AMI Model 227 Power Supply Operator Training Guidelines

10500 Orbital WayPacoima, California 91331 U.S.A.

MODEL 227 POWER SUPPLY

OPERATOR TRAINING GUIDELINES

Document No. 740085

MODEL 227

Operator Training GuidelinesArc Machines, Inc.

General Guidelines for Orbital Pipe Welding

This manual is intended for factory-approved Operator Training on the AMI Model 227 microprocessor-con-trolled power supply. The Model 227 Power Supply is available with two different levels of programmable controls beyond the basic controls required for orbital fusion welding. The simplest version has controls for rotation and wire feed. The Model 227 is also available with controls for torch oscillation and arc voltage (AVC) to operate the AMI full-function pipe weld heads. The Model 227 is also compatible with the AMI Model 9, Model 8, or Model 96 fusion weld heads, and an optional manual torch. The wire feed only version may be used to operate the Model 95 open-frame weld heads as well as the Model 9 fusion weld heads. Appropriate cables for each weld head must be used.

The Model 227 features a built-in library for extensive program storage and a thermal printer for QC func-tions. Off-line Programming is also a feature of the Model 227.

Effective date: January, 1998Document No. 740085Revised September, 1999

AMI Model 227 Operator Training Manual

Orbital Welding of Furnace Tubes at the ARCO Refinery, Long Beach, California Swinerton & Walberg Co. Reprinted from the Welding Journal

MODEL 227 OPERATOR TRAINING GUIDELINES

General Guidelines for Orbital Welding Pipe

Document No. 740085Effective date: January, 1998

Revised January, 2002

Table of ContentsINTRODUCTION

MODEL 227 WARNINGS

MODEL 227 POWER SUPPLY INSTALLATION

GENERAL OPERATION / SYSTEM FUNCTIONS

SEQUENCE OF EVENTS

TUNGSTEN SPECIFICATIONS

SHIELDING AND BACK-UP GASES

ARC VOLTAGE CONTROLLER (AVC)

PIPE END-PREPARATION FOR ORBITAL WELDING

PROGRAMMING THE MODEL 227 POWER SUPPLY

WELD PROCEDURE DEVELOPMENT

TROUBLESHOOTING

WELD CRITERIA /WELD QUALIFICATION

OFFLINE PROGRAMMING

APPENDICES

INDEX

1

2

3

4

5

6

7

8

9

10

11

12

13

14

15

16



1.4


1.1

Chapter 1. Introduction to Orbital Pipe Welding

The purpose of this manual is to acquaint the welding operator with the basic

installation and functions of the Model 227 Power Supply and to provide a guide for basic orbital GTA (TIG) welding operations and procedures.The manual is intended for use in an Arc Machines, Inc. Pipe Welder Training Class and IS NOT A SUB-STITUTE FOR THIS TRAINING. Operation of pipe welding equipment is a com-plex skill and requires a knowledge of welding. In addition to learning the theoretical material presented in this manual, practical “hands-on” training of at least a week is recommended in order to become proficient. Prior knowledge of manual welding and/or the ability to “read” a weld puddle is strongly recommended.

Software. You should be aware that the features and operation of the Model 227 are derived mostly from software. This document is based on the latest STANDARD version of M-227 SOFTWARE at the time of last revision (see revision page). Devi-ations in actual operation may be apparent if the machine in use has a different ver-sion of software. IMPORTANT: Note that an upgrade from Software version 1.4 to any later version requires not only the new software, but hardware modifications and recalibration of the Power Supply. Please contact the Arc Machines Service Depart-ment for documentation and information on how software updates affect operation. Operation of welding equipment by untrained persons is hazardous. Please refer to Arc Machines, Inc.’s Model 227 Power Supply Operation Manual, Document Num-ber 740063 for a complete description of the Model 227 physical and electrical spec-ifications, operation and programming functions.

The Model 227 Power Supply provides GTAW currents up to 225 Amperes of pulsed current with pulsation controls, high frequency arc starting, purge gas con-trols, weld head arc rotation, cold wire feed and automatic timing functions as basic features with torch oscillation and automatic arc voltage control (AVC) available as an option. A remote operating pendant is provided with the Model 227 as standard equipment. An optional torch cooling unit (CW) is available. Welding System. The Model 227 is part of a complete welding system intended for the GTA welding of tubes, pipes, and fittings. The complete system consists of the Model 227 Power Supply, adapter cable, gas lines and one or more of the several AMI weld heads, torches or torch fixture devices.

Weld heads that may be used with the Model 227 Power Supply include the Model 81 full-function, low-profile weld head which will weld pipe from 3/4” OD to 5.563” OD with as little as 1.75” radial clearance and

Model 81


6.325” axial clearance. This head has proven very successful in the orbitalwelding of boiler tubes and furnace tubes for the power generation and petro-chemical industries. Information specific to individual weld heads is not included in this manual.

The Model 15 Large Diameter pipe weld head may also be used with the Model 227. The Model 15 is designed for welding pipe from 4” pipe to all stan-dard pipe diameters, or it may be operated on a flat track. Although it is a full-function head with wire feed, the Model 15/227 combination has recently been used by the semiconductor and pharmaceutical industries as well as by paper mills for autogenous welding of schedule 10 pipe up to 14 inch IPS. Note that in order to use the the full-function heads with AVC and oscillator, the Model 227 must be equipped with an AVC/OSC PC board.

The Model 9 fusion weld heads are used extensively in the high-purity semicon-ductor and pharmaceutical industries where a smooth inner weld bead and cleanability are critical and are also recommended for food, beverage and dairy piping systems. These heads perform autogenous welds in the range of 1/8 inch to 7 inch OD with wall thicknesses of up to 0.154 inches.

The three Model 95 Series Open Frame orbital weld heads in conjuction with the Model 227 power supply represent an inexpensive pipe welding system which can be used with or without the addition of filler wire. They can accommodate sizes from 3/8 inch to 6 inch IPS pipe (6.625” OD) with wall thicknesses up to 3/4 inch. The Model 95s are suitable for a variety of joint designs such as ‘V’ prep, ‘J’ prep, socket and square butt, and are capable of welding a wide range of materials.

The Model 79 Weld Heads are sturdy, economical, full-function weld heads designed to be operated with or without the use of filler featuring automatic arc gap control, (AVC), and programmed torch oscillation or weave. Each head acco-modates a range of sizes using the same quick mount and dismount clamping drive housing as the Model 95 series weld heads.

Model 9

Model 95

Model 15

side view front view Model 79

1.2


Model 6

The Model 96 and Model 6 tube-to-tubesheet weld heads can be used with the Model 227 power supply for fusion welds and welds requiring filler material respec-tively. These heads are used for welding heat exchangers for a variety of industries.

All weld heads must be calibrated for travel speed on the power supply with which they are to be used. In applications requiring the use of filler wire, wire feed speed must also be calibrated to the power supply.

Appropriate cables must be used for each weld head as shown on the fold-out page.

Consult Operation and Training manuals for the individual weld heads for welding information specific to each head.

This manual is intended to be used in the context of an approved ARC MACHINES TRAINING CLASS to introduce welding operators to the Model 227 Power Supply. Basic concepts of SET-UP, Operation, and Programming are included. It is expected that the training class will provide the opportunity for “hands on” operation, programming, weld procedure development and troubleshooting. Con-sult the Model 227 Operation Manual (P/N 740063) for more specific or detailed information on the Model 227 Power Supply. Since the welding applications in which this equipment is used covers a variety of industries and situations, every user’s weld-ing application will be different. Thus it would be impossible to cover all of the small but important operational details in a manual such as this. Class participants are urged to take notes since all information needed may not appear in the training manual.

1.3


1.4


Chapter 2. Model 227 Warnings

2.1

This section, concerning safe operating procedures for the Model 227, should be read and

understood before proceeding to other sections of the training manual. It also contains precau-tions and warnings for the operation of welding equipment in general. In addition, users should reference and become familiar with “ANSI-49.1 Safety in Welding and Cutting” 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 very short burst of 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 unprotected or poorly protected against such interference.

WARNING: Magnetic fields from High Currents can affect pace-makers. PACEMAKER WEARERS ARE ADVISED TO CONSULT THEIR PHYSICIAN BEFORE OPERATING WELDING EQUIPMENT

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 peresonnel should open this equipment.

Safety Precautions


2.2

MODEL 227 WARNINGS Continued:

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 protec-tive clothing, footwear and head gear.

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. (See ANSI Publication Z87.1, Practice for Occupational and Educational Eye and Face Protection, latest edition.

WARNING: Weld materials can emit toxic fumes during welding. WELD ONLY IN AREAS WITH ADEQUATE VENTILATION.


MODEL 227 WARNINGS Continued:

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 Opera-tors and Maintenance Technicians who operate AMI equipment.

WARNING: Some systems, such as the M-207-HP are intended solely for indoor use and must be kept dry. Before operating, stor-ing, or handling, always make sure that the M-227, M-227-RP Pen-dant, weld heads, cables, and connections are not exposed to rain or standing water. SYSTEM COMPONENTS ARE NOT WATER PROOF.

WARNING: Keep hands and fingers clear from moving parts such as fans, gears, rotors, wire feed, rotation and AVC mechanisms.

WARNING: The Model 227 Power Supply is not intended for pipe thawing or heating in any form.

WARNING: The Model 227 Power Supply weighs in excess of 91lbs (41.3 kg). It has no handles and is not intended to be carriedby a single person. Be sure to follow your local, OSHA, internat-ional or employer guidelines for proper methods of lifting and relocating this equipment.

2.3


2.4

Recommendations for Safe Use of Orbital Welding Equipment

Welding personnel are advised to adhere to the following recommendations BEFORE OPERAT-ING THE MODEL 227 to insure smooth operation of the welding equipment with minimal down-time:

• VERIFY that the Model 227 is connected to the CORRECT INPUT AC power before turning on breaker. SEVERE EQUIPMENT DAMAGE may occur if connected to the wrong AC power source.

• CHECK ALL FITTINGS AND CONNECTORS for proper seating and make sure that all

protective boots are in place. Short circuits, poor connections or inert gas leaks may result from improper seating.

• USE ONLY ARGON or gas mixtures intended for GTAW use. NEVER CONNECT OXY-GEN OR ACETYLENE TO THE MODEL 227.

• ROUTE OR PROTECT CABLES so they will not be subject to heat, foot traffic, forklifts, etc. Do not allow HOT PIPES to come in contact with the cables.

• KEEP PROTECTIVE BOOTS and DUST caps on CABLES until ready to install. Improper care and use of cables is a major cause of downtime in any automatic welding system.

• INSURE ADEQUATE AIR FLOW to the Model 227 by keeping intake and exhaust vents of the power supply unrestricted.

• VERIFY THAT A SECURE BARE METAL CONNECTION EXISTS between the tube or pipe to be welded and welding ground before striking an arc.

• PROTECT WELD HEADS when not in use by storing in protective containers in which they were shipped, or in optional carrying case.

• NEVER GRIND NEAR AN EXPOSED WELD HEAD OR THE MODEL 227. Insure that the weld head and power supply are fully protected from dirt, dust and metal particulates.

• AVOID the use of acid, corrosives or other liquid substances. A light solution of isopropyl alcohol is the only approved liquid for cleaning of weld heads or the Model 227. Lubricants such as graphite, oil or grease are not to be used unless specifically recommended in the oper-ation manual for that equipment.


• DO NOT DROP WELD HEAD. Take extreme care when handling to avoid dropping power supplies, weld heads or cables.

• USE PIPE STAND, CLAMPS, ALIGNMENT TOOLS, etc. to hold tube or pipe in position for welding. DO NOT USE THE WELD HEAD FOR AN ALIGNMENT TOOL OR LEVER. Pretacking of components with a manual torch prior to orbital welding may be necessary in some applications.

RF and EMI EmissionsArc Machines’ policy is to comply with the IEC and FCC regulation. Every effort has been made to reduce RF emissions from our power supplies to the absolute minimum. Refer to the Model 227 Operation Manual for a more complete discussion of this topic.

“High Voltage” is present on exposed internal terminals of the power supplies. The ELEC-TRODE (tungsten and Model 9 rotors) is also an “exposed terminal” since by its nature the GTAW process requires the presence of an electrical potential on the electrode during arc start and welding. AMI Power Supplies all have a “bleeder” circuit to ground any residual potential after welding or after a failed arc start or “bad start”. It generally takes several seconds to return the electrode to ground potential and FAILURE of the circuit is possible. For this reason THE ELECTRODE SHOULD ALWAYS BE CONSIDERED A POSSIBLE SHOCK HAZARD. Obviously, there is more of a shock hazard when in SEQUENCE or just after welding, but poorly maintained equipment may present a shock hazard at any time unless the power is turned OFF.

If the electrode is changed with the power supply ON, it must be in TEST MODE and out of sequence. AVOID ALL CONTACT WITH WELDING GROUND, ELECTRODE OR WELD HEAD during ARC START!

SHOCK HAZARD WARNING

2.5


2.6

arning:

FUMES AND GASES can be hazardous to your health.

ARC RAYS can injure eyes and burn skin.

ELECTRIC SHOCK can KILL.

• Before use, read and understand all applicable manufacturer’s instructions, Material Safety Data Sheets (MSDSs), and your employer’s safety practices.

• Keep your head out of the fumes.

• Use enough ventilation, exhaust at the arc, or both, to keep fumes and gases away from your breathing zone and the general area.

• Wear correct eye, ear, and body protection.

• Do not touch live electrical parts.

• See American National Standard ANSI/ASC Z49.1, Safety in Welding, Cut-ting and Allied Processes, published by the American Welding Society, 550N.W. LeJeune Road, Miami, FL 33126, and OSHA Safety and Health Stan-dard, 29 CFR 1910, available from the U.S. Government Printing Office,Washington, DC 20402

W

Welding EquipmentRecommendations for the Safe Use of Orbital


Chapter 3. Model 227 Power Supply

Lesson 1: Equipment Installa-tion

In this Section you will learn to set up the Model 227 for operation, and to choose appropriate accessories for your application. Refer to the Model 227 OPERATION MANUAL (PN740063) for more detailed specifi-cations and installation instructions.

Electrical/Power RequirementsThe nature of the GTAW process cre-ates some POTENTIAL HAZARDS. In accordance with international safety regulations the EXCLAMATION SYMBOL indicates that this equip-ment is considered HAZARDOUS

until an operator has been made aware of these POTENTIAL HAZARDS by READING THIS MANUAL and referring to the Model 227 OPERATION MANUAL. The LIGHTNING FLASH SYMBOL indicates that there are potential electrical hazards. The use and display of these symbols make it the OPERATOR’S RESPONSIBILLITY TO INSURE THAT HE HAS READ AND/OR BEEN MADE AWARE OF ALL OF THE SAFETY-RELATED ITEMS CONTAINED IN THIS MANUAL. (See Section 2 of this manual for more complete safety information.)

Power Supply SpecificationsThe Model 227 Power Supply operates weld heads and torches comprising a Gas Tungsten Arc Welding (GTAW also known as TIG) system. In this process, the tungsten electrode, which is not consumed, carries welding current (DC, electrode negative) through the welding arc to the work, shielded by an inert gas, providing the heat required to melt the metal and weld the com-ponents together.

WARNING!

Model 227 Power Supply

3.1


3.2

MODEL 227 POWER SUPPLY

WITH REMOTE PENDANT AND COOLING UNIT (CW)

Model 227 Remote Pendant

Cable Connections

Model 227 Power Supplywith Cooling Unit (CW)

Heads Up Display with Arc Shield

Model 227 EMM Memory Module

Printer

Keyboard

Model 227 Power Supply

Model 207 CW


INPUT VOLTAGE: The Model 227 can be operated on Single Phase Nominal Input Voltage of either 110 VAC or 220 VAC selectable by a switch as shown on page 3.8. The acceptable range of input voltage is from 100 VAC to 240 VAC at frequencies from 50/60 Hz, with a maximum input current of 30 amperes for all input voltages. The tolerances vary with the input voltage. Maximum input current is based on maximum output current at maximum arc voltage.

OUTPUT POWER: The output is straight polarity, constant current DC regulation intended for GTA welding only. The minimum current output is 3 Amperes DC for all input voltages. The maximum current output depends upon the input voltage. If the machine is set up for 110 VAC input, the maximum current output is 100 Amperes continuous or peak pulse. If the machine is set up for 220 VAC, the maximum output current is 200 Amperes continuous cur-rent or peak currents of 225 Amperes DC. The M-227 is limited by software to not accept pro-grammed values for average currents (between primary and background) of greater than 200 Amperes. However, peak currents of up to 225 Amperes can be programmed provided the average current does not exceed 200 amperes.

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

Power Supply Panel Connections and Installation

Do not connect the Model 227 power supply to any AC power than the ones listed above. Make sure the Power Select Switch is set for the AC Power setting you wish to use.

Use this section of the manual (or refer to the Model 227 Operation Manual) as you go through the steps required to inspect and install the Model 227 Power Supply.

Inspection: Upack the Model 227 and inspect all items for physical damage and loose parts. Contact factory representative if damage is evident. If water condensation is apparent, dry the unit before using.

CHECK the list of items supplied with the Model 227, such as gas hoses, cables, tungstens, manuals, and electrical drawings, etc. to insure that all listed items were included in packing. Locate and assemble items that may be required for installation.

POWER: The Model 227 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 Model 227 is set up for

WARNING!

3.3


the correct AC power.

1. The Model 227 is supplied with a 25 ft. power cord. One end of the cord has a connector that plugs into the side of the Model 227. There is no plug attached to the other end and the wires are pigtailed. The user must supply and install a suitable AC connector compatible with the input AC power on which the machine will be operated. The power cord wires are color coded as follows:

NOTE: For additional ground reference the ground pin on the Model 227 Input AC connector on the input panel is identified by a silk-screened ground symbol next to the pin.

2. Install the AC line connector onto the power cord.

DO NOT PLUG THE MODEL 227 INTO THE AC POWER SOURCE UNTIL ALL INSTALLATION STEPS OF THIS MANUAL ARE COMPLETE.

3. Insure that the circuit breaker (CB-1) is in the OFF (down) position as shown in the figure on page 3.8.

4. Using the figures on page 3.8 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 110 VAC Output on one side and 220 VAC Output on the other side. The hole fits over the switch so that the appro-priate VAC setting for the switch position is displayed.

5. If the Model 227 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.

6. To change the power select switch position, remove the cover retaining screws (see figure on page 3.8) 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.

Black Hot (high line side)

White Neutral (low line side)

Green/Yellow Ground (protective earth ground)

3.4


Welding Gas ConnectionsAn Arc Input Gas Hose is supplied with the Model 227. This hose is made of material selected specifically for automatic welding. HOSES MADE FROM OTHER MATERIAL ARE NOT RECOMMENDED (such as rubber, nylon, or vinyl).

The 10 foot (3 m) hose should be installed from the gas regulator/flowmeter (user supplied) to the ARC GAS INPUT fittings required to mate with the Model 227 and most domestic (USA) inert gas flowmeters.

The arc gas line is controlled by a solenoid and flow sensor in the Model 227 and MUST be connected to the Model 227 and 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 over-tighten. Do not use plumbers tape, grease, or joint com-pound.

CAUTION: The Model 227 arc gas solenoid valve is rated at 50 PSI (345KPa) maximum pressure. DO NOT EXCEED THIS RATING.

No I.D. Purge Line is provided, but most GTAW welds will require the inside be purged with argon. Most piping situations will require I.D. purging from sources and entry points a long distance from the Model 227, so no outlet or monitoring of the I.D. purge is provided. How-ever, be sure to provide an I.D. purge if the weld procedure requires it.

Model 207-CW Water Cooling Unit InstallationIf a Model 207- CW is to be used for cooling the torch, it should be installed before making other cable connections. Make sure the coolant tank is filled with 3 gallons (11 liters) of clean distilled or deionized water or 2 gallons of DI water and 1 gallon (3.8 liters) of pure ethylene glycol. (It should be empty for shipping). Refer to the drawing on page 3.9 for installation.

Adapter Cable to Model 227 InstallationThe Model 227 is provided with a 40 ft. Pipe Weld Head Adapter Cable as standard equip-ment. This cable will be used for most weld heads. However, some weld heads will use a dif-ferent adapter cable or additional cables. The correct combination of cables and weld heads should be resolved at the time of order. Refer to pullout sheet PN 750038 at the back of this manual.

NOTE: The Pipe Weld Head Adapter Cable consists of a 40 foot Control Adapter Cable and a 40 foot Service Adapter Cable. The two cables are not tied together as a unit.

3.5


Always turn the power supply OFF before making any cable or connection changes to the Model 227 Power Supply.

Connecting the Service Adapter Cable:Connect the ELECTRODE connector of the Service Adapter Cable to the Electrode terminal of the Model 227. Align the keyway, push in and twist clockwise until fully locked.

Insert the male GAS quick-disconnect of the Service Adapter Cable into the Model 227 ARC GAS OUTPUT CONNECTOR.

Insert the two coolant quick disconnects into the COOLANT-IN and COOLANT-OUT connectors on the Model 207-CW (if it is being used). The cable coolant connectors are interchangeable and it does not matter which one goes to IN or OUT.

Connecting the Weld Head Control Cable:One end of an adapter cable ALWAYS connects to the weld head. The other end of the cable connects to the Model 227 or to a weld head extension cable. See figures on fold-out page. To install the Weld Head CONTROL cable, unscrew the dust caps on the electrical connectors on the cable and on the Model 227 just before installing. Insert the multi-pin electrical connec-tor into the Model 227 connector labelled PIPE WELD HEAD CONTROL. Note the position-ing keyway and NEVER FORCE or use tools on the cable connections. Hand tighten the connecting ring after the pins are firmly seated.

Insert the adapter connector on the CONTROL cable into the weld 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 from dangling.

Weld Head Installation:The male brass quick-disconnect on the adapter cable provides the electrode power and one leg of the coolant path. Connect it to the mating female quick disconnect on the weld head cable.

Connect the other coolant quick disconnect and gas quick disconnect (they are different types and sizes) to their mates on the Weld Head Cable.

WARNING!

3.6


After the Electrode, Coolant 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.

Ground (Welding Work) Cable Installation:A 50 ft. Ground Cable with a “C” type clamp on one end and a CAM-LOK quick disconnect on the other end is provided with the Model 227. Connect the quick disconnect to the GROUND connector on the Model 227 or the Ground Extension Cable if used.

Connect the Ground Clamp to a “bare” metal surface (rust, coatings, or oxide layer removed) on the pipe to be welded. The Ground Clamp should be placed as close to the weld as possible to assure a good electrical connection to ground.

Cable Operating Distances:Standard operating distance is 50 ft. obtained by the 10 ft. Weld Head Cable and the 40 ft. Pipe Weld Head Adapter Cable. A maximum distance of 100 ft. can be obtained with exten-sion cables added to the standard cables. These distances are the normal limits when the Model 207-CW is used. Greater operating distances are possible. Consult with an AMI techni-cal representative for more information.

Remote Pendant Installation Always turn the power supply OFF before making any cable or connection changes to the Model 227 power supply.

• Refer to the drawing of the 227-RP on page 3.24 and the explanation of the RP control keys.

• Insert the Model 227-RP cable connector into the Model 227 Panel Connector labeled REMOTE. The REMOTE connector is located next to the Pipe Weld Head Control Con-nector shown in the drawing on page 3.10.

• If a Model 227-RP extension is used, it is installed between the Model 227 and the RP.• If required the Model 227 can be operated without the RP unit.

CAUTION: Installation is now complete. Before preceding with POWER ON, make certain that you have a good understanding of basic SYSTEM FUNCTIONS and understand SAFE OPERAT-ING PROCEEDURES.

3.7


M

CH1

O D E L 207 C W C O N N EC TIO N

P LATE R E TA IN IN G S C R E W S

C B-1

C O VE R PLATE S W ITC HH O LE IN “U P P O SIT IO N FO R200 TO 240 “VAC O P ER ATIO N

P O W E R SE LEC T S W ITC HIN “U P ” PO SITIO N FO R 200 TO 240 VAC O PE R ATIO N

PO W E R SE LE C T SW ITC H IN “D O W N ” PO SITIO N FO R 100 TO 120 VAC O P ER ATIO N

O V ER P LATE SW ITC HO LE IN “D O W N ” PO S IT IO N FO R00 TO 120 VA C O PE R ATIO N

3.8


INSTALLATION OF THE MODEL 207 CW*

COVER SHOULD BE CLOSED DURING INSTALLATION

LOCKING PIN1 EACH CORNER

POWER CONNECTOR AND CABLE

MODEL 207-CW ON/OFF LOCATED TOLEFT OF THE POWER

SELECT SWITCH

COOLANT TANK AND FILL SPOUT LOCATED

INSIDE M207-CW

M207-CW COOLING UNIT

* Note that the cooling unit used with the Model 227 Power Supply (Model 207-CW) is the same unit as that used with the Model 207 power supply and is installed the same way. The 207-CW should be installed before connecting other cables to the power supply.

3.9


3.10

Model 227 Cable Connections

INSERT CONNECTORWITH KEYWAY ALIGNED

AND TIGHTENLOCKING RINGS

ARC GAS INPUT ARC GAS OUTPUT

SEPARATE GROUND CABLE AND ELECTRODE ON SERVICE ADAPTER CABLE

PLUG CABLES IN WITH KEYWAYS UP

AND ROTATE CLOCKWISEUNTIL LOCKED

ARC GASARC GAS

PIPE WELD HEAD CONTROL CABLE CONNECTOR. TUBE WELD HEAD CONNECTOR

207-CW CONNECTOR

KEYWAYS

ELECTRODE

GROUND

REMOTE


Lesson 2. General Operation and System Functions of the Model 227 Power Supply

In this lesson you will learn the basic operational functions of the Model 227. With the power supply plugged in to the appropriate line voltage and the circuit breaker (CB-1), turned ON, you are ready to examine the LIBRARY, PRINT FUNCTIONS and SET-UP features of the Model 227. Weld Head and Cables need not be plugged in for this excercise. Use this TRAINING MAN-UAL as a guide as you go over the various functions.

POWER ON/STATUS SCREEN

The STATUS SCREEN shown above will normally appear when power is turned on. Some-times the most recently used weld schedule will appear. If other screen appears, press the “C” key until the STATUS SCREEN appears.

Weld LibraryThe Model 227 is microprocessor-controlled and is capable of storing up to 99 weld schedules (programs) in its memory which is called the LIBRARY. Each weld schedule contains values for weld parameters and functions for a variety of tube, pipe, and fitting welds. To access the library from the STATUS SCREEN shown above, press the LIB key on the keyboard. The following screen will appear:

LIB

TO WELD PRESS LIB TO PROGRAM PRESS PROSYS HOURS - 00059.7 ARC HOURS 00000.5

TEMP-OK INPUTAC-OK GAS-OK LVPS-OK COOL-OK SENSOR1-OK 2-OK 3-OK

UPPER SCREEN

LOWER SCREEN

USE SCREENS TO FIND # PRESS ENTEROR IF # IS KNOWN ENTER # --- PRESS ENTER

001 1.500 .065 SS 95 10 *

# OD WALL MAT HEAD PASSES *

3.11


Weld schedules are listed numerically in the LIBRARY, but may not be numbered consecu-tively, so the first program may not be number 1. You may enter a program number from the keyboard (number followed by pressing ENTER) and the top line of the program will appear in the upper screen as shown below. To see the list of the programs in the LIBRARY press the PRINT key, or use the NEXT SCREEN and PREV SCREEN keys to advance through the pro-gram list.

To make a weld with the program displayed above, assuming all the correct cable and gas hose connections have been made, and the weld head is set up for the size tube or pipe shown on the first program line, the operator would press the WELD/TEST key to change the readout from READY TO TEST to READY TO WELD followed by the SEQUENCE START key.

Note that when a weld schedule is called up from memory, the first pass of the program will be displayed. To advance to the second or later pass use the NEXT PASS key. To return to pass 01, use the PREV PASS key. The Model 227 does not automatically change passes or levels, but begins welding at the pass or level shown at SEQ START.

PrinterThe built-in printer is a useful feature of the Model 227 which allows the opera-tor to print out the weld schedule being used. If a change is made in a weld schedule, this will be shown on the next print-out of the program. The newer software version provides for weld number, power supply and weld head serial numbers and welder ID number to be recorded on the print-out and used for weld documentation.

If the PRINT key is pressed from the STATUS SCREEN, a message with the date and current software version will be printed. If the PRINT key is pressed from the LIBRARY, a list of weld schedules in the LIBRARY will be printed. If the PRINT key is pressed with a weld schedule entered (READY TO TEST or READY TO WELD) a copy of the current weld schedule will be printed out. From the SET-UP screen, if PRINTER AUTO is selected, a print-out will

001 1.500 .065 SS 95 01 TO TEST# OD WALL MAT HEAD PASS READY

WELD

TEST

001 1.500 .065 SS 95 01 TO WELD# OD WALL MAT HEAD PASS READY

USE NEXT SCREEN FOR VALUES THEN F* KEYSTO CHANGE VALUES - USE SEQ START TO WELD

PRINT

3.12


occur after each weld is completed. If PRINTER MANUAL is selected, a message will only be printed after the PRINT key has been pressed.

Operate Mode SwitchNote that there is a key at the side of the top panel of the Model 207. The three key positions are: LOCK, OPERATE, and PROGRAM. If the key is removed while in any of the three posi-tions, the Model 227 will remain in that mode until changed with the key, thus preventing unauthorized changes in mode. LOCK: If a program is called up from the LIBRARY so that the display screen says READY TO WELD or READY TO TEST, and the key removed while in the LOCK position, the oper-ator will be able to weld using only the program which was entered at the time the key was removed. Pressing the “C” key will not return the operator to the STATUS SCREEN. Modifi-cations to the program may be made by the operator within the limits of the programmed OVERRIDES, but changes to the program will not be saved when the machine is turned off.

OPERATE: The Model 227 is capable of all standard welding operations with the exception of PROGRAMMING while in the OPERATE mode. This includes access to all weld sched-ules and the OPERATE MODE SET-UP screens, which are the first three SET-UP screens.

PROGRAM: PROGRAM Mode allows the operator full access to all the programming func-tions and all five SET-UP screens. The mode switch must be in PROGRAM mode in order to CREATE, MODIFY, TRANSFER, COPY or DELETE a weld schedule from the system memory.

FaultsThe Model 227 was designed to monitor certain functions essential to its successful operation. If a problem arises with one of these functions a system fault (FLT) will alert the operator to the problem.

TEMP FLT - A TEMP FLT indicates that the internal temperature of the power supply is too high. If a TEMP FLT occurs during the weld sequence it creates an ALL STOP condition.

COOL FLT - A COOL FLT indicates insufficient coolant flow to the torch. The COOL FLT is only active when a M-207-CW is in use. The fault can be disabled from the SET-UP screen. A COOL FLT condition during weld sequence will initiate ALL STOP.

LVPS FLT - This fault is indicative of a Low Voltage DC Power Supply problem. If a LVPS FLT occurs during weld sequence, an ALL STOP is initiated.

GAS FLT - A GAS FLT will occur if there is insufficient flow of gas to the torch. As with the previous faults, an ALL STOP will occur if the fault is present during weld sequence.

3.13


INPUT FLT - An INPUT FLT occurs when the input AC to the Model 227 is inadequate to achieve the desired outputs. This condition results in an ALL STOP if it occurs during sequence.

SENSOR 1,2,3 - User defined faults to be used with an oxygen analyzer or similar device.

BAD START - A BAD START indication occurs when the system was unable to sustain an arc during sequence.

STUB OUT - A STUB-OUT fault occurs during a weld if the arc voltage gets too low, or if the electrode touches the weld puddle. This causes an ALL STOP condition. After postpurge, the normal “return to home” sequence will also be disabled.

HIGH VOLTS - HIGH VOLTS is indicated if the arc voltage gets too high during a weld. This condition results in an ALL STOP.

GROUND FAULT - On weld heads which have Ground Fault Sense, a GROUND FAULT will occur if the Work Ground is not adequately connected to the work piece. This Fault will pre-vent the occurence of arc start.

OSC LIMIT - An OSC LIMIT fault will occur if the OSC limit switch is engaged during operation. This will create an ALL STOP condition. Applies only to those heads which have OSC LIMIT switches.

AVC LIMIT - If the AVC limit switch (on weld heads having these devices) is engaged, an ALL STOP condition will exist.

Faults are displayed at different times. TEMP, LVPS, or INPUT AC will be displayed when the Model 227 is first turned on. Other faults such as STUB OUT and HIGH VOLTS occur only during sequence.

Set-Up Function Menu

The SET-UP functions provide user options allowing for customization of some features as well as serving as a calculator for selected weld parameters. Pressing the SET-UP key will display the first SET-UP screen:

SETUP

CALCULATE WELD SELECT COOL-FLT REV. *** *** ON ***

FirstSet-UpScreen

3.14


Pressing the F key under CALCULATE will display the following screen:

Enter the Weld OD, Rotor OD and Arc Gap for Model 9 weld head (see Rotor OD chart on page 6.5) using the numerical keyboard. Press ENTER after each item. The TUNGSTEN LENGTH will be displayed under LENGTH.

To determine the ROTATION RPM, press the F key from the first Set-Up screen, and the fol-lowing screen appears:

Enter the diameter of the weld joint and the travel speed in inches per minute (IPM), pressing ENTER each time, and the RPM will be calculated.

WELD SELECT: The WELD SELECT feature allows the operator to choose any four of the weld programs from the LIBRARY to be accessible from the Model 227-RP. Press the F key under WELD SELECT from the first Set-Up screen :

Enter the Weld Schedule Number you wish to access from the RP from the numerical key-board and press ENTER. To select the next weld schedule, press the F key under the number (1 shown) to display the next number. If the number selected is not in the LIBRARY, you will be prompted with an INVALID NUMBER message. Press CE and try again. Repeat if addi-tional schedules are desired.

TUNGSTEN LENGTH ROTATION RPM *** ***

*.*** *.*** .*** *.***

PRESS C TO RETURN TO SET-UP SCREEN - PRESSINGC RETURNS TO STATUS SCREEN

F KEY

TOP

BOTTOM WELD OD? ROTOR OD? ARC GAP? LENGTH

*.*** *** *** BOTTOM

WELD OD? IPM RPM

BOTTOM

PICK SELECT # WITH F KEY - ENTER WELD #USE ENTER KEY WHEN ALL SELECT # ARE SET

SELECT # WELD SCHEDULE #

1 ***

TOP

3.15


The COOL - FLT can be enabled or turned off whether or not the Model 207 - CW is connectedby pressing the F key under COOL - FLT followed by ENTER.

REV. : Pressing the F key under REV. displays the following screen showing the revision number of the software currently installed.

Note that Set-Up screens may be different if your software version is other than that on which this manual is based. If your software version is 1.4 or less, upgrading to a later version requires hardware modifications and recalibration in addition to the new software.

Pressing the NEXT SCREEN key will bring up the second Set-Up screen:

Pressing the F key under PRINT EMM prompts the printer to print a list of weld schedules stored in the EMM (if installed) similar to printing the weld LIBRARY. See page 10.14 for more detailed information.

Changing the AMPS or TIME to tenths from whole numbers (000 to 000.0) allows the oper-ator to program weld schedules in tenths of an AMP or tenths of a second. This will affect all of the programs in the Library. If a program is entered with tenths of an amp or tenths of a second, and this is changed to whole numbers (1.0) on the SET-UP screen, the value will be rounded off the next time the program is opened. If whole numbers are entered, incrementing AMPs from the M-227-RP will increment 1 AMP at a time. If tenths are entered, AMPS will

CALCULATE WELD SELECT COOL-FLT REV. *** *** ON ***

FirstSet-UpScreen

F key

COOL-FLT OFF

F key

AMIWELD 227 STD. 1.5SOFTWARE INSTALLED

SecondSet-UpScreen

USE F KEY FOR OPTIONS - MORE OPTIONS ONNEXT SCREEN - USE C KEY TO END SET-UP

PRINT EMM AMPS <INC> TIME ARC-V-FLT *** 1.0 # 1.0 ONBOTTOM

0.1 0.1 OFF

F keys

NEXTSCREEN

3.16


be incremented in tenths.

ARC-V-FLT is normally “on” to detect STUB-OUTs. A STUB-OUT condition is created if the Arc Volts goes below 5 V and a HIGH VOLTS fault occurs if the Arc Volts goes over 20 V. ARC-V-FLT should be turned OFF for manual welding to permit touch starting of the arc.

Program Mode Set-Up Functions (The Operate Mode Switch must be set to Program in order to access these screens.)Pressing the NEXT SCREEN key will advance the SET-UP display to screen # 3:

MEASURES ENGLISH/MEASURES METRIC allows the operator to determine whether values displayed on Model 227 screens will be in metric or English units.

SENSORS - The Model 227 FAULT detection system has an external input feature that allows the user to monitor up to 3 external functions (such as an OXYGEN ANALYZER) and cre-ate a FAULT if the specified conditions are not met. (For example, less than 10 ppm O2). By pressing the F keys, any of the three sensors can be turned ON or OFF, and a selection made as to whether a FAULT should occur with a HIGH or LOW input signal.

Pressing the NEXT SCREEN key will advance the SET-UP display to screen # 4:

Pressing the F key under OSC JOG SPEED displays the following screens:

ThirdSet-UpScreen

MEASURES SENSORS PRINTERENGLISH *** MANUAL

MEASURES METRIC

PRINTER AUTO

F key F keyF key

USE F KEYS TO SET SENSORSPRESS ENTER KEY WHEN FINISHED

SENSOR # ON/OFF FAULT ON HIGH OR LOW 1 ON HIGH

TOP

BOTTOM

1, 2, 3 OFF LOW

F keys

FourthSet-UpScreen

BOTTOM

OSC JOG DATE AVC JOGSPEED RESET SPEED

N EXTSC R EEN

NEXTSCREEN

F key

3.17


The NEXT LEVEL key lowers the OSC JOG SPEED while the NEXT SCREEN key raises the speed. This function regulates the speed at which the OSC IN and OSC OUT move the torch for cross seam adjustment (steering). This setting will differ for different weld heads due to differences in sensitivity.

The AVC JOG SPEED can be set by pressing the F key under AVC JOG SPEED. Weld head models with AVC vary in their sensitivity and must be adjusted to achieve the best Touch Start performance. The JOG UP function is adjusted by using the NEXT LEVEL and NEXT SCREEN keys. The JOG DOWN function is adjusted with the PREV LEVEL and PREV SCREEN keys.

DATE RESET: Pressing the F key under DATE RESET from the fourth Set-Up screen allows the operator to set the current date and time. The current date will be shown on each print-out from the Model 227. The date will need to be reset for a change of time zone or if the battery (batram) fails.

Use the numerical keyboard to enter the month and press ENTER. The top screen will instruct the operator to ENTER DATE. When this is done, the top screen will say ENTER YEAR. The top screen will then instruct the operator to ENTER HOURS, ENTER MIN-UTES, and ENTER SECONDS which is done in the same way. Use the C key to return to the weld program or to the STATUS SCREEN.

OSC JOG ��. . . . . . .

TOP

BOTTOM

LEVEL/SCREEN KEYS CHANGE OSC JOG SPEEDPRESS C KEY TO CANCEL

��

JOG UPJOG DOWN

�� . . . . .

. . . . . .AVC JOG

DATE RESET

ENTER MONTH (ENTER DATE) (ENTER YEAR)TOP

BOTTOM ENTER DATE MONTH DATE YEAR ** ** **

3.18


Use the NEXT SCREEN key to advance to the fifth Set-Up screen:

Enter WELDER NAME and/or ID NUMBER using the letters from the above screens and numbers from the numerical keyboard. The F keys above the letters select for letters on the top rows, while the lower F keys are used to select letters or symbols on the bottom rows. Use the NEXT SCREEN key to display letters after P. Press ENTER when complete. Once the OPERATOR ID has been entered, this name or ID will appear on all weld schedule print-outs until it is replaced by another name or ID. It can not be erased.

SERIAL NUMBER:

Enter numbers from numerical keyboard. Press ENTER when number is complete.Once the power supply serial number has been entered, it will be retained in memory, but it will not appear on the weld schedule print-out.

Note: From the set-up menu pressing the C key will return to the previous screen or to the weld program (if entered) or to the STATUS SCREEN.

N EXTSC R EEN

FifthSet-Up Screen

OPERATOR SERIAL ID/NAME NUMBER

F key

ENTER WELDER ID/NAMEWELDER **********************************************

TOP

BOTTOMA B C D E F G HI J K L M N O P NEXT

SCR EEN

Q R S T U V W XY Z _ # @ ! ( )

BOTTOM

F key

ENTER POWER SUPPLY SERIAL NUMBERSERIAL # : *************************

3.19


2723

228

2419

126

3315

1721

187

1132

910

132

3

25 26 28 29

414

516

201

3031

MO

DE

L 2

27 P

AN

EL

KE

YS

3.20


Model 227 Panel Keys (See Figure on page 3.20)

A description of all the active operating keys on the system Main Panel follows. Note that the PAPER FEED and STOP PRINT keys are not present on systems with software versions ear-lier than 1.5.

1. ALL STOP KEY - This key is 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 begin POST-PURGE.

2. C KEY - The C key is used for screen clear or cancel. It will end (without storing) the screen being displayed and return to the beginning of any step. The screen will prompt the operator with an indication of what will happen if the C key is pressed.

3. CE KEY - The CLEAR ENTRY key is used to clear numbers entered with the numeric keys before the ENTER key is pressed. Use this key when a mistake is made using the numeric keys.

4. ENTER KEY - This key is used at the end of each step to indicate completion and to move to the next step or screen.

5. F KEYS - The F keys are FUNCTION keys numbered from 1 to 16. Each key is aligned with a portion of the display and are used to activate, cycle or alter the item displayed above or below it. Each key will alter different functions depending on what screen is being displayed. Use of the F keys is always prompted by the screens.

6. L KEY - The Model 227 is multi-lingual. Pressing this key will change the display from English to French to German, etc. The L key is always active.

7. LIB KEY - This key is used to access the LIBRARY which contains the weld schedules.

8. MANUAL PURGE KEY - The MANUAL PURGE KEY is used to manually turn on the gas solenoid. When ON, the gas solenoid will be energized, and it will stay on until the key is manually pressed again.

9. METER KEY - Only one of the displays is used as a BAR GRAPH METER during weld-ing. Limited functions are shown. Use this key to access the desired meter function. Remem-ber that meter readouts are provided for functional troubleshooting only. They are not intended for verification of system performance.

10. NEXT LEVEL KEY - This key is active when weld schedules with more than one level are being displayed. An will appear on the displays to indicate that more levels are pro-▼

3.21


grammed for that weld schedule.

11. NEXT PASS KEY - This key is used to retrieve from memory the parameters for the next weld pass of the weld program which is in use.

12. NEXT SCREEN KEY - This key is active when another screen (containing more data) is available for a weld schedule or function. An will appear on the display to indicate that more data is available on the next screen.

13. NUMERIC KEYS - These keys are used to select weld schedule numbers or to enter numbers during programming, overriding, and set-up functions.

14. PREV LEVEL KEY - This key returns the screen to the previous level of a weld schedule.

15. PREV PASS KEY - This key retrieves weld parameters used for the previous program pass.

16. PREV SCREEN KEY - Returns the display to the screen which was shown before the present one.

17. PRINT KEY - Pressing PRINT will cause the printer to print system hours and software revi-sion, or the weld schedule LIBRARY, or weld parameters for a complete pass depending on which screen is displayed at the time PRINT is pressed (See 3.12). No printout will occur if pressed during weld sequence.

18. PRO KEY - Pressing the PRO key from the Status Screen will access the programming mode, but the OPERATE MODE KEY must be in the PROGRAM position. The PRO KEY is also used to complete data storage after program entry or modification.

19. SEQ START KEY - If a weld schedule has been called up from the LIBRARY, pressing SEQ START will initiate the weld sequence.

20. SEQ STOP KEY - If this key is pressed during a weld sequence, the sequence will stop and initiate the downslope function.

21. SET-UP KEY - When pressed, this key allows access to various set-up options. Active at all times except during a weld sequence.

22. TVL CW JOG KEY - When this key is pressed, the weld head will rotate the electrode in the clockwise direction. This function active at all times.

23. TVL CCW JOG KEY - When this key is pressed, the weld head will rotate the electrode in the counterclockwise direction.

▼

3.22


24. WELD/TEST KEY - At POWER ON the Model 227 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 go into WELD mode in order to make a weld. Once the Model 227 is placed in WELD mode, it will stay in WELD mode as long as that weld program is displayed unless the WELD/TEST KEY is pressed again. If a new program is entered it will be in TEST until the key is pressed.

25. WIRE JOG FWD KEY - This key is used to feed the wire out manually before sequence for installation and set-up purposes.

26. WIRE JOG REV KEY - Used to pull the wire back manually before sequence for installa-tion and set-up purposes. This key should be used sparingly because most weld heads do not have a reel take up function and the wire can back-lash if too much wire is retracted.

27. WIRE MODE ON/OFF KEY - Wire will start to feed automatically after the end of Wire Start Delay ONLY if the wire mode is set to ON. When the remote pendant (RP) reads ON, wire will feed automatically. When the RP reads OFF, wire feed will only operate manually.

28. AVC UP JOG KEY - This function is used prior to and after welding to move the (AVC) (and torch) in the UP direction. (i.e., away from the work.)

29. AVC DOWN JOG KEY - This function is used prior to and after welding to move the (AVC) (and torch) in the DOWN direction. (i.e., towards the work.)

30. OSC IN JOG KEY - Used to STEER the torch towards the weld head (IN).

31. OSC OUT JOG KEY - Used to STEER the torch in the direction away from the weld head (OUT).

32. STOP PRINT KEY - This key will allow the operator to stop the printing process.

33. PAPER FEED KEY - This key allows the user to advance the paper in the printer.

3.23


Remote Pendant. The use of the Model 227 requires an understanding of system operation and should not be used before reading the previous sections of this manual and the preceding pages of this section. Items in the table below shown in gray are duplicates of keys contained on the Model 227 panel shown on page 3.20 and defined on pages 3.21-3.23. They work exactly the same as the

panel keys. When the RP is connected, these keys and the identical keys on the Model 227 panel are active at the same time. Pressing either key will perform the specified function.

SPCL F

WIREON/OFF

OSCIN

JOG

OSC

JOGOUT

PRITIME

BCKTIME

TVLCWJOG

TVLCCWJOG

PRITVL TVL

BCK WIREFEEDJOG

WIRERETRJOG

PRIAMPS

BCKAMPS

AVCUPJOG

AVCDOWNJOG

PR IW IRE

PRIAVC

BCKAVC NEXT PREV

OSCAMPL

INDWELLTIME

B C KW IRE

EXCTIME

OUTDWELLTIME

WELDTEST

SEQSTART

SEQSTOP

ALLSTOP

Model 227 Remote Pendant Operation

ARC MACHINES, INC.MODEL 227 REMOTE PENDANT

Standard Model 227 Remote Pendant Functions

1. 8 character digital status display

2. Special Function key

3. Wire Feed Mode key

4. Osc IN Jog key

5. Osc OUT Jog key

6. Primary Time Over-ride key

7. Back-ground Time Override key

8. Travel Jog Clockwise (CW) key

9. Travel Jog Counterclock-wise (CCW) key

10. Primary Travel Speed Override key

11. Back-ground Travel Speed Override key

12. Wire Feed Jog key

13. Wire Retract Jog key

14. Primary Amp Over-ride key

15. Back-ground Amp Override key

16. AVC UP Jog key

17. AVC DOWN Jog key

18. Primary Wire Feed Override key

19. Back-ground Wire Feed Over-ride key

20. Arrow UP key

21. Arrow Down key

22.Primary AVC Over-ride key

23. Back-ground AVC Override key

24. NEXT key

25. PREV key

26. Osc Amplitude Override key

27. IN Dwell time Over-ride key

28. Excur-sion time Override key

29. OUT Dwell time Override key

30. Weld/Test Mode key.

31. Sequence Start key

32. Sequence Stop key

33. All Stop key

8 char. display

3.24


Remote pendant Operation (continued):

The 8-character digital display is used to indicate to the operator the particular mode or area of a weld schedule the system is in.

When the Model 227 is first turned ON the RP display will say NO SEQ. This indicates to the operator that no weld schedule has been selected. When a schedule is selected the display will show 001 TEST. This indicates that PASS #1 of a weld schedule has been called up and that the system is in TEST mode. At other times it may indicate WELD or FLT depending on sys-tem status. When the weld sequence is started, the display will indicate progression through PREPURGE, UPSLOPE, LVL 01 (etc.), DOWNSLOPE and POSTPURGE.

NOTEIf the power was turned OFF while a weld schedule was displayed, the system will power up with that schedule displayed again. The NO SEQ display applies to power ON when power OFF occurred without a weld schedule selected.

The Override Keys allow the operator to change Amps, Volts, TVL, OSC and Wire values within pre-set programmed limits. After a Pass is called up, pressing one of these keys will change the display to show the value of that function. Using the Arrow up key will then increase the amount. Using the Arrow Down key will decrease the amount. These operations can also be done DURING SEQUENCE as well.

The values changed by Overrides will remain in effect only as long as that particular Pass is displayed unless they are saved. If another pass is called up and then the original pass is recalled, the values in the original pass will revert to the original ones unless the new values are saved. This can be done in two ways: 1) by pressing the PRO key 2) using the Special F key on the Remote Pendant and selecting “Store” from the menu and then pressing the UP arrow. A “stored” message will be displayed. Using the Override Keys only OVERRIDES the function value in the LEVEL displayed. During Sequence you cannot Override a value in another LEVEL. Before the start of Sequence it can be done by use of the MAN ADV special Function. See Special Function Key operation below for more details.

Special Function Key - The pendant Special Function key allows access and manipulation of many additional functions. This feature works only when not in weld sequence. Each time the Special Function key is pressed, the display will change in the following order:

1. PASS - This allows the user to select the next or previous pass in the Weld Schedule.

Pressing the NEXT key will access the next pass, if one is programmed. Pressing the

3.25


PREV key will access the last pass, if there is one. When pressed, the display will leave

the Special Function and show the Weld pass # and System mode (002 TEST) as previ-ously described.

2. PURGE - Press the NEXT key to manually change the state of the Gas Solenoid. It willturn ON or OFF depending on its condition. Press the NEXT Key again to return the GasSolenoid to its original state. You can continue to cycle the Solenoid in this way untilanother function is chosen.

3. PRINT - Allows printing of Weld Pass from the RP. Press the NEXT key to actuate the print function.

4. STORE - If the Operate Mode Key is in the PROGRAM position it is possible to perma-nently change some programmed values. Accessing the STORE special function at theend of the sequence and pressing the NEXT key will permanently change the functions tothe overridden values.

5. SELECT - As previously noted, the Model 227 can store in memory up to 100 weldschedules. Any 4 of these schedules can be programmed to be selected from the RP. Seepage 3.15 for details on how to select those programs you wish to access from the RP.Pressing the NEXT key will replace the existing weld schedule in the SELECT function.

6. PRE-WRAP - This function applies when using Model 95 series weld heads. Pressingthe NEXT key will engage the head Rotation and allow it to wrap the cable one timebefore starting sequence.

7. SET - Used in conjunction with a Model 6 Weld Head to move the Torch to a pre-set arcgap prior to starting the arc.

8. OSC MAN - Used to engage the OSC function and perform the same movement out ofsequence that it will perform in sequence. Used to check the OSC AMPL value which can be adjusted prior to welding if a change is needed.

9. MAN ADV - For OVERRIDE purposes, all weld schedule passes when called up frommemory or reset after welding are said to be at Level 1 values. To Override a Level 2 orgreater function before welding requires the Operator to select this Special Function andthe use of the Next key to Manually Advance to the desired LEVEL.

Remote Pendant Operation (continued): Special function key -

3.26


CAUTIONIf left in Level 02 or greater and Weld Sequence is started, the system will start at the Level displayed. Unless this is the desired effect, the user SHOULD ALWAYS USE THE MAN ADV FUNCTION and PREV Key to return the system to Level 01 before Weld Sequence.

NOTEExcept for PURGE, anytime a Special Function is actuated with the Next key it will do that function and then return to the 01 TEST display. To repeat that special function (such as a pass) or to access another special function will require pressing the Special Function Key again.

Optional Accessories

Heads-Up Display - The Model 227 Heads-Up Display is an optional accessory to be used in conjunction with the Model 227 RP. It features an arc shield that allows the operator to view the weld puddle during sequence while making adjustments to weld parameters via the RP. The RP 8 character display is visible through the display window.

EMM - The Model 227 Electronic Memory Module plugs in to a slot the side of the top panel of the Model 227 labelled EMM. To install the EMM, turn the Power Supply OFF. The connector is keyed so the EMM can only be inserted one way. The EMM may be used to TRANSFER a COPY of the LIBRARY from one Model 227 to another to maintain identical libraries. It can also serve as a back-up for the 227 library. See Section 10 Program-ming for more complete details.

Manual Torch - An optional Manual Torch is available for use with the Model 227. A manual torch is often used for tacking prior to orbital welding. A weld schedule for the manual torch must be entered into the Model 227 in order to operate the torch. See Section 4. Programmable Weld Parameters for weld schedule.

Remote Pendant Operation (continued):

3.27


Chapter 4 . Programmable Weld Parameters

The Model 227 Power Supply controls weld parameters for various welding applications. This

section includes a functional description of essential weld parameters. See section on Program-ming for rules of thumb for various welding applications.

PREPURGE and POSTPURGE: PREPURGE is the amount of time the gas will flow to the torch before an arc is struck, which is generally about 5-10 seconds for pipe welding. POST-PURGE time is the amount of time the gas will flow after the end of DOWNSLOPE to prevent oxidation. POST-PURGE is typically set at 10-20 seconds, but if excessive discoloration of the weld OD occurs, pre- and POSTPURGE times may be increased. For orbital tube welding these times should be increased to 30 to 60 seconds each depending on weld head size and purity requirements of the application.

UP-SLOPE: UP-SLOPE is the amount of time required to reach full current after arc detect at SEQUENCE START. UPSLOPE is usually set between 3 and 5 seconds.

DOWNSLOPE: DOWNSLOPE is the amount of time allowed for the welding current to decrease to the point of extinguishing the arc after the end of the last level or after initiating SEQUENCE STOP. DOWNSLOPE allows the weld bead to make a smooth transition from the molten puddle to a solid structure. A weld with too little or no DOWNSLOPE may show signs of cracking in the last weld bead or may have a pin hole where the arc extinguishes.

Model 15 Weld Head with dual wire-feeders mounted on a large-diameter stainless steel pipe.

4.1


ROTATION (ROT): ROTATION is the direction that the weld head will travel. This can be set for either clockwise (CW) or (CCW) by pressing the F key to change the selection and then press-ing ENTER. For orbital tube welding (Model 9 weld heads) this is normally set at CW. For orbital pipe welding, the direction may be changed for each pass to avoid winding the weld head cables tightly around the pipe as long as the weld head is equipped with dual wire feeders.

ROTATION DELAY: (ROT-DLY): ROTATION DELAY is set for the amount of time needed to establish a weld puddle that fully penetrates the weld joint. For fusion tube welding, this may be 1-2 seconds for thin-walled tubing, or up to 10 seconds for fusion welds on pipe. For orbital pipe welding 3 to 5 seconds beyond UPSLOPE (the time full current level is reached) is a good place to start.

START WIRE FEED DELAY (STR-WFDLAY): This is the amount of time programmed between arc start and the start of wire entry into the weld puddle. The time must be sufficient to allow the formation of a weld puddle. This is normally set at 1 to 3 seconds longer than UPSLOPE. and up to a full second after the start of travel unless the material is crack sensitive. If wire feed is begun before or at the same as travel the weld bead will form a high spot that will make tie-in dif-ficult.

WIRE FEED DELAY STOP (WFDLAY-STP): WIRE FEED DELAY STOP is the amount of time after the start of DOWNSLOPE that wire feed is allowed to continue before being turned off. This is generally used when welding material with a tendency to crack during DOWNSLOPE. Typical time is 0-1 second.

RETRACT: RETRACT sets the amount of time the wire feeder runs in reverse to retract the wire from the weld puddle when SEQUENCE STOP has been initiated, or when AUTOMATIC TIME has run out. Typical time: 0.3 - 0.6 seconds.

TIME MODE (T/MODE): TIME MODE may be set to either AUTO or MANUAL by pressing the “F” key. If AUTO is selected, an amount must be entered in the LEVEL time(s) and SEQUENCE STOP will initiate when the time for the last level programmed is up. If MANUAL is selected, the operator will press SEQUENCE STOP to iniate DOWNSLOPE and end the weld.

OSCILLATE MODE (OSC MODE): OSCILLATE MODE can be set ON or OFF by pressing the “F” key. For stringer beads OSC MODE is set to OFF. It is ON for oscillating or weave beads.

START AUTOMATIC VOLTAGE DELAY (STR-AVCDLY): This time is used to disable the sensitivity of the AVC until full welding current has been established. This time is normally set equal to the UPSLOPE.

Weld Parameters, continued:

4.2


Note: as skill level progresses with the Model 227 and orbital weld heads, more advanced techniques are possible. For example, the levels can be used to program multi-pass welds without the need to stop between each pass. In this case, the OSC MODE would be ON for the first level ( = first pass) even though this would be a stringer bead to allow for oscillation during the second and subsequent passes. Set the PULSE ON and OSC AMPL at .000. IN DWELL, EXC and OUT DWELL must all be given values, i.e., .01 each. Upon tying in on the root, advance to the next level with a value programmed for OSC AMPL, set DWELL and EXC times, and change pulse mode to SYNC. The weld schedule on page 4.13 is an example.

RESPONSE: The RESPONSE is a measure of the sensitivity of the AVC to a voltage change during welding. This number may vary from day to day or for any change in conditions. The range of settings will vary with the different weld heads as follows: M-81, 6 to 8; M-15, 1 to 3; Model 6, 5 to 7; Model 79, 4-7.

PULSE: PULSE can be set to OFF for manual welding, ON for stringer bead welds, or SYNC for welding weave beads. Make selections by pressing “F” key and then ENTER.

ROTATION (ROT): The ROTATION setting determines the way the weld head will travel around the weld joint during welding. The choices, CONT, STEP, or OFF are found by pressing the “F” key and then ENTER. When CONT (continuous) is selected, the weld head will travel at the PRIMARY IPM value only. When STEP is selected, the weld head will typically travel at the BACKGROUND IPM value, with the PRIMARY IPM set at (0.0) zero, but different values for PRIMARY and BACKGROUND IPM may be programmed and the rotation will STEP between the two values.

Note: you may change from STEP to CONT from one level to the next within a “PASS”. Example: The root can be done in LEVEL 1-4 in STEP with LEVELS 5 and 6 used for the hot pass set for CONT as shown in the weld schedule on page 4.13.

PRIMARY IPM: (PRIMARY ROTATION/ INCHES PER MINUTE) Weld head travel is programmed as speed in Inches Per Minute or Revolutions Per Minute (RPM) depending on the type of weld head used. If continuous rotation (CONT) is chosen, there will be a program value for PRIMARY IPM (PRI-IPM). This value will typically be between 2 and 7 IPM, with 5 IPM fairly standard for orbital tube welds. 4-6 IPM is typical for pipe welding with a J prep.

BACKGROUND IPM (IPM-BCK): In STEP MODE, the torch moves for the duration of the BACKGROUND PULSE TIME at the BACKGROUND IPM. Values for IMP-BCK are typically between 2 and 5 IPM. In CONT MODE the BACKGROUND IPM is zero.


4.3


TIME may be the time needed to complete a level or a pass. If time mode is set to AUTOMATIC, a value for time must be entered into the program. If rotation mode is CONT, the time for 1 pass is 60 seconds divided by the RPM plus time programmed for ROTATION DELAY and time required to tie-in the weld. Or simply run the weld head for one pass in TEST MODE to deter-mine the amount of time needed per one weld. If there is more than one level in the pass, the time for the pass (plus delay and tie-in) is divided by the number of levels to calculate the time per level. To convert inches per minute (IPM) to RPM and vice/versa :

IPM ÷ circumference of weld joint = RPM.

RPM x circumference of weld joint = IPM

Note: The circumference of the weld joint is the diameter x . ( = 3.141)If T/MODE MANUAL is selected, it is not necessary to enter a value for TIME.

PRIMARY AMPS (PRI-AMP): PRIMARY AMPS is the amount of welding current in effect during the PRIMARY PULSE TIME (The Model 227 can output a maximum of 225 Amps or 200 Amps as an average with Software version 1.5.). The amperage determines the amount of heat at a given time and travel speed. For orbital fusion tube welding the amount of amperage should be roughly proportional to the wall thickness of the weld joint with about 1 amp per 0.001” wall. For pipe welding with wire the amount of current will depend on the application, i.e., joint prep, land extention, thickness, and material type.

BACKGROUND AMPS (AMP-BCK): BACKGROUND AMPS the amount of current applied during the BACKGROUND PULSE TIME. It is generally set at 1/3 to 2/3 of the PRIMARY AMPS.

PRIMARY PULSE TIME (PRI-PULSE): The PRIMARY PULSE TIMER determines the amount of time the power supply operates at PRIMARY AMPS. For STRINGER BEADS with the PULSE MODE ON, the PRI-PULSE timer should be set to between 0.2 and 0.6 seconds.

BACKGROUND PULSE TIME (PULSE-BCK): The BACKGROUND PULSE timer deter-mines the duration of the pulse(s) during which the low or BACKGROUND AMPS is in effect. When welding STRINGER BEADS with PULSE MODE ON, the BACKGROUND PULSE timer should generally be set between 0.2 to 0.6 seconds. A good starting point would be 0.3 seconds.

PRIMARY WIRE FEED (PRI-WF): PRIMARY WIRE FEED specifies the rate that wire is supplied to the weld puddle during the PRIMARY PULSE TIME. The amount of wire fed to the weld joint will depend on the amperage and the amount of fill required. Start with a PRIMARY WIRE FEED value of 25% of the PRIMARY AMPS.

π π


4.4


BACKGROUND WIRE FEED (WF-BK): BACKGROUND WIRE FEED specifies the amount of wire that will be fed to the weld joint during the BACKGOUND PULSE time. Start with a BACKGROUND WIRE FEED of 75% of the PRIMARY WIRE FEED.

AUTOMATIC VOLTAGE CONTROL MODE (AVC MODE): AVC MODE is one of the most important features on the power supply and, must be fully understood. There are four modes to select from:

1. CONT (CONTINUOUS): In this mode the voltage senses during both primary and background pulse times. CONT mode is generally used for welding WEAVE BEADS. PRIMARY AVC will range between 7.5 to 11.5 and BACKGROUND AVC will range from .5 to .9 less than PRIMARY AVC.

2. SAMP/PRI (SAMPLE PRIMARY): In SAMP/PRI MODE the voltage will only be sensed during PRIMARY PULSE TIME. During BACKGROUND PULSE TIME the avc will lock and become inactive. SAMP/PRI MODE is generally used when welding STRINGER

BEADS.

3. SAMP/BCK (SAMPLE BACKGROUND): In SAMP/BCK MODE voltage is sensed during the BACKGROUND PULSE TIME only. This mode is rarely used.

4. OFF is used when a manual torch welding rig is connected to the M-227 for tacking or manual welding.

PRIMARY AUTOMATIC VOLTAGE CONTROL (PRI-AVC): PRIMARY AUTOMATIC VOLTAGE CONTROL maintains a set distance between the end of the tungsten electrode and the molten weld puddle. Refer to Section VII. for a more detailed description of AVC.

BACKGROUND AUTOMATIC VOLTAGE CONTROL (AVC-BCK): BACKGROUND AUTOMATIC VOLTAGE CONTROL specifies the distance between the electrode tip and the molten weld puddle. Values will change with conditions. Refer to Section VII.

OSCILLATOR AMPLITUDE (OSC/AMPL): This is the total amount of oscillated stroke of the welding torch. This measure-ment is incremented in thousanths of an inch from 0.001 to 0.999.

IN (IN DWELL): IN DWELL is the time the torch will remain stationary on the sidewalls for tying in. IN DWELL is at the sidewall nearest to the weld head. Start IN DWELL at about 0.3 and increase from pass to pass.


4.5


EXCURSION (EXC): In OSC MODE, EXC is the time allowed to move the torch across the groove from one sidewall to the other. Starting values are about 0.3 which will be increased from pass to pass.

OUTDWELL (OUT): In OSC MODE, OUTDWELL is the amount of time required for the torch to remain stationary for tying in to the sidewall furthest from the weld head. This time should start at about 0.3 and may be increased with each pass.

General Programming Rules of Thumb

A. For Stringer BeadsThe following weld parameter settings are recommended as a starting point when welding stringer beads (i.e. when oscillation is not used).

1) OD (Outside Diameter) Enter the size of the pipe or tube.

2) WALL - Enter the thickness of the tube or pipe to be welded.

3) MAT (Material Type): SS, Stainless Steel; CS, Carbon Steel, etc.

4) POS (Position of pipe or tube to be welded) 1G, 2G, 3G, 4G, 5G, 6G

5) HEAD (Welding head to be used) The model number should be stamped on the serial

number tag.

6) PASS - This is an automatic feature. As you develop the weld schedule, the power supply

will keep track of the number of passes entered to complete the weld.

7) PRE-PURGE : 5 to 10 seconds

8) PURGE-POST : 10 to 20 seconds

9) UP-SLOPE: 3 to 5 seconds

10) SLOPE-DOWN (Downslope): 5 to 10 seconds

11) ROT (Direction of weld head rotation) - CW/ Clockwise; CCW/ Counter clockwise

12) ROT-DELAY : 0.1 to 2 seconds longer than upslope

13) STR-WFDLAY (Start Wire Feed Delay): 1 to 3 seconds longer than upslope

14) WFDLAY-STP (Wire Feed Stop Delay): O to 1 second

15) RETRACT: 0.3 to 0.6 seconds

16) T/MODE (Time Mode) Auto or Manual

17) OSC MODE (Oscillate Mode) Generally “OFF” for stringer beads

4.6


18) STR AVCDLY (Start automatic voltage delay) Equal to upslope

19) AVCDLY-STP (Automatic Voltage Delay Stop) O to 1 second

20) STR/MODE (Start Mode) RF or TCH

21) RESPONSE: M-81 6 to 8 / M-15 1 to 3 / M-79 4 to 7/ M-6 1 to 3/ M-43 1 to 3

22) PULSE: ON

23) ROT (Rotation) CONT (Continuous) or STEP1. If CONT is chosen, programming will only let the operator enter primary values, and

the weld head will travel at a constant speed.2. If STEP is chosen, travel values should be entered for background only. In this mode,BACKGROUND PULSE and TRAVEL SPEED will regulate rotation.

24) PRI-IPM (Primary Inches per Minute) {IPM} or Rotations per Minute {RPM} depend-ing on the type of weld head used. If CONTINUOUS (CONT) is chosen, there should be a number entered under PRI with a value generally between 3.5 to 5 IPM or .25 to 4 RPM.

NOTE: For Stringer Beads, travel speed is normally between 3 to 6 Inches per Minute (IPM). For fusion butt welds on thin-wall tubing, 5 IPM is typical. For the Model 9 weld heads travel speed (IPM) must be converted to RPM by the following formula:

IPM ÷ circumference of weld joint = RPM (See page 4.3)

25) IPM-BCK (Background Rotation) Travel speed of the weld head. If background travel is chosen rotation mode will generally be put in STEP MODE.

26) TIME The number of seconds need to complete a weld. Enter TIME if time mode is set to automatic (16). If manual was chosen in item 16, this parameter will automatically enter MANUAL, and no value is needed.

27) PRI AMPS (Primary Amps) The value of current used during Primary Pulse Time.

NOTE: The value entered for PRI AMPS will depend entirely on the specific application. For fusion butt welds with the Model 9 weld heads, the PRI AMPS are correlated with the tube wall thickness with about 1 AMP of current for every 0.001 inch of wall. Thus, 49 AMPS would be required for a wall of 0.049”. Heavier walls would require more amps.

28) AMP-BCK (Background Amps): Amount of current used during Background Pulse

Rules of Thumb for Stringer Beads, continued:

4.7


Time. 1/3 to 2/3 The value entered for PRI AMPS.

29) PRI-PULSE (Primary Pulse) 0.3 seconds.

30) PULSE-BCK (Background Pulse) 0.3 seconds.

31) PRI WF (Primary Wire Feed) 25% of primary amp value.

32) WF-BCK (Background Wire Feed): 75% of the value entered in primary wire feed. The value entered for BCK WIRE will depend entirely on the amount of fill required and the BCK AMPS entered.

33) PRI AVC ( Primary Automatic Voltage Control).

34) AVC-BCK (Background Automatic Voltage Control).

35) AVC MODE (Automatic Voltage Control Mode)(1) CONT (Continuous) Used for welding with OSC, especially if OSC is over .200.(2) SAMP/PRI (Sample Primary) Use for stringer beads or if OSC is less than .200. (3) SAMP/BCK (Sample Background) Used for special applications.(4) OFF

36) OSC/AMPL (Oscillator Amplitude) Off for stringer beads unless using zero value on OSC for root pass and then going to OSC for fill and cap passes.

37) IN DWELL Not programmed if OSC mode OFF.

38) OUT DWELL: Not programmed if OSC mode OFF.

39) EXC (EXCURSION): Not programmed if OSC mode OFF.

B. For Oscillation BeadsGuidelines for Weld Parameters when OSCILLATION is ON: (See Pass 2 of sample Weld Schedule on page 10.2 and 10.11.)

1) OD (Outside Diameter) Enter the size of the pipe or tube.

2) WALL - Enter thickness of the pipe or tube to be welded.

3) MAT (Material Type): SS, stainless steel; CS, carbon steel, etc.

4) POS (Position of tube or pipe to be welded) 1G, 2G, 3G, 4G, 5G, 6G

Rules of Thumb for Stringer Beads, continued:

4.8


5) HEAD (Welding head to be used) Enter the model number which should be stamped on

the serial number tag.

6) PASS - This is an automatic feature. As you develop the weld schedule, the power supply

will keep track of the number of passes entered to complete the weld.

7) PRE-PURGE : 5 to 10 seconds.

8) PURGE-POST : 10 to 20 seconds

9) UP-SLOPE: 3 to 5 seconds

10) SLOPE-DOWN (Downslope): 5 to 10 seconds

11) ROT (Direction of weld head rotation) - CW/ Clockwise; CCW/ Counter Clockwise

12) ROT-DELAY : 0.1 to 2 seconds longer than upslope

13) STR-WFDLAY (Start wire feed delay): 1 to 3 seconds longer than upslope

14) WFDLAY-STP (Wire feed stop delay): O to 1 second

15) RETRACT: 0.3 to 0.6 seconds (Maximum is 1.0 sec.)

16) T/MODE (Time Mode) Auto or Manual

17) OSC MODE (Oscillate Mode) ON

18) STR AVCDLY (Start automatic voltage delay) Equal to or > upslope.

19) AVCDLY-STP (Automatic Voltage Delay Stop) O to 1 second or 1/3 of downslope time.

20) STR/MODE (Start Mode) RF or TCH

21) RESPONSE: M-81 6 TO 8 / M-15 1 TO 3 / M-79 4 TO 7

22) PULSE: SYNC (Choices are SYNC, ON, or OFF)

23) ROT (Rotation) CONT (Continuous) or STEP.A. IF CONT is chosen, programming will only let the operator enter in primary values, and

the weld head will travael constantly.

B. If STEP is chosen, travel values should be entered in background only. During Back-ground Mode, background pulse and travel speed will regulate rotation.

24) PRI-IPM (Primary inches per minute) {IPM} or rotations per minute {RPM} depending on the type of weld head used. If continuous (CONT) is chosen, there should be a number entered under PRI with a value generally between 3.5 to 5 IPM or .25 to 4 RPM.

4.9


25) BCK-IPM (Background rotation) Travel speed of the weld head during the background current pulse if rotation is in STEP MODE.

26) TIME The amount of seconds needed to complete a weld. Use if time mode is set to automatic (21). If MANUAL was chosen in item 21, this parameter will automatically enter manual, and no value is needed.

27) PRI AMPS (Primary Amps) The value of current used during primary pulse time.

28) BCK-AMP (Background amps): Amount of current used during background pulse time. 1/3 to 2/3 of the value entered for PRI AMPS.

29) PRI-PULSE (Primary Pulse) 0.0 seconds.

30) PULSE-BCK (Background Pulse) 0.0 seconds.

31) PRI WF (Primary wire feed) 25% of primary amp value.

32) BCK-WF (Background wire feed): 75% of the value entered in primary wire feed.

33) PRI AVC ( Primary Automatic Voltage Control).

34) BCK-AVC (Background Automatic Voltage Control).

35) AVC MODE (Automatic Voltage Control Mode) Set to CONT (with OSC “ON” and SYNC)

36) OSC/AMPL (Oscillator Amplitude) 0.125 (or other value).

37) IN DWELL 0.3 and may be increased from pass to pass.

38) OUT DWELL: 0.3 and may be increased from pass to pass.

39) EXC (EXCURSION): 0.3 and increase from pass to pass.

4.10


Pulse-to-pulse spacing should not exceed 1/2 the diameter of the puddle on fill passes and in the range of 0.33 to 1.0 times the wall thickness on root or square butt fusion passes.

As a starting point, set the primary and background pulses to equal times. Particularly on root passes, the arc voltage should be kept as low as practical to maintain a nar-row, deep penetration zone.

Surface travel speed will usually be in the range of from 2 to 6 inches per minute.

Note: For General Guidelines for Stringer Beads and Weave Beads, refer to the Sample Weld Program on page 10.2 and 10.11. For the first or stringer bead pass, the OSC Mode was OFF, PULSE ON, and travel (ROT) in STEP mode. IPM was entered under the back-ground (BCK) RPM with the primary RPM set at 0. AVC MODE was SAMP/PRI which indi-cates the AVC was only in effect during the primary pulse time. No values were entered for OSC, IN DWELL, OUT DWELL, or EXC since no oscillation was intended.

For the second pass of the sample weld program a weave bead was programmed by selecting OSC MODE ON. The PULSE was syncronized (SYNC) with the oscillation to provide maximum currents during the IN DWELL and OUT DWELL and background or low amperage during the excursion (EXC). Travel (ROT) is CONT (continuous) with PRI RPM programmed. There is no background RPM in CONT mode. For the weave bead, the AVC MODE is CONT which means it samples during the excursions across the groove as well as at the sidewalls to keep the arc gap constant. The diagram below illustrates the sychronization of Oscillator, Weld Current and Wire Feed functions.

TORCH MOVEMENT - OSCILLATOR MODE “ON”SYNCHRONIZED WITH PULSE AND WIRE FEED

INDWELL

OUTDWELL

PRIMARY AMPSPRIMARY WIRE

PRIMARY AMPSPRIMARY WIRE

EXCURSION

BACKGROUND AMPSBACKGROUND WIRE

4.11


C. Programming Rules of Thumb for Orbital Fusion Tube WeldsThe Model 227 Power Supply can be programmed for orbital fusion welds on tubing using the Model 9 Series weld heads. Model 9 Weld Heads must be calibrated for rotational speed on the Model 227 prior to use. Note also that fusion tube weld programs in either STEP or CONT mode can be used for fusion welds on thin-walled pipe using the Model 15 weld head.

Orbital welds are generally done as a single pass weld. The weld sequence consists of a timed PREPURGE, arc start, pulsed LEVEL 1 CURRENT (AMPS), ROTATION DELAY, travel at the pro-grammed RPM, a series of level changes in which the current is usually reduced from level-to-level. There are generally 4 to 6 levels followed by a timed DOWN-SLOPE during which the current is reduced until the arc goes out. After a timed POSTPURGE, the weld head rotor returns automatically to the home position. The following guidelines are suggested starting values when writing a weld schedule “from scratch”.

Welding Current: LEVEL 1 PRIMARY AMPS is based on wall thickness with about 1 Amp for each 0.001” wall. Thus for a tube with 0.049” wall, the starting primary amps would be 49. Slightly higher amps than this are required for heavier walled tubing. Thus for a wall thick-ness of 0.065 wall a starting value of 65 amps is recommended, but the actual amps on a working weld schedule is likely to be anywhere from 65-85 amps.

The BACKGROUND AMPS is typically set at 30% of the primary amps. It is customary to set the background amps at the same value for each level although this parameter can be changed from level to level if desired.

The LAST LEVEL PRIMARY AMPS is 20% less than level 1 Amps (or 80% of level 1).

INTERMEDIATE LEVEL AMPS: The amperage is usually reduced from level to level. To do this evenly, subtract the LAST LEVEL PRIMARY AMPS from the FIRST LEVEL PRIMARY AMPS, and divide that number by the number of levels minus 1 to determine the number of amps to be subtracted for each subsequent level. Example: First level primary amps = 49; last level pri-mary amps = 39. 49 minus 39 = 10 amps. For a 4 level program, divide 10 by 3 which equals 3.3. LEVEL 2 AMPS = 49 - 3.3 = 45.7 amps. LEVEL 3 AMPS = 45.7 - 3.3 = 42.4 amps.

Note: Calculated weld current valules are approximate. Current values will vary somewhat from heat-to-heat of stainless steel. Current levels must be adjusted to achieve a uniform, fully penetrated weld bead around the entire weld circumference.

RPM: The RPM (revolutions per minute) is based on travel speed. To have the same travel speed, the RPM to weld a small diameter tube would have to be much faster than for a large diameter tube. Travel speed is typically about 5 inches per minute (IPM). It may be slower for heavier-walled tubing and faster for thin-walled tubing. For rotation in CONT, only primary RPM is used. For rotation STEP, the primary RPM is typically 0.0 and the RPM is pro-grammed as background RPM.

4.12


The above weld schedule is for welds of 12 inch schedule 10 pipe using the Model 15 pipe weld head. The preparation was a square butt and the shielding and purge gases were argon. Levels 1-4 are used for the first pass which is a stringer bead without the addition of wire.

Since we did not wish to stop travel between passes, and since OSC MODE cannot be changed from LEVEL to LEVEL, but only from PASS to PASS, OSC MODE is ON in Level 1 but not active. Zero or minimal values are entered in OSC/AMPL, IN, EXC and OUT in preparation for the second pass which is completed with levels 5 and 6. Levels 5 and 6 have been changed from STEP to CONT rota-tion, PULSE is changed from ON to SYNC and PULSE TIMES are not programmed since these functions are taken over by excursion and dwell times, which must be entered. Wire feed rates are also entered for levels 5 and 6.

LVL PULSE ROT PRI--IPM--BCK 5 SYNC CONT 2.7 TIME PRI--AMP--BCK PRI-PULSE-BCK 5 550 110 85 PRI -WF-BCK PRI--AVC--BCK AVC MODE 5 25 20 9.3. SAMP/PRI OSC/AMPL IN EXC OUT 5 .275 0.40 0.55 0.40

LVL PULSE ROT PRI--IPM--BCK 6 SYNC CONT 2.7 TIME PRI--AMP--BCK PRI-PULSE-BCK 6 550 107 85 PRI -WF-BCK PRI--AVC--BCK AVC MODE 6 25 20 9.2 SAMP/PRI OSC/AMPL IN EXC OUT 6 .275 0.40 0.55 0.40

ALL PARAMETERS PERFORMED AS PROGRAMMED

OPERATOR:

# OD WALL MAT POS HEAD PASS017 12.75 .180 SS 5G 15 1PRE-PURGE-POST UP-SLOPE-DOWN ROT-DLY 5 10 3.0 10.0 CCW 12.0STR-WFDLY-STP RETRACT T/MODE STLV OSC6.5 +0.0 0.4 AUTO 50 ONSTR-AVCDLY-STP STR/MODE RESPONSE3.0 3.0 RF 1

LVL PULSE ROT PRI--IPM--BCK 1 ON STEP 0.0 4.0 TIME PRI--AMP--BCK PRI-PULSE-BCK 1 310 155 45 1.50 1.75 PRI -WF-BCK PRI--AVC--BCK AVC MODE 1 0 0 10.1 SAMP/PRI OSC/AMPL IN EXC OUT 1 .000 0.01 0.01 0.01

LVL PULSE ROT PRI--IPM--BCK 2 ON STEP 0.0 4.0 TIME PRI--AMP--BCK PRI-PULSE-BCK 2 310 153 45 1.50 1.75 PRI -WF-BCK PRI--AVC--BCK AVC MODE 2 0 0 10. SAMP/PRI OSC/AMPL IN EXC OUT 2 .000 0.01 0.01 0.01



Example of a Weld Schedule in which the LEVELS are used to create a second PASS. The first pass is done as a stringer bead using levels 1-4, and the second pass is done with oscillation using levels 5 and 6.

4.13


Formula for converting IPM to RPM:

IPM ÷ tube circumference = RPM

Example: To find the RPM for a 2 inch OD tube welded at 5 IPM Tube circumference = 2.00 X 3.14 = 6.28 inches. 5 IPM ÷ 6.28 inches = 0.796 or 0.8 RPM

Note: the value of π is 3.141.; the circumference of a tube = π x the tube OD

Time: The total time for all the weld levels combined is 1) the time required to complete 1 revolution = 60s ÷ RPM + 2) time programmed for ROTATION DELAY (usually 1 or 2 seconds or until full penetration is achieved) + 3) time required for tie-in or overlap = about 2 sec at 5 IPM depending on wall thickness.

Time for each level is found by dividing the Total Time as calculated above by the number of levels programmed.

Downslope Time: Usually 5 -10 seconds depending on tube size.

Prepurge and Postpurge times: 30 seconds to one minute or more depending on weld head size and level of weld OD quality needed.

Pulse times: 0.1 sec or less for small tubing such as 1/4 or 3/8 inch OD, or 0.2 sec for .049 or 0.065” wall. Primary and background pulse times are typically equal. Longer pulse times may be used for heavier wall or for programs with rotation in STEP mode. If the primary pulse time is made longer than the background pulse, the weld will be hotter while if the back-ground pulse times are made longer than the primary pulse times, the weld will be cooler.

Rotation: Rotation can be programmed as CONT, STEP, or OFF. It is usually CONT in which the rotor maintains a constant speed throughout the weld sequence or for any level that is pro-grammed CONT. STEP programs may be useful for fusion welds on heavy-walled tube or thin-walled pipe or for tube-to-fitting welds with somewhat irregular wall thicknesses or fit-up. To convert a standard (CONT) program to STEP you will double or slightly more than double the total time, double the pulse times, set the primary RPM to 0.0 and enter the calcu-lated RPM in background RPM. Both amperage and pulse times can be adjusted to give opti-mal penetration in all levels. Verify that the programmed time is sufficient for adequate tie-in.

4.14


Tungsten lengths for Model 9 Weld Heads must be consistent from weld to weld. The for-mula for determination of tungsten length is: (see Rotor Diameter chart on page 6.5)Tungsten length formula:

(ROTOR OD - TUBE OD) ÷ 2 - ARC GAP = TUNGSTEN LENGTH

Gas flow rates to the Model 9 Weld Heads must also be consistent from weld to weld. Con-sult Model 8 and Model 9 Flow Rate Chart on page 7.4 for factory recommendations.

Note: It is standard procedure when modifying tube weld schedules to keep the RPM and times constant and to increase or decrease penetration by raising or lowering the amps. You must verify full penetration at the start of the weld by checking the amount of penetration achieved during ROTATION DELAY. Note: For more detailed guidelines for fusion tube welding, consult the Arc Machines, Inc, Model 207 Operator Training manual P/N 740052.

4.15

ARC MACHINES, INC.MODEL 207A/207-HP TUBE WELD SCHEDULE

LVL PULSE ROT PRI....RPM....BCK . . 2 ON-OFF CONT-OFF-STEP _____ _____ TIME PRI...AMP...BCK PRI...PULSE...BCK . . 2 _____ _____ ______ _____ _____




# O.D. WALL TYPE MAT QTY ____ _____ _____ ______ _____ _____

PRE-PURGE-POST UP-SLOPE-DOWN ROT...DLY . . CW-CCW . ______ ______ ______ ______ _____

LVL PULSE ROT PRI....RPM....BCK . . 5 ON-OFF CONT-OFF-STEP _____ ______ TIME PRI...AMP...BCK PRI...PULSE...BCK . . 5 _____ _____ ______ _____ _____

LVL PULSE ROT PRI....RPM....BCK . . 6 ON-OFF CONT-OFF-STEP _____ _____ TIME PRI...AMP...BCK PRI...PULSE...BCK . . 6 _____ _____ ______ ______ _____

DATE: _________________________ PREPARED BY: ___________________APPROVED BY: ___________________CUSTOMER: _____________________NOTES: ____________________________________________________________JOINTDESCRIPTION: ____________________MATERIAL: ______________________HEAT NO: ________________________ ----------------------------------------------------

WELD HEAD INFORMATIONMODEL NUMBER: ________________ARC GAS: ________ CFH: __________PURGE GAS: ________ CFH: _______

TUNGSTEN DATA O.D.: ________ TIP. DIAM.: ______2% CERIATED 2% THORIATED

TUNGSTEN LENGTH FORMULA

1) ROTOR O.D. _ TUBE O.D. _ ARC GAP = TUNGSTEN 2 LENGTH _ ARC GAP = TUNGSTEN ÷ 2 LENGTH

---------------------------------------------------------

KEY FORMULAS

1) Tube O.D. X π = Circumference 3.14 _______ X ________ = _______

2) I.P.M. ÷ Circumference = RPM________ ÷ _________ = __________

3) 60 secs ÷ RPM = Time for 360° 60_______ ÷ ________ = _________

TOTAL WELD TIME

(Time for 360° + Rot. Dly. + Overlap = Total Weld Time)_________ + ________ + ________ = ____________

(Total Weld Time ÷ No. of Levels = Time per Level)

_____________ ÷ ___________ = __________

REVISED MAY, 1998

4.16


Programming the Manual TorchThe optional Manual Torch is often used for pretacking of tubes, pipe, or fittings prior to orbital welding. In most of these applications, the tacks are done autogenously, ie, without filler. With the Model 227 Power Supply, it is necessary to enter a program specifying an upper PRIMARY AMPERAGE level and TIME sufficient to complete the tack. For the program below, PULSE is OFF. If pulsation is desired, (PULSE ON), BACKGROUND AMPS must also be programmed. An ON/OFF foot switch or a foot control pedal with variable current control may be used. When the pedal is completely depressed, full programmed amps are delivered. A ground cable must be connected from the power supply to the work. The arc can be started automatically by pressing SEQUENCE START from the RP or you can start sequence by stepping on the foot pedal or foot switch.

For high-purity applications, or for alloys such as titanium, an ID or back purge during tacking is essential. This applies even if the tacks do not penetrate to the tube ID.

For high-purity thin-walled tube applications, if tacking is permitted, the current is typically pulsed. The size of the tack should be no larger than necessary to provide the desired support.

The following is an example of a tacking program for pipe welds on the Model 227:

ARC MACHINES, INC.

AMIWELD 227 STD1.5 COPYRIGHT 199608 DEC 97 11:39:20

OPERATOR: WELDLAB

# OD WALL MAT POS HEAD PASS 066 0.000 0.000 SP 5G MAN 1

PRE-PURGE-POST UP-SLOPE-DOWN 5 5 1.0 3.0 T/MODE STVL

AUTO 40

LVL PULSE 1 OFF TIME PRI--AMP--BCK PRI--PULSE-BCK 1 68 94

SEQUENCE STOPPED

4.17


4.18


Chapter 5. Sequence of Events

The following events occur after the initiation of SEQUENCE START in accord

with instructions in the weld program: PREPURGE, ARC START, UPSLOPE, WELD LEVELS, DOWNSLOPE AND POSTPURGE. Some events or parameters have a large effect on the weld, while others have little or none. It is important to understand each event.

What does it do?When does it do it?What effect does it have on the weld?

Note: These 3 questions are the most important questions which operators and program-mers must be able to answer in order to successfully operate the orbital welding equipment.

1. EVENT 1. The PREPURGE timer starts counting after pushing the SEQUENCE START-membrane panel key on the power supply or remote pendant, and gas flow to the weld head or

SEQ

START

Graph of Weld Parameter Functions for the Model 227 Power Supply. Events are shown from the intitiation of SEQUENCE START to the end of DOWNSLOPE for Weld Current, wire feed, travel and AVC. Parameters are shown with pulsation but synchronization is not intended to be accurate.

5.1


tungsten begins. The length of time between initiation of SEQUENCE START AND ARC START is the PREPURGE time. The gas flow solonoid remains on during the entire weld sequence until the end of POSTPURGE.

2. EVENT 2. ARC START occurs at the end of PREPURGE. Arc starting may be accomplished by TOUCH START or RF START (radio frequency) modes. In Touch Start Mode, the tungsten touches the work and comes back to a preset function to set the arc gap. The arc gap is the distance between the end of the electrode, where the arc initiates, and the work. The arc gap is determined by the AVC Jog Speed (adjustable from the SET-UP screen), with faster jog speeds resulting in a wider arc gap. The arc gap should be approximately 1/8 inch.

For RF START the tungsten must be physically set to the operational arc gap. A high-frequency pulse will be generated to establish an arc between the tungsten electrode and the weld joint.

The Model 227 Power Supply has an ARC DETECT feature which determines whether or not an arc has been established. If it has, then the sequence procedes to EVENT 3. If not, the power

SETUP

ARC GAP1/8” (3.18 mm)

5.2


supply and RP display a ‘FLT’ and, if the printer is set for AUTO, it prints a BAD START mes-sage.

3. EVENT 3. LEVEL 1. TIME, START LEVEL, UPSLOPE, TRAVEL START DELAY, AND WIRE START DELAY - (See Sequence of Events Graph, page 5.1). When the ARC is initiated, the following functions all start at the same time:

A. LEVEL 1 TIME. Once the arc is established, all weld functions are considered tobe in Level I. The Level 1. Timer starts to count and remains in Level 1 until the pro-grammed time has elapsed (Auto Mode) or until manually advanced to Level 2 or Downslope (SEQUENCE STOP).

B. WELD CURRENT START LEVEL. As the arc is estabilshed the initial current stabililzes at the START LEVEL which is adjustable from 5 -100 Amps via the weld schedule. A START LEVEL of 50 Amps is suitable for most applications. Fewer amps are required for thin-walled material. Start Level below 20 Amps may make starting the arc difficult.

C. WELD CURRENT UPSLOPE. An UPSLOPE may be used in order to raise the current to full Level 1 values slowly. (Full current on the root pass of heavy-walled material could result in a blown-out weld. Upslope is used to gradually establish the weld puddle on subsequent passes.) The UPSLOPE timer starts counting when the arc is established and the programmed time determines how long it will take to reach full Level 1 Amps. If Pulse Mode is ON, the amplitude of the current pulses gradu-ally increases during upslope until full Level 1 Primary and Background currents are reached. A time of 3-5 seconds is suggested for WELD CURRENT UPSLOPE.

D. PRIMARY and BACKGROUND PULSE TIMES. With Pulse Mode ON, the Pri-mary Amps continues for the duration of the programmed Primary Pulse Time and the Background Amps continues for the programmed Background Pulse time. Pulsing between a high current pulse (PRIMARY) that melts the metal and a low current pulse (BACKGROUND) during which the metal starts to freeze helps to control the weld puddle in all positions. If Pulse Mode is OFF, weld current remains at the Level 1 Pri-mary Amps. If Pulse Mode SYNC is selected, pulsation is sychronized with torch oscillation (See 3 H below). Pulse times can also be synchronized with rotation for stringer beads (Rotation STEP MODE).

E. TRAVEL START DELAY - Torch rotation is delayed until the TRAVEL START DELAY time has elapsed. This time is usually set slightly longer than the UPSLOPE time to allow for full penetration of the weld joint prior to the start of rotation. Both ROTATION and TRAVEL START DELAY timers start counting when the arc is established. Level 1 travel time (AUTO MODE) is reduced by the programmed

5.3


TRAVEL START DELAY time.

F. WIRE FEED DELAY - Wire is not generally added to the weld until full current is applied at the end or just after the end of UPSLOPE. The arc must be hot enough to melt wire entering the weld puddle. If WIRE FEED DELAY is programmed, it would be about 2 sec. longer than the current upslope, but WIRE FEED can also be turned off and started manually.

A WIRE FEED UPSLOPE is possible but not generally used. If wire is programmed to start after 60% of the UPSLOPE is complete, wire feed will begin at 60% of the programmed value and continue WIRE FEED UPSLOPE until the full Level 1 value is reached.

G. AVC UNLOCK DELAY TIMER. The AVC or Arc Voltage Control is used to maintain a constant arc gap during welding. As the arc volts are increased, the arc gap gets larger so that at 150 Amps an AVC setting of 10 will result in an arc gap of about 1/8 inch. AVC cannot be applied during upslope since at a 50 Amp current setting an AVC setting of 10 Volts could result in an arc gap of up to 12 inches. The AVC UNLOCK DELAY TIMER is typically set to unlock the AVC after full current is achieved or at least 80% of the UP-SLOPE time has elapsed.

H. OSCILLATOR UPSLOPE (OPTIONAL) If torch oscillation is programmed, full oscillator amplitude will be reached at the end of current UPSLOPE. OSCILLATOR pulse times don’t change during the UPSLOPE, but the width of the excursion increases until full oscillator amplitude is achieved.

WIREMODE

OFF/ON

5.4


4. EVENT 4. FULL LEVEL FUNCTIONS. After the arc is established and the UPSLOPE TRAVEL and WIRE START DELAY are completed, the following FULL LEVEL FUNCTIONS will be in effect.

A. LEVEL 1 TIME will be counting towards zero (0.0) if AUTO mode is selected.

B. LEVEL 1 PULSE MODE. Can be programmed to be ON, OFF or SYNC. If it is OFF, only PRIMARY functions will occur. If it is ON, the system will pulse between PRIMARY and BACKGROUND function values. PULSE MODE ON is typically used for stringer beads. If PULSE MODE is in SYNC, PRIMARY AMPS occur during the OSCILLATOR DWELL times and BACKGROUND AMPS occur during EXCURSION (see figure on page 4.11.)

C. LEVEL 1 PRIMARY PULSE TIME. If the LEVEL 1 PULSE MODE is ONthis function will operate. The duration of Primary Amps is controlled by the

programmed PRIMARY PULSE TIME.

D. LEVEL 1 BACKGROUND PULSE TIME. If the LEVEL 1 PULSE MODEis ON, this function will operate. The duration of the Background Amps iscontrolled by the programmed BACKGROUND PULSE TIME.

E. LEVEL 1 PRIMARY AMPS. The value programmed for LEVEL 1 PRIMARY AMPS (5-225 Amps) will be reached at the end of UPSLOPE. AMPERAGE is the major determinant of heat input into the weld. Increasing amperage increases the amount of penetration while decreasing amperage results in less penetration.

WELD CURRENT WITH PULSATION ON

5.5


F. LEVEL 1 BACKGROUND AMPS. If LEVEL 1 PULSE MODE is pro-grammed to ON or SYNC the current will be pulsing between the programmedPRIMARY AMPS and the BACKGROUND AMPS. BACKGROUND AMPS is usually set to a lower value than PRIMARY AMPS to provide control of the weldpuddle.

G. LEVEL 1 TRAVEL MODE. TRAVEL MODE can be programmed in one of three modes. CONT (continuous), OFF, or STEP. At the end of TRAVEL STOP DELAY, if the TRAVEL MODE is programmed:

OFF, rotation will not occur.

CONT, the torch will travel at the PRIMARY RPM/IPM* value.

STEP, the torch travel speed will pulse between the PRIMARY RPM value and the BACKGROUND RPM value in synchronization with the current pulse. If the pulse mode is OFF, travel will run at the PRIMARY RPM value only. (In STEP, the Primary RPM is usuallly set to 0.0, or much less than the Background RPM.)

H. LEVEL 1 PRIMARY RPM. After the TRAVEL STOP DELAY if the LEVEL 1 TRAVEL MODE is programmed in the CONT mode, the torch will travel at the PRIMARY RPM rate. If the travel mode is STEP the torch will travel at the BACK-GROUND RPM rate for the duration of the BACKGROUND PULSE TIMES .

I. LEVEL 1 BACKGROUND RPM. If the travel mode is STEP, the torch will travel at the BACKGROUND RPM rate for the duration of the BACKGROUND PULSE TIMES. If travel mode is CONT, BACKGROUND RPM is ignored.

NOTE: TRAVEL DIRECTION is programmable in the CLOCKWISE (CW) or COUNTERCLOCKWISE (CCW) direction (as one faces the torch). The direction is not programmable by LEVELS, but remains the same throughout the weld sequence. It may be changed for additional PASSES.

J. LEVEL 1 PRIMARY WIRE. After the WIRE START DELAY time is complete and if the Wire Mode is AUTO, the Wire will start to feed. If wire Mode is MANUAL it must be turned ON by the operator. PRIMARY WIRE feed rate occurs during the Primary Current Pulse. Typical wire feed speed is 30-80 IPM depending on wall thickness and wire dimensions. The maximum wire feed speed is determined by the weld head/wire feed motor.

K. LEVEL 1 BACKGROUND WIRE. Wire is fed at the BACKGROUND WIRE rate during the Background Current Pulse. (PULSATION MODE ON) The PRIMARY WIRE, feed speed is generally greater than the BACKGROUND WIRE feed speed to enable the wire to push the puddle in. If PULSATION MODE

*Note: Model 15 and Model 81 programmed in IPM. Models 95, 9, 6, 43, 96 and 79 are programmed in RPM.

5.6


is SYNC, the PRIMARY WIRE feed speed occurs during the IN DWELL and OUT DWELL, while BACKGROUND WIRE feed speed operates during EXCURSION.

L. LEVEL 1 AVC MODE (OPTIONAL). AVC MODE can be programmed as CONTINUOUS (CONT), OFF, or SAMPLE PRIMARY or SAMPLE BACKGROUND. AVC is used to maintain a constant arc gap. If CONT, the AVC continuously measures the arc voltage and adjusts the gap during both Primary and Background current conditions. At 150 Amps of welding current, an AVC setting of 10 will typically result in a 1/8 inch arc gap. This is not a constant value, but may require adjustments. The AVC is sensitive to environmental factors such as temperature and humidity.

AVC OFF is typically used for manual torch operation when arc gap control is not needed.

AVC SAMPLE MODE is set to maintain a constant arc gap during either Primary or Background current pulses. AVC SAMPLE MODE is typically used for stringer beads while AVC CONT is generally used for a weave. If the AVC is set too high, wire will drip into the puddle. If the AVC is too low, the wire will drag at the edge of the puddle. The optimum distance between the end of the tungsten and wire entering the weld puddle for most welding with a Model 81 or 79 series is typically between 3/32 and 7/64 inch. For heavier-wall pipe with the Model 15, the arc gap may be as much as 5/32 inch (3.6 mm).

M. LEVEL 1 TORCH OSCILLATION (OPTIONAL). The torch will oscillate (weave) for the distance programmed in OSCILLATOR AMPLITUDE (OSC/AMPL) for the time programmed in EXCURSION (EXC) and will remain at the

TRAVEL DIRECTION

Distance betweenend of electrode andwire entering the weld puddle shouldbe from 3/32” (2.4 mm)

5/32” (3.6 mm)depending on weldhead used.

to

5.7


sidewalls for the time programmed in (IN) and OUTDWELL (OUT) respectively. OSCILLATOR MODE must be programmed ON for OSCILLATION to occur.

If PULSE MODE is programmed SYNC, PRIMARY AMPS will occur during the IN DWELL and OUT DWELL times while BACKGROUND AMPS will be in effect during EXCURSION. This results in greater heat input at the sides where it is needed, with less heat applied as the torch moves from side-to-side. If pulse mode is ON, oscillation will have no effect on pulsation.

5. EVENT 5. LEVEL 2 TO LAST PROGRAMMED LEVEL. As the arc continues to rotate around the weld joint, it is usually necessary to program changes in current, AVC, wire feed speed, pulse times, modes, or rotation speed. A programmed change is accomplished by a change in LEVEL of which the Model 227 can accept 100 for each WELD SEQUENCE (PASS). Each additional LEVEL contains the same functions and options as LEVEL 1.

In TIMER MODE, AUTO, each LEVEL TIME sets the duration of that LEVEL (UP TO 999 SEC). In TIMER MODE, MANUAL,the system remains in a LEVEL until MANUAL ADVANCEDby the operator. MANUAL ADVANCE (via the REMOTEPENDANTor panel front) with NEXT LEVEL key advancesthe SEQUENCE to the next programmed LEVEL, or, if already in the LAST LEVEL, advances to DOWNSLOPE (equivalent to pushing SEQUENCE STOP).

6. EVENT 6. DOWNSLOPE. At the end of the last programmed level, the weld current must be reduced graduallyin order to prevent a “crater crack” at the end of the weld. In DOWNSLOPE the

WELD CURRENT DOWNSLOPE - PULSATION

SEQSTOP

NEXTLEVEL

5.8


LAST LEVEL PRIMARY AMP value and the BACKGROUND AMP value (if pulsed) are gradually decreased towards zero until the arc is extinguished.

DOWNSLOPE time is programmable with typical values between 5 and 15 sec (about 5 sec. for a root pass). At the end of DOWNSLOPE when the current is less than 3 amperes, all other functions will stop.

TRAVEL STOP DELAY. (Not programmable). Travel will continue at the fullprogrammed value for about 2/3 of the programmed current downslope time.

WIRE STOP DELAY starts counting at the end of the last level and wire will continue to feed until this time is complete(when WIRE MODE is ON). If WIRE STOP DELAY ispositive, wire feed will stop at the number of seconds programmed following the end of the last level or after the initiation of SEQUENCE STOP. If WIRE STOP DELAY isnegative, wire feed will stop at the number of seconds programmed before the end of the last level or immediately after initiating SEQUENCE STOP. (For the Model 6 it adds tothe the last level time.) If WIRE MODE is turned OFFmanually, the wire will stop feeding.

AVC LOCK DELAY (OPTIONAL) The AVC will ceaseto operate in the time programmed in AVC LOCK DELAY after the start ofDOWNSLOPE.

OSCILLATOR AMPLITUDE DOWNSLOPE (OPTIONAL) (Not programmable). If OSCILLATOR MODE is ON, the oscillator amplitude will gradually decrease during DOWNSLOPE from the last level value.

POSTPURGE. When the arc is extinguished, gas will continue to flow to the torch for the time programmed in POSTPURGE. This time should be sufficient to prevent excessive discoloration of the weld due to oxidation.

RETURN TO HOME AND RESET. At the end of the timed POSTPURGE the weld heads which have RETURN TO HOME functions (Model 9, Model 95 and Model 79) will return to the “home” or open position for removal from the weldment. The Model 227 Power Supply will reset and be ready to make another weld.

Note: Pushing the ALL STOP panel key at any time during the WELD SEQUENCE will stop the arc and all other programmed functions except for POSTPURGE.

ALLSTOP

WIREON/OFF

5.9


Chapter 6. Tungsten Specifications

Tungsten Type - AWS color code

The use of tungsten electrodes is an essential component of the GTAW (TIG) process. Consistency of tungsten electrode properties such as type, length, diameter, tip configuration and grind is impor-tant for maintaining the repeatability and quality of orbital welds and these must be controlled for optimal weld performance. The GTAW process in which the electrode conducts current for the arc but

Table 1: Comparable Classification in ISO Standard 6848

AWSClassification

ISO Codification

Chemical Identification

EWP (green) WP (green) Pure Tungsten

EWCe-2 (orange) WC20 (gray) 2% Ceriated

EWLa-1 (black) WL 10 (black) 1% Lanthanated

EWLa-1.5 (gold) 1.5% Lanthanated

EWLa-2 (blue) 2% Lanthanated

EWTh-1 (yellow) WT 10 (yellow) 1% Thoriated

EWTh-2 (red) WT 20-(red) 2% Thoriated

EWZr-1 (brown) WZ3 (brown) 1% Zirconiated

EWG (gray) Unspecified alloy

Tungsten Color Code according to ANSI/AWS specificatiion A5.12/A5.12M.

6.1


• Common Tungsten Diameters

0.040” 1/16”0.020” tip

1/16”0.030” tip

3/32”0.040” tip

is not consumed by the heat of welding depends upon the high melting point of tungsten which

has the highest melting point of any metal, 6098o F (3370o C), compared to the melting point of

iron which is 2800o F (1538o C). Tungsten properties are improved by the addition of 2% thoria or ceria which improve the arc strike characteristics and arc stability. Pure tungsten is seldom used for GTAW because thoriated and ceriated tungstens have superior properties, especially for orbital GTAW applications. For tube welding applications, ceriated tungsten is always recommended, as this type maintains a sharper tip and exhibits substantially longer lifetime than other types and has excellent arc ignition characteristics. Ceriated tungsten is non-radioactive. Tungsten is sup-plied as rods to be cut and machined into electrodes. The unprocessed rods are color-coded as to type: green for pure tungsten, orange for 2% ceriated, red for 2% thoriated, etc. according to AWS Specification A5.12/A5.12M as shown in the figure on the previous page. The ISO Interna-tional Standard 6848 has a similar tungsten type identification system as shown in Table 1.

Importance of Tungsten Geometry

Electrodes with a ground finish are dimen-sionally more uniform. A smooth finish is always preferable to rough or inconsistent fin-ish, since consistency in electrode geometry is essential for consistent weld results. Elec-trons emitted from the tip (DCEN) transfer heat from the tungsten tip to the weld. A finer

tip permits the current density to be maintained at a very high level but may result in shorter tung-sten life. For orbital tube or pipe welding, it is important for the electrode tip to be machine ground to assure repeatability of the tungsten geometry and thus, the welds.

Tungsten Diameters and Tip DiametersTaper angle affects the current/voltage characteristics of the arc and must be specified and controlled. Arc Machines, Inc.

recommends an 18o included angle for the electrode tip for all tungsten diameters used in the orbital tube and pipe weld heads. The tip shape has a con-trolling effect on the shape of the arc and on the amount and depth of weld penetration. A blunt tip forces the arc to origi-nate at the same place on thetungsten from weld-to-weld

18o

length

Diam.

tip diam.

Common Tungsten Diameters

6.2


which helps with consistency.

The arc gap at a particular current value determines the voltage and thus the power applied to the weld. For fusion tube welding, the tungsten length is used to set the arc gap. The arc gap will remain constant as long as the tube is perfectly round. Pipe is never perfectly round and the arc gap must be controlled either with a mechanical device or with automatic arc voltage control (AVC) used to maintain a constant arc gap around the entire weld circumference. The AVC is dis-cussed in more detail in Section 8 of this manual.

Tungsten Diameters

Electrode diameters for fusion welding are based on wall thicknesses. Model 9 weld heads, except for the Model 9-250 and Model 9-500 which only accept .040” tungsten, accept two differ-ent tungsten diameters as shown in Table 2. For the Model 9AF-750, the Model 9-900, and the Model 9/AF-900 weld heads, 1/16” diameters are used for most applications. For the larger heads, the use of either 1/16” or 3/32” diameters is based on wall thickness. The use of 1/16” tungsten for wall thicknesses up to .093”, and 3/32” tungsten for heavier wall thicknesses is recommended.

Tip diameters

The tip diameters are specified for orbital fusion tube weldings as shown in Table 3. Tip diameters are typically based on wall thickness with a finer tip used for thinner-walled materials. Tungstens

Table 2: Model 9 Weld Head Tungsten Diamters

Weld Head Tungsten Diameters

9-500 .040 ------*

9AF-750 .040 .062 (1/16”)

9-900, 9/AF-900 .040 1/16”

9-1500 to 9-7500 1/16” 3/32”

Tube/Pipe Wall Thickness Tungsten Tip Diameter

.020”/.035” .020

.049”/.083” .030”

.091”/.154” .040” 0.040” Tip Diameter used with 3/32” Diameter Tungsten

Table 3. Tungsten Tip Diameters Based on Wall Thickness

6.3


of a particular diameter may be ground to the users’ tip diameter specifications.

Pipe Welding Electrode DimensionsIn pipe welding with weld heads having a ceramic gas cup, the amount of tungsten stick-out will vary with the situation. The stick-out should be as short as possible to provide the best gas cover-age, and minimal stick-out is possible on cap passes, or autogenous square butt preparations. However, when welding in a groove, additional tungsten stick-out may be needed to position the tungsten without interference by the gas cup.

Tungsten life: Tungsten life will vary with the application, quality of the gas, and cleanliness of the metal. Obviously, a great many more welds per tungsten are possible on 1/4 inch tube than on larger pipe. However, factors such as moisture or oxygen in the shielding gas can have a serious detrimental effect on tungsten life. The use of mixed gases* such as 95%Ar/5%H2 or 75%He/25%Ar, can also severely limit tungsten life. Similarly, oxidation or other surface contaminants on the metal can adversely affect tungsten wear. The rule of thumb is to change the tungsten if the weld quality deteriorates. For high-purity tube welds, tungsten is often changed after a set number of welds for that particular application.

*Note: The use of mixed gases is not recommended for some materials. Check welding references before using.

6.4


MODEL No. ROTOR O.D.

9-250 .802 IN.

9-500 1.388 IN.

9AF-750 2.000 IN.

9-900 2.000 IN.9/AF-900 1.875 IN.

9-1500 3.187 IN.9AF-1500 2.252 IN.9E-1500 2.687 IN.8-2000 3.452 IN9-2500 4.380 IN.

9AF-2500 3.156 IN.9E-2500 4.280 IN.

9-3500 5.380 IN.*9-3500 4.031 IN.9E-3500 5.310 IN.8-4000 5.310 IN9-4500 6.875 IN.*9-4500 4.920 IN.9E-4500 6.280 IN.

9ER-4500 5.776 IN.9-7500 10.044 IN.*9-7500 8.280 IN.

* For Heads using the optional tungsten extender (P/N - 130907 -XX).

MODEL 8 and 9 ELECTRODE DIMENSIONS

ROTOR DIAMETER

* NOTE: Maximum recommended Arc Gap for the 9-250 and the 9-500 is 0.045”.

In instances where out-of-roundness on thin walled tubing occurs (normally 2.500” O.D. or larger), a .070” Arc Gap is recommended.

TUBE/PIPEWALL THICKNESS

RECOMMENDEDARC GAP

.020”/.035” .030”

.049”/.085” .050”

.091”/.154” .070”

TUBE/PIPEWALL THICKNESS

RECOMMENDEDTIP DIAMETER

.020”/.035” .020”

.049”/.085” .030”

.091”/.154” .040”

ARC GAPARC GAP

ROTOR ODROTOR OD

TUBE ODTUBE OD

ROTOR O.D. - TUBE O.D. ROTOR O.D. - TUBE O.D. - ARC GAP =- ARC GAP =

22

TUNGSTENTUNGSTEN LENGTH LENGTH

TUNGSTENTUNGSTEN LENGTH LENGTH± .003”± .003”

6.5


Chapter 7. Shielding and Back-Up Gases

Argon and Gas Mixtures

Metals have a tendency to oxidize in air. This tendency is accelerated when heated to welding temperatures. Moisture, and even nitrogen, which forms the largest component of the atmo-sphere, may have detrimental effects. An inert gas used to shield the molten weld puddle and adjacent areas from these effects is an essential component of the GTAW process. For orbital fusion welding in enclosed weld heads, the head forms a chamber of inert gas providing protec-tion of the entire OD weld joint. A back-up gas, used to purge the ID of the weld joint is typically recommended for orbital welding applications.

Gas type. The type of gas used as a shielding gas has a profound effect on the character of the arc and the amount and depth of penetration. Argon is the most commonly used shielding gas for orbital GTAW processes, but mixtures of helium and argon (75% helium/ 25% argon), as well as argon and hydrogen (95% argon/ 5% hydrogen), may be used for particular applications. Both gas mixtures provide a hotter arc than argon and deeper penetration at the same current settings. The helium/ argon mixture is the preferred gas for weld-ing carbon steel. The argon/hydrogen mixture produces a cleaner-appearing weld at similar levels of oxygen contamination than pure argon, with a smoother weld bead and is used for some high-purity applications on stainless steel. The weld bead is typically narrower, but may not be nar-rower on very low-sulfur materials. However, the arc is less stable with a tendency towards arc wander, and tungsten life is severely affected. Since the addition of hydrogen affects penetration, precise control of the gas mixture is essential to maintain the consistency of the weld, especially for thin-walled materials. Hydrogen is deleterious to the properties of some metals. It may cause hydrogen induced cracking, porosity, etc. Check material specifications for recommended shield gases for various alloys.

Flow rates. It is important to control the flow rates of the purge gases, both to the torch and to the ID of the weld joint. Insufficient flow can result in a poor purge and discoloration of the weld and heat-affected-zone (HAZ). Excessive flow to the weld OD can disturb the arc, causing arc-out or arc-wander, while excessive flow to the ID may cause pressurization resulting in ID concavity (“suck-back”) or a blow-out. For fusion tube welding, follow the recommendations for individual Model 9 weld heads.

Argon dewar in-use for purging welds on pharma-ceutical piping. Photo courtesy of Immunex.

7.1


Purity requirements. Orbital welding equipment does not require gas of higher purity than man-ual welding equipment, but typically, if the application requires the quality provided by orbital welding, the purging requirements are more stringent because of the nature of the application. Purge gas purity specifications are usually more relaxed for pipe welding applications than for tube welding applications, but there has been an increase in the use of pipe welding in high-purity applications. In general, argon gas of 99.99% purity is considered adequate. For high-purity appli-cations, the specified range of impurities ranges from the low parts-per-million levels (ppm) to the low parts-per-billion (ppb) range. Discoloration, or heat tint, resulting from oxygen in the purge gas forms in colors ranging from a pale straw color to dark brown, or dark brown and black (sug-ared), and from a pale grey or bluish haze to a deep intense blue, with the deeper colors indicative of higher oxygen concentrations. A number of papers have appeared in the welding literature showing a direct relationship between oxygen levels in the purge gas, heat tint, and loss of corro-sion resistance of stainless steel and duplex materials after welding. Welds on reactive materials, such as titanium, also show severe detrimental effects resulting from oxidation and benefits from improved purity of the purge gas and effective shielding.

Purging techniques. Purging techniques involve maintaining the purity of the purge gas to the point of use, i.e., the OD and ID of the weld puddle and HAZ. This requires air-tight hoses and connectors. Welded stainless steel tubing would be an obvious choice, but it is not very practical and is typically used only in very-high-purity applications. All types of plastic tubing are perme-able to atmosphere to some degree. The Polyflow® tubing supplied with the Arc Machines equip-ment is very good. Specifications for the various types of plastic tubing listing permeability to oxygen and moisture can be obtained from the plastic tubing manufacturers. The use of rubber or similar type purge hoses is not consistent with high-quality welding. Some type of diffuser may be used to disperse the argon flow to assure that the entire weld joint is covered. A gas lens in the torch diffuses the flow to the weld OD. A diffuser at the connection of the gas hose to end cap can

Basic ID purge set-up for large pipe. Gas supply (cylinder or other source), regulator and flowmeters, gas hoses and purge plugs with airtight connections. Shown with optional oxygen analyzer.

AR

GO

N

10” PIPE

O2

Anal.

ID PURGE SET- UP FOR 10” PIPE

WELDJOINT

PIPESTANDPIPE PURGE

EXIT

7.2


7.3

be used to disperse the argon stream entering the pipe ID. (See drawing on page 7.3.). Analyti-cal equipment such as oxygen and moisture analyzers can be used to verify that purge gas exiting the ID of the tube or pipe being welded has approximately the same level of purity as the source gas. If it does not, the location of the leak(s) must be found. Adequate prepurge and postpurge times for the application must be allowed for. Heat tint is formed when elements and compounds in the base metal diffuse or vaporize from the base metal in the heat of welding, form oxides, and are deposited on the surface of the weld and HAZ. A high ID purge flow rate may remove this material from the weld area before it is deposited. Sometimes deposits, particularly of manganese which vaporizes at lower temperatures than the other elements, are seen on the downstream side of the weld only. Caution must be excercised to avoid overpressurizing the weld. If a high flow rate is used, a larger exit orifice for the purge gas is required to prevent ID concavity or a blow-out.

Welding should be done with good ventilation to avoid breathing harmful materials that may be produced during welding. For weld development it is good to have a transparent end cap in order to view the progress of the weld, especially the weld root. Transparent plastic material, such as Lexan® or plexiglass, that can take some heat and can be cut to a round shape and held in place with tape is practical. Gas hose connections to the purge plugs must be air-tight.

A diffuser, which acts similarly to a shower head on a stream of water, may be used to break up the flow of argon to the weld ID to assure complete gas coverage. Sintered materials are sometimes used for this purpose.

Diffuser


Recommended Gas Flow Rates for Model 9 Weld Heads

Use the following chart to determine the flow rate and minimum purge time required for the weld head being used, and record these values on the weld schedule sheet.

Table 3: GAS PRE-PURGE/POST PURGE

Weld Head Flow RateMinimum Purge Time (sec.) for

preliminary weld schedule

CFH (liters/min.)

9-250 7 - 10 (1.9 - 4.7) ---------------------------------- 20

9-500 8 - 12 (1.9 - 5.6) ---------------------------------- 20

9AF-750 10 - 14 (4.7 - 6.6) ---------------------------------- 20

9/AF-900 12 - 15 (5.6 - 7.0) ---------------------------------- 20

9-1500 15 - 25 (7.0 - 11.8) ---------------------------------- 20

9AF-1500 15 - 25 (7.0 - 11.8) ---------------------------------- 20

9-2500 25 - 30 (11.8 - 14.1) ---------------------------------- 30

9-3500 25 - 30 (11.8 - 14.1) ---------------------------------- 30

9-4500 30 - 40 (14.1 - 18.8) ---------------------------------- 60

9-7500 30 - 40 (14.1 - 18.8) ---------------------------------- 60

8-4000 15 - 25 (7.0 - 11.8) ---------------------------------- 30

‘E’ TYPE WELD HEADS

9E-1500 25 - 35 (11.8 - 16.5) ---------------------------------- 30

9E-2500 25 - 40 (11.8 - 18.8) ---------------------------------- 30

9E-3500 30 - 40 (14.1 - 21.2) ---------------------------------- 30

9E-4500 35 - 50 (16.5 - 23.5) ---------------------------------- 60

9E-7500 40 - 60 (18.8 - 28.2) ---------------------------------- 60

Note: The same gas flow rates apply to both standard and AF type weld heads of the same size, while flow must be increased for the E type heads. (1 CFH = 0.47 liter/min.)

7.4


Introduction

One of the most important functions in an AMI welding system is the AVC. Unfortunately, it is also the most misunderstood and misused function as well.

The sole purpose of an AVC is to control the GAP between the electrode and the metal being welded. In order to have an existing weld procedure REPEAT from weld to weld, this distance must always be the SAME.

If a “practical” ARC GAP CONTROLLER could be devised then that is what this function would be called. However, the only “practical” method discovered up to now is to measure the ARC VOLTAGE, which is proportional to arc length, and use it as a “REFERENCE”. Unfortunately, this reference can be affected by many things and proper operation requires both operators (welders) and procedure developers to be aware of these things and to be ALLOWED to correct for these effects.

BASIC ARC VOLTAGE CONTROL

In principle, the operation of an Arc Voltage Controller is simple. Arc Voltage changes with the Arc Gap (more gap, more voltage). After the welding arc is struck it will tell the system to maintain a certain voltage. The system senses this voltage and in conjunction with an AVC motor (attached to the torch) moves the torch up or down (changing the arc gap ) until it finds the “certain voltage” asked for.

The problem is that 10 volts may be an arc gap of 0.125” today and it could be 0.156” tomorrow (or even this afternoon) or it could still be 0.125”. This deviation is caused by many factors that cannot be controlled by the system. AN OPERATOR MUST BE AWARE OF THIS AND BE PREPARED AND ALLOWED TO CHANGE THE AVC TO RETURN THE ARC GAP TO WHAT IS WAS WHEN THE PROCEDURE WAS DEVELOPED.

Chapter 8. Nature of an Arc Voltage Controller (AVC) by Gregory P. Erickson, V.P. Engineering, Arc Machines, Inc. September, 1992

8.1


REMEMBER that the width and depth of penetration must be the same each time for a weld to repeat and the width and depth of penetration are primarily controlled by:

ELECTRODE SHAPE

CURRENT VALUE

ARC GAPThe first two items also affect the arc gap as well, so they are intertwined with each other.

THE PHYSICS OF ARC VOLTAGE AND ARC GAP

There are over 120 different technical things that could cause the arc gap to change for a given Arc Voltage. However, the following list includes some of the most common reasons.

Change of currentChange the current with the same AVC setting and the ARC GAP will change.

Change of electrode shapeChange the electrode shape with the same AVC setting and the ARC GAP will change.The width and depth of penetration will also change.

Change of electrode conditionElectrode contamination and wear can cause ARC GAP changes for the same voltage.

Change in electrical contact (resistance)

Change of gas typeChanging gas type (helium for argon, etc.) with the same AVC setting or a change of gas quality (moisture, other gases, etc.) will change the ARC GAP.

Gas disturbancesChange in gas flow rate to the torch, or wind in the welding environment will change theARC GAP.

Change of barometric pressure and dew pointRapid and large changes can cause ARC GAP changes for the same voltage.

Electrodes are changed all the time and quality, shape and electrical contact will vary. Gas is changed all the time and the quality is variable. Operators tend to make slight current changes without making the appropriate change to the AVC.

Nature of an Arc Voltage Controller (continued)

8.2


MAINTAINING ARC GAP

How does an operator know when the arc gap is correct? How much change will need to be made in the AVC setting? These are very common questions with NO COMMON ANSWER. It must be based on the application.

A common method of measuring the arc gap (while welding ) is to preset the Filler Wire to the electrode distance (and insure that it will not change) and use the point of wire entry into the puddle as a gauge. Too big a gap and the wire will be burning off in the arc (not puddle), too small a gap and the wire will be hitting in front of the puddle

The arc voltage can then be adjusted for proper wire entry. This method works well, BUT YOU MUST KNOW THE WIRE ENTRY IS CORRECT.

Nature of an Arc Voltage Controller (continued)

8.3


Chapter 9. Pipe End Preparation for Orbital Welding

Pipe end-preparation requirements for orbital welding applications are considerably more critical than for manual pipe end-preparations. Preparation of the pipe is a key to the success of automatic orbital welding procedures. Since welding equipment does not sense or react to changes in the preparation, the preparation and fit-up must be precise in order to realize the repeatability and consistency expected of orbital welding. The use of machining tools designed for precision end-preparation is strongly recommended. It should be understood that weld programs are very prep-sensitive which means that even small changes in prep geometry can have major effects on weld quality.

Modified “J” Prep

The preferred end-preparation for orbital pipe welds with wall thicknesses greater than about 0.154 inches is the “modified J” preparation. In most cases with carbon steel, alloy 316 SS, 304 SS and similar materials the best results with this type of preparation are obtained when the dimensions fall within the ranges shown in the sketch at left for wall thicknesses up to 0.500 inch.

The key feature of this design is to make sure that Dimension”B” (land extension) is nearly equal to Dimension “A” (land thickness).

Radius “R” is smaller for thinner-wall pipes and larger for heavy-wall pipes. The first root pass can be done fusion-only (often, STEP weld technique is beneficial). but adding a little filler wire is, usually, a preferred method. The filler wire amount (during the first pass with filler wire) must be such that the sidewalls of the joint are not touched.

Bevel. The bevel should be between 20-30° depending on the radius. For heavier wall thicknesses, a compound J-preparation with a 20-37.5° inner bevel and a 7-15° outer bevel may be used. It should be clearly understood that the exact joint configuration must be established by each user to

End-preparation for copper-nickel pipe for offshore firewater system. Photo courtesy of Harmony Construction.

9.1


suit the particular conditions and requirements of the specific application. The angle of the bevel should be based on access and ease of welding versus the amount of fill which will determine weld time. The greater the angle, the easier it is to weld, but the more filler and time will be needed to complete the weld.

Radius. Whether or not a radius cut between the bevel and the land is needed is determined by the type and size of the root desired. If the root bead width can be kept on the land area and the root bead is kept flat, then a radius is not needed. If the root bead has filler or is convex in shape, then a radius should be used to allow the material to flow smoothly into the bevel. If there is a crease between the root and the bevel, it will be difficult to assure penetration on the first fill pass. The radius should usually be equal to 1/2 of the land thickness

Land. The land should be thick enough to prevent repenetration on the first fill pass, but thin enough to allow control of the least amount of metal during the root pass.

Tacks. Tack welds should be without filler, partial-penetration, using the TIG process and inert gas shielding of the I.D. of the joint.

(Note: Using a “V” type joint will almost always result in bad root welds. The reason is that, when the point of the “V” melts, it forms a concave meniscus. The surface tension of the molten metal then pulls the puddle up, into the “V”, and creates “suckback” or a concave back bead. Anyone who paid attention in science classes in school can easily figure this out).

Square butt weld

The orbital welding of pipe with wall thicknesses of 0.154” and less can be done as fusion butt welds with the pipe prepped with a square butt end-preparation. Orbital welds of pipe sizes up to 10 or 12 inch shedule 10 can be done as fusion butt welds in a single pass with the Model 15 weld head. A cap pass with wire may be done if a crown on the

Use of insert rings with square butt end preparation

9.2


Fusion

Modified “J” Pipe end preparations for heavy wall thicknessesfiller wire required:

Use of insert rings with square butt end preparations, continued:

Heavy-wall with filler

9.3


weld O.D. is desired. A slight bevel may be used if wire is to be added to the weld.

Insert Rings. Insert rings of various types, with or without the addition of filler material, may be used to provide a smooth root, or for the addition of desirable alloying materials to the weld metal. If an EB insert is used, the land extension must be enough to allow the bulb on the insert to sit under . the land and not extend under the bevel area, otherwise penetration control is difficult. If a washer type of insert such as a K-Ring is used, then the length of the land can be reduced. This will reduce the width of the preparation preventing repenetration on the first fill pass and also reduce the amount of filler required. (See drawings on previous page.)

Prep Tolerances

There are five basic areas of the preparation and fit-up that must be controlled:

• The land thickness variations should not exceed 5% of the nominal land specified.

• The high/low alignment of the lands of the two pipes to be welded should not exceed 5%of the land.

• The square cut ends should be precise enough so that when butted together any gap betweenportions of the land face does not exceed 5% of the land thickness.

• The angle of the bevel should not deviate around the weld or from weld to weld more than 2 degrees.

• To assure uniform thickness of the land and eliminate high/low fit-up, an I.D. cut should bemade first to assure a constant diameter. Caution and practicality should be taken in this

area due to minimum wall requirements of the piping system.

9.4


Cleaning

The cleanliness of the weld prep, particularly the area of the weld joint within an inch or two of the ends to be joined, has a marked effect on weld quality. Dirt, grease, rust and other contami-nants must be removed prior to welding. Failure to clean the joint area may result in porosity, excessive slag, discoloration, and cracking or other structural weakness. On heavily oxidized pipe, the oxide layer should be removed by grinding to get down to bare metal.

High-purity applications require more stringent cleaning procedures. The use of fluorinated hydrocarbons and other organic solvents potentially harmful to the environment has been replaced by deionized water and for some applications, a solution of isopropyl alcohol. Users should become aware of approved cleaning procedures for their particular industry.

9.5


Chapter 10. Programming the Model 227 Power Supply

Programming Functions

The Model 227 Power Supply has sufficient memory to store up to 99 weld pro-grams. However, users may elect to create their own weld programs “from scratch” or to modify an existing weld schedule to suit the needs of a particular application. A weld schedule or program consists of values for weld parameters which are controlled by the power supply such as welding currents, level times, travel speed (RPM), wire feed and oscillator functions, etc. Other factors which affect the weld but are not con-trolled by the power supply such as tungsten type and geometry, gas type and flow rates, are covered in Section 6, Tungsten Specifications and Section 7, Shielding and Back-Up Gases. The purpose of this section is to explain the basic programming functions and to illustrate by example the process of entering a new weld schedule into the Model 227 library. The proce-dures for modification of an existing weld program, and COPYING, DELETING and TRANSFERRING a program will also be covered.

A sample weld schedule for welding 8 inch stainless steel schedule 10 pipe with a wall of 0.154 inches is shown as an example. The Weld Schedule consists of two passes. The first pass is a fusion pass with no filler wire done as a stringer bead with the current pulse synchro-nized with the travel (travel mode STEP). The second pass is a weave bead with the oscilla-tor function ON and the current pulse synchronized with the oscillation. This

PRO

10.1

AMI Model 227 Operator Training Guidelines

Programming, continued:

��

��

��

��

��

��

��

��

��

�� ARC MACHINES, INC.

AMIWELD 227 STD 1.4 COPYRIGHT 199527 JUNE 97 10:21:41

# OD WALL MAT POS HEAD PASS 050 8.625 .154 SS 5G 15 1

PRE-PURGE-POST UP-SLOPE-DOWN ROT--DLY 5 10 2.0 10.0 CCW 2.5STR-WFDLY-STP RETRACT T/MODE OSC MODE 2.0 +0.0 0.3 MAN OFFSTR-AVCLDY-STP STR/MODE RESPONSE

2.0 0.0 RF 1

LVL PULSE ROT PRI--IPM--BCK

1 ON STEP 0.0 4.5 TIME PRI--AMP--BCK PRI-PULSE-BCK

1 MAN 90 35 0.80 1.2 PRI-WF-BCK PRI--AVC--BCK AVC MODE

1 0 0 11.0 SAMP/PRI OSC/AMPL IN EXC OUT

1

ARC MACHINES, INC.AMIWELD 227 STD. 1.4 COPYRIGHT 1995

27 JUNE 97 10:22:50

# OD WALL MAT POS HEAD PASS050 8.626 SS 5G 15 2

PRE-PURGE-POST UP-SLOPE-DOWN ROT--DLY

5 10 2.0 10.0 CCW 2.5STR-WFDLY-STP RETRACT T/MODE OSC MODE 2.0 +0.0 0.3 MAN ONSTR-AVCDLY-STP STR/MODE RESPONSE 2.0 0.0 RF 1

LVL PULSE ROT PRI--IPM--BCK 1 SYNC CONT 4.5

TIME PRI--AMP--BCK PRI-PULSE-BCK

1 MAN 85 70 PRI-WF-BCK PRI--AVC--BCK AVC MODE

1 40 40 10.0 9.5 CONT 1 OSC/AMPL IN EXC OUT1 .200 0.25 0.35 0.25

PASS 2

Sample Model 227 Weld Program

PASS 1

10.2


technique provides ample heat at the sidewalls by having PRIMARY AMPS on during the IN-DWELL and OUTDWELL, and less heat at the weld centerline by having BACKGROUND AMPS on during the EXCURSION.

Let’s assume that you have been given the above weld program and want to enter it into the Model 227 Power Supply LIBRARY. This is a programming function. To access Programming Mode, press the C key to reach the Status Screen, make sure the OPERATE mode switch is in the PROGRAM position. The top Status Screen reads as follows:

Press PRO. The following screens will appear on the display:

Chose CREATE from the programming menu by pressing the F key directly beneath CREATE.

You must enter a number between 1 and 100 in order to continue. The number chosen must be one that is not already listed in the power supply library. Print the LIBRARY to find an avail-able number, or from the STATUS SCREEN, press LIB and use the NEXT SCREEN key to scroll through the library. Enter the number from the keyboard and press ENTER. If the num-ber chosen is already in use, you will receive an INVALID NUMBER message. If this happens, press the CE key on the keyboard and try again.

CREATE MODIFY COPY DELETE TRANSFER

*** *** **** **** ****

USE F KEYS TO SELECT PROGRAMMING MODEOR USE C KEY TO RETURN TO STATUS SCREEN

TO WELD PRESS LIB TO PROGRAM PRESS PROSYS HOURS - 00059.7 ARC HOURS 00000.5

Entering a New Weld Program: CREATE

PRO

ENTER NEW WELD # -- THEN PRESS ENTER KEY

PRESS THE C KEY TO CANCEL WELD PROGRAMMING

#

0.00

TOP

BOTTOM

T O P

BOTTOM

10.3


# 50 was selected for the weld number. The following screens appear:

The numbers under OD will be blinking. Enter the OD for the pipe size you wish to weld and press ENTER. At this time, the numbers under WALL will start to blink. You must enter the information for the blinking parameter before going on to the next. If you make a mistake and have not yet pushed ENTER, you can correct it by pressing CE. If you have already pressed ENTER for that parameter, continue to enter the numbers until you have finished the Level. At that time you can return to the screen with the error by using the PREVIOUS SCREEN key.

When the OD and WALL have been entered, the following screens will appear:

Select SS (stainless steel) from the above menu by using the F key. Other menu options include carbon steel (CS), monel (MNL), titanium (TI), hastelloy (HAS), inconel (INC), vac-uum arc remelt (VAR), and special (SP). SP can be used for other weldable materials or for special programs such as those used for calibration of the weld heads.

CREATE, continued

TOP

BOTTOM

ENTER WELD OD -- THEN PRESS THE ENTER KEYPRESS THE C KEY TO CANCEL PROGRAMMING MODE

# OD WALL MAT POS HEAD PASS

50 0.000 .000 *** *** *** 1

PREVSCREEN

BOTTOM # OD WALL MAT POS HEAD PASS

50 8.625 0.154 *** *** *** 1

BOTTOM

TOPUSE F KEYS TO SELECT MATERIAL TYPE

PRESS ENTER AFTER SELECTION

SS CS MNL TI HAS INC VAR SP

*** *** *** *** **** *** *** ***

10.4


The following screens provide for a choice of welding position. For this weld schedule the 5G (pipe horizontal) position is selected. Use the F key under 5G and press ENTER.

Other choices include 1G (downhand, pipe rotated), 2G (pipe vertical), 3G (plate weld, verti-

cal), 4G, (overhead position on plate) and 6G (pipe stationary at a 45o angle).

The next selection is the choice of weld heads. The weld head shown in the Sample Program is the Model 15. Select the number of the weld head by pressing the F key under the weld head number and ENTER.

TOP

When the weld head number has been entered, the following set of screens appear:

TOP

USE F KEYS TO SELECT WELD POSITION

PRESS ENTER AFTER EACH SELECTION

1G 2G 3G 4G 5G 6G*** *** *** *** *** ***

CREATE, continued:

6 7 9 15 43 45 81 82

*** *** *** *** *** *** *** ***

THEN PRESS ENTER KEY

USE F KEYS TO SELECT HEAD TYPE

ENTER VALUE FOR BLINKING ITEMTHEN PRESS ENTER KEY

PRE-PURGE-POST UP-SLOPE-DOWN ROT--DLY 0 0 0.0 0.0 CW 0.0

*** *** *** *** *** ***

Second WeldHeadScreen

87 89 95 96 97 MAN

BOTTOM

BOTTOM

TOP

BOTTOM

10.5


Enter each item beginning with pre-purge. As each entry is completed the next item will start to blink. Do not skip an item. After entering the values on the previous screen, the bottom screen should appear as shown.

The PREPURGE and POST PURGE times specify the time that the gas will flow from the weld torch before the arc is initiated and after it is extinguished. UPSLOPE indicates the time from arc start until full Level 1 Amps is reached, DOWNSLOPE is the time it takes to reduce the last level current to the point where the arc is extinguished. The direction of rotation is either clockwise (CW) or counterclockwise (CCW). Travel or rotation delay (DLY ) is the time specified for the torch to remain stationary after arc initiation. The next set of screens appears as follows:

After entering the values from the sample weld program, the bottom screen should appear as follows:

A wire feed start delay of 2.0 seconds means that wire will start to feed at the end of the 2.0 second UPSLOPE. A RETRACT value of 0.3 specifies the amount of time required to retract the wire from the puddle after the initiation of DOWNSLOPE by any one of several possible ways. Timer mode is manual (MAN) which means the level is not timed, but ends when the operator presses NEXT LEVEL or SEQUENCE STOP. Oscillator mode OFF is selected because the root pass for this program is a stringer bead.

BOTTOM PRE-PURGE-POST UP-SLOPE-DOWN ROT--DLY 5 1 0 2.0 10.0 CCW 2.5

CREATE, continued:

ENTER VALUES FOR BLINKING ITEM


STR--WFDLY--STP RETRACT T/MODE OSC MODE 0.0 +0.0 0.0 AUTO ON

STR--WFDLY--STP RETRACT T/MODE OSC MODE 2.0 +0.0 0.3 MAN OFF

TOP

SEQSTOP

BOTTOM

BOTTOM

10.6


The next set of screens appears as follows:

Enter the values from the sample program as shown:

The AVC start delay for this program is timed so that the AVC becomes functional at the end of UPSLOPE. The START MODE is RF (radio frequency). The choices for START MODE are RF (automatic) and TOUCH in which the tungsten touches the work to initiate the arc. The RESPONSE is a relative indication of the AVC sensitivity and varies with the weld head being used. After these entries have been made, the top screen remains the same while the next parameters are as shown:

The choices for PULSE are ON, OFF, and SYNC. Select the appropriate mode by using the F key under each selection. For this pass, ON is chosen. The choices for rotation (ROT) are CONT, STEP, and OFF. For this program, STEP is selected for the root pass. STEP allows the programming of different RPM (IPM) values during PRIMARY and BACKGROUND current pulses. On this pass, the PRIMARY IPM is zero (no travel) while the IPM is 4.5.

The next values to be entered are as shown:

ENTER VALUES FOR BLINKING ITEM


STR--AVCDLY--STP STR/MODE RESPONSE 0.0 0.0 RF 0

CREATE, continued:

STR--AVCDLY--STP STR/MODE RESPONSE 2.0 0.0 RF 1

TOP

BOTTOM

BOTTOM

BOTTOMLVL PULSE ROT PRI-IPM-BCK 1 ON STEP 0.0 4.5

BOTTOMLVL - TIME PRI--AMP--BCK PRI-PULSE-BCK 1 MAN 0 0 0.00 0.00

10.7


Since T/MODE manual was selected, no time is entered for Level 1. When PRI is blinking, enter the PRIMARY AMPS, which for this pass is 90 Amps. Then enter the background Amps which is 35 for this pass. When the amperage values have been entered from the keyboard, followed by the ENTER key for each value, repeat the process for the pulse times which are 0.80 for the primary pulse and 1.2 seconds for the background pulse time. Since STEP was selected for the travel mode, there will be no travel during the primary pulse time with the pri-mary amps set at 90, and a travel speed of 4.5 IPM during the background pulse time when the amps are set at 35. This technique provides a well-penetrated, well controlled weld bead when the parameters are set correctly for the material.

The next screen to be entered :

AVC MODE Sample-Primary (SA-P) was selected. This means that the AVC is functioning only during the Primary Pulse time. A Primary AVC of 11 is shown on the Sample Program, but keep in mind that this a relative value and may require changing from day to day (see Sec-tion VIII of this manual).

Since the Oscillator mode is OFF, and Pulse mode is ON (not SYNC) no oscil-lator screen is available for programming for this pass. The first pass is now complete. To store the schedule for the first pass in the power supply Library, press PRO. The OVERRIDE screen will appear with overrides for all weld parameters set for 100%. The overrides give the percent that the welding oper-ator may change a weld parameter from the power supply control panel. The values range from 0 (no change) to 100% and may be changed by pressing the F key under the item followed by ENTER. When the overrides have been set, press PRO a second time.

LVL - TIME PRI--AMP--BCK PRI-PULSE-BCK 1 MAN 90 35 0.80 1.2 BOTTOM

CREATE, continued:

LVL PRI--WF--BCK PRI-AVC-BCK AVC MODE 1 0 0 0.0 0.0 CONT

BOTTOM

LVL PRI--WF--BCK PRI-AVC-BCK AVC MODE 1 0 0 11 0.0 SA-P

BOTTOM

PRO

10.8


The first pass of the Sample Weld Program has now been stored in the Library. Press C to return to the Status Screen. Pressing LIB and entering the program number (50 for the Sample Weld Program) will call up the program for welding.

Modifying a Weld ProgramThere are basically two ways that you can modify a 227 weld schedule. In Welding Mode you can locate the parameter or item to be changed by using NEXT and PREVIOUS SCREEN keys, and NEXT and PREVIOUS LEVEL keys. Use the F keys to select the item and enter the number from the keyboard. Press ENTER after each change has been made. In welding mode, the change will not be stored unless the Mode Select Switch is in the Program Position and a weld is made. After the weld, a screen will appear that asks if you wish to store the changes. To store the changes, press the F key under YES and then ENTER. If YES is not entered, or if the C key is pressed or the power supply is turned off before storing the program, any changes will be lost and the program will revert to its original (unmodified) state.

F KEYS SELECT ITEM - NEXT/PREV FIND ITEM

PRESS PRO KEY WHEN FINISHED

TOP

TIME AMP IMP WF AVC PLS DLY OSC

100 100 100 100 100 100 100 100

Programming, continued: MODIFY

BOTTOM

USE F KEYS TO SELECT OPTIONS

PRESSING C KEY WILL CANCEL ALL CHANGES

STORE MODIFY *** ***

PRO

REVISE MEMORY TO INCLUDE CHANGES?

YES NO

TOP

BOTTOM

10.9


To make a permanent change in a weld program without making a weld, or to add or delete a level or a pass, you must use the MODIFY program function. From the Status Screen, press-ing Pro will call up the Programming Screen:

Select MODIFY by pressing the F key and pressing ENTER. Enter the Sample Program num-ber (or other program number that you wish to modify). The first line of the program as it appears from the Library will appear.

Use the NEXT SCREEN or PREVIOUS SCREEN keys to locate the parameter to be changed. As an example let’s assume you wish to change the Level 1 PRIMARY AMPS from 90 to 95. Advancing the NEXT SCREEN key will locate the screen with the welding currents:

Press the F key under PRI until the number (90) blinks. Enter the value (95 for this pass) from the keyboard and press ENTER. To store the change, press the PRO key twice, and then choose STORE. Use the C key to return to the Library, call up the Program number to verify that the desired change has been made correctly.

CREATE MODIFY COPY DELETE TRANSFER *** *** *** *** ***

MODIFY, continued:

# OD WALL MAT POS HEAD PASS

50 8.625 .154 SS 5G 15 1

LVL - TIME PRI--AMP--BCK PRI-PULSE-BCK 1 MAN 90 35 0.80 1.2

LVL - TIME PRI--AMP--BCK PRI-PULSE-BCK 1 MAN 95 35 0.80 1.2

10.10


To add another Level or PassYou must be in Programming Mode (CREATE or MODIFY) to add or delete a Level or Pass. To add a second pass to the Sample Program press NEXT PASS. Press NEXT PASS again.

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AMIWELD 227 STD 1.4 COPYRIGHT 199527 JUNE 97 10:21:41

# OD WALL MAT POS HEAD PASS 050 8.625 .154 SS 5G 15 1

PRE-PURGE-POST UP-SLOPE-DOWN ROT--DLY 5 10 2.0 10.0 CCW 2.5STR-WFDLY-STP RETRACT T/MODE OSC MODE 2.0 +0.0 0.3 MAN OFFSTR-AVCLDY-STP STR/MODE RESPONSE

2.0 0.0 RF 1

LVL PULSE ROT PRI--IPM--BCK 1 ON STEP 0.0 4.5 TIME PRI--AMP--BCK PRI-PULSE-BCK

1 MAN 90 35 0.80 1.2 PRI-WF-BCK PRI--AVC--BCK AVC MODE 1 0 0 11.0 SAMP/PRI OSC/AMPL IN EXC OUT

1

ARC MACHINES, INC.AMIWELD 227 STD. 1.4 COPYRIGHT 1995

27 JUNE 97 10:22:50

# OD WALL MAT POS HEAD PASS050 8.626 SS 5G 15 2

PRE-PURGE-POST UP-SLOPE-DOWN ROT--DLY 5 10 2.0 10.0 CCW 2.5STR-WFDLY-STP RETRACT T/MODE OSC MODE

2.0 +0.0 0.3 MAN ONSTR-AVCDLY-STP STR/MODE RESPONSE 2.0 0.0 RF 1

LVL PULSE ROT PRI--IPM--BCK 1 SYNC CONT 4.5

TIME PRI--AMP--BCK PRI-PULSE-BCK

1 MAN 85 70 PRI-WF-BCK PRI--AVC--BCK AVC MODE

1 40 40 10.0 9.5 CONT 1 OSC/AMPL IN EXC OUT1 .200 0.25 0.35 0.25

PASS 1

PASS 2

10.11


When the NEXT PASS key is pressed these screens appear: Press NEXT PASS again.

When the top line of the program including the schedule number and PASS 2 appear, you can change the parameters by locating the item with the NEXT/ PREV LEVEL and NEXT/ PREV SCREEN keys. PASS 2 will be identical to PASS 1 at this point. You must scroll through the pro-gram and make the necessary changes. The circled items on the Sample Program on the previous page indicate changes to be made from PASS 1 to PASS 2. Using the NEXT SCREEN key, locate the item to be changed:

Use the F key under OSC MODE to change the selection from OFF to ON and press ENTER.

Advance to the next screen which requires changes:

Change the pulse to SYNC, the rotation to CONT and the Primary IMP to 4.5 using the F keys. Press ENTER after each change. There is no Background IPM when ROT is CONT.

MODIFY, continued:

NEXTPASS

TO CREATE ANOTHER PASS PRESS NEXT PASS

PRESS PRO KEY IF COMPLETE

TO MAKE CORRECTIONS USE PREVIOUS SCREEN KEY

TOP

BOTTOM

STR--WFDLY--STP RETRACT T/MODE OSC MODE 2.0 +0.0 0.3 MAN OFF

STR--WFDLY--STP RETRACT T/MODE OSC MODE 2.0 +0.0 0.3 MAN ON

PASS 1

PASS 2

LV L P U L S E R O T P R I-IP M -B C K 1 O N S T E P 0 .0 4 .5

LV L P U L S E R O T P R I-IP M -B C K 1 S Y N C C O N T 4 .5

PASS 1

PASS 2

10.12


Since Oscillator Mode ON was selected for this pass, the oscillator amplitude (OSC/AMPL) and Excursion and Dwell times must be entered. Enter each value shown on the Sample Program using the keyboard and pressing ENTER after each entry.

This completes PASS 2 of the Sample Program. To store the changes, press PRO, set the Over-rides, if required, push PRO again and press the F key under STORE as shown for PASS 1.If you wish to add another pass or level use the NEXT LEVEL or NEXT PASS key BEFORE PRESSING THE PRO KEY. If the program has already been stored in memory, from the status screen press PRO. Choose MODIFY from the Program Menu, enter the program number and press the NEXT LEVEL or NEXT PASS key. Another level or pass identical to the previous level or pass will be added to the program. Make the necessary changes as shown above and press the PRO key two times followed by choosing STORE from the screen.

Other Programming Functions

COPY

The COPY feature of the Model 227 is useful for creating a program similar to an existing pro-gram without affecting the original program. To access the COPY feature, make sure the OPER-ATE MODE SWITCH is in the PROGRAM position, press PRO from the Status Screen to call up the programming menu, and press the F key under COPY. Enter the program number you wish to copy and press ENTER. Changes in the copy can now be made using the MODIFY feature as described above, or the new program can be called up from the Library and modified in weld mode. Changes may be stored after welding as described on page 10.9.

1 .200 .25 0.35 0.25

1 OSC/AMPL IN EXC OUTPASS 2

MODIFY/COPY

NEXTLEVEL

NEXTPASS


10.13


DELETE a Weld Program:

To delete a program from the Library, with the OPERATE MODE SWITCH in the PROGRAM position, press the PRO key from the status screen to access the Programming Menu. Select DELETE by pressing the F key under the word DELETE and pressing ENTER. Enter the number of the program you wish to delete from the numeric keyboard. A warning will appear that pressing ENTER again will remove the weld program from the Library. Verify that the number of the pro-gram you wish to delete is correct and press ENTER again to delete the program. THIS WILL PERMANENTLY DELETE THE WELD PROGRAM FROM MEMORY.

TRANSFER (or RECEIVE) Weld Program(s):

The Model 227 Electronic Memory Module (EMM) is an optional accessory which may be used to transfer weld schedule information from one Model 227 Power Supply to another. The EMM must be plugged into the slot on the upper Model 227 housing. Begin the TRANSFER function from the Status Screen with the Operate Mode Switch in PROGRAM. Press PRO and from the Program Menu, press the F key beneath the word TRANSFER and press ENTER. The Screen will ask if you wish to TRANSFER THE ENTIRE LIB, RECEIVE THE ENTIRE LIB, or RECEIVE ONE WELD #. Use the appropriate F key to make a selection and press ENTER.

CAUTION: All information on the EMM will be erased from the EMM prior to TRANSFER-RING data from the M-227. The entire Library of the M-227 may be transferred to the EMM, or the entire Library of the EMM may be received by the M-227. Individual weld programs may be downloaded one at a time from the EMM to the M-227 (RECEIVE Mode), however, single weld programs may not be transferred from the M-227 to the EMM.

It is a good idea to keep a copy of the M-227 Library on an EMM to restore the Library in case of component failure or accidental deletion of weld data.


DELETE/TRANSFER


10.14


Chapter 11. Weld Procedure Development

Operation

The purpose of this section is to teach the basic operation of orbital pipe welding equipment at a skill level sufficient to apply it productively on real world applications. The welding power supply and weld head represent a high level of technical sophistication; however, anyone with the desire to learn and minimum mechanical aptitude can become a successful operator. Obviously, the level of welding knowledge will have a bearing on how easily an individual can develop procedures.

The first point to understand regarding the automatic (or mechanized) pipewelding process is that, with one exception, it is NOT an adaptive process. The machine can not sense what is happening within the puddle and make corrections; it can only perform as it was programmed. The reason for all the sophistication is to make the programmed process as reliable as possible so that it will be “forgiving” to minor process variables such as fit-up variations, interpass temperature variations, material chemistry variations, surface contaminants, etc.

11.1


One of the major differences between manual and automatic pipe welding is that in automatic pipe welding, the current is pulsed between two levels. The primary current is generally much higher than could be sustained on a continuous basis without blowing a hole, or having the molten puddle run downhill. The other level, or background current, is usually much lower and would only produce a very small molten puddle if held on a sustained basis.

By switching or pulsing between the two levels, the molten puddle alternately expands and contracts and produces an effect like a series of overlapping spot-welds. Each “spot” overpenetrates, but before it can start to sag and run downhill, the current switches to the background level and the puddle starts to freeze.

The result of this action is a weld proce-dure which can accommodate a wider range of process variations while maintain-ing good control over weld bead geometry. While the primary amps with pulsed cur-rent is greater than for the same weld done with constant current, the overall heat input is less.

The objective of almost all of the control features is to maintain positive control over the size, shape and position of the weld puddle.

Process Development

The objective for most process development activities is to develop a weld procedure which will provide the necessary weld quality levels at the lowest practical cost, with minimal rework.

In order for a weld procedure to be successfuly applied in production, it must be “forgiving” enough to minimize the effects of:

A. Material chemistry variations.

B. Joint fit-up and geometry tolerances.

C. Welding position.

D. Operator errors and tracking variations.

PRIMARY PULSE BACKGROUND PULSE

11.2


F. Other physical effects such as temperature, humidity, wind, and surface contamination.

While there may be many different approaches to develop a specific procedure, the followingparagraphs will describe techniques which are successful and avoid some of the pitfalls thatresult in an “unforgiving” procedure.

Where to start:Because automatic pipe welding is NOT an adaptive process, the success of a weld procedure is highly dependent on the weld joint geometry and fit-up, particularly for the root, or first pass.

A clean-up cut on the I.D. and consistent root face and land extensions are readily achievable with the pipe prepping equipment available today.

Consumable inserts, while not mandatory from a process standpoint, may be acceptable by code and do offer an additional margin of tolerance to poor fit-up.

Tack welds should always be made with the GTAW process. They should be small and uniform and not consume the insert (if applicable). On alloys where back purge is required, it should be utilized for the tack welds. All tack welds should be wirebrushed to present a clean surface.

When planning to develop a given procedure, several samples should be prepared in advance, along with sufficient filler materials.

11.3


A good starting point for any new procedure is an existing procedure which is similar in material and joint preparation.

If the similar procedure was for a different pipe or guide ring diameter, the TRAVEL SPEED setting should be adjusted accordingly.

The tacked pipe samples should be securely attached to the stand with the ground cable connected and, if required, backpurging set up. It will be useful, particularly on the root and hot passes, to be able to see the I.D. of the root during welding.

After setting in an initial set of weld parameters, mount the guide ring and the weld head over the joint.

Set up the torch, wire entry, and tungsten stickout as per similar procedure. Center the tungsten in the groove and jog the AVC down until the tungsten just touches the work. Observe that there is no interference between the torch and wire manipulator assembly and the joint. If an interference exists, it may be necessary to take one or more of the following actions:

A. Increase the tungsten stickout.

B. Readjust the wire nozzle to tungsten geometry.

C. Change to a smaller gas cup.

D. Open up the joint to a greater angle.

E. Increase the root land dimension.

F. Add or change the type of consumable insert.

Root PassWith the weld head mounted on the pipe, an appropriate weld schedule called up from the Model 227 Library, and all adjustments and calibrations complete, begin root pass development procedures. At this point, jog the weld head to the top of the pipe (if welding in the 5G position), initiate a SEQUENCE START and follow the steps described on the ROOT PASS PROCEDURE REFINEMENT flow chart in this sec-tion. It may take several joints to optimize the root pass since it is the most difficult pass to weld. Because of its degree of difficulty, do not be overly concerned with speed on the root pass. A for-giving root pass procedure will be more cost-effective than one which runs three times faster, if the faster procedure has occasional defects.

ROOT PASS

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11.4


11.5


Hot PassThe procedures utilized for the hot pass are generally slower and cooler than the remaining fill passes in order to avoid remelting the root pass. Most hot pass procedures utilize oscillation across the joint with the dwell positions over the edges of the root bend. This action makes use of the side walls as a heat sink and results in a flat contour for subsequent fill passes.

The HOT PASS PROCEDURE REFINEMENT flow chart describes the steps to refine a hot pass proce-dure.

Fill PassesWhile the system may be used to make fill passes which oscillate across the complete width of the joint, we do not recommend this practice for the following reasons:

A. Since the cross seam tilt can not be used for a full width fill pass, the angle of the sidewall will require a long tungsten stick-out to avoid hitting the sidewall with the gas cup. The long tungsten stickout may result in poor gas coverage.

B. On heavier wall pipe, full width oscillation will result in poor gas coverage due to the bead being wider than 1/2 the gas cup diameter.

C. Even with a long tungsten stickout, it may not be possible on a full width oscillation fill pass to position the tungsten during the dwells over the edges of the previous bead. This action can result in not fusing or a cold lap on the previous bead.

D. A considerably higher deposition rate can be achieved on fill passes using the “oscillated stringer technique.”

We recommend making fill passes with an oscillation amplitude of 1/2 the gas cup diameter, the torch tilted in the cross seam plane into the adjacent sidewall, and non symmetrical dwell times. THE FILL PASS PROCEDURE REFINEMENT flow chart describes the steps to refine a fill pass proce-dure. Other tips on fill pass techniques include the following:

A. The larger the size of the molten puddle, the greater the likelihood of cold lapping.

B. It is best to start the fill pass sequence with the oscillator centering set so that the tungsten is closer to the center of the joint and move it toward the sidewall after the AVC is unlocked. This precludes the tungsten contacting the sidewall before the AVC has unlocked.

FILL PASSES CAP PASS

HOT PASS

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11.6


C. Reduce the tungsten stickout as the joint is filled, to maintain the best possible gas cover-age.

D. A good technique, when developing fill passes, is to push the deposition rate to the limits and then reduce it until the procedure is forgiving (i.e. about 15-20%).

E. Try to keep the joint as level as possible and avoid leaving a narrow crack between the last bead and the opposite sidewall. If that occurs, either grind it out or run a non-oscillated fusion pass along the crack to burn it in. Note: Wash passes are not typically accepted by codes.

F. The arc length should not be excessive, but it should be high enough to avoid undue stub-out occurrences.

G. A relatively blunt (0.040” flat) tungsten will give longer service, since the plasma charac-teristics will change less as it becomes eroded and contaminated from the metal vapors.

Cap PassFor most applications, the fill pass procedures may be used all the way out to and including the cap passes. For those applications where the cap pass cosmetics are critical, a slow, and lower power, cap pass with a reduced amount of wire may be run which oscillates over the width of the weld bead. It is important that the surface travel be slow enough to avoid getting the puddle out of the gas coverage.

General CommentsThe following recommendations do not represent absolutes, but should prove useful in developing a starting point where a similar weld procedure is not available:

A. In general, square butt fusion welding should be used on applications where the wall thick-ness is less than 0.200 inches or 15% of the O.D.

B. Many features of orbital welding can be related to manual welding. For example, TRAVEL START DELAY (ROTATION DELAY) mimics the action of a hand welder who holds the torch sta-tionary to establish a puddle before moving the torch. A manual welder changes the current based on penetration. In orbital welding we aim to control the current precisely from weld to weld and program the machine to make current changes from level to level. The machine attempts to maintain a constant arc gap via the AVC, while a manual welder does this visually. He may speed up or slow down travel speed to control penetration, while the machine is usu-ally operated at a consistent travel speed. Current, pulse times, and wire may be changed within levels during welding.

GrindCrack Reweld

11.7


11.8


11.9


C. It is important to understand the timing of the delays with respect to other functions. For example, WIRE FEED DELAY provides time to reach full current before feeding wire. Con-sult Section 5 for a full explanation of the various DELAY functions.

D. Current pulsing to maintain puddle control should almost always be used.

E. Synchronizing the wire to the current pulsing is almost always an advantage.

D. Synchronizing the travel (STEP MODE) to the current pulsing is almost always an advan-tage.

E. For weave beads when OSCILLATION is used, the sychronization of current pulse (AMPERAGE) with WIRE, TRAVEL, and OSCILLATION is the key. See diagram on page 4.11.

F. It is not always necessary to stop between each pass. By using different levels, you can pro-gram the Model 227 to automatically advance to the next pass and weld the pipe all the way out.

G. Aim to automate the weld procedure as much as possible. This means, consistency of wall joint prep, alignment, fit-up, weld head set-up, so that little or no changes (overrides) are required during production welding.

H. If the filler wire is balling up as it enters the puddle, the wire speed is too low for the power level, or is not adjusted properly. Wire or AVC would need to be adjusted if wire is hitting the pipe before it reaches the puddle.

F. If the torch is bobbing up and down as the current pulses, either the primary or background AVC setting is wrong for the primary or background current setting. As the differential between the primary and background current increases, the differential between the primary and background voltage will also have to increase in order to maintain a consistent arc length.

Weld Process Documentation

Good documentation practices can streamline and enhance the procedure development cycle. Documenting even bad results can identify the parameter configurations which did not work. A good practice is to utilize the procedure sheets and mark up the settings used as each pass is com-pleted, along with remarks about what looks acceptable and what needs refinement. This is best done by quartering the pipe and evaluating each section until the desired quality is met.

The bead placement section should have a 1:1 scaled joint and it also should be filled in at the end of each pass. As the procedure is refined to an acceptable level, a production procedure sheet can be prepared, along with any supplemental instructions which will be needed by the production welders.

11.10


Chapter 12. Troubleshooting

Process Problems

The purpose of this section is to provide the user (welding engineer or operator) with a series of checks which he can perform to correct some process related problems before having to call on maintenance support. These checks are keyed by the symptom most likely to be observed by the operator. They are presented in a flow chart format on the next page. The flowchart is based on the assumption that the process under question is developed and has performed satisfactorily in the past.

12.1


PIPE WELD TROUBLE SHOOTING

IS THE PROBLEM A WIREFEED PROBLEM?

IS THE PROBLEM A

TRAVEL PROBLEM?

IS THE PROBLEM AN INTERLOCK

PROBLEM

B

A

1.INSURE THAT A LOOP OR OTHER RESTRICTION IN THE SPOOL DOES NOT EXIST.2. INSURE THAT THE WIRE NOZZLE AND LINER ARE NOT CLOGGED OR RESTRICTING THE WIRE.3. INSURE THAT THE TENSION ON THE FEED ROLLS IS SUFFICIENT.4. ASSURE THAT THE WIRE ENTRY IS PER THE PROCEDURE.5. IF THE PROBLEM PERSISTS CALL FOR MAINTENANCE.

1. IF GAS FAULT IS ON, PERFORM THE FOLLOWING: A. CHECK THE INLET GAS PRESSURE. B. CHECK THAT ALL THE QUICK DISCONNECTS ARE SEATED AND THE HOSES ARE NOT KINKED. C. CHECK THAT THE GAS LENS IS UNOBSTRUCTED. D. IF PROBLEMS PERSIST, CALL FOR MAINTENANCE.

3. IF GROUND FAULT IS ON, PERFORM THE FOLLOWING:A. CHECK THAT ALL THE WORK (GROUND) CONNECTIONS ARE SECURE.B. CHECK THAT THE GUIDE RING IS MAKING GOOD ELECTRICAL CONTACT TO THE PIPE. (AT LEAST PART OF THE SURFACE SHOULD BE MECHANICALLY CLEANED).C. IF THE PROBLEM PERSISTS, CALL FOR MAINTENANCE.

4. IF THE OSCILLATOR LIMIT FAULT IS ON, MOVE THE OSCILLATOR CENTERING CONTROL TO THE CENTER POSITION. IF NECESSARY, REPOSITION THE GUIDE RING. IF THE PROBLEM PERSISTS, CALL FOR MAINTENANCE.

5. IF THE AVC LIMIT FAULT IS ON, JOG THE AVC AWAY FROM THE LIMIT, RESET THE TORCH HEIGHT, IF NECESSARY.

6. IF THE STUBOUT FAULT IS ON PERFORM THE FOLLOWING:A. CHECK THE TUNGSTEN GEOMETRY AND WIRE ENTRY.B. VERIFY THAT THE WELD PARAMETERS (PROGRAM) ARE CORRECT.C. IF THE PROBLEM PERSISTS, CALL FOR MAINTENANCE.

FOR OTHER FUNCTIONAL SEQUENCING OR OPERATIONAL PROBLEMS, VERIFY THAT THEY PERSIST AFTER TURNING THE PRIMARY POWER ON AND OFF. IF THE PROBLEM PERSISTS, CALL FOR MAINTENANCE.

NO

YES

YES

1. INSURE THAT THE CABLES DO NOT WRAP UP. 2. INSURE THAT THE CORRECT CAM ROLLERS ARE INSTALLED WITH THE FLAT FACE MATCHING THE STEP.3. INSURE THAT NO RADIAL OBSTRUCTIONS IMPEDE TRAVEL.4. IF THE PROBLEM PERSISTS, CALL FOR MAINTENANCE.

2. IF THE COOLANT FAULT IS ON, PERFORM THE FOLLOWING:A. CHECK ALL THE QUICK DISCONNECTS FOR SEATING.B. CHECK ALL HOSES FOR KINKS.C. CHECK THE COOLANT RETURN FILTER (WITH POWER OFF). REPLACE IF FOULED.D. ADD WATER IF COOLANT LEVEL IS LOW OR OUT.E. IF THE PROBLEM PERSISTS, CALL FOR MAINTENANCE.

YES

12.2


Chapter 13. Weld Criteria and Weld Qualification

rbital welding technology provides the means to achieve welds of high-quality with a very high degree of repeatability. However, ultimately, the quality of welds that are produced will depend upon the quality requirements of the particular industry, and the weld specification to which the welds are performed. Several organizations have written codes applicable to pipe weld-ing. These codes have been written to qualify manual welds done with various welding processes including stick welding (SMAW), MIG welding, (GMAW), submerged arc, (SAW), and manual TIG, (GTAW). Orbital welding is a mechanized version of GTAW and orbital GTAW welds can be qualified to applicable codes in the same way as manual welds are qualified. Weld testing requirements may vary according to the severity of service for which the welds are intended or the type of material used. For example, radiography, pressure testing, corrosion testing, Charpy impact, or other types of testing may be needed. The weld schedule print-out from the Model 227 is often attached to the PQR (Procedure Qualification Record) as part of the supporting documen-tation. Code requirements vary from industry to industry as well as from country to country. It is the responsibility of the end user to determine the code requirements for his application. Arc Machines is not expert in all areas of code pertaining to pipe welding, but since our customers fre-quently ask for basic information on weld qualification, a brief summary is included here.

Note: Arc Machines, Inc. does not do weld qualification testing or certification.

I.D. of a finished autogenous weld on 10” schedule 10 electropolish-

ed pipe as seen though the transparent Lexan® purge dam. A dif-fuser was used to disperse the gas stream.

O

13.1


Welding Procedures are Essential

A. Purpose of Welding ProceduresA step-by-step direction for producing a specific weldment which will meet service require-ments, insure consistent quality, and provide repeatability of process.

B. Types of Welding Procedures Used1. Broad - procedures which cover many types of welding, material, and joint design.

2. Narrow - procedures which apply to a specific process, material and joint design. The dif-ference between these two procedure types would be the variables which apply.

C. Procedures Should be Detailed1. Essential variables - These are variables which if changed would affect the mechanical properties of the weld. A change in any essential variable would require the weld procedure to be rewritten and requalified. Example: a change in shield gas composition.

2. Non-essential variable - If a change in a variable does not affect the mechanical properties of a weld, then such a change would only require a revision of the document and not a requal-ification.

Note: This section is intended as a brief introduction to weld qualification procedures. The Code user is responsible to assure that his welding qualifications are suitable for the welding application.

Weld Qualification and DocumentationTo qualify an orbital welding procedure to ASME Section IX of the Boiler and Pressure Vessel Code:

1. Test coupons must be made that satisfy your company’s visual criteria and/or those out-lined in ANSI/ASME B31.1 Code for Pressure/Power Piping (or other applicable code).The test coupons must be sent to a qualified test lab for destructive testing which include bend and tensile tests. For the PQR, cross sections, (macros) are required for fillet welds.

2. Bend tests are predetermined over a certain sized radius. Two each root, and face bends must be performed. The weld zone and heat-affected zone (HAZ), which extends for 1/2 inch on both sides of the weld, must be carefully inspected for cracking.

3. Tensile testing must be done to examine for the following:a. PSI at which the specimen breaks must equal or exceed the tensile stress of the materi-

13.2


als being joined. Forms for the Weld Procedure Specification (QW-482) and the Proce-dure Qualification Record (QW-483) must be filled out.

Longitudinal Area = D2 x p Transverse = Load divided by Area Area = T x W 4b. Should the specimen break on the weld, as opposed to being adjacent, (but still meetthe minimum base criteria in PSI) the sample is acceptable.

c. The welder performing the test and creating the weld samples has now become certified (Form QW-484 or equivalent must be filled out.) Bend or X-ray of the test coupons is required.

4. Welder certification: Each welder (welding operator) must submit either 6” of linear weld for certification or multiple coupons, but no more than 4. All welds of 1” or below will require a test for each size.

5. By ASME Code, you have now proven that the process and techniques used meet ASME criteria for procedure qualification.

Applicable Codes:• ASME Boiler and Pressure Vessel Codes (Section IX for piping. For Boiler Proper - welds

inside first relief are governed by ASME Section I. N.B.I.S.• ANSI/ASME Code for Pressure Piping, B31

B31.1 Power Piping .........................................................1992B31.2 Fuel Gas Piping ...................................................... 1968B31.3 Chemical Plant and Petroleum Refinery Piping ............1990B31.4 Liquid Transportation Systems for Hydrocarbons, Liquid Petroleum Gas, Anhydrous Ammonia, and Alcohols ....1989

• American Welding Society Codes (AWS D10.9; D1.1)• American Petroleum Institute Codes (API 650, 651)• US Department of Defense Military Specs (MIL 278 or NAV SEA 250-1500-1)• American Society for NDT

Visual weld criteria usually include absence of visible cracking and porosity, full penetration of the weld bead to the pipe or tube ID, uniform weld bead without excessive width variation, little or no ID or OD concavity, (some reinforcement is desirable on welds with filler added), weld and HAZ free from (or nearly so) from discoloration resulting from oxidation, uniform, well-spaced weld beads, and good alignment of welded parts, etc. You must be able to recognize an acceptable weld for your industry!

The ASME has recently published the ASME Bioprocessing Equipment Standard (ASME

13.3


BPE-1997) which addresses acceptance criteria for orbital welds on bioprocess equipment and piping systems. In addition to the visual acceptance criteria stated in ANSI/B31.3, it defines acceptable weld profiles and permissible levels of ID discoloration. ASME Section IX and B31.3 are referenced in this standard. In addition, SEMI (Semiconductor Equipment and Materials International) has written specifica-tions for the semiconductor industry for which the welding is primarily, but not exclusively, fusion butt welds of small diameter 316L stainless steel tubing. The SEMI F2 - Specificataion for Seamless Austenitic Stainless Steel Tubing for Semiconductor Manufacturing Applications details acceptable fabrication techniques for high-purity welding. Other SEMI standards, F3, F6, etc.also apply to the orbital welding of stainless steel tubing. SEMI references ASME Section IX, B31.3 and AWS D10.9.

Example Orbital Weld Procedure

An example of an actual orbital weld procedure qualified to ASME Section IX of the Boiler and Pressure Vessel Code is shown on pages 5-9. This procedure was for autogenous welds of stain-less steel tube or pipe (P8 to P8 Groups 1) with wall thicknesses of 0.035-0.125 inches OD and for diameters consistent with weld head range. This procedure is intended to be used as a reference only. Individual customers are responsible for making their own test coupons, performing bend and tensile tests and and completing the necessary forms.

References:

ASME: American Society of Mechnical Engineers, United Engineering Center, 345 East 47th Street, New York, NY 10017

SEMI: Semiconductor Equipment and Materials International, SEMI North America, 805 East Middlefield Road, Mountain View, California 94043-4080 USA Phone: 415-964-5111.

Houle, Michael J. Practical Guide to ASME Section IX Welding Qualifications. Practical Guide Book Series - Volume 2, CASTI Publishing, Inc., 1996.

Woods, Glynn E., and Roy B. Baguley. Practical Guide to ASME B31.3 Process Piping. Practi-cal Guide Book Series - Volume 3, CASTI Publishing, Inc., 1996.

13.4


13.5


13.6


13.7


13.8


13.9


13.10


Chapter 14. Offline Programming (OLP)

Offline Programming Software (OLP 1.4) Functional DescriptionThe AMI OLP Software package is actually two major pieces of software combined into a single program, which are designed to interact with each other. The major modules in the product are called Offline Programming (OLP) and Weld Data Recording (WDR). WDR is available for the Model 207 Power supply only. In concert with supporting hardware and a suitable IBM‘ compati-ble personal computer they form a complete operational weld data record system. OLP software is not available for Macintosh systems running under non-Windows‘ compatible operating systems.

The Offline Programming Software product, in conjunction with its supporting equipment, pro-vides a method of transferring weld schedule parameter information between Arc Machines microprocessor-controlled power supplies and a personal computer. Writing a new weld schedule from scratch on a personal computer for later transfer to an AMI power supply is possible using the OLP software. However, the primary use of the OLP package is for the safe storage and trans-fer of weld schedule information to-and-from an AMI power supply using a personal computer. Weld schedule information contained in a power supply can be transferred into a personal com-puter for storage, e-mailed to a distant computer, or loaded onto a floppy disk and mailed to a remote site to be transferred into a distant power supply. Currently the AMI model 215, 227, 207A, and 207-HP power supplies with appropriate software and hardware are supported by the OLP software package.

OLP also allows compatible weld schedules to be transferred between different types of power supplies provided both power supplies support the weld head selected within each weld schedule. As an example, a weld schedule written for a Model 9 weld head can be converted and transferred between the M215, M227 and M207A power supplies as these weld heads are supported by all three power supplies. However, weld schedules for a model 81 weld head could be converted and transferred only between the M227 and the M215 since only those power supplies support the M81 weld head. Such a weld schedule could not be transferred to the M207A power supply, as this weld head does not operate with the M207A.

Weld schedule information can be organized into “Groups” of weld schedules. Each group can be given a unique name and used to categorize the weld schedules within the group. Such grouping could be used for weld schedules with similar purposes such as welding a specific alloy type or welding with a specific weld head. Transferring weld schedules between groups is also supported. This allows the user to assemble custom groups of weld schedules for subsequent loading into a number of power supplies prior to the start of a specific job.

14.1


All screens and language prompts in the OLP software package can be written in multiple lan-guages, translated and entered by the user. Completed weld head and system set-up information can be added to the weld schedules stored in the OLP software. This allows for complete weld schedule repeatability at a later date, one week or ten years, after the weld schedule was stored. See Chapter 15 Appendix 2. pages 15.5-15.6 for list of items required for installation and opera-tion of OLP.

The first screen of the OLP Software shown below displays the AMI Logo, and the Toolbar from which various functions may be accessed:

14.2


The Toolbar shown below is visible from each screen and is used to access various screens and functions listed below using the MENU COMMANDS and ICONS.

TOOLBAR

Before proceeding with the OLP function, you must first specify the power supply you are using. Select SYSTEM from the Toolbar and then SET UP to display the following screen.

Select M227 and the preferred language, which in this case is English, and then OK.

System Setup Screen:

1. COPY A WELD SCHEDULE 10. CREATE NEW WELD DATA RECORD2. DELETE A WELD SCHEDULE 11. OPEN EXISTING WELD DATA RECORD3. MOVE A WELD SCHEDULE 12. GET PROJECT DATA4. TRANSFER WELD SCHEDULES 13. EXPORT WELD DATA RECORDS 5. GROUPS 14. SET-UP: LANGUAGES, GROUPS, ETC.6. EXIT OLP 15. CALCULATE: TUNGSTEN LENGTH, RPM, ETC. 7. LIBRARY OF WELD SCHEDULES 16. OFF-LINE PROGRAMING HELP 8. MODIFY A WELD SCHEDULE 17. HOW TO USE WINDOWS HELP9. CREATE A NEW SCHEDULE 18. ABOUT OFF-LINE PROGRAMMING (VERS.)

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18

MENU COMMANDS

ICONS

14.3


MENU COMMANDS

System Menu

The System menu provides access to the OLP system functions, such as languages, users, and power supply.

Languages Selects language in use.Language menu Allows adding, deleting, and renaming of languages.Power Supply Selects the current Power Supply for weld schedule editing.

Logins menu Allows adding, deleting, and renaming of OLP users. Prompts Selects Standard or Military type prompts (Model 215 only). Avc Mode Selects Standard or Extended AVC prompts (Model 215 only).

File Menu

The File menu provides commands to: COPY, DELETE or MOVE weld schedules; provides com-mands for transferring weld schedules between OLP and power supplies or converting to a single file that can be e-mailed or stored on a floppy disk; modifying the weld head motor speed range of a weld schedule; editing the weld schedule groups; and exiting the application.

Copy Weld Schedule Copies a weld schedule.

Delete Weld Schedule Deletes a weld schedule.

Move Weld Schedule Moves a weld schedule.Weld Schedule to DOS File Converts a weld schedule to a single file DOS File to Weld Schedule Converts a single file to a weld schedule.

Transfer Weld Schedule Sends or receives weld schedules.

Edit Weld Schedule groups Adds, deletes, or renames weld schedule groups.

Change Motor Speed Changes the weld head motor speeds for a weld schedule.

Exit Exits Off-Line Programming.

Edit Menu

The Edit menu provides commands to create, modify or display weld schedules.

14.4


Display Library Displays the library for the selected power supply.

Create Weld Schedule Creates a new weld schedule.

Modify Weld Schedule Modifies an existing weld schedule.

Weld Record Menu

The weld record menu provides commands to create, modify, and export Weld Data Records. It also provides a automatic retrieval of weld data information from the power supply via a PCMCIA card or EMM (Model 207 Power Supply only).

New Record Creates a new weld data record.

Open Record Opens an existing weld data record.

Get Weld Data Retrieves weld data from a PCMCIA card (Model 207 only) or an EMM.

Export Records Exports weld data records to text files.

Tools Menu

The Tools menu provides access to the Weld Calculator dialog.

Weld Calculator Calculates IPM, RPM, Level Time, and Tungsten Length.

Help Menu

The Help menu provides access to the help system and the about OLP dialog box.

Contents Displays the help contents page.

Using Help Accesses how to use the Windows Help Utility.

About Displays the version number of Off-Line Programming.

Creating a new weld program on OLP:

To create a program using OLP, open the Library from the Edit Menu or the “create a new sched-ule” icon. The Library displays the list of programs stored in OLP. To create a new program with the Library open highlight an open number and select “create” from the bar at the bottom of the screen.

14.5


Library Screen

When “Create” is selected, the following screen for weld head selection, and speed selection for the travel motor and wirefeed motor is displayed. Scroll through the weld head menu, highlight the desired weld head, and click OK. In this case the Model 81 weld head was selected which will be used for an example weld program.

14.6


The software will prompt the operator to tube or pipe OD, type of weld, i.e., tube, pipe or fitting, and material type. It will give the option of entering the non-programmable variables such as type of gas and flow rate, tungsten length, etc. The Model 227 Weld Schedule COMMENT SCREEN is displayed below showing the prompt for weld OD:

Set Material:

14.7


Set Wall: In this case weld diameter of 3.5 was entered for an example weld program show-ing a weld of 3 inch schedule pipe in a Model 81weld head.

Set Position:

At this point you must decide whether you wish to enter the optional comments before com-pleting the mandatory weld parameters: If “Yes” is selected you will be asked for torch infor-mation. For the Model 8 and Model 9 weld heads, this information can be found in Chapter 6 of this manual.

14.8


Torch Setup Information is shown below filled in with typical information for the Model 81 weld head. Your application may require somewhat different values.

Essential Comments When torch information has been entered, you may enter Essential Comments on gas type, ID and OD flow rates, insert information, etc. See Chapter 7 of this manual for information on gas types and flowrates.

14.9


One Level Functions Enter Program information for the weld head you are using on the screen below. Items not relevant to the head selected are shown in gray and can not be entered. Values shown are for the example Model 81 weld schedule. Note that One Level Functions are in effect for an entire pass regardless of the number of levels. One Level Functions may be changed for other passes of the same program. For example, in the program shown below and on pages 4.11 (pass 1) and 4.13 (passes 2 and 3) Osc Mode is OFF for the first pass and ON for subsequent passes.

14.10


Weld Schedule Level Once the One-Level Functions have been entered, the following screen is displayed shown below with values entered for a Model 81 welding 3.5 inch pipe. When Osc Amplitude is set to zero, values for Out Dwell, Excursion Time and In Dwell are also zero. Since Travel Step is CONT background travel is 0.0. When program entry is complete and OK is clicked, the lower screen showing the program is displayed. Programming is cov-ered in Chapter 10 of this manual.

14.11


Override Percentage Limits may be set for various weld parameters as shown above by selecting OVERRIDES from the M227 WELD SCREEN shown on page 14.11. The example shown on the screen on the previous page is for a pipe 3.5 inches in diameter with a wall of 0.154 inches in a Model 81 weld head. Since Timer Mode Manual was selected, no Level Time was entered. No background AVC is entered since the AVC mode is sample primary (SA-P).

The first pass of this schedule is a stringer bead and no oscillation is programmed and no val-ues are entered for IN-DWELL, EXCURSION TIME or OUT-DWELL. In order to enter OSCILLATOR AMPLITUDE, OSC MODE must be set to ON on the One Level Function screen.

When a is shown at the right of a selection in OLP, this indicates a menu selection. AVC Mode choices are SA-P (Sample Primary), OFF, CONT, and SA-B (sample background). Choices for Pulse Mode are OSC (Sync in which the oscillation is synchronized with the cur-rent), OFF and ON. Travel Step (the same as Rotation on a Model 207 Power Supply) offers a selection of CONT (continuous rotation), OFF, or STEP in which the current pulses are syn-chronized with rotation.

An additional Level can be added by clicking on Level 2 of the M227 Weld Screen. This results in a duplicate of the Level 1 values in the Level 2 column. Clicking on any of these parameters brings up the Weld Schedule Level screen shown on the previous page from which the parameters can be edited.

To add a new pass: Click “OK” from the M227 Weld Screen to bring up the Pass Number screen shown on page 14.13. Highlight the number 1 and select Copy Pass. The Add Pass.

14.12


will become visible and clicking on it will add a second pass identical to the first. The new pass can then be edited by selecting Edit Pass. Selecting CMT allows for editing of the Comments Screen.

The lower screen on this page and the top screen on the next page show passes 2 and 3 of the example Model 81weld program. The One Level Function screen shown at the bottom of page 14.14 has been modified to set OSC Mode to ON for these two passes.

14.13


Pass 3 of example weld program:

One Level Function modified for passes 2 and 3 by changing OSC Mode to ON:

14.14


Weld RecordsThis section deals with creating, storing and moving weld records that may be used in a qual-ity control program for weld documentation.

Selecting New Record from the Weld Records menu on the tool bar displays the following screen:

Fill in the requested information and store the new record by selecting Save.

Note that Get Weld Data which is used to retrieve data from a PCMCIA card is available for the Model 207 Power Supply only. With the Model 227 Power Supply, weld schedules for

14.15


Model 9 weld heads only can be retrieved from an EMM.

Calculate Function of OLP

In addition to the Weld Data Recording and Offline Programming, AMI OLP Software has a CALCULATE function for calculating Tungsten Length and Weld Time. The Weld Calculator is found by selecting TOOLS from the toolbar. Weld program RPM (revolutions per minute) is calculated from the Tube O.D. and the desired travel speed in IPM (inches per minute). The RPM, Tube O.D. and wall thickness are typed in and used in the calculation of Total Weld Time (sec.) which includes time for all weld levels (in a single pass) but not purge time or downslope. Select DONE when calculation has been completed.

14.16


Chapter 15. Appendices

Appendix 1. General Programming Terms

1) OD (Outside Diameter) The size of the pipe or tube you will be welding.

2) WALL. Thickness of the pipe or tube to be welded.

3) MAT (Material Type) Tthe material to be welded. SS (Stainless Steel), CS (Carbon Steel), etc.

4) POS. (Position in which pipe or tube is to be welded) 1G, 2G, 3G, 4G, 5G, 6G.

5) HEAD. The Model Number of the weld head to be used.

6) PASS. This is an automatic feature. As you develop your weld schedule, the power sup-ply will keep track of the number of passes programmed.

7) PRE-PURGE. Amount of time set for the gas to flow before striking an arc.

8) PURGE-POST (POST PURGE). Amount of time programmed after DOWNSLOPE to prevent oxidation of the weld.

9) UP-SLOPE. Amount of time from ARC DETECT at SEQUENCE START to arrive at full PRIMARY AMPS.

10. SLOPE-DOWN (DOWNSLOPE). Amount of time needed to make a smooth transi-tion of the weld bead, from SEQUENCE STOP to POST PURGE time.

11) ROT (ROTATION). The direction in which the weld head will travel. Either CW (CLOCKWISE) or CCW (COUNTERCLOCKWISE).

12) ROT-DLY (ROTATION DELAY) Amount of time needed to establish penetration, or a weld puddle, before the weld head begins to travel.

13) STR-WFDLAY (START WIRE FEED DELAY) Amount of time used to hold the wire out of the weld until a puddle has been established.

14) WFDLAY-STP (WIRE FEED DELAY STOP) Amount of time used if needed during DOWNSLOPE to have wire-feeding capabilities, generally used to prevent cracking when

15.1


welding material with high chrome content.

15) RETRACT Amount of time the wire feeder will run in reverse to retract the wire from the weld puddle at SEQUENCE STOP.

16) T/MODE (TIME MODE) Can be set to AUTO or MANUAL. If AUTO is selected, an amount of time (seconds) must be entered in LEVEL TIME. When the time has elapsed, SEQUENCE STOP is initiated automatically.

If MANUAL is selected, the operator will press SEQ-STOP to initiate weld completion.

17) OSC MODE (OSCILLATE MODE) Can be ON or OFF. This function will be put in the OFF MODE for stringer beads and ON MODE for oscillating weld beads.

18) STR-AVCDLY (START AUTOMATIC VOLTAGE DELAY) Time is used to disable the sensitivity of the AVC until full current has been established.

19) AVCDLY-STP (AUTOMATIC VOLTAGE DELAY STOP) Time is generally set at ZERO (0.0 SEC) to disable the AVC during downslope.

20) STR/MODE (START MODE) Can be set to RF/RADIO FREQUENCY or TCH/TOUCH. This mode is optional.

21) RESPONSE. THIS SETS THE AMPLITUDE OF THE AVC RESPONSE TO A PARTICULAR VOLTAGE CHANGE DURING WELDING.

22) PULSE. Can be set to OFF for manual welding, ON for stringer bead welds, or SYNC (SYNCHRONIZE) for welding weld beads.

23) ROT (ROTATION) The weld head travel mode can be set to CONT (CONTINU-OUS), STEP, or OFF.

24) PRI-IPM (PRIMARY ROTATION) Weld head travel speed may be set in INCHES PER MINUTE (IPM) or REVOLUTIONS PER MINUTE (RPM) depending on the type of weld head used.

25) IPM-BCK (BACKGROUND ROTATION). This sets the weld head travel speed if background travel is used.

26) TIME. The amount of seconds needed to complete a weld or a pass. Use if TIME

General Programming Terms, continued:

15.2


MODE is set to AUTOMATIC . IF time mode MANUAL is selected, this parameter will automatically enter MANUAL.

27) PRI-AMP (PRIMARY AMPS). Amount of current used during PRIMARY PULSE TIME. To be determined for each application.

28) AMP-BCK (BACKGROUND AMPS) Amount of current used during CURRENT used during BACKGROUND PULSE TIME. Generally 1/3 TO 2/3 of PRIMARY AMPS.

29 )PRI-PULSE. (PRIMARY PULSE) This timer determines the length of the time in PRIMARY AMPS when running stringer beads with PULSE MODE “ON”.

30) PULSE-BCK. (BACKGROUND PULSE) This timer determines the length of time of the BACKGROUND current (amps) pulse. Used when running stringer beads with PULSE MODE “ON”.

31) PRI-WF (PRIMARY WIRE FEED) The amount of wire fed during PRIMARY PULSE TIME. This will be determined by the amount of amps that are used and by the amount of fill required.

32) WF-BCK. (BACKGROUND WIRE FEED). The amount of wire fed during BACK-GROUND PULSE TIME.

33) PRI-AVC (PRIMARY AUTOMATIC VOLTAGE CONTROL) This setting deter-mines the THE DISTANCE (arc gap) between the molten puddle and the time of the tung-stend during the PRIMARY CURRENT PULSE. This distance will be automatically maintained once a value has been entered.

34) AVC-BCK (BACKGROUND AUTO-MATIC VOLTAGE CONTROL) The distance between the molten puddle and the time pf the tungsten during the BACKGROUND CUR-RENT PULSE. This distance will automati-cally be maintained once a value is entered.

WELD

HEAD

OSCILLATOR AMPLITUDE

EXCURSION

OUTDWELLINDWELL

General Programming Terms, continued:

15.3


35) AVC MODE (AUTOMATIC VOLTAGE CONTROL MODE) This is one of the most important features of the power supply and must be fully understood. There are four modes that can be entered:

1) CONT (CONTINUOUS) In this mode the voltage will be sensing in both PRIMARY and BACKGROUND PULSE TIMES. This mode is generally used

when welding weave beads.

2) SAMP/PRI (SAMPLE PRIMARY) In this mode, voltage will only be sensedduring the PRIMARY PULSE TIME. During BACKGROUND PULSE TIME theAVC will lock and become inactive. This mode is generally used when weldingstringer beads.

3) SAMP/BCK (SAMPLE BACKGROUND) In this mode the voltage will be sensed during BACKGROUND PULSE TIME. During PRIMARY PULSE TIMEthe AVC will lock and become inactive. This mode will be used when the BACKGROUND AMPS are greater than PRIMARY AMPS. This mode is rarely used.

4) OFF is used when a MANUAL WELD RIG is connected to the M-227 for tack-ing or manual welding.

36. OSC/AMPL (OSCILLATOR AMPLITUDE) The total amount of OSCILLATOR STROKE. This measurement is entered into the M-227 in increments of from 0.001 to .999.

37) IN (IN DWELL) During OSC MODE, IN-DWELL is the amount of time entered for the torch to remain stationary for typing in to the side wall. IN-DWELL is the sidewall area nearest to the weld head.

38) EXC (EXCURSION) In OSC MODE, time must be entered for the torch to travel from one side of the groove to the other. This is the EXCURSION TIME.

39) OUT (OUTDWELL) During OSC MODE, the amount of time entered for the torch to remain stationary for tying in to the side wall. OUTDWELL is the side wall furthest away from the weld head.I

15.4


NOTES

To DELETE a WELD SCHEDULE: Press the “C” KEY twice. The TOP SCREEN should read:

Press PRO. Tthe BOTTOM SCREEN should read:

Press the F key under DELETE. The bottom screen should give you a warning to make sure this is what you want to do. Press ENTER again and the weld schedule will be deleted.

To DELETE A LEVEL - Go to the amount of time that is entered for that level and ENTER “0”. The bottom screen should give a warning to make sure this is what you want to do. PRESS ENTER again and this level will be deleted.

CREATE MODIFY COPY DELETE TRANSFER

TO WELD PRESS LIB TO PROGRAM PRESS PRO

15.5


Appendix 2. Equipment Required to Support OLP for the Model 227 Power Supply

Model 227 power supplies equipped with STD 1.4 or higher software:1. P/N 1368301-01 Software package Off-line Programming 12. P/N 13B272513-01 RS232 Optical Interface 1

REQUIRED CUSTOMER SUPPLIED EQUIPMENT: (minimums)IBM‘ Compatible 486 minimum (Pentium™ recommend) Equipped with the following: Windows 95™ or Windows 98™ Operating System8 MB RAM (recommend 16 MB)40 MB hard disk minimum3.5 inch floppy disk drive 1.44 MB Monochrome Graphics Monitor (recommend VGA color) Mouse or equivalent Pointing DeviceRS232 serial port

OLP Functional Equipment Explanation:A complete OLP system consists of the following elements:1. AMI RS232 Fiber optical interface converter cable assembly from an AMI power supply

directly to a personal computer.2. IBM‘ Personal computer (see specifications above)3. AMI OLP Software

Fiber-Optic connection Cables:The computer communication from the power supply is first passed though a cable that connects to the RS232 Converter described below. The computer information is in the form of light passing through a pair of fiber-optic cables. The fiber-optic cables are used to electrically isolate the power supply and the personal computer from electrical noise and interference that could disrupt

15.6


the data communications or damage the computers in the PC or in the power supply.Model 207 and M 227 fiber-optic interface cables:Fiber-optic communication cable used with the Model 207 and 227 has a 9-pin “D” type electrical connection on one end of the assembly and two optical fibers on the other end. The optical fibers are terminated with color-coded connectors.

The fiber-optic cables are attached to the M207 or M227 via two bulkhead fittings located on the left-hand side of the gray computer housing. Both connectors are color coded. Each connector is to be mated with its matching color.

The opposite end of the fiber-optic connection cable has a round electrical connection on it. This connector attaches directly to the RS232 port located on a personal computer.

RS232 Interface Box (older systems only- replaced by new interface cable):The RS232 interface box is used to convert the fiber-optic signals from the interface cables into electrical signals that can be used by a computer or other similar device. The RS232 Interface box can be purchased in either 110 or 240 volts AC versions depending on the local power voltage at your work location.

The final computer communication exits the RS232 interface via a 24-pin “D” style connector. Such connectors are commonly used in the computer industry and are easily interfaced with other devices.

Connection cable from the RS 232 Interface converter to an IBM‘ Personal computer (older system only- replaced by newer fiber optic connection cables)The specific connecting cable between the RS232 interface and your personal computer will vary in configuration depending on the RS232 connection located on your computer. One end of the cable needs to have a 25 pin Male “D” connector on it. The opposite end of the cable must have a connector suitable for attaching to your computer. The wiring between the two ends of the cable is pin-to-pin. In other words pin #1 on one end of the cable is wired to pin #1 on the opposite end. This is true for all other connections at both ends of the cable.

15.7


PIPE SIZ XXH

1/8

1/4

3/8 7 0.2947.5

1/2

3/4 8 0.308

7.81 0 0.358

9.1

1 1/4 0 0.382

9.71 1/2 1 0.400

10.2

2 3 0.436

2 1/2 5 0.55214.0

3 7 0.600

15.2

3 1/2 0.63616.2

4 1 0.67417.1

4 1/2 0.71018.0

5 5 0.75019.1

6 8 0.86421.9

7 0.875

8 6 0.87522.2

9

10 5

Pipe Dimensions: Stainless, Carbon Alloy, Aluminum, Nickel

Pipe Schedule Inches a and Milimeters

EOutside Diameter 5 10 20 30 40 STD 60 80 XH 100 120 140 160

0.405 0.035 0.049 0.068 0.068 0.095 0.095

10.3 0.9 1.2 1.7 1.7 2.4 2.4

0.540 0.049 0.065 0.088 0.088 0.119 0.11913.7 1.2 1.7 2.2 2.2 3.0 3.0

0.675 0.049 0.065 0.091 0.091 0.126 0.126 0.1817.1 1.2 1.7 2.3 2.3 3.2 3.2 4.7

0.840 0.065 0.083 0.109 0.109 0.147 0.147

21.3 1.7 2.1 2.8 2.8 3.7 3.7

1.050 0.065 0.083 0.113 0.113 0.154 0.154 0.21

2.9 2.9 3.9 3.9 5.5

1.315 0.065 0.109 0.133 0.133 0.179 0.179 0.2533.4 1.7 2.8 3.4 3.4 4.5 4.5 6.4

1.660 0.065 0.109 0.140 0.140 0.191 0.191 0.25

1.7 2.8 3.6 3.6 4.9 4.9 6.4

1.900 0.065 0.109 0.145 0.145 0.200 0.200 0.2848.3 1.7 2.8 3.7 3.7 5.1 5.1 7.1

2.375 0.065 0.109 0.154 0.154 0.218 0.218 0.3460.3 1.7 2.8 3.9 3.9 5.5 5.5

2.875 0.083 0.120 0.203 0.203 0.276 0.276 0.3773.0 2.1 3.0 5.2 5.2 7.0 7.0 9.5

3.500 0.083 0.120 0.216 0.216 0.300 0.300 0.4388.9 2.1 3.0 5.5 5.5 7.6 7.6 11.1

4.000 0.083 0.120 0.226 0.226 0.318 0.318101.6 2.1 3.0 5.7 5.7 8.1 8.1

4.500 0.083 0.120 0.237 0.237 0.281 0.337 0.337 0.437 0.532.1 3.0 6.0 6.0 7.1 8.6 8.6 11.1 13.5

5.000 0.247 0.355127.0 6.3 9.0

5.563 0.109 0.134 0.258 0.258 0.375 0.375 0.500 0.622.8 3.4 6.6 9.5 9.5 12.7 15.9

6.625 0.109 0.134 0.280 0.280 0.432 0.432 0.562 0.71168.3 2.8 3.4 7.1 7.1 11.0 11.0 14.3 18.27.625 0.301 0.500

8.625 0.109 0.148 0.250 0.277 0.322 0.322 0.406 0.500 0.500 0.593 0.718 0.812 0.90219.1 2.8 3.8 6.4 7.0 8.2 8.2 10.3 12.7 12.7 15.1 18.2 20.6 23.0

9.625 0.342 0.500

244.5 8.7 12.7

10.750 0.134 0.165 0.250 0.307 0.365 0.365 0.500 0.593 0.500 0.718 0.843 1.000 1.12273.1 3.4 4.2 6.4 7.8 9.3 9.3 12.7 15.1 12.7 18.2 21.4 25.4 28.6

15.8


15.9

Index

Symbols“Groups” of weld schedules Ch.14, p.1AA.C. power cord Ch.3, p.4acceptable weld Ch.13, p.3Adapter cable to Model 227 installation Ch.3,p.5add or delete a level or a pass Ch.10, p.10advanced techniques Ch.4, p.3Alignment tools Ch.2, p.5ALL STOP Ch.3, p.14, Ch.5, p.9ALL STOP key Ch.3, p.21alternate voltage label Ch.3, p.4American Petroleum Institute Codes Ch.13, p.3American Society for NDT Ch.13, p.3American Welding Society Codes Ch.13, p.3AMI OLP Software package Ch.14, p.1ANSI/ASC Z49.1, Safety in Welding, Cuttingand Allied Processes Ch.2, p.6ANSI/ASME Code for Pressure Piping, B31Ch.13, p.3Appendix 1. General Programming TermsCh.15, p.1Applicable Codes Ch.13, p.3Arc Detect Ch.5, p.2arc gap Ch.6, p.3, Ch.8, p.2Arc Gap Controller Ch.8, p.1arc gas line Ch.3, p.5arc gas solenoid valve Ch.3, p.5Arc input gas hose Ch.3, p.5arc length Ch.11, p.7Arc Start Ch.5, p.2Argon Ch.7, p.1argon/hydrogen mixture Ch.7, p.1ASME Bioprocessing Equipment Standard(ASME BPE-1997) Ch.13, p.3ASME Boiler and Pressure Vessel CodesCh.13, p.3automatic arc voltage control Ch.6, p.3AVC CONT Ch.5, p.7AVC DOWN JOG key Ch.3, p.23AVC Lock Delay Ch.5, p.9

AVC MODE Sample-Primary (SA-P) Ch.10,p.8AVC OFF Ch.5, p.7AVC Sample Mode Ch.5, p.7AVC sensitivity Ch.10, p.7AVC start delay Ch.10, p.7AVC Unlock Delay Timer Ch.5, p.4AVC UP JOG key Ch.3, p.23BBackground amps Ch.4, p.12backpurging set up Ch.11, p.4back-up gas Ch.7, p.1Bad Start Ch.5, p.3BAR GRAPH METER Ch.3, p.21bead placement Ch.11, p.10Bend tests Ch.13, p.2Bevel Ch.9, p.1blow-out Ch.7, p.1bluish haze Ch.7, p.2blunt tungsten Ch.11, p.7boiler tubes Ch.1, p.2CC key Ch.3, p.21Cable operating distances Ch.3, p.7cap pass Ch.9, p.2, Ch.11, p.7CE key Ch.3, p.21Charpy impact Ch.13, p.1circuit breaker (CB-1) Ch.3, p.3, Ch.3, p.4,Ch.3, p.11Cleaning Ch.9, p.5clean-up cut on the I.D. Ch.11, p.3Code organizations Ch.13, p.1Code requirements Ch.13, p.1cold lapping Ch.11, p.6consumable inserts Ch.11, p.3, Ch.11, p.4Control adapter cable Ch.3, p.5COOL - FLT Ch.3, p.16Cooling Unit (CW) Ch.3, p.2COPY Ch.10, p.13corrosion resistance Ch.7, p.2corrosion testing Ch.13, p.1cover plate Ch.3, p.4

Index. 1


index - continued

current pulsation Ch.11, p.2current pulse synchronized with the oscillationCh.10, p.1current pulse synchronized with the travelCh.10, p.1Current pulsing Ch.11, p.10Current value Ch.8, p.2Ddeionized water Ch.9, p.5deleting a program from the Library Ch.10,p.14diffuser Ch.7, p.2direction of rotation Ch.10, p.6Discoloration Ch.7, p.2Downslope Ch.5, p.8Eelectrical contact (resistance) Ch.8, p.2Electrical/Power Requirements Ch.3, p.1electrode shape Ch.8, p.2electrode type Ch.8, p.2Electronic Memory Module (EMM) Ch.3, p.27enclosed weld heads Ch.7, p.1ENTER Ch.3, p.12ENTER key Ch.3, p.21entering a new weld schedule Ch.10, p.1Equipment Installation Ch.3, p.1equipment required to support OLP Ch.15, p.6Essential variables Ch.13, p.2Example Weld Schedule Ch.4, p.13Exclamation symbol Ch.3, p.1FF keys Ch.3, p.21, Ch.10, p.8Faults

AVC LIMIT Ch.3, p.14BAD START Ch.3, p.14COOL FLT Ch.3, p.13GAS FLT Ch.3, p.13

GROUND FAULT Ch.3,p.14

HIGH VOLTS Ch.3, p.14,Ch.3, p.17

INPUT FLT Ch.3, p.14

LVPS FLT Ch.3, p.13OSC LIMIT Ch.3, p.14SENSOR 1,2,3 Ch.3, p.14Sensors Ch.3, p.17STUB-OUT Ch.3, p.14, Ch.3, p.17TEMP FLT Ch.3, p.13

Fiber-optic connection cable Ch.15, p.6fiber-optic interface cables Ch.15, p.7Fill Pass Procedure Refinement Ch.11, p.6Fill Passes Ch.11, p.6filler wire Ch.9, p.1filler wire balling up Ch.11, p.10fit-up Ch.9, p.1, Ch.11, p.3fit-up variations Ch.11, p.1fluorinated hydrocarbons Ch.9, p.5Formulas

Background Amps Ch.4, p.4converting IPM to RPM Ch.4, p.14inches per minute (IPM) to RPM Ch.4, p.4Primary Amps Ch.4, p.4Time for one level or pass Ch.4, p.3Tungsten length Ch.4, p.15Tungsten length calculation Ch.6, p.5

Full Level Functions Ch.5, p.5full penetration Ch.13, p.3FUNCTION keys Ch.3, p.21furnace tubes Ch.1, p.2Ggas cup size Ch.11, p.4Gas flow rates Ch.7, p.1Gas Mixtures Ch.7, p.1gas regulator/flowmeter Ch.3, p.5gas type Ch.8, p.2Graph of Weld Parameter Functions Ch.5, p.1Ground (welding work) cable Ch.3, p.7ground cable Ch.4, p.18ground finish Ch.6, p.2GTAW Ch.3, p.1GTAW process Ch.2, p.5, Ch.6, p.1, Ch.7, p.1GTAW welds Ch.13, p.1guide ring diameter Ch.11, p.4

Index. 2


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HHeads-Up Display Ch.3, p.27heat input Ch.11, p.2heat tint Ch.7, p.2high/low alignment Ch.9, p.4Hot Pass Ch.11, p.6hydrogen induced cracking Ch.7, p.1IIBM‘ compatible personal computer Ch.14, p.1ID purge line Ch.3, p.5inert gas Ch.7, p.1Input power Ch.3, p.3Input Voltage Ch.3, p.3Insert rings Ch.9, p.2insert rings Ch.9, p.4Inspection Ch.3, p.3Invalid number Ch.3, p.15, Ch.10, p.3ISO International Standard 6848 Ch.6, p.2isopropyl alcohol Ch.2, p.4, Ch.9, p.5JJoint fit-up and geometry tolerances Ch.11, p.2LL key Ch.3, p.21Land Ch.9, p.2, Ch.9, p.4Level 1

AVC Mode Ch.5, p.7Background Amps Ch.5, p.6Background Pulse Time Ch.5, p.5Background RPM Ch.5, p.6Background Wire Ch.5, p.6Primary Amps Ch.5, p.5Primary Pulse Time Ch.5, p.5Primary RPM Ch.5, p.6Primary Wire Ch.5, p.6Time Ch.5, p.5Torch Oscillation Ch.5, p.7Travel Mode, OFF, CONT, STEP Ch.5, p.6

Level 1 Pulse Mode Ch.5, p.5Level 1 Time Ch.5, p.3Level 2 To last programmed level Ch.5, p.8LIB key Ch.3, p.21LIBRARY Ch.3, p.22

Library Ch.3, p.11, Ch.3, p.12, Ch.3, p.22,Ch.10, p.3lightning flash symbol Ch.3, p.1line voltage Ch.3, p.11list of items supplied with the Model 227 Ch.3,p.3MM-227 Library Ch.10, p.14MAN ADV Ch.3, p.26Manual Advance Ch.5, p.8MANUAL PURGE key Ch.3, p.21Manual Torch Ch.3, p.27manual welding Ch.11, p.7Material chemistry variations Ch.11, p.2Material Safety Data Sheets Ch.2, p.6memory Ch.10, p.1METER key Ch.3, p.21Model 207 CW Ch.3, p.9Model 207-CW water cooling unit Ch.3, p.5Model 227

basic operation Ch.11, p.1currents up to 225 Amperes Ch.1, p.1Electronic Memory Module (EMM) Ch.10,

p.14memory Ch.10, p.1Panel Keys Ch.3, p.21

Model 227-RP extension Ch.3, p.7Model 81 weld head Ch.1, p.1model 81 weld head Ch.14, p.1Model 9 weld head Ch.14, p.1Modified “J” Prep Ch.9, p.1Modify Ch.10, p.10Modifying a Weld Program Ch.10, p.9Moisture Ch.7, p.1moisture analyzers Ch.7, p.3multi-pass welds Ch.4,p.3NNEXT LEVEL key Ch.3,p.21NEXT PASS key Ch.3,p.12, Ch.3, p.22

Index. 3


index - continued

NEXT SCREEN key Ch.3, p.12, Ch.3, p.22nitrogen Ch.7, p.1Non-essential variable Ch.13, p.2NUMERIC keys Ch.3, p.22numerical keyboard Ch.3, p.19OOffline Programming Ch.14, p.1Operate Mode Switch Ch.3, p.13, Ch.3, p.17,Ch.10, p.3, Ch.10, p.13

LOCK Ch.3, p.13OPERATE Ch.3, p.13PROGRAM Ch.3, p.13

Operation Ch.11, p.1Operator errors and tracking variations Ch.11,p.2Optional Accessories Ch.3, p.27organic solvents Ch.9, p.5OSC IN JOG key Ch.3, p.23OSC MAN Ch.3, p.26OSC OUT JOG key Ch.3, p.23oscillated stringer technique Ch.11, p.6Oscillator Amplitude Downslope Ch.5, p.9oscillator centering Ch.11, p.6Oscillator mode OFF Ch.10, p.6, Ch.10, p.8Oscillator Mode ON Ch.10, p.13Oscillator Upslope Ch.5, p.4Output power

maximum current output Ch.3, p.3minimum current output Ch.3, p.3

Override Key Ch.3, p.25OVERRIDE screen Ch.10, p.8oxide layer Ch.9, p.5oxygen analyzers Ch.7, p.3oxygen contamination Ch.7, p.1PPAPER FEED key Ch.3, p.21PAPER FEEDkey Ch.3, p.23

PASS Ch.3, p.25PASS 2 Ch.10, p.12permanent change in a weldprogram Ch.10, p.10Pipe end-preparation Ch.9, p.1

plastic tubing Ch.7, p.2Postpurge Ch.5, p.9Power select switch Ch.3, p.3, Ch.3, p.4Power supply

Panel Connections and Installation Ch.3,p.3

Specifications Ch.3, p.1PQR (Procedure Qualification Record) Ch.13,p.1Prep tolerances Ch.9, p.4PREPURGE and POST PURGE times Ch.10,p.6pressure testing Ch.13, p.1PREV LEVEL key Ch.3, p.22PREV PASS key Ch.3, p.12, Ch.3, p.22PREV SCREEN key Ch.3, p.12, Ch.3, p.22Previous Screen key Ch.10, p.4PRE-WRAP Ch.3, p.26primary to background pulse ratio Ch.4, p.11Print Functions Ch.3, p.11PRINT key Ch.3, p.12, Ch.3, p.22Printer Ch.3, p.12PRINTER AUTO Ch.3, p.12PRINTER MANUAL Ch.3, p.13print-out from the Model 227 Ch.13, p.1PRO key Ch.3, p.22, Ch.10, p.3Process Development Ch.11, p.2process variations Ch.11, p.2production procedure sheet Ch.11, p.10Programming Functions

COPY Ch.10, p.13CREATE Ch.10, p.3DELETE Ch.10, p.14MODIFY Ch.10, p.9TRANSFER Ch.10, p.14

Programming Mode Ch.10, p.3, Ch.10, p.11Programming rules of thumb

For Oscillation Beads Ch.4, p.8Stringer Beads Ch.4, p.6

Protectioneye, ear, and body Ch.2, p.6

Pulse

Index. 4


index - continued

ON, OFF, and SYNC Ch.10, p.7Pulse mode ON Ch.10, p.8Pulse Times Ch.5, p.3Pulse-to-pulse spacing Ch.4, p.11purge end cap Ch.7, p.3Purge gas purity specifications Ch.7, p.2Purging techniques Ch.7, p.2Purpose of Welding Procedures Ch.13, p.2Qquartering the pipe Ch.11, p.10Rradiography Ch.13, p.1Radius Ch.9, p.2Recommended Gas Flow Rates for Model 9Weld Heads Ch.7, p.4REMOTE connector Ch.3, p.7Remote pendant Ch.3, p.2Remote pendant installation Ch.3, p.7Response Ch.10, p.7responsibility for code requirements Ch.13, p.1Retract Ch.10, p.6Return To Home and Reset Ch.5, p.9RF and EMI Emissions Ch.2, p.5RF Start Ch.5, p.2root land dimension Ch.11, p.4Root Pass Procedure Refinement Ch.11, p.4Rotation

CONT Ch.4, p.15CONT, STEP, and OFF Ch.10, p.7OFF Ch.4, p.15STEP Ch.4, p.14, Ch.4, p.15

rotation delay (DLY ) Ch.10, p.6RPM (revolutions per minute) Ch.4, p.14RS232 Interface box Ch.15, p.7SSafety Ch.2, p.1Sample Model 227 Weld Program Ch.10, p.2Sample Weld Program Ch.10, p.11SEMI (Semiconductor Equipment andMaterials International) Ch.13, p.4SEQ START key Ch.3, p.22SEQ STOP key Ch.3, p.22

Sequence of Events Ch.5, p.1Sequence Start Ch.5, p.1SEQUENCE START key Ch.3, p.12Service adapter cable Ch.3, p.5SET Ch.3, p.26Set-Up Ch.3, p.11Set-Up Function Menu Ch.3, p.14Set-Up Functions

ARC-V-FLT Ch.3, p.17AVC Jog Speed Ch.3, p.18Calculate Ch.3, p.15Changing AMPS or TIME to tenths Ch.3,

p.16DATE RESET Ch.3, p.18MEASURES ENGLISH/MEASURES

METRIC Ch.3, p.17OSC Jog Speed Ch.3, p.18Power Supply SERIAL NUMBER Ch.3,

p.19Print EMM Ch.3, p.16REV. Ch.3, p.16Rotation RPM Ch.3, p.15Tungsten Length Ch.3, p.15Weld Select Ch.3, p.15Welder ID Number Ch.3, p.19WELDER NAME Ch.3, p.19

SET-UP key Ch.3, p.14, Ch.3, p.22shielding gas Ch.7, p.1Software version Ch.3, p.16Software version 1.4 Ch.1, p.1SPECIAL FUNCTION key Ch.3, p.27Special Function Key Ch.3, p.25square butt fusion welding Ch.11, p.7Square butt weld Ch.9, p.2Start Mode RF Ch.10, p.7Start Mode TOUCHCh.10, p.7starting point for a newprocedure Ch.11, p.4STATUS SCREENCh.3, p.19Status Screen Ch.3, p.11,

Index. 5


index - continued

STOP PRINT key Ch.3, p.21STOP PRINTkey Ch.3, p.23storage and transfer of weld scheduleinformation Ch.14, p.1STORE Ch.10, p.10storing a weld schedule Ch.10, p.8storing the changes Ch.10, p.9stringer bead Ch.10, p.1, Ch.10, p.6Stringer beads Ch.4, p.7stringer beads. Ch.4, p.5suckback Ch.9, p.2Sychronization of Oscillator, Weld Current andWire Feed functions Ch.4, p.11Synchronizing the travel (step mode) to thecurrent pulsing Ch.11, p.10Synchronizing the wire to the current pulsingCh.11, p.10TT/MODE manual Ch.10, p.8Tack welds Ch.11, p.3Tacking

high-purity Ch.4, p.19Tacks Ch.9, p.2Taper angle Ch.6, p.2Tensile testing Ch.13, p.2Test coupons Ch.13, p.2TEST MODE Ch.2, p.5Timer mode manual (MAN) Ch.10, p.6Timer Mode, Auto, Manual Ch.5, p.8titanium Ch.7, p.2torch is bobbing up and down Ch.11, p.10Touch Start Ch.5, p.2Training Ch.1, p.3TRANSFER Ch.10, p.14Travel Direction Ch.5, p.6travel speed Ch.4, p.7Travel Speed setting Ch.11, p.4

Travel Start Delay Ch.5, p.3Travel Stop Delay Ch.5, p.9Troubleshooting flow chartCh.12, p.1Tungsten

Color Code Ch.6, p.1Diameters Ch.6, p.3Diameters and Tip Diameters Ch.6, p.2Electrode Dimensions

Model 8 and Model 9 Ch.6, p.5pipe Ch.6, p.4

life Ch.6, p.4Specifications Ch.6, p.1stickout Ch.11, p.4, Ch.11, p.7Tip diameters Ch.6, p.3Type Ch.6, p.1

tungsten2% thoria Ch.6, p.2ceriated Ch.6, p.2melting point Ch.6, p.2

Tungsten Diameters Ch.6, p.3Tungsten Electrode Dimensions

pipe Ch.6, p.4TVL CCW JOG key Ch.3, p.22TVL CW JOG key Ch.3, p.22UUS Department of Defense Military SpecsCh.13, p.3VV type joint Ch.9, p.2ventilation Ch.7, p.3Visual weld criteria Ch.13, p.3WWarnings

Disconnect the input power Ch.2, p.1Do not weld in enclosed areas Ch.2, p.3emission of toxic fumes Ch.2, p.2energized electrical parts Ch.2, p.1factory training is essential Ch.2, p.3fires or explosions Ch.2, p.2Follow OSHA international or employer

guidelines Ch.2, p.3High Frequency Radio Wave Ch.2, p.1Magnetic fields Ch.2, p.1NEVER CONNECT OXYGEN OR

ACETYLINE TO THE MODEL227. Ch.2, p.4

Index. 6


index - continued

non-flammable protective clothing Ch.2,p.2

severe burns from touching newly weldedcomponents Ch.2, p.2

System components are not waterproofCh.2, p.3

welding arc emits ultra-violet (UV)radiation Ch.2, p.2

welding on sealed containers or pipes Ch.2,p.2

weave bead Ch.10, p.1weave beads Ch.11, p.10Weld Criteria Ch.13, p.1Weld Current Start Level Ch.5, p.3Weld Current Upslope Ch.5, p.3weld data record system Ch.14, p.1Weld Data Recording Ch.14, p.1weld documentation Ch.3, p.12Weld head cable Ch.3, p.6Weld head calibration Ch.1, p.3, Ch.4, p.12Weld head control cable Ch.3, p.6Weld head installation Ch.3, p.6weld head selection Ch.10, p.5weld head serial numbers Ch.3, p.12Weld Heads

Model 15 Large diameter pipe weld headCh.1, p.2

Model 6 tube-to-tubesheet weld head Ch.1,p.3

Model 6 tube-to-tubesheet weld headsCh.1, p.3

Model 79 Weld Heads Ch.1, p.2Model 9 fusion weld heads Ch.1, p.2Model 95 Series open frame Ch.1, p.2

Weld headsModel 96 Ch.1, p.3

weld joint geometry Ch.11, p.3Weld Library Ch.3, p.11weld number Ch.3, p.12, Ch.10, p.4Weld parameters Ch.4, p.1

Automatic Voltage Control Mode Ch.4, p.5Background Automatic Voltage Control

(AVC-BCK) Ch.4, p.5Background IPM Ch.4, p.3Background Pulse Time Ch.4, p.4Background Wire Feed Ch.4, p.5Downslope Ch.4, p.1Excursion (EXC) Ch.4, p.6IN (IN DWELL) Ch.4, p.5Oscillate Mode Ch.4, p.2Oscillator Amplitude (OSC/AMPL) Ch.4,

p.5Outdwell (OUT) Ch.4, p.6Postpurge Ch.4, p.1Prepurge Ch.4, p.1Primary Automatic Voltage Control (PRI-

AVC) Ch.4, p.5Primary IPM Ch.4, p.3Primary Pulse Time Ch.4, p.4Primary Wire Feed Ch.4, p.4Pulse ON/OFF Ch.4, p.3Response Ch.4, p.3Retract Ch.4, p.2Rotation (ROT) Ch.4, p.2, Ch.4, p.3Rotation Delay Ch.4, p.2SAMP/BCK Ch.4, p.5SAMP/PRI Ch.4, p.5Start Automatic Voltage Delay Ch.4, p.3Start Wire Feed Delay Ch.4, p.2Time Mode Ch.4, p.2Up-slope Ch.4, p.1Wire Feed Delay Stop Ch.4, p.2

Weld pass # Ch.3, p.26Weld Procedure Development Ch.11, p.1Weld Process Documentation Ch.11, p.10Weld samples Ch.11, p.3Weld schedule Ch.10, p.1WELD/TEST key Ch.3,p.23weldable materialsCh.10, p.4welder certificationCh.13, p.3Welding current Ch.4,

Index. 7


index - continued

Welding position Ch.11, p.2welding position Ch.10, p.5Welding System Ch.1, p.1Where to start Ch.11, p.3wire deposition rate Ch.11, p.7wire entry Ch.8, p.3, Ch.11, p.4Wire Feed Delay Ch.5, p.4

wire feed start delay Ch.10, p.6Wire Feed Upslope Ch.5, p.4WIRE JOG FWD key Ch.3, p.23WIRE JOG REV key Ch.3, p.23wire manipulator assembly Ch.11, p.4WIRE MODE ON/OFF key Ch.3, p.23Wire Stop Delay Ch.5, p.9

Index. 8

Documents

AMI Model 227 Power Supply Operator Training Guidelines