Arc Machines 207 User Manual

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. 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,	04/20/98	GPE
			8.1, 8.2, 8.3.
	D	3583	Revised page 7.4 Step 13 add new Current Offset	3/20/00	GPE
			adj.
	E	3684	Removed ref to Miller coolant page 8.2	7/20/00	GPE
	F	5779	Removed 207A-HP (OBS)	8/10/10	DC

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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.

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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	1.5
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

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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

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	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

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1.0INTRODUCTION

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.

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1.1SAFETY 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.

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WELD ONLY IN AREAS WITH ADEQUATE

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SECTION I - INTRODUCTION

1.1SAFETY 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.

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.

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.

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1.1SAFETY 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.

1.2OPERATIONAL 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.

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1.2OPERATIONAL 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.When storing or handling weld heads, always keep them in the protective containers they are shipped in, or optional carrying case, until ready to install.

9.When operating, storing or handling, insure that the system is protected against dirt, dust, etc. NEVER GRIND NEAR AN EXPOSED WELD HEAD OR THE M-207A.

10.Do not use acid, corrosives, liquid “Easy Out” or any liquid substance on the M- 207A or any AMI weld head. When cleaning, use only a light solution of Isopropyl alcohol on a soft cloth .

11.When handling, take extreme care to avoid dropping the M-207A, weld heads, cables or any accessories.

12.Do not attempt to move tube end into position using the weld head as a lever.

13.Do not add any lubrication like graphite, oil or grease to the weld heads or power supply unless it is specified in the operation or maintenance manual for that equipment.

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1.3SHOCK 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.

All AMI Power Supplies contain a “bleeder” circuit to ground any residual potential after welding or after an aborted or bad “arc start” attempt. However, these circuits take a few seconds to operate or COULD FAIL.

“THE ELECTRODE SHOULD ALWAYS BE CONSIDERED A POSSIBLE SHOCK HAZARD”. This is especially true when ever the system is in “weld sequence” ready to weld, is welding or has just finished welding. However, equipment/component failure, system abuse, or improper maintenance could result in electrical potential at the weld head “even when not in weld sequence”.

The users/operators of this equipment must take all precautions necessary to avoid contact with the ELECTRODE at “ALL TIMES”. The only exception is when actually replacing or adjusting the electrode and this should be done “WITH THE POWER TURNED OFF”.

If performed with the power “ON” the system must be in test mode out of weld sequence and the USER MUST OBSERVE COMMON SAFETY PRACTICES such as grounding the electrode to insure discharge before actually touching it.

REMEMBER, there is a “POSSIBLE” shock hazard in all welding power supplies at “ALL” times.

Most AMI Power Supplies feature High Frequency (HF) Arc Starting. This is a High Voltage/High Frequency electrical transmission process. To eliminate any HF shock possibility “AVOID ALL CONTACT” with the Welding WORK (ground), the ELECTRODE or the WELD HEAD during arc start.

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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.

2.0ELECTRICAL

1. RATING PLATE DEFINITIONS

	1) Company:		Country:	3) Model:		6) Standards:
	ARC MACHINES, INC.		USA	Model 207A		NEMA EW1
						IEC 974-1
	8) Process:	10) Type:		9) Output:
		___________		Minimum		Maximum
		_ _ _ _ _ _ _ _ _ _
				3A / 5V	150A / 20V
	G.T.A.W		DC
	23) Shock Rating:	11) No-load Voltage:		12) Duty Cycle:
	S	U0	= 59V	X = 100% ALL RATED OUTPUTS
	15) Input:	18) Voltage:		19) Input Current:		21/22) Rating/Class:
		U1 = 110V		I1max = 30A I1eff	= 30A	IP21
	1~ 50/60 HZ		220V	20A	20A

1)- Manufacturer and Country of Origin

3)- Model Number Rating Plate applies to.

4)- Serial Number (located on M-207A Center Plate, not on rating plate).

6)- International and USA Standards that the equipment meets.

8)- Weld Process symbol for GTAW welding.

9)- Rated minimum output amperes and output voltage (same all models). Rated maximum output amperes and output voltage. M-207A maximum rated current is 150 amperes at 20 volts and M-207A-1 are

limited to rated maximum of 100 amperes at 20 volts. All Models are limited to 100 Amperes while connected to 110 VAC.

10)- Symbol that output is Direct Current (DC) only.

11)- Rated No Load Output Voltage (open circuit voltage) is 59 volts for

M-207A 79 volts for M-207A-1.

. 12) - All M-207A models are 100 % Duty Cycle for their rated outputs (9). 15) - Input Voltage type contains symbol for single (1) phase Alternating

Current (AC) input at 50 or 60 Hz frequency.

18)- Nominal Input Voltage value is 110 VAC or 220 VAC

19)- Rated maximum required supply current. Given for both I1 maximum (I1max) and I1 effective (I1eff). Both are rated at 30 Ampere service for 110 VAC operation and 20 ampere service for 220 VAC operation.

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2.0ELECTRICAL

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.

23)- “S” Symbol indicates a welding power source which is suitable for an environment with an increased electric shock hazard.

2.INPUT POWER, DETAIL - All M-207A Models, as shipped standard, can operate on the following Single Phase input AC:

Voltage	Tolerance	Freq.	Max Input Current
100 VAC	+ 32%, -10%	50/60 Hz	30 amperes
110 VAC	+ 20%, -18%	50/60 Hz	30 amperes
115 VAC	+ 15%, -22%	50/60 Hz	30 amperes
120 VAC	+ 10%, -25%	50/60 Hz	30 amperes
200 VAC	+ 32%, -10%	50/60 Hz	20 amperes
208 VAC	+ 27%, -13%	50/60 Hz	20 amperes
220 VAC	+ 20%, -18%	50/60 Hz	20 amperes
230 VAC	+15%, -22%	50/60 Hz	20 amperes
240 VAC	+ 10%, -25%	50/60 Hz	20 amperes

+/- % indicates the allowable input voltage change to maintain performance as specified. Maximum input current is based on maximum output current at maximum arc voltage. See section 3.1 for installation.

3.OUTPUT POWER - Straight polarity, constant current DC regulation intended for GTAW welding only. Static characteristic of all power supplies is flat.

All Models ...................	= 3 to 100 amperes DC using 100 to 120		VAC input.
M-207A-1	=	3 to 100 amperes DC using 200 to 240	VAC input.
M207A .........................	=	3 to 150 amperes DC using 200 to 240 VAC input.

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2.0ELECTRICAL

4. CIRCUIT BREAKER - ON/OFF, two pole, 30 Ampere at 250 VAC.

2.1PHYSICAL 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)

2.2PROGRAMMABLE and OPERATIONAL FUNCTIONS

PREPURGE TIME ...............................................	=	010	- 999 seconds
POSTPURGE TIME ...........................................	=	000	- 999 seconds
UPSLOPE TIME ..................................................	=	00.0	- 99.9 seconds
DOWNSLOPE TIME ..........................................	=	00.0	- 99.9 seconds
ROTATION START DELAY .............................	=	00.0	- 99.9 seconds
ROTATION MODE SETTINGS ........................	=	CONT - STEP - OFF
PRIMARY ROTATION SPEED ........................	=	0.00	- 20.0 RPM
BACKGROUND ROTATION SPEED ..............	=	0.00	- 20.0 RPM
PULSE MODE SETTINGS ................................	=	ON	- OFF
PRIMARY PULSE TIME ...................................	=	0.00	- 9.99 seconds
BACKGROUND PULSE TIME ..........................	=	0.00	- 9.99 seconds
LEVELS ..............................................................	=	1	- 99
LEVEL TIME (each level) ...................................	=	000	- 999 seconds*
PRIMARY CURRENT ........................................	=	3	- 150 amperes*
BACKGROUND CURRENT ..............................	=	3	- 150 amperes*

* = Can be in increments of 0.1

2.3MULTI-LEVEL FUNCTIONS - The following functions can be programmed to change value during a given weld sequence.

FUNCTION	POSSIBLE CHANGES
LEVEL TIME ......................................................	= 1 to 99 levels

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2.3MULTI-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).........................................	= 1 to 99 levels
PRIMARY ROTATION ............................................	= 1 to 99 levels
BACKGROUND ROTATION RPM.........................	= 1 to 99 levels
ROTATION MODE (CONT/STEP/OFF) .................	= 1 to 99 levels

2.4AMBIENT TEMPERATURE RANGE - 32 F (0 C) to 110 F (45 C).

2.5 CABLE OPERATING DISTANCE LIMITS - Standard	= 25’	(7.6 m)
Maximum	= 100’	(30.5 m)

The standard distance consists of a 15’ adapter cable and a 10’ weld head cable combined together. The maximum distance is achieved by adding extension cables to the standard cables.

The above are considered normal limits. With special options, distances of 500 feet or more can be achieved. Consult an AMI representative for more information.

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3.0INSPECTION

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. An exact list of these items is included with each power supply shipment. This manual will reference some of those items so before beginning installation these items should be located and be available.

3.1POWER CONNECTION

WARNING

Do not connect the M-207A power supply to any AC power other than the ones listed in section 2.0.2.

The M-207A can operate on 9 different input line voltages and must be set up for the one you are using. Use the following procedure to insure that the M-207A is set-up for the correct AC power.

1.The M-207A is supplied with a 25’ power cord. One end has a connector on it that plugs into the side of the M-207A. The wires on the other end are pigtailed (no connector). A suitable AC line connector, matching the input power, must be supplied and installed by the user. Color coding of the

power cord is as follows:

Black .................	= Hot (high line side)
White .................	=	Neutral (low line side)
Green/Yellow ....	=	Ground (protective earth ground)

NOTE

For additional ground reference there is a ground symbol silk-screened next to the ground pin on the M-207A Input AC connector on the Input Panel.

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3.1POWER 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). The switch is concealed by a cover plate and only the top of the switch handle can be seen through a hole in the plate. The plate is labeled as to what voltage the switch is currently set for.

5.If the M-207A is to be run on 100, 110, 115 or 120 VAC this switch must be in the 110 VAC position. If it is to be run on 200, 208, 220, 230 or 240 VAC it must be in the 220 VAC position. If it is in the correct position, proceed to step 3.2.

6.To change the power select switch position, remove the cover retaining screws (see figure 3) and remove the cover. Set the switch to the alternate position and install the cover plate. It must be flipped over so the hole in the plate will fit over the switch handle in the new position. This will automatically expose the alternate voltage label on the other side.

3.2WELDING GAS CONNECTIONS

NOTE

The following instructions are for M-207A

1.Three gas hoses are supplied with M-207A. These hoses are made of material selected specifically for automatic welding. HOSES MADE FROM OTHER MATERIAL ARE NOT RECOMMENDED (especially rubber, nylon or tygon).

2.One 10 foot (3m) hose should be installed from the gas regulator/flowmeter (user supplied) to the ARC GAS INPUT fitting on the M-207A. This hose is supplied with all fittings required to mate with the M-207A and most domestic (USA) inert gas flow meters.

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3.2WELDING 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.

CAUTION

The M-207A arc gas solenoid valve is rated at 50 PSI (345 KPa) maximum pressure, DO NOT EXCEED THIS RATING.

3.The other 10’ (3 m) hose is intended for I.D. PURGE GAS INPUT and its connection to and through the M-207A is optional. It is supplied with fittings to connect from the gas source regulator/flowmeter to the PURGE GAS input bulkhead fitting on the M-207A.

The M-207A does not supply a solenoid for control of I.D. PURGE GAS. The line feeds straight through to the output quick-disconnect. If the output hose is plugged in, gas will flow at all times. This feature is best for benchtype weld development but not normally used for field I.D. purging of long lengths of tube.

If you wish to use this option, install the hose and fittings loosely by hand, tighten the retaining nuts slightly with a wrench to insure there are no leaks, but do not over-tighten. The use of plumbers tape or grease is not recommended (see figure 4).

4.The 25 foot (7.6 m) hose is intended to supply the I.D. purge from the M- 207A to the weld. One end has a quick-disconnect on it that mates with the PURGE GAS output bulkhead fitting on the M-207A. If used, the quickdisconnect provides a convenient method for starting or stopping the flow of I.D. purge gas. If you wish to use this option, insert the male quickdisconnect of the hose into the M-207A connector labeled PURGE OUTPUT (see Figure 2 and 4).

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3.3ADAPTER 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. The other end connects to the M-207A or to a weld head extension cable. The connector types and keyways are different for each item (except gas).

Use the following steps for connection to the M-207A (see figure 2 and 4).

2.Connect the GROUND and ELECTRODE connectors to their respective terminals on the M-207A. Align the keyways, push in and twist clockwise until fully locked.

3.Weld head CONTROL connector - Just before installing, unscrew the dust caps on the cable and M-207A connector labeled WELD HEAD CONTROL. Insert the cable connector into the M-207A panel connector. Note the positioning keyway and NEVER FORCE or use tools on the cable connections. Hand tighten the connecting ring after the pins are firmly seated.

4.Insert the cable male gas quick-disconnect into the M-207A ARC GAS OUTPUT connector. Do not insert it in the purge gas output connector.

5.If the M227/207-CW or M207-CW optional cooling unit is being used, insert the two coolant quick-disconnects into the COOLANT IN and COOLANT OUT connectors on the CW. The cable coolant connectors are interchangeable and it does not matter which one goes to in or out. See section 8.1 for CW installation instructions.

3.4WELD HEAD INSTALLATION - The weld head cable connects to the adapter cable. Refer to figure 2 and 4 as you perform this 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.

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SECTION III - INSTALLATION

3.4WELD 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.Unscrew the CONTROL connector dust caps on both cables just before installing. Insert the adapter connector into the head connector. Note the positioning keyway and NEVER FORCE or use tools on the cable connections. Using just your hand, tighten the connecting ring until the pins are firmly seated. Screw the two dust caps together to prevent them form swinging around.

4.Installation is now complete.

CAUTION

Before proceeding with POWER ON it is EXTREMELY important to have a basic understanding of SYSTEM FUNCTIONS. Read section IV (system functions) before proceeding with OPERATION (section V) or PROGRAMMING (section VI).

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SECTION IV - SYSTEM FUNCTIONS

4.0INTRODUCTION

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. Details of function ranges and tolerances can be found in section II of this manual and in AMI Specification No. 207. Details about operating these functions can be found in section V.

4.1FUNCTIONAL DESCRIPTION, GENERAL

1.LIBRARY - The heart of the M-207A is its MEMORY. The values of each function , for a given weld, are only programmed one time. After that the

M-207A will store the function values (for that weld) by WELD

SCHEDULE NUMBER (#) and description.

When a particular weld type is needed to be made the Operator can locate it in the WELD SCHEDULE LIBRARY by description or by weld schedule number (#).

2.WELD SEQUENCE AND LEVELS - Selected weld schedules are started by manually initiating the SEQUENCE START. Once the sequence is started the system operation of functions is totally automatic.

In addition to functions to start and stop the weld, the weld sequence includes the ability to preset changes in function values and modes. These changes are called LEVELS and as many as 100 levels can be used for each weld sequence. All weld schedules start with (and must have) Level 1.

If preset changes are desired they will be set in LEVELS 2, 3, etc. The LEVELS advance from 1 to 2, 2 to 3, etc. automatically as a function of time.

3.CURRENT SOURCE AND CONTROL - The M-207A is a pulsed, 150 ampere, constant current, straight polarity, GTAW power source. The current value(s) can be set between 3 and 150 Amps

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SECTION IV - SYSTEM FUNCTIONS

4.1FUNCTIONAL 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.PULSATION - The system can rapidly change or PULSE back and forth between two (2) different values of CURRENT and two different values of TRAVEL. The normal or HIGH value is designated the PRIMARY value. The other or LOW value is designated the BACKGROUND value.

This pulsation is done as a function of time by using the PRIMARY and BACKGROUND PULSE TIMES to set an exact amount of time for each PRIMARY and BACKGROUND function to occur.

6.OVERRIDES - The weld schedule programmer can set the M-207A to allow the operator to change the value of some weld schedule functions. The programmer can also set limits to the amount of changes the operator can make to each function.

7.FAULT STATUS - The system continuously monitors certain functions such as gas flow, coolant flow (if used), system temperature and input AC. If there are any problems the system will alert the operator and in some cases, where weld quality might be affected, the system will stop the welding process.

8.GAS FUNCTIONS - As stated, the M-207A is intended for the GTAW process. This process requires a welding gas (usually inert) for operation, and the M-207A is equipped with a gas solenoid and input/output connectors for the control of the welding (arc) gas.

9.PRINT FUNCTIONS - Built into the M-207A is a thermal Printer. The printer allows copies of the Library and complete weld schedule to be made.

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SECTION IV - SYSTEM FUNCTIONS

4.2WELD LIBRARY AND WELD DESCRIPTION

Each weld schedule programmed into the system memory is identified and displayed (when selected) with the following information:

1.	#	= Individual WELD SCHEDULE NUMBER from 001 to 100.
2.	OD	= Outside diameter in inches or mm of the weld.
3.	WALL = Wall thickness in inches or mm of the weld.
4.	TYPE	= Uses abbreviations to identify the type of weld the schedule is for
		(see section 4.9 for list).
5.	MAT	= Uses abbreviations to identify the base material the schedule is for
		(see section 4.9 for list).
6.	QTY	= Indicates the number of times this weld schedule has been used since
		last reset.

4.3WELD SEQUENCE - Although the M-207A can be used as a manual welding power source, it is primarily intended to follow an automatic SEQUENCE. After a weld schedule is selected and the weld is setup, the SEQUENCE will be

manually started by the operator and the following events will occur automatically (see figure 5 for the timing chart):

1.EVENT 1: PREPURGE - Welding gas will start to flow (for the entire weld) from the gas source (user supplied) through the power supply to the weld head. Complete gas coverage should be obtained before the arc is struck. How long it flows before the arc is struck is called the PREPURGE TIME. Minimum programmable time is 10 seconds.

2.EVENT 2: ARC START - When PREPURGE time is complete a high frequency pulse will be generated to establish an arc between the electrode and the weld joint.

3.EVENT 3: LEVEL 1 TIME, START LEVEL, UPSLOPE, TRAVEL START DELAY - When the arc starts the following functions all start at the same time:

1.LEVEL 1 TIME - When the arc is established all weld functions are considered to be in LEVEL 1. The LEVEL 1 Timer will start to count and the M-207A will stay in LEVEL 1 until this time is complete.

2.WELD CURRENT START LEVEL - As the arc is established the weld current will jump to a small value. This current is used to stabilize the arc and is called the START LEVEL. Its value is adjustable and may need to be changed depending on certain conditions.

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