MODEL 207A AND 207A-1 OPERATION MANUAL 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.
MODEL 207A AND 207A-1 OPERATION MANUAL 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.
MODEL 207A AND 207A-1 OPERATION MANUAL TABLE OF CONTENTS SECTION SECTION I 1.0 1.1 1.2 1.3 SECTION II 2.0 2.1 2.2 2.3 2.4 2.5 SECTION III 3.0 3.1 3.2 3.3 3.4 SECTION IV 4.0 4.1 4.2 4.3 4.4 4.5 4.6 4.7 4.8 4.9 4.10 DESCRIPTION INTRODUCTION Introduction Safety Precautions Operational Precautions Shock Hazard Warning 1.1 1.2 1.5 1.7 SPECIFICATIONS Electrical Physical Construction Programmable Functions and Ranges Multi-Level Functions Ambient Temperature Range Cable Operating Length Limits 2.1 2.3 2.3 2.
MODEL 207A AND 207A-1 OPERATION MANUAL TABLE OF CONTENTS SECTION SECTION V 5.0 5.1 5.2 5.3 5.4 5.5 5.6 5.7 5.8 5.9 5.10 5.11 SECTION VI 6.0 6.1 6.2 6.3 6.4 6.5 SECTION VII 7.0 7.1 7.2 7.3 7.4 7.5 7.6 SECTION VIII 8.0 8.1 8.2 8.
MODEL 207A AND 207A-1 OPERATION MANUAL TABLE OF CONTENTS LIST OF ILLUSTRATIONS FIGURE FIGURE FIGURE FIGURE FIGURE FIGURE FIGURE FIGURE FIGURE 1 2 3 4 5 6 7 8 DESCRIPTION PAGE SYSTEM CONFIGURATION INSTALLATION LOCATIONS AC POWER SET-UP CABLE CONNECTIONS SEQUENCE TIMING CHART PANEL KEY LOCATIONS USE OF NEXT/PREV KEYS M227/207-CW & M207-CW INSTALLATION v Doc. No. 740044 Rev F 1.4 3.3 3.4 3.5 4.7 4.8 5.3 8.
MODEL 207A AND 207A-1 OPERATION MANUAL 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).
MODEL 207A AND 207A-1 OPERATION MANUAL 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.
MODEL 207A AND 207A-1 OPERATION MANUAL 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.
MODEL 207A AND 207A-1 OPERATION MANUAL 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.
MODEL 207A AND 207A-1 OPERATION MANUAL SECTION I - INTRODUCTION 1.2 OPERATIONAL PRECAUTIONS 6. Before operating, insure that the M-207 has adequate air flow. Do not restrict the intakes or exhaust vents of the power supply. 7. Before operating, always insure that there is bare metal contact between the weld head components which connect to GROUND (clamp inserts, etc.) and the tube or pipe to be welded. 8.
MODEL 207A AND 207A-1 OPERATION MANUAL SECTION I - INTRODUCTION 1.3 SHOCK HAZARD WARNING As already stated in this manual “High Voltage” is present on exposed internal terminals. The ELECTRODE (tungsten and M-9 rotors) is also an “exposed terminal” and by its nature the GTAW process requires electrical potential to be present on the electrode during arc starting and of course during the welding.
MODEL 207A AND 207A-1 OPERATION MANUAL SECTION II - SPECIFICATIONS The following contains only general specifications about the M-207A Power Supply. More detailed information is available in AMI Specification No. 207. 2.0 ELECTRICAL 1. RATING PLATE DEFINITIONS Country: 1) Company: USA ARC MACHINES, INC. 8) Process: 3) Model: ___________ __________ 23) Shock Rating: S 15) Input: 1~ 50/60 HZ 1) 3) 4) 6) 8) 9) - 10) 11) .
MODEL 207A AND 207A-1 OPERATION MANUAL SECTION II - SPECIFICATIONS 2.0 ELECTRICAL 1. RATING PLATE DEFINITIONS 21) - International Protection (IP) rating. M-207A and M-207A-1 are rated IP21 which includes protection against a limited amount of exposure to rain (does not make it weather proof or intended for all weather usage). . 22) - All M-207A models are class I. No symbol is used for class I equipment.
MODEL 207A AND 207A-1 OPERATION MANUAL SECTION II - SPECIFICATIONS 2.0 ELECTRICAL 4. CIRCUIT BREAKER - ON/OFF, two pole, 30 Ampere at 250 VAC. 2.1 PHYSICAL CONSTRUCTION - (power supply only) Cabinet material - aluminum Height - 10.9 in (276.9 mm) cover closed - 9.3 in (236.2 mm) cover removed Width - 22.75 in (577.9 mm) Depth - 19.25 in (489.0 mm) including handle Weight - 78 lbs (35.4 kg) (M-207A and M-207A-1) 2.2 PROGRAMMABLE and OPERATIONAL FUNCTIONS PREPURGE TIME ...................................
MODEL 207A AND 207A-1 OPERATION MANUAL SECTION II - SPECIFICATIONS 2.3 MULTI-LEVEL FUNCTIONS (continued) FUNCTION POSSIBLE CHANGES PRIMARY CURRENT.............................................. = 1 to 99 levels BACKGROUND CURRENT.................................... = 1 to 99 levels PRIMARY PULSE TIME.......................................... = 1 to 99 levels BACKGROUND PULSE TIME................................ = 1 to 99 levels PULSE MODE (ON/OFF).........................................
MODEL 207A AND 207A-1 OPERATION MANUAL SECTION III - INSTALLATION 3.0 INSPECTION 1. After unpacking, inspect all items for obvious physical damage and loose parts. If damage is evident, contact a factory representative before using. NOTE If water condensation is apparent, dry the unit before using. 2. All M-207A models are shipped with a variety of peripheral equipment such as gas hoses, fittings, manuals (including this one) and electrical drawings.
MODEL 207A AND 207A-1 OPERATION MANUAL SECTION III - INSTALLATION 3.1 POWER CONNECTION 2. Install the AC line connector onto the power cord. NOTE DO NOT PLUG THE M- 207A INTO THE AC POWER SOURCE UNTIL ALL INSTALLATION STEPS ARE COMPLETE. 3. Insure that the circuit breaker (CB-1) is in the down or OFF position (see figure 2 and 3). 4. Using figure 2 and 3 as a reference, locate the power SELECT SWITCH (next to the input power connector).
MODEL 207A AND 207A-1 OPERATION MANUAL SECTION III - INSTALLATION 3.2 WELDING GAS CONNECTIONS 2. (continued) NOTE The arc gas line is controlled by a solenoid and flow sensor in the M-207A and MUST BE connected to the M-207A (not directly to the weld head or torch). After installing the hose and fittings loosely by hand, tighten the retaining nuts slightly with a wrench to insure there are no leaks, but do not overtighten. The use of plumbers tape or grease is not recommended.
MODEL 207A AND 207A-1 OPERATION MANUAL SECTION III - INSTALLATION 3.3 ADAPTER CABLE TO M-207A INSTALLATION NOTE Although the Adapter Cable is used with most M-9 weld heads, some do not use it (such as the M9-500). Consult your weld head manual for more details. WARNING Always turn the power supply off before making any cable or connection changes to the M-207A power supply. 1. One end of the adapter cable ALWAYS connects to the weld head.
MODEL 207A AND 207A-1 OPERATION MANUAL SECTION III - INSTALLATION 3.4 WELD HEAD INSTALLATION (continued) 1. Insert the adapter cable GROUND, ELECTRODE AND GAS connectors into the mating weld head cable connectors. 2. After the ELECTRODE, GROUND and GAS connectors are secure and checked, slide the rubber boots on each line together and secure them in place. These boots provide both a safety factor to prevent shorting to ground and also act as a retainer to prevent the connectors from coming apart. 3.
MODEL 207A AND 207A-1 OPERATION MANUAL SECTION IV - SYSTEM FUNCTIONS 4.0 INTRODUCTION The M-207A is intended for use with AMI orbital welding heads and has functions designed for these weld heads. This section describes what these functions are and may, where needed for clarification, indicate how they are commonly (but not always) used. Step 4.1 is general description; the remaining steps describe, in more detail, the items of steps 4.1. Only FUNCTION is discussed here.
MODEL 207A AND 207A-1 OPERATION MANUAL SECTION IV - SYSTEM FUNCTIONS 4.1 FUNCTIONAL DESCRIPTION, GENERAL 4. TRAVEL FUNCTION - The system is equipped with a motor servo controller that provides the power and regulation for rotating the arc around the weld seam. The system controls the movement in revolutions per minute (RPM). NOTE The motor servo can only work properly if the weld head being used is equipped with a motor assembly designed for operation on the M-207A. 5.
MODEL 207A AND 207A-1 OPERATION MANUAL SECTION IV - SYSTEM FUNCTIONS 4.2 WELD LIBRARY AND WELD DESCRIPTION Each weld schedule programmed into the system memory is identified and displayed (when selected) with the following information: 1. 2. 3. 4. # OD WALL TYPE 5. MAT 6. QTY 4.3 = Individual WELD SCHEDULE NUMBER from 001 to 100. = Outside diameter in inches or mm of the weld. = Wall thickness in inches or mm of the weld.
MODEL 207A AND 207A-1 OPERATION MANUAL SECTION IV - SYSTEM FUNCTIONS 4.3 WELD SEQUENCE 3. 4. EVENT 3: LEVEL 1 TIME, START LEVEL, UPSLOPE, TRAVEL. START DELAY 3. WELD CURRENT UPSLOPE - Sometimes it may be necessary to raise the weld current to full value slowly. This is called UPSLOPE. When the arc is established the weld current will start to rise to the PRIMARY and BACKGROUND (if pulsed) value programmed in LEVEL 1. The time it takes to rise to full value is the UPSLOPE TIME. 4.
MODEL 207A AND 207A-1 OPERATION MANUAL SECTION IV - SYSTEM FUNCTIONS 4.3 WELD SEQUENCE 4. EVENT 4: FULL LEVEL FUNCTIONS 4. LEVEL 1 BACKGROUND PULSE TIME - If the LEVEL 1 PULSE MODE is ON this function will operate (see Event 3). 5. LEVEL 1 PRIMARY AMPS - After UPSLOPE the system will be regulating this programmed value of current. 6. LEVEL 1 BACKGROUND AMPS - If the LEVEL PULSE MODE was programmed to ON, the system will be pulsing between the PRIMARY VALUE and the BACKGROUND VALUE. 7.
MODEL 207A AND 207A-1 OPERATION MANUAL SECTION IV - SYSTEM FUNCTIONS 4.3 WELD SEQUENCE 4. EVENT 4: FULL LEVEL FUNCTIONS NOTE Travel direction is programmable CLOCKWISE or COUNTERCLOCKWISE. After the TRAVEL START DELAY the arc will rotate in the programmed direction. The direction is not programmable by LEVELS. It will rotate the arc in the same direction for the entire WELD SEQUENCE. 5.
MODEL 207A AND 207A-1 OPERATION MANUAL SECTION IV - SYSTEM FUNCTIONS 4.4 PANEL KEYS - The following are descriptions of all active operating keys contained on the system (see figure 6). 1. ALL STOP KEY - Active only during weld sequence in test or weld mode. When pressed it will stop the sequence, turn off the arc with no downslope and start the postpurge process (see 4.3 event 7). 2.
MODEL 207A AND 207A-1 OPERATION MANUAL SECTION IV - SYSTEM FUNCTIONS 4.4 PANEL KEYS 11. NUMERIC KEYS - Used to select weld schedule number (#) or to enter numbers during programming, overriding and set-up functions. 12. PREV LEVEL KEY - Same as NEXT LEVEL but levels appear in reverse order. 13. PREV SCREEN KEY - Same as NEXT SCREEN but screens appear in reverse order. 14. PRINT KEY - Only works if the printer option is used.
MODEL 207A AND 207A-1 OPERATION MANUAL SECTION IV - SYSTEM FUNCTIONS 4.4 4.5 PANEL KEYS 21. WELD/TEST KEY - At power on the M-207A will always be in the TEST mode. In TEST mode a weld sequence can be run but NO ARC will be struck. The user must press this key to initiate WELD mode. Once this is done the M-207A will stay in WELD mode as long as the same weld schedule is displayed. Changing schedules will cause the system to return to the TEST mode. 22.
MODEL 207A AND 207A-1 OPERATION MANUAL SECTION IV - SYSTEM FUNCTIONS 4.5 OPERATE MODE SWITCH CAUTION Authorization and access to the OPERATE MODE KEY should be controlled. When the switch is set to the PROGRAM mode the operator may permanently MODIFY (change) or DELETE weld schedule information contained in the system memory. 4.6 FAULTS The M-207A has the ability to monitor certain functions. If they are not working correctly a system fault (FLT) will alert the operator to the problem.
MODEL 207A AND 207A-1 OPERATION MANUAL SECTION IV - SYSTEM FUNCTIONS 4.6 FAULTS (continued) The method of alerting the operator depends on what the fault is and when it occurs. A problem with TEMP, LVPS or INPUTAC when the M-207A is first turned on will create a FAULT SCREEN and the fault must be corrected before the M-207A will proceed with any other functions. A problem with COOL, GAS or SENSOR is common at power on or when preparing for welding.
MODEL 207A AND 207A-1 OPERATION MANUAL SECTION IV - SYSTEM FUNCTIONS 4.8 SET-UP FUNCTIONS 3. HEAD-CAL - Provides a method for calibrating a M-9 weld head to the power supply. 4. REV - Used to display the SOFTWARE REVISION of an M-207A. Depending on intended use, M-207A’s may have different software revisions. 5. PRINT EMM - Used to print a copy of the EMM memory. 6. ARC V FLT - Used to de-activate STUB OUT and HIGH VOLT faults.
MODEL 207A AND 207A-1 OPERATION MANUAL SECTION IV - SYSTEM FUNCTIONS 4.9 GLOSSARY OF DISPLAY SYMBOLS AND ABBREVIATIONS - The M-207A displays contain many abbreviations. The following is an alphabetical listing (symbols last) of most abbreviations. AL = Aluminum AMP = Amperage AF = Automatic weld fitting BCK = Background (low value of a function that pulses). CAL = Calibrate or calibration CCW = Counterclockwise - looking at M-9 from COVER SIDE.
MODEL 207A AND 207A-1 OPERATION MANUAL SECTION IV - SYSTEM FUNCTIONS 4.9 GLOSSARY (continued) ROT DLY = Rotation or travel start delay time RPM = Revolutions per minute SKT = Socket type weld SP = Special material and weld type. SS = Stainless steel SYS HOURS = System hours indicate total power-on time. TEMP = Power supply internal temperature TI = Titanium T/TS = Tube to tubesheet # = Weld schedule number * = Indicates that more information is available 4.
MODEL 207A AND 207A-1 OPERATION MANUAL SECTION IV - SYSTEM FUNCTIONS 4.10 GLOSSARY OF DISPLAY TERMS (continued) ROTOR OD SENSOR 1, 2, 3 STORE TRANSFER TYPE WALL WARNING = Outside diameter of M-9 rotor. = User defined faults. = Puts weld information into memory. = Allows copying of memory to another M-207A or to the M-207-EMM. = Describes the basic type of weld. = Wall thickness of the weld. = Used to indicate that if step is continued a permanent loss of information will result. 4.17 Doc. No.
MODEL 207A AND 207A-1 OPERATION MANUAL SECTION V - OPERATION 5.0 INTRODUCTION Operation covers those steps that must be taken to actually perform a weld. Programming and development of schedules are not covered in this section. It is very important to insure before operating, that the operator has INSTALLED the M-207A per section III and has a good understanding of functions from section IV. Function explanations are not covered in this section.
MODEL 207A AND 207A-1 OPERATION MANUAL SECTION V - OPERATION 5.1 INITIAL POWER ON/STATUS SCREEN 4. (continued) NOTE If the input power is too low it is possible for the screens not to turn on, or to be scrambled or get a fault screen indicating a LVPS fault. If these conditions occur recycle CB1. If they continue to occur check the input power and the power setup of the M-207A UPPER SCREEN TO WELD PRESS LIB SYS HOURS - 00000.0 TEMP-OK COOL-OK TO PROGRAM PRESS PRO ARC HOURS - 00000.
MODEL 207A AND 207A-1 OPERATION MANUAL SECTION V - OPERATION 5.2 USE OF NEXT/PREV SCREENS/LEVELS (continued) The weld schedule can be programmed to have up to a 100 levels of screen 2 and 3. When viewing screen 2 or 3 the operator can press the NEXT LEVEL key to view the values for the next level (if programmed). When displaying level 2 or greater, pressing the PRE LEVEL key will then display the previous level.
MODEL 207A AND 207A-1 OPERATION MANUAL SECTION V - OPERATION 5.3 WELD SCHEDULE SELECTION 4. To find the weld schedule you want press the NEXT SCREEN key. The next weld schedule in memory will be displayed. Continue pressing the NEXT SCREEN key until the desired weld schedule appears. When the desired schedule appears, press the ENTER key. After a few seconds your selected weld schedule will appear on the display. 5.
MODEL 207A AND 207A-1 OPERATION MANUAL SECTION V - OPERATION 5.4 VIEWING FUNCTION VALUES 2. (continued) 2. Press the NEXT LEVEL or NEXT SCREEN key to review the entire weld schedule as depicted in figure 7 and make changes if desired (see 5.5). 3. Press the SEQ START key to run this weld sequence. (See 5.9 5.
MODEL 207A AND 207A-1 OPERATION MANUAL SECTION V - OPERATION 5.6 OVERRIDING FUNCTION VALUES, DURING WELD SEQUENCE It is possible to over-ride the value of the following functions during Weld Sequence: Level Time Primary Pulse Time Prepurge Time Travel Start Delay Primary Amps Background Pulse Time Post Purge Time Background Amps Primary RPM Background RPM Overrides during sequence can only be done by use of the F KEYS (see in 5.5.3). The numeric keypad cannot be used.
MODEL 207A AND 207A-1 OPERATION MANUAL SECTION V - OPERATION 5.7 SET UP FUNCTIONS 1. SET UP FUNCTIONS IN OPERATE MODE 3. HEAD CAL - This feature is used to calibrate Travel (rotation) speed of the Weld Heads and MUST BE USED ANY TIME A CHANGE OF WELD HEADS IS MADE. See Section 5.7 for operation. 4. REV - Pressing the F key under this will show the current software REVISION installed. This can be important when discussing problems or features with an AMI representative.
MODEL 207A AND 207A-1 OPERATION MANUAL SECTION V - OPERATION 5.7 SET UP FUNCTIONS 1. SET UP FUNCTIONS IN OPERATE MODE 8. WELD DATA RECORDING (WDR) - Selecting this feature will access another screen that will allow the user to turn on WDR and/or turn on WELD ID recording. From this screen WDR STORAGE can be selected as “NOT SAVED” or “PCMCIA”. If “NOT SAVED” is selected then WDR is turned OFF and operation is normal.
MODEL 207A AND 207A-1 OPERATION MANUAL SECTION V - OPERATION 5.7 SET UP FUNCTIONS 2. SET UP FUNCTIONS IN PROGRAM MODE - If the System Mode is set to PROGRAM these additional functions can be shown after the first two SET UP screens. 1. START LEVEL - Right after the arc is struck an initial current is used to stabilize the arc. This is called START LEVEL and can be programmed for a value from 5 to 100 amperes.
MODEL 207A AND 207A-1 OPERATION MANUAL SECTION V - OPERATION 5.7 SET UP FUNCTIONS 2. SET UP FUNCTIONS IN PROGRAM MODE 5. DATE RESET - Prints contain the DATE of print. The DATE can be RESET by using this feature. 6. QTY - RESET - The M-207A keeps count of how many times an individual WELD # is successfully run. It also TOTALS this count for the entire LIBRARY. This information can be viewed on the LIBRARY Screen and is also printed when a PRINT of the LIBRARY or individual WELD # is made.
MODEL 207A AND 207A-1 OPERATION MANUAL SECTION V - OPERATION 5.8 AUTO ROTATION CALIBRATION 2. (continued) AUTO TRAVEL SPEED CALIBRATION WELD HEAD SELECTION MENU SELECT MAX. RPM (STAMPED ON HEAD TAG) 20.0 2.0 OTHER MANUAL Read the Serial Number Tag on the Weld Head and note the MAX RPM rating (a M9-500 is 20 RPM). 3. Use the F key under either 20.0, 2.
MODEL 207A AND 207A-1 OPERATION MANUAL SECTION V - OPERATION 5.8 AUTO ROTATION CALIBRATION 7. For operation on other systems and MANUAL calibration all AMI weld heads have a Calibration Potentiometer. An exact setting of this POT is not required for AUTO CAL but if it is set near one end the system may not be able to accurately calibrate.
MODEL 207A AND 207A-1 OPERATION MANUAL SECTION V - OPERATION 5.9 MANUAL ROTATION CALIBRATION 2. Press the F key under MANUAL. The screen will return to the first SET UP screen and the system is now set for MANUAL calibration. Press the C key to return to the STATUS screen. 3. To manually calibrate the user will need to have a Weld Schedule in the Library programmed in accordance to the Calibration Procedure contained in the operation manual for the particular Weld Head being used.
MODEL 207A AND 207A-1 OPERATION MANUAL SECTION V - OPERATION 5.10 WELDING OPERATION NOTE Before running a weld schedule the weld head must be calibrated to the M-207A. When a weld head is switched from one power supply to another it must be recalibrated to the new power supply. If the weld head being used has not been calibrated, perform the calibration procedure per step 5.8 or 5.9. All of this step is based on the OPERATE MODE switch being in the OPERATE or PROGRAM position. 1.
MODEL 207A AND 207A-1 OPERATION MANUAL SECTION V - OPERATION 5.10 WELDING OPERATION 7. (continued) (bar-graph meters will appear here) PRE-PURGE-POST UP-SLOPE-DOWN ROT-DLY* 60 60 0.0 9.0 CW 1.5 When prepurge starts, the time programmed will start counting down on the screen. The upper display will be bar graphs that will indicate approximate value of current, voltage and rotation speed. 8. As the sequence progresses (see 4.3) the screens will change to follow its progress. 9.
MODEL 207A AND 207A-1 OPERATION MANUAL SECTION V - OPERATION 5.11 PRINTER OPERATION 4. (continued) 2. LIBRARY SCREEN - When the LIB key is pressed and any of the library screens are being displayed a copy of the description of ALL WELD SCHEDULES in memory can be printed. This print out will include each WELD SCHEDULE NUMBER, OD, WALL, TYPE, MATERIAL, QUANTITY of the welds performed and the DATE. At the bottom of the print out will be the total QUANTITY of welds performed by the system. 3.
MODEL 207A AND 207A-1 OPERATION MANUAL SECTION VI -PROGRAMMING 6.0 INTRODUCTION Programming is simply the name used to describe the process of entering or changing the values for functions in a particular weld schedule. The PROGRAM mode may be used to CREATE a new weld schedule or to MODIFY (make changes) to an existing weld schedule. The PROGRAM mode is also used to create a new weld schedule by COPYING an existing weld schedule and then MODIFYING the copy of the original with the desired changes.
MODEL 207A AND 207A-1 OPERATION MANUAL SECTION VI - PROGRAMMING 6.1 CREATE A WELD SCHEDULE 1. (continued) NOTE Use of the C key - Anytime during programming the entire process can be stopped by pressing the C key. If this is done the M-207A will ask the programmer to confirm that cancellation of the programming sequence is desired. If the C key is pressed again, all data ENTERED TO THAT POINT for THAT weld schedule will be ignored (not put in memory) and the system will return to the status screen.
MODEL 207A AND 207A-1 OPERATION MANUAL SECTION VI - PROGRAMMING 6.1 CREATE A WELD SCHEDULE 5. After pressing the ENTER key follow the instructions on the screen for entering the WALL thickness. 6. The M-207A will then give you a choice of 8 TYPES of welds. Use the F keys to pick the type and then press ENTER. Then use the same method for MAT (material). 7. Single Level functions will then appear: ENTER VALUE FOR BLINKING ITEM THEN PRESS ENTER KEY PRE-PURGE-POST UP-SLOPE-DOWN ROT--DLY 000 000 00.0 00.
MODEL 207A AND 207A-1 OPERATION MANUAL SECTION VI - PROGRAMMING 6.1 CREATE A WELD SCHEDULE 9. When the PRO key has been pressed, indicating the end of level programming, the system will display the OVERRIDE screen: USE F KEYS TO SELECT ITEM - % PRESS ENTER KEY WHEN ALL % ARE SET TIME AMP 100 100 RPM 100 PRG SLP PLS DLY 100 100 100 100 The system automatically defaults to 100 % override. This means the operator can make up to a 100 % change to any of these functions. 10.
MODEL 207A AND 207A-1 OPERATION MANUAL SECTION VI - PROGRAMMING 6.2 MODIFY A WELD SCHEDULE 2. Modifying a weld schedule works similar to reviewing a weld schedule in the operate mode (see section V). Use the NEXT/PREV SCREEN and NEXT/PREV LEVEL keys to find the function and level to be modified. 3. When the function value or mode to be modified is found use the F key above or below it to enable it to be modified. Use the numeric keys to enter the new value, for changes of mode use the F key again.
MODEL 207A AND 207A-1 OPERATION MANUAL SECTION VI - PROGRAMMING 6.3 COPY A WELD SCHEDULE 4. If you ask for a weld schedule that does not exist or try to COPY it to an existing number the system will notify you that it is an INVALID NUMBER and to press the CE key and try again. 6.4 TRANSFER/RECEIVE WELD SCHEDULE MEMORY NOTE The M-207-EMM option is required to perform library TRANSFER. Actual operation described in this section can change slightly depending on the use of “canned programs.
MODEL 207A AND 207A-1 OPERATION MANUAL SECTION VI - PROGRAMMING 6.4 TRANSFER/RECEIVE WELD SCHEDULE MEMORY 4. Press the PRO key, then press the F key above or below the word TRANSFER The Screen will then ask if you want to TRANSFER THE ENTIRE LIB, RECEIVE THE ENTIRE LIB or RECEIVE ONE WELD #. Use the appropriate F key to select your choice and then press the ENTER key. CAUTION Prior to TRANSFERRING data from the M-207A to the M-207-EMM the M-207-EMM memory is erased.
MODEL 207A AND 207A-1 OPERATION MANUAL SECTION VII - CALIBRATION 7.0 INTRODUCTION This procedure is intended for calibration/certification of system performance by the user. Except for the Current Servo all system functions are controlled by the processor and no calibration points or steps are required. Rotation calibration is contained in section 5 and is automatically done by the M-207A. It can be verified by a physical count of rotation versus time if required.
MODEL 207A AND 207A-1 OPERATION MANUAL SECTION VII - CALIBRATION 7.2 CURRENT CALIBRATION The M-207A contains components for measuring the actual amount of current. Normal calibration is intended for adjusting the circuitry based on measuring these devices. True verification of current output for Quality Control purposes must be done with an External Calibration Shunt that is calibrated by an independent agency and controlled by a users QC or QA department.
MODEL 207A AND 207A-1 OPERATION MANUAL SECTION VII - CALIBRATION 7.2 CURRENT CALIBRATION 2. Set up a Weld Head rated for 100 amperes continuous duty and insert a tube, or pipe, or copper rod that can withstand 100 amperes of continuous current with no rotation. If these items are not available then use a Hand Torch on a large plate with the torch fixed so it cannot change the gap during calibration. It is also possible to purchase a Carbon Pile (load bank) that will take the place of a torch or weld head.
MODEL 207A AND 207A-1 OPERATION MANUAL SECTION VII - CALIBRATION 7.2 CURRENT CALIBRATION 9. DO NOT INSERT THE PROBES UNTIL AFTER THE ARC IS STRUCK. The high frequency start may damage some meters. 10. Press the SEQ START key. 11. As soon as the arc is struck (after prepurge) insert the Probes into the center plate test points or into the external shunt if it is being used. 12. During all ODD numbered Levels (100 amperes) the DMM should read as follows: Center Plate Test Points.. = 4.00 VDC +/- 0.
MODEL 207A AND 207A-1 OPERATION MANUAL SECTION VII - CALIBRATION 7.3 GENERAL MAINTENANCE INSTRUCTIONS CAUTION Always disconnect the AC power cable from the line voltage before attempting to work with this welding power supply. 1. AIR FILTER - The M-207A power supply has one (1) foam air filter. Inspect this air filter regularly. The foam filter may be washed in water and detergent, dried and reused or replaced. Do not operate unit without filter in place.
MODEL 207A AND 207A-1 OPERATION MANUAL SECTION VII - CALIBRATION 7.4 SYSTEM FAULT CORRECTIONS When a System Fault occurs prior to or during welding it is required for the operator to clear the fault condition before welding. When a fault occurs during sequence or attempting sequence the FAULT SCREEN will appear. Some faults are only temporary and the fault is corrected when the arc goes out. But all faults will cause the FAULT SCREEN to appear and let the operator know why the sequence was stopped.
MODEL 207A AND 207A-1 OPERATION MANUAL SECTION VII - CALIBRATION 7.4 SYSTEM FAULT CORRECTIONS 3. GAS - This fault will only occur at the beginning of or during a Weld Sequence. If the arc gas flow through the system should stop, or be to low, a fault will occur. Check that the Gas Source (user supplied) is turned on and that adequate gas is available. Check all Gas Hoses and connections for free flow, this is usually the problem.
MODEL 207A AND 207A-1 OPERATION MANUAL SECTION VII - CALIBRATION 7.4 SYSTEM FAULT CORRECTIONS 6. STUB OUT - This fault will only occur when an arc is present and will no longer exist when the arc goes out. If the arc voltage gets too low or the electrode should touch the weld puddle then a fault will occur. It creates an ALL STOP but does not operate the “return to home” function after Postpurge. The operator should check to see if the electrode is stuck to the tube being welded.
MODEL 207A AND 207A-1 OPERATION MANUAL SECTION VII - CALIBRATION 7.4 SYSTEM FAULT CORRECTIONS 8. BAD START - (continued) When a BAD START occurs check the electrode connection and electrode condition first. Also check to insure that CERRIATED electrodes are being used. They have proven to be much more effective than THORIATED electrodes for RF transmission and longer life. BAD STARTS can also be caused by not having the proper START LEVEL set. See Section 5.6.2 for START LEVEL information.
MODEL 207A AND 207A-1 OPERATION MANUAL SECTION VII - CALIBRATION 7.5 ERROR MESSAGES 1. MEMORY CHECK (continued) NOTE When the print key is pressed any weld schedule with a directory or link error will automatically be “DELETED”. Any schedule with a sum check error will be flagged corrupted on the print out and the user should call up that weld schedule and verify the parameter values. A typical print out could look like this: ARC MACHINES, INC. COPYRIGHT 1996 AMIWELD 207A 2.1 SYS HOURS - xxxxx.
MODEL 207A AND 207A-1 OPERATION MANUAL SECTION VII - CALIBRATION 7.6 MISCELLANEOUS MAINTENANCE ITEMS 1. BATRAM (continued) Replacing the BATRAM requires accessing the inside of the M-207A. A complete replacement procedure is available in the M-207A Maintenance Manual (#740078). 2. RS232 COMMUNICATIONS The M-207A can shut down the RS232 port on it own if it detects non-intelligent information on it. This can be caused by ambient light or improper set up.
MODEL 207A AND 207A-1 OPERATION MANUAL SECTION VIII - OPTIONS 8.0 INTRODUCTION The following are installation and operation instructions for M-207A options. Some options have their own manual and these items are not discussed in this section. WARNING Always turn the power supply OFF before making any cable or connection changes to the M-207A power supply. 8.1 M227/207-CW & M207-CW COOLING UNIT SPECIFICATIONS/INSTALLATION 1. Specifications 1. AC Input Power - supplied from the M-207A power supply. 2.
MODEL 207A AND 207A-1 OPERATION MANUAL SECTION VIII - OPTIONS 8.1 M227/207-CW & M207-CW COOLING UNIT SPECIFICATIONS/INSTALLATION 4. Installation 2. (continued) NOTE All cooling systems are subject to problems from mineral buildup, algae and bacteria. Frequent changes of coolant and flushing of the system are necessary to keep any cooling system running efficiently. Frequency of changes is strictly dependent on the environment and quality of coolant used. Monitor your cooling system carefully and often.
MODEL 207A AND 207A-1 OPERATION MANUAL SECTION VIII - OPTIONS 8.1 M227/207-CW & M207-CW COOLING UNIT SPECIFICATIONS/INSTALLATION 5. Operation 2. Both M227/207-CW & M207-CW contain flow sensors. Any time the CW unit is turned ON a signal will be sent to the M-207A that indicates if the flow is adequate If it is the M-207 STATUS screen (at power up) displays COOL-OK. If it is not OK the screen will display COOL-FLT. Any time there is a COOL-FLT the problem must be corrected in order to weld. 3.
MODEL 207A AND 207A-1 OPERATION MANUAL SECTION VIII - OPTIONS 8.2 M-207-RP REMOTE PENDANT 2. Operation (continued) 1. The following functions and features are provided by the Remote Pendant: 1. Sequence Start key 2. Sequence Stop key 3. All Stop key 4. Rotation jog CW key 5. Rotation jog CCW key 6. Weld/Test mode key 7. Manual Purge key 8. Print key 9. 8 character digital status display 10. Weld # key 11. Amps Up key 12. Amps Down key 2.
MODEL 207A AND 207A-1 OPERATION MANUAL SECTION VIII - OPTIONS 8.2 M-207-RP REMOTE PENDANT 2. Operation (continued) 4. As previously noted, the M-207A can store in memory up to 100 weld schedules. Any 4 of these schedules can be programmed to be selected from the RP. The Weld # key is used to select one of these 4 weld schedules. To initially set up which schedules can be selected from the M-207-RP press the SET UP key on the M-207A (this operation cannot be done from the RP).
MODEL 207A AND 207A-1 OPERATION MANUAL SECTION VIII - OPTIONS 8.3 M-207-EMM EXTERNAL MEMORY MODULE 1. The M-207-EMM is used to TRANSFER a COPY of the library of one M207A to another M-207A to maintain identical libraries for multiple system users. It is also used as a security device to retain a copy of the library which cannot be changed accidentally. WARNING Always turn the power supply OFF before making any cable or connection changes to the M-207A power supply. 2.
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