Exel Orbital EPS-2000, Operation Manual

Page 1: ...Page C Copyright 2005 Exel Orbital All Rights Reserved 1 2 3 4 5 6 Version 1 01 Date June 2005 ...

Page 2: ... Main Memory Moving a Weld Schedule from CF Card to Main Memory Page 11 Moving a Weld Schedule from Main Memory to CF Card Moving a Weld Schedule from Main Memory to CF Card Moving a Weld Schedule from Main Memory to CF Card Page 12 Creating a Weld Schedule 4 Level Weld Page 14 Creating a Weld Schedule S3 Page 17 Viewing or Modifying a Weld Schedule Page 18 Chapter 4 Making a Weld Page 19 Weld Tra...

Page 3: ...Exel Orbital All Rights Reserved 1 2 3 4 5 6 C Copyright 2001 Exel Orbital Systems All Rights Reserved EPS 2000 Power Supply Chapter 1 Start Chapter 1 Start Chapter 1 Start Up Up Up Version 1 11 01 Revision Date November 2001 ...

Page 4: ...ase This case is suitable for shipment Open the case by unlatching the 6 latches Open the lid of the case If the lid does not open readily there may be a vacuum inside due to air travel Push the pressure release button then open the lid In the bottom of the case is the power supply operations manual the line cord and a purge connector Place the power supply on a stable work surface ...

Page 5: ... 2000 Power Supply Above is the Exel RDR 05 Rotor Driver The line cord provided is 20 amp rated for 250 volt service The EPS 2000 Power Supply can oper ate Arc Machines orbital welding heads as well A source of purge for the power supply is required Use the purge connector provided It may be necessary to cut off the plug provided on the line cord and replace it with one suitable for the outlet int...

Page 6: ...ound motor gas and remote if applicable of the welding head to the power supply Chapter 1 Start Up Notes 1 The EPS 1000 does not require a dedicated circuit 2 Power Input 85 to 265 volts and 47 to 63 hertz 3 Purge Input 15 to 80 psi or 100 to 530 Kpa Above is a view of the back of the EPS 2000 Power Supply with all necessary connectors visible Connect the Argon or mixed gas purge inlet from the so...

Page 7: ...tch on Chapter 1 Start Up The Main Screen will appear on the touch screen Select the desired Language then touch any spot on the screen to continue The Library Screen above appears so that a weld schedule may be created or loaded from memory If Password protection selected enter that password here 1 2 ...

Page 8: ...All Rights Reserved 1 2 3 4 5 6 C Copyright 2001 Exel Orbital Systems All Rights Reserved EPS 2000 Power Supply Chapter 2 Library and Memory Chapter 2 Library and Memory Chapter 2 Library and Memory Version 1 11 01 Revision Date June 2005 ...

Page 9: ...l Orbital All Rights Reserved 1 2 3 4 5 6 Loading a Weld Schedule from the Main Memory Select the desired weld schedule from the Main Memory in the left column Select Load Schedule The selected weld schedule appears on the screen ...

Page 10: ...F Card being sure that it is seated completely into the slot The eject button should pop up Eject Button Touch the VIEW CARD button and all weld schedules in the card will be dis played in the right column Select the desired schedule and the name will appear in the pink window above the right column Touch LOAD FROM CARD and the weld schedule will load ...

Page 11: ... 1 2 3 4 5 6 Moving a Weld Schedule from CF Card to Main Memory Select the desired weld schedule to transfer to main memory and it will ap pear in the pink window Select CARD TO MEMORY and the weld schedule will be copied to the Main Memory in the left column ...

Page 12: ...l All Rights Reserved 1 2 3 4 5 6 Moving a Weld Schedule from Main Memory to CF Card Select the desired weld schedule to transfer to the CF Card Select MEMORY TO CARD and the weld schedule will be copied to the CF Card in the right column ...

Page 13: ...ights Reserved 1 2 3 4 5 6 C Copyright 2001 Exel Orbital Systems All Rights Reserved EPS 2000 Power Supply Chapter 3 Create a Weld Chapter 3 Create a Weld Chapter 3 Create a Weld Schedule Schedule Schedule Version 1 11 01 Revision Date June 2005 ...

Page 14: ...he above screen appears Enter the Material Type that will be welded by touching the field and using the QWRTY keypad that appears Fill in all the Material Fields Enter the Electrode Data and select the electrode material from the pull down menu CHANGE AFTER alarms the op erator to change the electrode In the Levels category select the Weld Type to be made ...

Page 15: ...Enter Level 1 data and click UPDATE GRAPH both the polar and linear graph of time current and rotation are shown With a multi level weld it is convenient to click the fill button to copy Level 1 infor mation to all subsequent levels Level 2 contains the same information as level 1 Change the relevant field in this case 41 High amps UPDATE GRAPH 1 2 1 2 1 2 Edit Level 3 in the same manner as Level ...

Page 16: ...ulsed Weld Schedule is now complete 1 2 1 2 To save the newly created weld sched ule touch SAVE The Library Menu appears in Save As mode Displaying a default name in the Schedule Name field Click SAVE TO MEMORY to save the schedule in internal memory or SAVE TO CARD to save to the CF Card If the default name is undesired touch the SCHEDULE NAME field and a KWRTY keypad appears to rename ...

Page 17: ... to the multi level weld de veloped on the previous pages use the settings for Level 1 and Level 4 Input Level 1 High amps for Point 1 and Level 4 High amps for Point 2 Time is the total of Level 1 2 3 4 time from the Multi Level weld Lev Time High Low Freq High 1 1 9 42 10 5 6 50 2 1 9 41 10 5 6 50 3 1 9 40 10 5 6 50 4 1 9 38 10 5 6 50 Speed 8 8 8 8 The S3 Weld is complete Note Below are the valu...

Page 18: ...om the WELD Screen touch the SCHEDULE button Enter the Programmer Password which gives access to the weld schedule See Pass Words in the Utility Section The first screen to appear is Schedule Screen 1 Click the Right Arrow to move to Schedule Screen 2 Click the Left Arrow to move back to Schedule Screen 1 ...

Page 19: ...Orbital All Rights Reserved 1 2 3 4 5 6 C Copyright 2001 Exel Orbital Systems All Rights Reserved EPS 2000 Power Supply Chapter 4 Making A Weld Chapter 4 Making A Weld Chapter 4 Making A Weld Version 1 11 01 Revision Date June 2005 ...

Page 20: ...the field where information is to be entered and a QRTY keypad appears Press ENTER when complete and the QRTY keypad disappears Continue filling in all remaining fields This information will now appear on the Weld Report making tracking easier Note 1 To open or create a weld sched ule see Library and Memory Library and Memory Library and Memory or Cre Cre Cre ate a Weld Schedule ate a Weld Schedul...

Page 21: ...2 When loading a new weld schedule or turning power on the Rotor Driver or motor must first be calibrated Push the CALIBRATE button then select the proper switch setting on the Rotor Driver then push CALIBRATE During calibration 4 revolutions will be made and timed When calibration is complete push OK ...

Page 22: ...or Driver calibration a test weld can be made to be certain of proper set tings and calibration by pushing TEST As the power supply cycles through the test sequence it purges rotates the weld head and graphs theoretical current When TEST is complete the power sup ply will return to its STANDBY mode ...

Page 23: ...6 Making a Weld To make a weld be sure that the weld head is ready and properly fixtured then push START The power supply will cycle through the weld sequence displaying all critical op erating variables When the weld is complete the power supply returns to STANDBY mode ...

Page 24: ...eld head The head will rotate only when the button is pushed To home the weld head push the HOME button Purge my be used at any time by press ing PURGE Pressing PURGE prior to a weld does not affect weld purging STOP may be used at any time and will terminate any sequence started During a weld pre purge will be the final sequence ...

Page 25: ...ght 2001 Exel Orbital Systems All Rights Reserved EPS 2000 Power Supply Chapter 5 Chapter 5 Chapter 5 Utility Passwords Utility Passwords Utility Passwords Printing Reports and Faults Printing Reports and Faults Printing Reports and Faults Version 1 11 01 Revision Date June 2005 ...

Page 26: ...e electrode This value can be adjusted from 25 to 40 Amps POWER ADJUST This value establishes the adjustment the operator is given during welding This value is given as a of the programmed current The operator has the ability to adjust power in 1 increments up or down to the pro grammed limit in POWER ADJUST DO YOU WANT TO SAVE ALL DATA LOG Answer YES or NO to this If you answer NO weld reports wi...

Page 27: ...icate stub out or insufficient gap between the electrode and work This value is usually set at 5 volts HIGH VOLTAGE The maximum allowable volt age This settings is used to indicate excessive gap between the electrode and work and other anomalies such as insufficient or missing purge This value is usually set at 12 volts CURRENT The tolerance in terms of varia tion from the average current programm...

Page 28: ...y Password Allows 1 Access to the LIBRARY 2 Access to Weld Screen 3 adjustment of the weld schedule 4 Print weld schedule 5 Print weld report 6 View weld report 7 Memory copy to and from CF Card Security Password Allows 1 All items on Security Password 2 Access to Weld Schedule Screen 3 Access to Utility Screen Enter the desired password for both Pro grammer and Security Se list below for privileg...

Page 29: ...eviates outside the alarm set value see Alarm Settings The above message will appear if volt age goes below the alarm set value see Alarm Settings The above message will appear if volt age goes above the alarm set value see Alarm Settings The above message will appear if speed deviates outside the alarm set value see Alarm Settings The above message will appear to alert the operator must change th...

Page 30: ...All Rights Reserved 1 2 3 4 5 6 The above message will appear if pres sure goes below the alarm set value see Alarm Settings The above message will appear if pres sure goes above the alarm set value see Alarm Settings 7 8 Alarms and Faults ...

Page 31: ...welding screen does not read zero after the gas supply has been disconnected and the valve opened it will be necessary to zero the pressure transducer First disconnect the gas supply Second push the PURGE button in the Utility Menu Third push ZERO PRESSURE Go back to the Weld screen and the pressure gauge should read 0 zero 3 2 ...

Page 32: ... Copyright 2005 Exel Orbital All Rights Reserved 1 2 3 4 5 6 Printing To print from the power supply select either PRINT SCHEDULE or PRINT RE PORT the onboard printer will print the desired form Thermal Printer ...

Page 33: ...o the CF Card To view the weld reports simply remove the CF Card and insert into the CF Card reader of your computer Open Microsoft Excel Click FILE then OPEN and go to the lo cation of the CF Card the open LOG then the file called DATA The box above appears Click NEXT and click NEXT again at the following box then click FINISH Excel populates the spreadsheet with the weld report data ...