AMI 227 Bedienungsanleitung
10500 Orbital Way
Pacoima, California 91331 U.S.A.
MODEL 227 POWER SUPPLY
OPERATION MANUAL
Document No. 740063
MODEL 227
OPERATION MANUAL
Doc # 740063 Rev E
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 express
written permission of Arc Machines, Inc.
The information in this document has been carefully reviewed and is believed to be accurate.
However, no responsibility is assumed for inaccuracies.
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 THIS 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 THIS MANUAL.
Publication date : First Edition - February 12, 1992
Copyright 1992 by Arc Machines, Inc.
All rights reserved
REV
DCO # CHANGE DESCRIPTION
DATE
APR
A
2367
Revised to include required IEC-974 information 10/03/96 GPE
B
3053
Add M227/207-CW Spec-info pgs: iv, v, 1.1, 2.4, 4.14,
4.16, 5.7, 7.6, 7.8, 8.1, 8.2. 04/08/98 GPE
C
3583
Added Offset adj. Information to sect. 7. Replaced Sect. 7,
Pg. i & iv.
03/23/00 GPE
D 3682 Removed ref to miller coolant pages 8.1,8.2 7/19/00 GPE
E 4633 Correct typo in section 7.2.14 2/25/08 LEC
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MODEL 227
OPERATION MANUAL
Doc # 740063 Rev E
EFFECTIVITY
Features and operation of the Model 227 are derived mostly from SOFTWARE. This
document is based on the latest STANDARD version of SOFTWARE at the time of last
revision (see revision page).
Some deviations in actual operation, from this document, are possible depending on the
software version of a particular machine. Please feel free to contact Arc Machines
Service Department for documentation or information on how software updates effect
this document.
ii
MODEL 227
OPERATION MANUAL
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TABLE OF CONTENTS
SECTION DESCRIPTION PAGE
SECTION I INTRODUCTION
1.0 Introduction 1.1
1.1 Safety Precautions 1.2
1.2 Operational Precautions 1.4
1.3 RF and EMI emissions 1.5
1.4 Shock Hazard Warning 1.8
SECTION II SPECIFICATIONS
2.0 Electrical 2.1
2.1 Physical Construction 2.3
2.2 Programmable Functions 2.3
2.3 Multi-level Functions 2.4
2.4 Non-Programmable Functions 2.4
2.5 Ambient Temperature Ranges 2.4
2.6 Cable Operating Distance Limits 2.4
SECTION III INSTALLATION
3.0 Inspection 3.1
3.1 Power Connection 3.1
3.2 Welding Gas Connections 3.2
3.3 Adapter Cable to M-227 Installation 3.3
3.4 Weld Head Installation 3.7
3.5 Ground (Work) Cable Installation 3.7
3.6 Remote Pendant Installation 3.8
SECTION IV SYSTEM FUNCTIONS
4.0 Introduction 4.1
4.1 Functional Description, General 4.1
4.2 Weld Library and Description 4.3
4.3 Weld Sequence 4.3
4.4 Panel Keys 4.11
4.5 Operate Mode Switch 4.14
4.6 Faults 4.14
4.7 Sensor 1,2,3 Faults 4.16
4.8 Set-Up Functions 4.16
4.9 Glossary of Abbreviations 4.17
4.10 Glossary of Terms 4.18
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MODEL 227
OPERATION MANUAL
Doc # 740063 Rev E
TABLE OF CONTENTS
SECTION DESCRIPTION PAGE
SECTION V OPERATION
5.0 Introduction 5.1
5.1 Initial Power-On 5.1
5.2 Use of Next/Prev 5.2
5.3 Weld Schedule Selection 5.3
5.4 Pass Advance 5.4
5.5 Viewing Function Values 5.6
5.6 Overriding Function Values 5.6
5.7 Set Up Functions 5.7
5.8 Remote Pendant Operation 5.11
5.9 Rotation Calibration 5.14
5.10 Wire Feed Calibration 5.15
5.11 Manual Advance Function 5.16
5.12 Welding Operation 5.17
5.13 Printer Operation 5.18
SECTION VI PROGRAMMING
6.0 Introduction 6.1
6.1 Create a Weld Schedule 6.1
6.2 Modify a Weld Schedule 6.4
6.3 Copy a Weld Schedule 6.5
6.4 Transfer/Receive a Weld Schedule 6.5
6.5 Delete a Weld Schedule 6.6
6.6 Program Select Function 6.6
SECTION VII CALIBRATION
7.0 Introduction 7.1
7.1 Equipment Required 7.1
7.2 Current Servo 7.2
7.3 AVC Servo 7.4
7.4 Oscillator Servo 7.5
7.5 General Maintenance 7.7
7.6 System Fault Corrections 7.8
7.7 Error Messages 7.11
7.8 Miscellaneous Maintenance 7.12
SECTION VIII OPTIONS
8.0 Introduction 8.1
8.1 M227/207-CW & M207-CW Cooling Units 8.1
8.2 M-227-EMM External Memory Module 8.3
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MODEL 227
OPERATION MANUAL
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LIST OF ILLUSTRATIONS
NUMBER DESCRIPTION PAGE
FIGURE 1 SYSTEM CONFIGURATION 1.7
FIGURE 2 INSTALLATION LOCATIONS 3.4
FIGURE 3 AC POWER SET-UP 3.5
FIGURE 4 CABLE CONNECTIONS 3.6
FIGURE 5 SEQUENCE TIMING CHART 4.7
FIGURE 6 PANEL KEY LOCATIONS 4.8
FIGURE 7 USE OF NEXT/PREV KEYS 5.5
FIGURE 8 STANDARD REMOTE PENDANT 5.10
FIGURE 9 M227/207-CW or M207-CW INSTALLATION 8.4
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MODEL 227
OPERATION MANUAL
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SECTION I - INTRODUCTION
1.0 INTRODUCTION
This manual is intended to assist users of this equipment in set-up and basic
operation. Automated welding requires a good deal of operator expertise which
also requires AMI supplied, hands-on training. THIS MANUAL IS NOT
INTENDED AS A SUBSTITUTE FOR THAT TRAINING.
The Model 227 (M-227) welding power supply is part of a complete welding
system intended for the welding of tubes, pipes and fittings (see figure 1). The
complete system consists of the M-227 power supply, adapter cable, gas lines and a
variety of different AMI Welding Heads or Torch Fixture devices (Heads and
Fixtures are sold separately).
The standard version of the M-227 power supply provides GTAW current with
pulsation controls, high frequency arc starting, purge gas controls, weld head arc
rotation, cold wire feed, Arc Voltage Control, Torch Weave/Steering (Oscillation)
and automatic timing functions. Another version is available without the
AVC and
Oscillator functions. The M-227 includes a Remote Operators Pendant and comes
ready to weld. Users need only to supply input AC power, regulated gas source
with flow meter and the appropriate weld head or manual torch.
Some operation conditions may require optional components such as the M227/207-
CW Cooling Unit (for liquid cooled weld heads and torches). The M-227 family
of options also includes memory back up devices, off-line programming and quality
assurance options such as chart recorders.
The system can also be used as a manual welding power source using an optional
manual torch with a variety of manual welding options such as a variable current
foot controller with remote start/stop switch.
NOTE
In-depth weld development instructions, weld head set-up, maintenance and
troubleshooting are contained in other manuals, documents and training classes
and are not included in this manual. Contact your AMI representative for more
information about these items.
1.1
MODEL 227
OPERATION MANUAL
Doc # 740063 Rev E
SECTION I - INTRODUCTION
1.1 SAFETY PRECAUTIONS
This section contains cautions and warnings concerning the operation of this
equipment and welding equipment in general. However, in addition to reading
this manual and before operating this or any welding equipment, users should
reference and be familiar with “ANSI-49.1 Safety in Welding and Cutting”.
This standard is published by the American National Standards Institute and the
American Welding Society.
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 un-protected or poorly
protected against such interference.
WARNING: Magnetic Fields from High Currents can affect
pacemakers. 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.
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.
1.2
MODEL 227
OPERATION MANUAL
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SECTION I - INTRODUCTION
1.1 SAFETY PRECAUTIONS
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 (IR). 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. WELD ONLY IN AREAS WITH ADEQUATE
VENTILATION.
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
Operators and Maintenance Technicians who operate AMI
equipment.
WARNING: Before operating, storing or handling, always
make sure that the M-227, M-227-RP Pendant, weld heads and
cables are not exposed to rain or standing water. SYSTEM
COMPONENTS ARE NOT WEATHER-PROOF.
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MODEL 227
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SECTION I - INTRODUCTION
1.1 SAFETY PRECAUTIONS
WARNING: Keep hands and fingers clear from moving parts
such as fans, gears rotors, Wire Feed, Rotation and AVC
Mechanisms.
WARNING: The M-227 Power Supply is not intended for
pipe thawing or heating in any form.
WARNING: The M-227 Power Supply weighs in excess of
91 lbs (41.3 kg). It has no handles and is not intended to be
carried by a single person. Be sure to follow your local, OSHA,
international or employer guidelines for proper methods of
lifting and re-locating this equipment.
1.2 OPERATIONAL PRECAUTIONS
The following is a check list for operating personnel to follow to insure minimum
system down-time due to improper operation and handling:
1. TOO AVOID severe equipment damage VERIFY that the M-227 is
connected to the correct Input AC power (see section 3.1).
2. Before operating, check all fittings and connectors for proper seating and that
all protective boots are in place. If not properly seated or protected, short
circuits, poor connections or inert gas leaks could occur.
3. The M-227 is intended for typical GTAW gases ONLY. NEVER CONNECT
OXYGEN OR ACETYLENE TO THE M-227.
4. Before operating, insure that all cables are routed or protected in such a way
that they will not be subject to heat, equipment and/or personnel traffic. Insure
that the cables DO NOT come in contact with HOT PIPE.
5. When storing or handling cables, always keep the protective boots and dust
caps on all connectors and fittings until ready to install. A major cause of
downtime in any automatic welding system is improper care and use of cables.
1.4
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