulated from analog ground
H Current meter signal Not insulated from analog ground
J System enable input Insulated from analog ground
K Command signal input (+) Insulated from analog ground
L Command signal input (-) I Insulated from analog ground
M System analog ground
N CP/ CC control Not insulated from analog ground
P CP / CC control Not insulated from analog ground
Q
R
S
T
U
V
W
X
Y
Z

=/#:>*)6$?:>@*"$AB33CC$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$D'&;6*"$B.$8&E*$B.
F*G.$H
!"#$%&#'()*+,$-)#.$%/0*1$234$5/67("*$8/7*"$9:;;1<$

Chapter 5. Welding with the Model 501 Hot Wire

Power Supply
Operation. It is highly recommended that
the hot wire sense (Voltage Feedback
Input) input be utilized with the Model
501 power supply. The key feature of the
Model 501 is the accuracy and repeat-
ability of the wire heating. Using Voltage
Feedback is much more accurate and
therefore results in more repeatable
welds than sensing through the hot wire
and welding ground cables. Using this
feature requires the connection of a wire
from the hot wire guide tube, and a wire
from work ground to the Voltage Feed-
back Input receptacle on the Model 501
power supply. The preferred connection
point on the hot wire guide tube is the
Allen screw that connects the AC power
cable to the guide tube, the ground con-
nection should be to a good work ground
location. A manipulator on the hot wire torch
provides 3-axis control for precise
positioning of wire into the weld pool.
In many cases, the Model 501 will be an
addition to a customer’s existing cold
wire GTAW (TIG) welding installation. In these cases, the joint
preparation, welding amperage, wire diameter and wire feed
speed have already been established. When the Arc Machines’ hot
wire system is added to an existing system, some changes are
necessary. The hot wire guide tube, should be insulated and
aimed at the trailing edge of the weld puddle. The wire entry angle of 45 to
50 degrees is typically steeper than is common with cold wire. Because of the
wide variation of applications, only general instructions can be provided, the
user must expect to “tune-in” the system values by trial and error. For a
given wire feed speed, if the voltage setting is too high, a “popping” noise will
be heard as the wire melts before entering the puddle. If the voltage is too
low, the wire will not be completely consumed in the weld puddle and will
“bird’s nest.” When the voltage is correct, and the wire is properly melting in
the puddle, the wire will narrow about 1/16” (1.5mm) before it enters the
puddle and a faint hum, or buzz, corresponding to the hertz of the system
input voltage (50 Hz or 60 Hz) will be audible near the weld puddle. After this
is achieved, the wire feed speed can be increased and the Model 501 voltage

=/#:>*)6$?:>@*"$AB33CC$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$D'&;6*"$2.$8&E*$4.
F*G.$H
!"#$%&#'()*+,$-)#.$%/0*1$234$5/67("*$8/7*"$9:;;1<$

adjusted accordingly. Arc Machines recommends that wire feed speed be

increased in stages and the hot wire voltage adjusted accordingly, until an
optimum balance between welding or cladding current, wire feed speed and
hot wire voltage is achieved. For new installations, a similar “trial and error”
procedure should be followed.

Welding with the Model 501 is application-dependent and thus giving specif-
ics for a particular welding procedure is not practical. However, in general the
operator forms a puddle with the GTAW system and begins feeding wire. Ide-
ally there should be no depression in the puddle. Wire melts as it enters the
puddle and rolls in smoothly. If a depression forms in the puddle or the wire
hits the bottom of the puddle, then adjust the hot wire power or wire feed
speed until the puddle smooths out. If the wire is “popping” in space and
burning back this indicates there is too much hot wire power or not enough
wire feed.

Good wire “stick-out” must be maintained. Stick-out is the length of exposed

wire between the end of the wire feed tube and the weld pool. Maintaining a
constant wire stick-out length and contact point on the puddle is important
for maintaining consistency of process from set-up to set-up. Changing the
stick-out changes the resistance value and makes it impossible to achieve
repeatability of process.

=/#:>*)6$?:>@*"$AB33CC$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$D'&;6*"$2.$8&E*$I.
F*G.$H
!"#$%&#'()*+,$-)#.$%/0*1$234$5/67("*$8/7*"$9:;;1<$

Chapter 6. Joint Preparation for Hot Wire GTA

Welding

8'/6/$@<$!"#$%&#'()*+,$-)#.
P reparation of the joint is a key to the success of automatic welding
procedures. The advantages of hot wire technology can best be realized in
downhand welding where the highest deposition rate can be achieved. This
would most likely be either a flat surface such as for cladding operations or
joining of circumferential joints in the 1G welding position in which the
weldment is rotated and the electrode remains stationary.

Joint preparations are considerably more critical for automatic welding

applications than for manual applications. Since welding equipment does not
sense or react to changes in the preparation, the preparation and fit-up must
be precise in order to realize the repeatability and consistency expected of
automatic machine or orbital welding. The use of machining tools designed for
precision joint preparation is strongly recommended. It should be understood
that weld programs are very prep-sensitive which means that even small
changes in preparation geometry can have major effects on weld quality.

=/#:>*)6$?:>@*"$AB33CC$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$D'&;6*"$K.$8&E*$4.
F*G.$H
!"#$%&#'()*+,$-)#.$%/0*1$234$5/67("*$8/7*"$9:;;1<$

Hot Wire GTA welding of pipe is most efficient

when the pipe can be rotated and the electrode
remains in place.

=/#:>*)6$?:>@*"$AB33CC$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$D'&;6*"$K.$8&E*$I.
F*G.$H
!"#$%&#'()*+,$-)#.$%/0*1$234$5/67("*$8/7*"$9:;;1<$

Chapter 7. Assembly and Electrical Drawings

The following documents are attached:

1. 501 Hotwire PS Basic Assembly Drawing 25E010101

2. 501 Hotwire PS Remote Pendant Assembly Drawing 25E010102

3. 501 Hotwire PS Wiring Diagram 47E010101

4. 501 Hotwire Remote Control Wiring Diagram 47E010102

5. 501 Hotwire PS Wiring Diagram CE 47E010105

=/#:>*)6$?:>@*"$AB33CC$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$D'&;6*"$A.$8&E*$4.
F*G.$H
!"#$%&#'()*+,$-)#.$%/0*1$234$5/67("*$8/7*"$9:;;1<$

Chapter 8. Icons and Symbols

Table 1. Graphical Symbols Index

NO. Symbol Function, Key- Application Source
word or Phrase

Line To Signify a Power Line ANSI/NEMA

1 or Cord

Circuit Breaker To Signify a Circuit ANSI/NEMA

2 Breaker in an Electrical
Circuit

Direct Current Signifies Direct Current IEC 417

3 (DC) 5031

Earth (Ground) To Signify the Earth IEC 417

4 (Ground) Connection 5017

Work Connection To Signify a Work Piece ISO 7000-0453

5 Connection

Electrode Nega- To Signify Electrode ANSI/NEMA

6 tive Negative Connection or
Switch Position

7 Electrode To Signify an Electrode ANSI/NEMA

8 Ventilating and To Signify a Ventilating ISO 7000-0089

Air Circulating Fan or Air Circulating
Fan

9 Protective Boots To Signify Secure Con- AMI

over Cable nection with Protective
Connector Boots

10 Exclamation Point To Signify Warning, Dan- IEC 417

ger, Caution 5036A

11 Lightning Symbol for Severe Elec- IEC 417

trical Shock Hazard 5036A

=/#:>*)6$?:>@*"$AB33CC$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$D'&;6*"$L.$8&E*$4.
F*G.$H
!"#$%&#'()*+,$-)#.$%/0*1$234$5/67("*$8/7*"$9:;;1<$

Table 1. Graphical Symbols Index

12 Dangerous Volt- To Signify Dangerous IEC 417
age Voltage 5036A

13 Read Operator’s To Signify that the Oper- SAE

Manual ator’s Manual Should be
Read

14 Torch Signifies a Welding or ANSI/NEMA

Cutting Torch

15 Gas Tungsten Arc To Signify a GTAW Torch ISO 7000-0465

Welding (GTAW)
Torch

16 Tack Welding To Signify Tack Welds ISO 7000-0465

(GTAW) with a GTAW Torch

17 Orbital GTAW To Signify the Orbital ISO 7000-0465

GTAW Process AMI

18 Input Voltage/ To Signify Input Voltage IEC 417

V

Power (Power) 5034

ANSI/NEMA

19 Pipestand To Signify use of a AMI

Pipestand

20 Stop of Action To Signify the Stop (of ANSI/NEMA

Action) Function or Con-
trol

21 Process Cycle To Signify One Com- ANSI/NEMA

plete Process Cycle
(Weld Sequence)

22 Weld Current To Signify Welding Amps ANSI/NEMA

During Process Cycle

23 Arc Volts To Signify Arc Volts Dur- ANSI/NEMA

ing Process Cycle

=/#:>*)6$?:>@*"$AB33CC$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$D'&;6*"$L.$8&E*$I.
F*G.$H
!"#$%&#'()*+,$-)#.$%/0*1$234$5/67("*$8/7*"$9:;;1<$

Table 1. Graphical Symbols Index

24 Pulse Signifies Pulse Function ANSI/NEMA
or Control

25 Sequence To Signify Advancing to ANSI/NEMA

Advance the Next Sequence
Event (Level)

26 Sequence To Signify Returning to ANSI/NEMA

Deadvance the Previous Sequence
Event (Level)

27 Air (Gas) Pres- To Signify Air (or Gas) ANSI/NEMA

sure Pressure Function or
Control

28 Purge by Gas To Signify Purging of Air ISO

(by Gas) 7000-0474

29 Remote Signifies Remote Opera- ANSI/NEMA

tion or Control

30 Start To Signify the Start (of ANSI/NEMA

Action) Function or Con-
trol

31 Pushbutton To Signify a Pushbutton ANSI/NEMA

Switch used to Start or
Stop a Function

32 Panel/LOCAL To Signify Panel/Local ANSI/NEMA

Function or Switch such
as a Switch to Change
Between a Local Control
and a Remote Control

33 ON-OFF Switch To Signify an ON-OFF ANSI/NEMA

Switch

34 Receptacle To Signify a Receptacle ANSI/NEMA

Type Connector

35 ON To Signify the ON State ANSI/NEMA

of a Function

=/#:>*)6$?:>@*"$AB33CC$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$D'&;6*"$L.$8&E*$J.
F*G.$H
!"#$%&#'()*+,$-)#.$%/0*1$234$5/67("*$8/7*"$9:;;1<$

Table 1. Graphical Symbols Index

36 OFF To Signify the OFF State ANSI/NEMA
of a Function

37 Hand To Signify Manual ANSI/NEMA

Control of a Function or
Tool

38 Disturbance (or To Signify a Disturbance ISO 7000-0228

change) in the Proper Run of a
Procedure, or Fault Con-
dition

39 Fast To Signify Fast Action or SAE

Operation

40 Slow To Signify Slow Action or SAE

Operation

41 Travel Speed To Signify Travel or Run SAE

Speed

42 Electrode Travel To Signify Travel Speed SAE

Speed of the Electrode or Torch ANSI/NEMA
AMI

43 Direction of To Signify Direction of ANSI/NEMA

electrode travel Electrode Travel /AMI

44 Electrode Travel To Signify the Time after ANSI/NEMA

Start Delay Arc Start that the Elec- /AMI
trode Begins to Move

45 Electrode Travel To Signify the Time ANSI/NEMA

Stop Delay between the end of the /AMI
last Level and travel
Stop.

46 ALL STOP To Signify shut down of ANSI/NEMA

Power Supply AMI

47 Sequence STOP To Signify stopping of ANSI/NEMA

the weld cycle AMI

48 Sequence START To Signify initiation of ANSI/NEMA

weld sequence AMI

=/#:>*)6$?:>@*"$AB33CC$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$D'&;6*"$L.$8&E*$B.
F*G.$H
!"#$%&#'()*+,$-)#.$%/0*1$234$5/67("*$8/7*"$9:;;1<$

Table 1. Graphical Symbols Index

49 Start Delay Time To Signify a Timed Delay ANSI/NEMA
in Starting a Function AMI

50 Stop Delay Time To Signify a Timed Delay ANSI/NEMA

in Stopping a Function AMI

51 Rotating Switch To Signify Increase or ANSI/NEMA

Decrease of a Quantity
by Rotating

52 Rotating Switch Signifies an increase/ ISO

with Set Positions decrease of quantity N95 31
with a rotary control in
steps

53 A Amperage (con- To Signify Amperage or S1

trol) Amperage Control

54 V Voltage (control) To Signify Voltage or S1

Voltage Control

55 HF High Frequency S1

56 HZ HERTZ To Signify Cycles per S1

Second

57 5G 5G Welding To Signify Pipe Horizon-

Position tal Position

58 Wire Feed To Signify a Wirefeed ANSI/NEMA

Unit or Wirefeed Func-
tion

59 Wirefeed Manual Cold Jog (Inch) Towards ANSI/NEMA

Advance Workpiece

60 Wirefeed Retract Cold Jog (Inch) Away ANSI/NEMA

Manual From Workpiece

61 Wirefeed To Signify the Feeding of ANSI/NEMA

Advance Wire Forward Towards
the Workpiece

62 Wirefeed Retract To Signify the Feeding of ANSI/NEMA

Wire Away from the
Workpiece

63 Wirefeed Speed To Signify the Speed of ANSI/NEMA

Wirefeed Advance AMI

=/#:>*)6$?:>@*"$AB33CC$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$D'&;6*"$L.$8&E*$2.
F*G.$H
!"#$%&#'()*+,$-)#.$%/0*1$234$5/67("*$8/7*"$9:;;1<$

Table 1. Graphical Symbols Index

64 Wirefeed Start To Signify the Time after ANSI/NEMA/AMI
Delay Sequence Start that
Wire begins to Feed

65 Wirefeed Stop To Signify the Amount of ANSI/NEMA/AMI

Delay Time Time Programmed for
Wire Stop Delay

66 Wire Diameter To Signify the Diameter ANSI/NEMA

of the Welding Wire

67 Wire Manipulator To Signify the Position or ANSI/NEMA

Position Position Control of the AMI
Wire Manipulator

68 Diameter Signifies diameter such ANSI

as the diameter of wire Y14.5 M
or electrode (or pipe) 1982

69 Leading Wire To Signify Wire Entry ANSI/NEMA

Entry into the Leading Edge of AMI
the Weld Pool

70 Trailing Wire To Signify Wire Entry ANSI/NEMA

Entry into the Trailing Edge of AMI
the Weld Pool

71 Users Symbol To indicate that only Microsoft/AMI

qualified users should
operate equipment

=/#:>*)6$?:>@*"$AB33CC$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$D'&;6*"$L.$8&E*$K.
F*G.$H
!"#$%&#'()*+,$-)#.$%/0*1$234$5/67("*$8/7*"$9:;;1<

D';&G
A Draw-
ing,
AC current, 1.2
7.3
AC voltage, 1.2
501 Hotwire Wiring Diagram, 7.4
alignment, 2.4
duplex stainless steels, 1.3
alignment tools, 2.4
ANSI-49.1 Safety in Welding and Cutting, E
2.5 electric shock, 2.1
Applications, 1.2 external controller, 4.3
arc blow, 1.2 external voltage sensor, 4.1
arc eye, 2.3 external wire feed controller, 4.2
Arc Starting, 2.2 eye protection, 2.1
Arc Welding Precautions, 2.1 F
B facing, 2.4
birds nest, 5.1 fit-up, 6.1
bleeder circuit, 2.2 G
bypass switch, S2, 4.3 gas cylinders, 2.4
C gas flow rate, 2.4
circuit breaker (CB-1), 2.4 ground connection, 5.1
Circuit Breaker (ON/OFF), 4.1 ground (work) connection, 2.4
cladding GTAW
cladding current, 5.2 GTAW head, 4.1
cladding operations, 6.1 GTAW power supply, 4.2, 4.3
demonstration, 1.3 GTAW process, 2.2
cold wire, 1.1 GTAW torch, 1.1, 2.1
Connector, 4.1 GTAW torch cooling, 4.1
constant current mode, 1.2 H
Controls
HF Arc Start, 2.2
current, 1.1
high amperage, 4.1
voltage, 1.1
high voltage, 2.2
Cooling
high-nickel alloys, 1.3
water cooling, 4.1
hot wire
corrosion resistance, 1.3
downhand welding, 1.3
D hot wire AC Current, 4.1
deposition rates, 1.2, 6.1 hot wire current, 4.3
digital data acquisition, 1.4 hot wire GTA welding of pipe, 6.2
Don’ts, 2.4 hot wire GTAW, 1.3
downhand welding, 6.1 hot wire guide tube, 5.1
DO’S, 2.2 hot wire power, 5.2
Do’s and Don’ts, 2.2 hot wire remote connector pins, 4.4
drawings hot wire sense, 5.1
Hotwire Power Supply Basic Assembly hot wire torch, 1.3, 4.1, 5.1
Drawing, 7.1 hot wire tube, 2.1
Hotwire Power Supply Basic Assembly hot wire voltage, 1.2
Drawing - Page 2., 7.2 hot-wire torch, 1.4
Hotwire Remote Control Assembly I
Drawing, 7.5 Input Power connector, 4.1
Remote Control Wiring Diagram, 7.6 input voltage, 5.1
501 Hotwire Remote Control Assembly

!"#$%&'()*"3)-.//00)))))))))))))))))))))))))))))))D';&G3)H?=&)I
1&23)4
!"#$%&#'()*+,$-)#.$%/0*1$234$5/6$M("*$8/7*"$9:;;1<

D';&G))#"'(<'$&;K)
internal voltage, 1.2 stick-out, 5.2
J System Configu-
rations, 4.2
Joint preparations, 6.1
M T
tanks and vessels, 1.3
machining tools, 6.1
manipulator - 3-axis control, 5.1 TEST mode, 2.1
mechanical properties, 1.3 trailing edge, 5.1
metallurgy, 1.3 true RMS, 1.2
Model 2, 1.1, 1.3, 1.4 true sine wave, 1.2
Model 415 GTAW power supply, 1.2, 1.3, V
1.4, 4.1, 4.2, 4.3 voltage, 1.1, 5.1
Model 501 specifications, 3.1 open circuit voltage, 2.1
Modified ‘J’ Prep, 6.2 voltage feedback input, 5.1
multi-servo control, 1.4 W
M-501 remote connector, 4.1 Warnings
O Disconnect the input power, 2.5
orbital applications, 1.3 Do not weld in enclosed areas, 2.7
orbital welding, 6.1 emission of toxic fumes, 2.6
P energized electrical parts, 2.5
factory training is essential, 2.7
personnel, 2.2
fires or explosions, 2.6
pipe stands, 2.4
High Frequency Radio Wave, 2.5
preparation geometry, 6.1
Magnetic fields, 2.5
protective covers, 2.3
never weld on sealed containers or
Q pipes, 2.6
quick-disconnect, 2.3 non-flammable protective clothing,
R 2.6
remote service personnel qualifications, 2.5
remote connector, 4.1 severe burns from touching newly
remote programming pendant, 4.1, welded components, 2.6
4.2 System components are not water-
RF, 2.2 proof, 2.7
RF and EMI emissions, 2.4 welding arc emits ultra-violet (UV) ra-
diation, 2.6
S water cooling, 4.1
safety glasses, 2.3 wire
safety precautions, 2.1, 2.5 wire entry angle, 5.1
screens or barriers, 2.3 wire feed, 4.3, 5.2
SEMI wire feed speed, 4.2, 5.1
SEMI F79-0703, 2.6 wire feeder, 4.1
sense and ground wires, 4.1 wire feeder, separate, 4.3
sequence, 2.1 work-cell manufacturing, 1.4
servo, 4.1
SHOCK HAZARD, 2.1
Numerics
stand-alone unit, 4.1, 4.2 1G welding position, 1.2, 6.1
300 series stainless steel, 1.3

!"#$%&'()*"3)-.//00)))))))))))))))))))))))))))))))D';&G3)H?=&)J
1&23)4