Arc Machines 207A Bedienungsanleitung
MODEL 207A AND 207A-1
OPERATION MANUAL
Doc. No. 740044
Rev F
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 - August 15, 1989
Copyright 1989 by Arc Machines, Inc.
All rights reserved
REV. DCO # CHANGE DESCRIPTION
DATE
APR
A
N/A
Revised Pg I, ii, iii,iv 9/29/93 GPE
B 2357 Revised to include required IEC-974 information 8/15/96 GPE
C 3059 Added M227/207-CW info: pg. iv, v, 1.1, 3.7, 4.12, 7.5, 7.7,
8.1, 8.2, 8.3.
04/20/98 GPE
D 3583 Revised page 7.4 Step 13 add new Current Offset
adj.
3/20/00 GPE
E 3684 Removed ref to Miller coolant page 8.2 7/20/00 GPE
F 5779 Removed 207A-HP (OBS) 8/10/10 DC
i
MODEL 207A AND 207A-1
OPERATION MANUAL
Doc. No. 740044
Rev F
EFFECTIVITY
Features and operation of the Model 207A, Model 207A-1 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 207A AND 207A-1
OPERATION MANUAL
Doc. No. 740044
Rev F
TABLE OF CONTENTS
SECTION DESCRIPTION PAGE
SECTION I INTRODUCTION
1.0 Introduction 1.1
1.1 Safety Precautions 1.2
1.2 Operational Precautions 1.5
1.3 Shock Hazard Warning 1.7
SECTION II SPECIFICATIONS
2.0 Electrical 2.1
2.1 Physical Construction 2.3
2.2 Programmable Functions and Ranges 2.3
2.3 Multi-Level Functions 2.3
2.4 Ambient Temperature Range 2.4
2.5 Cable Operating Length Limits 2.4
SECTION III INSTALLATION
3.0 Inspection 3.1
3.1 Power Connections 3.1
3.2 Welding Gas Connections 3.2
3.3 Adapter Cable to M-207A Installation 3.7
3.4 Weld Head Installation 3.7
SECTION IV SYSTEM FUNCTIONS
4.0 Introduction 4.1
4.1 Functional Description, General 4.1
4.2 Weld Library and Weld Description 4.3
4.3 Weld Sequence 4.3
4.4 Panel Keys 4.9
4.5 Operate Mode Switch 4.11
4.6 Faults 4.12
4.7 Sensor 1,2,3 Faults 4.13
4.8 Set-Up Functions 4.13
4.9 Glossary of Abbreviations 4.15
4.10 Glossary of Terms 4.16
iii
MODEL 207A AND 207A-1
OPERATION MANUAL
Doc. No. 740044
Rev F
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 5.4
5.4 Viewing Function Values 5.5
5.5 Overriding Function Values Before Seq 5.6
5.6 Overriding Function Values During Seq 5.7
5.7 Set Up Functions 5.7
5.8 Auto Rotation Calibration 5.11
5.9 Manual Rotation Calibration 5.13
5.10 Welding Operation 5.15
5.11 Printer Operation 5.16
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 6.6
6.5 Delete A Weld Schedule 6.7
SECTION VII CALIBRATION
7.0 Introduction 7.1
7.1 Equipment Required 7.1
7.2 Current Servo 7.2
7.3 General Maintenance 7.5
7.4 System Fault Corrections 7.6
7.5 Error Messages 7.9
7.6 Miscellaneous Maintenance Items 7.10
SECTION VIII OPTIONS
8.0 Introduction 8.1
8.1 M227/207-CW & M207-CW Cooling Unit 8.1
8.2 M-207-RP Remote Pendant 8.3
8.3 M-207-EMM External Memory Module 8.7
iv
MODEL 207A AND 207A-1
OPERATION MANUAL
Doc. No. 740044
Rev F
TABLE OF CONTENTS
LIST OF ILLUSTRATIONS
FIGURE DESCRIPTION PAGE
FIGURE 1 SYSTEM CONFIGURATION 1.4
FIGURE 2 INSTALLATION LOCATIONS 3.3
FIGURE 3 AC POWER SET-UP 3.4
FIGURE 4 CABLE CONNECTIONS 3.5
FIGURE 5 SEQUENCE TIMING CHART 4.7
FIGURE 6 PANEL KEY LOCATIONS 4.8
FIGURE 7 USE OF NEXT/PREV KEYS 5.3
FIGURE 8 M227/207-CW & M207-CW INSTALLATION 8.6
v
MODEL 207A AND 207A-1
OPERATION MANUAL
Doc. No. 740044
Rev F
SECTION I - INTRODUCTION
1.0 INTRODUCTION
This manual is intended to assist users of this equipment in set up and basic
operation. Automatic fusion welding requires a good deal of operator expertise
which requires AMI supplied training. THIS MANUAL IS NOT INTENDED AS
A SUBSTITUTE FOR THAT TRAINING.
The basic Model 207A (M-207A) welding power supply is part of a complete
welding system intended for fusion welding of metal tubes, pipes and fittings (see
Figure 1). The complete system consists of the M-207A power supply, adapter
cable, gas lines and any of the AMI Model 9 (M-9) series of tube welding heads
(M-9 heads sold separately).
The M-207A power supply provides GTAW current with pulsation controls, high
frequency arc starting, purge gas controls, weld head arc rotation and automatic
timing functions. The M-207A is supplied (as standard) 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 operating conditions may require optional components such as the remote
pendant option (M-207-RP), weld head cooling unit option (M227/207-CW or
M207-CW) and extension cables. The M-207A family of options also includes
quality assurance options such as chart recorders and Weld Data Recording
Software.
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 or a 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 207A AND 207A-1
OPERATION MANUAL
Doc. No. 740044
Rev F
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 207A AND 207A-1
OPERATION MANUAL
Doc. No. 740044
Rev F
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. 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: Some systems, are intended solely for in-door
use and must be kept dry.
Before operating, storing or handling, always make sure that
the M-207A, M-207-RP Pendant, weld heads and cables are
not exposed to rain or standing water. SYSTEM
COMPONENTS ARE NOT WEATHER-PROOF.
1.3
MODEL 207A AND 207A-1
OPERATION MANUAL
Doc. No. 740044
Rev F
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-207A Power Supply is not intended for
pipe thawing or heating in any form.
WARNING: The M-207A weighs in excess of 75 lbs. Be sure
to follow local, OSHA, International or employers 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-207A 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-207A is intended for typical GTAW gases ONLY. NEVER CONNECT
OXYGEN OR ACETYLENE TO THE M-207A.
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.
1.5
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