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AMI 227 Operation Manual

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10500 Orbital Way
Pacoima, California 91331 U.S.A.
MODEL 227 POWER SUPPLY
OPERATION MANUAL
Document No. 740063

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  • Page 1 10500 Orbital Way Pacoima, California 91331 U.S.A. MODEL 227 POWER SUPPLY OPERATION MANUAL Document No. 740063...
  • Page 2 MODEL 227 OPERATION MANUAL NOTICE This document and the information contained herein is the property of Arc Machines, Inc.. It is proprietary and submitted and received in confidence. It shall be used only for the purpose for which it is submitted and shall not be copied in whole or in part without the prior express written permission of Arc Machines, Inc.
  • Page 3 MODEL 227 OPERATION MANUAL EFFECTIVITY Features and operation of the Model 227 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.

  • Page 4: Table Of Contents

    Non-Programmable Functions Ambient Temperature Ranges Cable Operating Distance Limits SECTION III INSTALLATION Inspection Power Connection Welding Gas Connections Adapter Cable to M-227 Installation Weld Head Installation Ground (Work) Cable Installation Remote Pendant Installation SECTION IV SYSTEM FUNCTIONS Introduction Functional Description, General...
  • Page 5 SECTION VII CALIBRATION Introduction Equipment Required Current Servo AVC Servo Oscillator Servo General Maintenance System Fault Corrections Error Messages 7.11 Miscellaneous Maintenance 7.12 SECTION VIII OPTIONS Introduction M227/207-CW & M207-CW Cooling Units M-227-EMM External Memory Module Doc # 740063 Rev E...
  • Page 6 MODEL 227 OPERATION MANUAL LIST OF ILLUSTRATIONS NUMBER DESCRIPTION PAGE FIGURE 1 SYSTEM CONFIGURATION FIGURE 2 INSTALLATION LOCATIONS FIGURE 3 AC POWER SET-UP FIGURE 4 CABLE CONNECTIONS FIGURE 5 SEQUENCE TIMING CHART FIGURE 6 PANEL KEY LOCATIONS FIGURE 7 USE OF NEXT/PREV KEYS...

  • Page 7: Introduction

    (see figure 1). The complete system consists of the M-227 power supply, adapter cable, gas lines and a variety of different AMI Welding Heads or Torch Fixture devices (Heads and Fixtures are sold separately).

  • Page 8: Safety Precautions

    MODEL 227 OPERATION MANUAL SECTION I - INTRODUCTION SAFETY PRECAUTIONS This section contains cautions and warnings concerning the operation of this equipment and welding equipment in general. However, in addition to reading this manual and before operating this or any welding equipment, users should reference and be familiar with “ANSI-49.1 Safety in Welding and Cutting”.
  • Page 9 Operators and Maintenance Technicians who operate AMI equipment. WARNING: Before operating, storing or handling, always make sure that the M-227, M-227-RP Pendant, weld heads and cables are not exposed to rain or standing water. SYSTEM COMPONENTS ARE NOT WEATHER-PROOF. Doc # 740063 Rev E...

  • Page 10: Operational Precautions

    If not properly seated or protected, short circuits, poor connections or inert gas leaks could occur. 3. The M-227 is intended for typical GTAW gases ONLY. NEVER CONNECT OXYGEN OR ACETYLENE TO THE M-227.

  • Page 11: Rf And Emi Emissions

    THE M-227. 10. Do not use acid, corrosives, liquid “Easy Out” or any liquid substance on the M- 227 or any AMI weld head. When cleaning, use only a light solution of Isopropyl alcohol on a soft cloth . 11. When handling, take extreme care to avoid dropping the M-227, weld heads, cables or any accessories.
  • Page 12 RF PROTECTION AMI policy is to comply with the IEC (and thus FCC) regulations. Our design rules and procedures include testing and observing this area. We can assure our customers that every effort has been made to reduce RF emissions to the absolute minimum from our power sources.
  • Page 13 MODEL 227 OPERATION MANUAL SYSTEM CONFIGURATON Doc # 740063 Rev E...

  • Page 14: Shock Hazard Warning

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

  • Page 15: Electrical

    11) - Rated No Load Output Voltage (open circuit voltage) is 59 volts. 12) - The M-227 is a 100 % Duty Cycle for the rated outputs (9). 15) - Input Voltage type contains symbol for single (1) phase Alternating Current (AC) input at 50 or 60 Hz frequency.
  • Page 16 22) - The M-227 is rated as class I. No symbol is used for class I equipment. 23) - “S” Symbol indicates a welding power source which is suitable for an environment with an increased electric shock hazard.

  • Page 17: Physical Construction

    MODEL 227 OPERATION MANUAL SECTION II - SPECIFICATION PHYSICAL CONSTRUCTION Cabinet material - aluminum Height = 13.9 inch (353.1mm) cover closed 12.3 inch (312.4 mm) cover removed Width = 22.75 inch (577.9 mm) Depth = 19.25 inch (489.0 mm) Weight = 91 lbs (41.3 kg)

  • Page 18: Multi-Level Functions

    The above are considered normal limits and using a standard M227/207-CW or M207-CW Cooling Unit Option. With special options, greater distances can be achieved.Consult with an AMI technical representative for more information. Doc # 740063 Rev E...

  • Page 19: Inspection

    Use the following procedure to insure that the M-227 is set-up for the correct AC power. 1. The M-227 is supplied with a 25 ft power cord. One end has a connector on it that plugs into the side of the M-227. The wires on the other end are pig- tailed (no connector).

  • Page 20: Welding Gas Connections

    The plate is labeled as to what voltage it is currently set for. 5. If the M-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.

  • Page 21: Adapter Cable To M-227 Installation

    ADAPTER CABLE TO M-227 INSTALLATION The M-227 comes standard with a 40 ft Pipe Weld Head Adapter Cable. This will be used for most Weld Heads. However, some Weld Heads will use a different Adapter Cable or additional cables. The correct cables required should be resolved at the time of order.
  • Page 22 MODEL 227 OPERATION MANUAL INSTALLATON LOCATONS Doc # 740063 Rev E...
  • Page 23 MODEL 227 OPERATION MANUAL AC POWER SET-UP Doc # 740063 Rev E...
  • Page 24 MODEL 227 OPERATION MANUAL CABLE CONNECTIONS Doc # 740063 Rev E...

  • Page 25: Weld Head Installation

    A 50 ft Ground Cable with a “C” type clamp on one end and a Cam-lok quick dis-connect is provided. Connect the quick dis-connect to the GROUND connector on the M-227 or the Ground Extension Cable if one is provided.

  • Page 26: Remote Pendant Installation

    M-227 power supply. Insert the M-227-RP cable connector into the M-227 Panel connector labeled REMOTE. If a M-227-RP extension is used, it is installed between the M-227 and the If required the M-227 can be operated without the RP Unit. CAUTION...

  • Page 27: System Functions

    3 and 225 Amps. NOTE The M-227 is limited, by software, not to be able to be programmed for an average current (between primary and background) greater than 200 Amperes. However, a peak pulse can be up to 225 amperes as long as the average does not exceed 200 amperes.
  • Page 28 TORCH OSCILLATION - The standard M-227 comes with an OSC Motor Servo. A version of the M-227 is also available without OSC. The OSC in conjunction with a weld head with an OSC motor is used to perform both cross-seam steering during a weld and to provide welding weave across the weld during rotation.

  • Page 29: Weld Library And Description

    11. GAS FUNCTIONS - As stated, the M-227 is intended for the GTAW process. This process requires a welding gas (usually inert) for operation and the M-227 is equipped with a gas solenoid and input/output connectors for the control of the welding (arc) gas.

  • Page 30: Weld Sequence

    LEVEL 1. If the TIMER MODE is in AUTO the LEVEL 1 Timer will start to count and the M-227 will stay in LEVEL 1 until this time is complete. If the TIMER MODE is set to MANUAL the...
  • Page 31 MODEL 227 OPERATION MANUAL SECTION IV - SYSTEM FUNCTIONS WELD SEQUENCE EVENT 3: 6. WIRE FEED START DELAY - Feeding of the Wire should not occur, in most cases, until travel has started. When the arc is established the WIRE FEED START DELAY time will begin to count. When this time is complete the wire will be able to feed if the Wire Mode is set to ON.
  • Page 32 MODEL 227 OPERATION MANUAL SECTION IV - SYSTEM FUNCTIONS WELD SEQUENCE EVENT 4: FULL LEVEL FUNCTIONS - 3. LEVEL 1 PRIMARY PULSE TIME - If the LEVEL 1 PULSE MODE is ON this function will now be timing the Primary pulses (see Event 3).
  • Page 33 MODEL 227 OPERATION MANUAL SEQUENCE TIMING CHART Doc # 740063 Rev E...
  • Page 34 MODEL 227 OPERATION MANUAL PANEL KEY LOCATIONS Doc # 740063 Rev E...
  • Page 35 MODEL 227 OPERATION MANUAL SECTION IV - SYSTEM FUNCTIONS WELD SEQUENCE EVENT 4: FULL LEVEL FUNCTIONS - 10. LEVEL 1 PRIMARY WIRE - After the Wire Start Delay time is complete the Wire Feeder will feed at the Primary Wire Feed value whenever the system is in Primary and the Wire Mode is set to ON.
  • Page 36 MODEL 227 OPERATION MANUAL SECTION IV - SYSTEM FUNCTIONS WELD SEQUENCE EVENT 5: LEVEL 2 TO LAST PROGRAMMED LEVEL - As the arc is rotated around the weld it is usually necessary to program changes in the current, pulse times, modes and rotation speed. These changes are called LEVELS and up to 100 can be programmed for each sequence.
  • Page 37 Use of the F keys is always prompted by the screens. L KEY - The M-227 is multi-lingual. Pressing this key will change the display from English to French to German, etc.. The L key is always active.

  • Page 38: Panel Keys

    MODEL 227 OPERATION MANUAL SECTION IV - SYSTEM FUNCTIONS PANEL KEYS 10. NEXT LEVEL KEY - Active when weld schedules with more than one level are being displayed. An * will appear on the displays to indicate that more levels are programmed for that weld schedule.
  • Page 39 23. TVL CCW JOG KEY - Active at all times. When pressed the weld head will rotate the electrode in the counterclockwise direction. 24. WELD/TEST KEY - At power on the M-227 will always be in the TEST mode. In TEST mode a weld sequence can be run but NO ARC will be struck.

  • Page 40: Operate Mode Switch

    MODE LOCK - After weld schedule has been selected it may be locked-in to prevent selection of any other weld schedule. This feature is intended primarily for when the operator is welding out-of-sight of the M-227 or if a supervisor wishes to insure that ONLY a particular weld schedule is used.
  • Page 41 The method of alerting the operator depends on what the fault is and when it occurs. A problem with TEMP, LVPS or INPUTAC when the M-227 is first turned on will create a FAULT SCREEN and the fault must be corrected before the M-227 will proceed with any other functions.

  • Page 42: Sensor 1,2,3 Faults

    SECTION IV - SYSTEM FUNCTIONS SENSOR 1, 2, 3 FAULTS The M-227 has 3 separate inputs that the user can define for creating a fault condition based on some external problem. The most common is connecting a gas analyzer(s) to the M-227 to detect excessive Oxygen in the I.D. purge of a weld.
  • Page 43 MODEL 227 OPERATION MANUAL SECTION IV - SYSTEM FUNCTIONS GLOSSARY OF DISPLAY SYMBOLS AND ABBREVIATIONS - The M-227 displays contain many abbreviations. The following is an alphabetical listing: = Aluminum = Amperes = Background (low value of a function that pulses)
  • Page 44 MODEL 227 OPERATION MANUAL SECTION IV - SYSTEM FUNCTIONS 4.10 GLOSSARY OF DISPLAY TERMS - The M-227 displays contain many terms that do not relate directly to a function or sequence. The following is a listing of those terms: AMIWELD...

  • Page 45: Introduction

    Programming and development of schedules are not covered in this section. It is very important to insure, before operating, that the operator has INSTALLED the M-227 per section III and has a good understanding of functions from section IV. Function explanations are not covered in this section.

  • Page 46: Use Of Next/Prev

    MODEL 227 OPERATION MANUAL SECTION V - OPERATION INITIAL POWER ON/STATUS SCREEN (continued) UPPER SCREEN TO WELD PRESS LIB TO PROGRAM PRESS PRO SYS HOURS - 00000.0 ARC HOURS - 00000.0 LOWER SCREEN TEMP-OK INPUTAC-OK GAS-OK LVPS-OK COOL-OK SENSOR1-OK 2-OK 3-OK Actual hours will appear where the above show 0.

  • Page 47: Weld Schedule Selection

    MODEL 227 OPERATION MANUAL SECTION V - OPERATION USE OF NEXT/PREV SCREENS/LEVELS PURGE - SLOPE - ROT DELAY = Displays the time for Prepurge, Postpurge, Upslope, Downslope Rotation Direction and Rotation Start WF DELAY - RETRACT - T/MODE - OSC MODE = Displays settings...

  • Page 48: Pass Advance

    MODEL 227 OPERATION MANUAL SECTION V - OPERATION WELD SCHEDULE SELECTION 2. (continued) USE SCREEN KEYS TO FIND # PRESS ENTER OR IF # IS KNOWN ENTER #--- PRESS ENTER WALL HEAD PASSES * 1.500 .065 Instructions are displayed on the upper screen. The first weld schedule in memory (may not be #001) will be displayed on the lower screen.
  • Page 49 MODEL 227 OPERATION MANUAL USE OF NEXT/PREVIOUS KEYS Doc # 740063 Rev E...

  • Page 50: Viewing Function Values

    3. Press the SEQ START key to run this weld sequence OVERRIDING FUNCTION VALUES Each weld schedule in the M-227 library can be programmed to allow unlimited, limited or NO changes to be made to the function values of the weld schedule. If the weld schedule allows changes to be made use the following procedure.

  • Page 51: Set Up Functions

    M-227-RP Remote Pendant. Press the F key under Weld Select and follow the instructions on the display. 3. COOLANT FAULT - If the Coolant Fault is ON the M-227 will look to see if an optional M227/207-CW or M207-CW Cooling Unit is connected. If it is then the M-227will require that coolant be flowing or else it will create a fault.
  • Page 52 SET UP screen. 8. OPERATOR ID - This feature allows the Operator to enter his name into system memory and the M-227 will record that name onto every print out run after a weld sequence. 9. SERIAL NUMBER - This feature allows the entry of the Power Supply Serial number into system memory and the M-227 will record that SN# onto every print out run after a weld sequence.
  • Page 53 HIGH input signal. Reference AMI drawing 45B072514 for pin connections and electrical signal information about HIGH and LOW. 2. PRINTER MODE - The M-227 can be set up to make a print out of the WELD # automatically (AUTO) after every Sequence. If set to MANUAL print will only be made if the PRINT key is pressed after a weld sequence.
  • Page 54 MODEL 227 OPERATION MANUAL STANDARD REMOTE PENDANT 5.10 Doc # 740063 Rev E...

  • Page 55: Remote Pendant Operation

    32. OUT Dwell time Override key 33. 8 character digital status display 2. Items 1 to 13 above are duplicates of keys contained on the M-227 panel. They work exactly the same as the keys on the panel. When the RP is connected these keys and the identical ones on the M-227 panel are active at the same times.
  • Page 56 MODEL 227 OPERATION MANUAL SECTION V - OPERATION REMOTE PENDANT (RP) OPERATION 3. (continued) When the weld sequence is started the display will indicate progression through PURGE, UPSLOPE, LVL 01 (etc.), DOWNSLOPE and then POSTPURGE. 4. The Override Keys allow the operator to change Amps, Volts, TVL, OSC and Wire Values (with-in set limits) .
  • Page 57 STORE special function at the end of the sequence and pressing the NEXT key will permanently change the functions to the overridden values. 5. SELECT - As previously noted, the M-227 can store in memory up to 100 weld schedules . Any 4 of these schedules can be programmed to be selected from the RP .

  • Page 58: Rotation Calibration

    MODEL 227 OPERATION MANUAL SECTION V - OPERATION ROTATION CALIBRATION NOTE For proper operation, Weld Head rotation speed must be calibrated for the power supply it is connected to. If weld heads are switched they must be re-calibrated on that system before welding commences .

  • Page 59: Wire Feed Calibration

    MODEL 227 OPERATION MANUAL SECTION V - OPERATION ROTATION CALIBRATION 5. Create or recall from the LIBRARY the appropriate Weld Schedule and connect the Weld Head to be calibrated. Insure that the system is SAFE to rotate and that the System Mode is in TEST. Note the starting position of the Weld Head and Press Sequence Start.

  • Page 60: Manual Advance Function

    All of the previous calibrations were based on the TIMER MODE being in the AUTO position. If the TIMER MODE is in the MAN (manual) Mode the Levels can only be advanced by the operator from the RP. Level Advance from the M-227 panel is not possible When not in Sequence the Next key on the RP is used in conjunction with the Special Function Key .

  • Page 61: Welding Operation

    Before running a weld schedule the weld head must be calibrated to the M-227. When a weld head is switched from one power supply to another it must be re-calibrated to the new power supply. If the weld head being used has not been calibrated, perform the cal procedure in this section.

  • Page 62: Printer Operation

    1. The printer receives its power from the M-227 and does not require any external manipulations (other than installing the paper roll). 2. The printer is activated by using the PRINT key on the M-227 panel or the PRINT Special Function on the RP . The PRINT function will only activate the printer under the conditions of step 3 (below).
  • Page 63 MODEL 227 OPERATION MANUAL SECTION V - OPERATION 5.13 PRINTER OPERATION 3. (continued) 3. INDIVIDUAL WELD SCHEDULE - When a weld schedule has been selected from memory a complete copy of all of the function values can be printed by pressing the PRINT key. This can be done at any portion of the weld schedule is being displayed except during an ACTUAL WELD SEQUENCE.

  • Page 64: Introduction

    STATUS screen. This section explains very basic operation of each of these programming functions. For the most part the M-227 is self teaching because of the instructions on the screens, only general information is given in this section.
  • Page 65 5. After pressing the ENTER key follow the instructions on the screen for entering the wall thickness. 6. The M-227 will then give you a choice of materials. Use the F key to select the proper one and Press Enter.
  • Page 66 NOTE If pulse mode is set OFF the system will not ask for background functions, backgrounds are only needed when pulsing. However, the M-227 will automatically default a value for pulse times in case the pulse mode should be turned ON later in a modify operation. There must be a value for Pulse Times.

  • Page 67: Modify A Weld Schedule

    MODEL 227 OPERATION MANUAL SECTION VI - PROGRAMMING CREATE A WELD SCHEDULE 11. The system will then ask if you want to store the weld schedule in memory or to MODIFY it. Remember that until it has been STORED it does not exist in memory.

  • Page 68: Copy A Weld Schedule

    CE key and try again. TRANSFER/RECEIVE WELD SCHEDULE MEMORY If a user has more than one M-227, it is usually a good idea to keep both libraries identical. This is done by TRANSFERRING a COPY of the LIBRARY of one system into the M-227-EMM;...

  • Page 69: Delete A Weld Schedule

    1. To initially set up which schedules can be selected from the M-227-RP press the SET UP key on the M-227 (this operation cannot be done from the RP). The SET UP screen can be obtained from the STATUS screen or a Weld...
  • Page 70 4, just the ones you want selectable from the RP . When all choices (up to 4) are made go back to the STATUS screen. 3. The M-227-RP will now be able to select one of the WELD #’s entered by use of the Special Function Key, SELECT function.

  • Page 71: Introduction

    MODEL 227 OPERATION MANUAL SECTION VII - CALIBRATION INTRODUCTION This procedure is intended for calibration/certification of system performance by the user. Expect for the Current Servo all system functions are controlled by the processor and no calibration points or steps are required . Rotation and Wire Feed calibration are contained in Section V.
  • Page 72 SECTION VII - CALIBRATION CURRENT CALIBRATION The M-227 contains components for measuring the actual amount of current. Normal calibration is intended for adjusting the circuitry based on measuring these devices. True verification of current output for Quality Control purposes must be done with an External Calibration Shunt that is calibrated by an independent agency and controlled by a QC or QA department.
  • Page 73 Cable or manual torch. Current is always measured along the ground return path. 5. Insure everything is ready to strike an arc. Turn M-227 power ON. The system should return to your calibration weld procedure. Set the Weld/Test Mode to WELD.
  • Page 74 MODEL 227 OPERATION MANUAL SECTION VII - CALIBRATION CURRENT CALIBRATION (continued) 13. Wait for machine to advance to and even level or 10 Amps. 14. During Weld Seq. Even Levels the DMM should read as follows: Center Plate Test Points = 0.20 VDC +/- 0.001 VDC.
  • Page 75 MODEL 227 OPERATION MANUAL SECTION VII - CALIBRATION ARC VOLTAGE CONTROLLER (AVC) CALIBRATION Cont. OSC AMPL .500 PRE-PURGE-POST UP-SLOPE-DOWN ROT--DLY STR WFDLY STP RETRACT T/MODE STLV STR AVDLY STP STR/ MODE RESPONSE TOUCH 2. Prepare the system to strike an arc.
  • Page 76 MODEL 227 OPERATION MANUAL SECTION VII - CALIBRATION TORCH OSCILLATION (OSC) AMPLITUDE CALIBRATION Cont. Select Weld Schedule Number ____ and verify that the FIRST PASS it is programmed as follows: TIME PRI-AMP--BCK PRI-PULSE-BCK 0.00 0.00 PULSE PRI--IPM-BCK 0.00 0.00 PRI-WF-BCK...

  • Page 77: General Maintenance

    Always disconnect the AC power cable from the line voltage before attempting to work with this welding power supply. 1. AIR FILTER - The M-227 power supply has one (1) foam air filter. Inspect this air filter regularly. The foam filters may be washed in water and detergent, dried and reused or replaced.

  • Page 78: System Fault Corrections

    1. TEMP - The M-227 has internal temperature probes. If the Power Supply gets hot the a fault occurs. This can occur only if there is some type of blockage of air...
  • Page 79 Power Supply is set up for that voltage (see section 3) The other reason would be a failure of the LVPS. Always check the AC input first and if that is OK call an AMI Seville representative. 5. COOL - Monitors the coolant flow out of the M227/207-CW or M207-CW cooling unit.
  • Page 80 ARC Voltages and could cause an undesirable FAULT if this option is left ON. 9. BAD START - If for any reason the M-227 cannot achieve a stable Arc at the end of PREPURGE the system will display this statement.

  • Page 81: Error Messages

    SYSTEM FAULT CORRECTIONS Cont. 10. Cont. In these cases check the input AC voltage first and insure that the M-227 is set for the correct input Voltage. Another possible reason for no display or scrambled displays is RF interference. Although the M-227 is protected against this, certain...

  • Page 82: Miscellaneous Maintenance

    M-227 Maintenance Manual. RS232 COMMUNICATIONS The M-227 can shut down the RS232 port on it own if it detects non-intelligent information on it. This can be caused by ambient light or improper set up. The RS232 port will not be re-activated until the power has been re-set.

  • Page 83: Introduction

    60 PSI, along with an external flow rate FAULT detect switches. Installation 1. Insure that the M-227 is OFF, remove the power cable from the M-227 and set the CW ON/OFF switch to the OFF position. 2. The cooling unit is shipped dry and requires 3 gallons (11.4 liters) of CLEAN DISTILLED or DE-IONIZED water.
  • Page 84 Mode is ON the M-227 will look to see if the Cooling Unit is connected. If it is, the M-227 will require that coolant be flowing or else it will create a fault. If for some reason the Cooling Unit is connected but not being used the operator can change the Coolant Fault Set Up to OFF and no coolant fault will be detected.

  • Page 85: M-227-Emm External Memory Module

    This connector should be inserted into the slot on the side of the M-227 labeled EMM. It is keyed and can only be inserted one way. When installed, turn the M-227 ON and perform the desired TRANSFER or RECEIVE functions as described in Section VI of this manual.
  • Page 86 MODEL 227 OPERATION MANUAL SECTION VIII - OPTIONS M227/207-CW OR M207-CW INSTALLATION Doc # 740063 Rev E...

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