Operator's Manual - Arc Machines, Inc.

190 Pages·2005·13.74 MB·English

10500 Orbital Way
Pacoima, California 91331 U.S.A.
MODEL 307 POWER SUPPLY
OPERATOR TRAINING GUIDELINES
Document No. 740096
Doc. Rev. A
HEADQUARTERS GERMAN OFFICE
Arc Machines, Inc. Arc Machines GmbH
10500 Orbital Way Markelsbach 2
Pacoima, CA 91331 U.S.A. D-53804 Much, Germany
Tel.: [phone] Tel.: 02245 / 91680
Fax: [phone] Fax: 02245 / 916868
[email protected] [email protected]
EUROPEAN OFFICE UK OFFICE
Arc Machines, Inc. Arc Machines UK Limited
Chemin du Lavasson 2 Unit 4, Raynesway Park Drive
CH-1196 Gland Derby, DE21 7BH England
Switzerland Tel.: 01332 / 574000
Tel.: +41 / 22 / 995.00.51 Fax: 01332 / 757757
Fax: +41 / 22/ 995.00.59 [email protected]
[email protected]
www.arcmachines.com
Document No. 740096
Rev. A
MODEL 307
Operator Training Guidelines
Arc Machines, Inc.
General Guidelines for Orbital Tube and Pipe Welding
The Arc Machines Model 307 is designed to be a versatile orbital
welding control and power supply system. The Windows™-based-
Model 307 features the absolute latest state-of-the art technology,
from its 200 ampere second-generation solid state power supply to
its color VGA display with touch screen. The Windows™ environ-
ment makes the Model 307 uniquely suited for weld logging and
weld documentation. The basic Model 307 features a complete com-
plement of controls including gas flow and available water cooling
necessary to operate AMI orbital weld heads for in-place field weld-
ing tasks ranging from small diameter fusion tube welds to welding
thin-wall piping with filler wire addition.
Effective Date: September 1, 2004
Copyright 2005, Arc Machines, Inc.
Arc Machines, Inc. Model 307 Orbital Welder Training
Model 307 Operator Training Guidelines
Notice
This document and the information contained herein is the property of Arc
Machines, Inc. It is proprietary and submitted and received in confidence. It
shall be used only for the purpose for which it is submitted and shall not be
copied in whole or in part without the prior express written permission of Arc
Machines, Inc.
The information in this document has been carefully reviewed and is believed
to be accurate. However, no responsibility is assumed for inaccuracies.
Information and instructions in this document are subject to change and Arc
Machines, Inc. reserves the right to change specifications and data without
notice.
WARNING!
The nature of the GTAW process creates some POTENTIAL HAZARDS. In
accordance with international safety regulations the EXCLAMATION SYMBOL
indicates that this equipment is considered HAZARDOUS until an operator has
been made aware of these POTENTIAL HAZARDS by READING THIS MAN-
UAL. The LIGHTNING FLASH SYMBOL indicates that there are potential elec-
trical hazards. The use and display of these symbols make it the OPERATOR’S
RESPONSIBILITY TO INSURE THAT HE HAS READ AND/OR BEEN MADE
AWARE OF ALL SAFETY-RELATED ITEMS CONTAINED IN THIS MANUAL.
Publication date: First Edition - September 2004
Copyright 2005 by Arc Machines, Inc.
All rights reserved.
REV DCO# CHANGE DESCRIPTION DATE APR
Document No. 740096 i.
Rev. A
Arc Machines, Inc. Model 307 Orbital Welder Training
MODEL 307 OPERATOR TRAINING GUIDELINES
EFFECTIVITY
Features and operation of the Model 307 are derived mostly from SOFTWARE.
This document is based on the latest STANDARD version of SOFTWARE at the
time of last revision (see revision page).
Some deviations in actual operation, from this document, are possible
depending on the software version of a particular machine. Please feel free to
contact Arc Machines Service Department for documentataion or information
on how software updates effect this document.
Document No. 740096 ii.
Rev. A
Table of Contents
INTRODUCTION
1
2 SAFE OPERATION
3 ICONS, BUTTONS, SYMBOLS
4 MODEL 307 INSTALLATION
SEQUENCE OF EVENTS/
5
WELD PARAMETERS
POWER SUPPLY OPERATION
6
& FUNCTIONS
7 MODEL 307 LIBRARY
AUTOGENERATION OF WELD
8
SCHEDULES
MANUAL CREATION OF
9
MODEL 307
WELD SCHEDULES
OPERATOR TRAINING 10 ASSOCIATED DATA
GUIDELINES
11 WELDING WITH THE 307
WELD PROCEDURE
12
OPTIMIZATION
General Guidelines for
WELD HEAD CALIBRATION
Orbital Welding of Tube
13
& Thin-Wall Pipe & OPERATION
END-PREPARATION FOR
14
ORBITAL WELDING
TUNGSTEN
15
SPECIFICATIONS
PURGE GASES AND PURGE
16
PARAMETERS
WELD CRITERIA/WELD
17
QUALIFICATION
DATA ACQUISITION/
18
ADVANCED FUNCTIONS
19 APPENDICES
Document No. 740096
Effective Date: September 1, 2004 20 INDEX
Draft May 2005
Arc Machines, Inc. Model 307 Orbital Tube Welder Training
C
hapter 1. Introduction to Orbital Welding with
the Model 307 Power Supply
A
rc Machines’

new Windows™-
based Model 307 Power
Supply is designed for
autogenous orbital GTA
welding. In addition to
the standard tube-weld-
ing functions it also has
wire feed capabilities.
The Model 307 was
developed for economy
and ease of use and will
automatically generate a
weld schedule or pro-
gram when the Arc
Machines weld head and
weld component dimen- Arc Machines’ Model 307 Power Supply and Model 8-2000 weld
head on a cleanroom bench at the WELDEX show in the UK.
sions are entered. To
meet the Industry’s demands for quality assurance (QA) and weld data
collection, the Model 307 has extensive capabilities to store and transmit
detailed weld documentation and historical data.
Welding personnel can program the Model 307 in time per level or simply
enter the desired weld head position in rotational degrees for the end of
each level, and time required to complete the level will be entered auto-
matically. Weld parameters are clearly visible on the 307’s touch screen
and can easily be modified by the operator if changes should be necessary.
Input Power. The Model 307 Power Supply operates on 110 to 240 VAC,
50/60 Hz, single phase only, without reconnection.
Weld Current. The Model 307 has a programmable range of 5 to 200
amperes of primary welding current, while average current is software-lim-
ited to 150 amps or less. The Model 307 will warn users if programmed
current values exceed recommendations for particular weld heads.
Weld Heads. The Model 307 operates all standard AMI fusion weld heads
including the Model 8 and Model 9 series, Model 4, Model 85, and Model 96.
It can also operate the Model 95 series of wire-feed weld heads. The motor
controls can accept DC tachometer velocity feedback, or quadrature-encod-
er position and velocity information.
Document No. 740096 Chapter 1. Page 1.
Rev. A
Arc Machines, Inc. Model 307 Orbital Tube Welder Training
Left and above: Welding in a dairy plant with a Model 8-4000 weld head.
Right: A Model 4-500 bench mount weld head.
Real-time digital data acquisition. The Model 307 captures and displays
real-time streaming data for welding current, pulsation, arc voltage and
travel speed during the weld and displays the data in graphical form on the
Model 307 screen at the end of the weld. The power supply can compare
the actual data gathered during the weld and report whether the weld
parameters were performed within pre-set acceptance limits.
Weld Logging. The Model 307’s Intel® Pentium® processor makes this
power supply uniquely suited for weld logging and weld documentation.
Weld records are created by the Model 307 when a weld identification (ID)
number is assigned to the weld. Users can select from a variety of fields of
Associated Data which include weld head and power supply serial num-
bers; material type and heat numbers of tubing, fittings or other weld com-
ponents; gas type, flow rates to weld head and weld I.D., dewar serial
number; and electrode type and geometry.
Project management. Rapid retrieval of weld records is important for
users who may be subject to audits from the FDA or other regulatory
agency. Weld records stored in the Model 307 memory can be retrieved by
project, weld identification number, date, welding operator, or other field.
Weld records can be downloaded onto elec-
tronic media or to a computer for compilation
of records for a particular job thus avoiding
the necessity of re-entering this data manu-
ally. Weld I.D. numbers as well as other iden-
tifying data may also be printed onto an
adhesive-backed plastic label that can be
used for weld identification purposes.
It should be understood that no welding
machine can unequivocally detect and indi- Model 95-6625 Weld Head with wire-
cate the quality of a particular weld. The Feed capabilities welding a flange to a
pipe in Guatemala. Photo courtesy of
Model 307 can, however, provide a detailed
Alimentos Maravilla S.A.
Document No. 740096 Chapter 1. Page 2.
Rev. A
Arc Machines, Inc. Model 307 Orbital Tube Welder Training
record of each weld, so that if quality questions arise, the process of trac-
ing the root cause of a problem is greatly simplified.
Statement of purpose: This manual is intended for use in an Arc
Machines, Inc. Model 307 Tube Welder Training class taught by a factory-
approved Arc Machines, Inc. Instructor. IT IS NOT A SUBSTITUTE FOR
THAT TRAINING. The purpose of such a class is to enable welding person-
nel to quickly and easily understand the basic functions and safe operation
of the Model 307 Power Supply and appropriate weld head(s) and to use this
equipment successfully in their application.
Students must be able to correctly set up the power supply and be able to
calibrate and install the weld head with correct tube-clamp inserts and the
correct tungsten type, diameter and length. They must understand the
basics of purging and know how to set the correct flow rates for the weld
head they are using.
Hands-On. Students are given sufficient hands-on training to enable them
to generate weld programs, to make welds, and to evaluate the welds.
Trainees should also be familiar with the end-preparation requirements for
orbital welding. They are expected to recognize an acceptable weld for
their industry or application and be able to make adjustments in the weld
program or procedures in order to produce welds that comply with the
standards of their industry.
Upon successful completion of this course, which is typically comprised of
two 8-hour days and, at the discretion of the instructor, students will
be awarded an Arc Machines, Inc. Certificate of Completion.
Document No. 740096 Chapter 1. Page 3.
Rev. A
Arc Machines, Inc. Model 307 Orbital Tube Welder Training
C S
hapter 2. afe Operating Procedure -
S
afety Precautions for Model 307 Operation
AVOID ALL
CONTACT
WITH THE
WELDING
WORK Electrode installa-
tion in a Model 8
(GROUND) OR
weld head.
ELECTRODE
DURING ARC
START
THE ELECTRODE SHOULD ALWAYS BE
CONSIDERED A POSSIBLE SHOCK HAZARD.
This is especially true whenever the system is:
• IN SEQUENCE
• READY TO WELD,
• IS WELDING,
• OR HAS JUST FINISHED WELDING.
When replacing or adjusting the electrode:
• Set power supply to “TEST” mode
Most AMI Power Supplies feature RF (radio frequency) Arc
Starting. This is a High Voltage/High Frequency electrical trans-
mission process. The GTAW process requires electrical potential
(high voltage) to be present on the electrode and on exposed
internal terminals during arc starting and during welding. ALL
AMI Power Supplies contain a “bleeder” circuit to ground any
residuals or potential after welding or after an aborted or bad
“arc start” attempt. However, these circuits take a few seconds
to operate or could fail.
Document No. 740096 Chapter 2. Page 1.
Rev. A