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

REV. DCO # CHANGE DESCRIPTION

DATE

APR

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

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.

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

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

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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