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MODEL 227

OPERATION MANUAL

Doc # 740063 Rev E

SECTION VII - CALIBRATION

7.0

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.

An examination of internal electronics will find several adjustment points. These

points are “Factory Pre-set” only and ARE NOT adjusted by the user.

WARNING

All personnel attempting to calibrate, trouble-shoot, or repair this system must be

familiar with its operation. They must understand the circuits and have a complete

understanding of the controls and their interrelationships.

All personnel must be aware of the location of hazardous voltage-carrying conductors

terminals, heat sinks, etc., and must employ safety precautions when working with a

welding machine.

Any testing or recording instruments connected to any points in the machine or to the

welding head may be exposed to extremely high transient voltage at the time the arc

starter operates . ENSURE THAT ALL TEST EQUIPMENT IS DISCONNECTED

DURING ARC START.

NOTE

Wire Feed and Rotation (Travel) Calibration, in conjunction with a Weld Head, are

performed on a frequent basis and are covered as part of Section V (operation).

7.1

EQUIPMENT REQUIRED FOR CALIBRATION

1. Digital Multimeter (DMM), minimum 4 - digit readout. Suggested: Fluke Model

8060A or equal . The meter must have floating inputs (not connected to line or

chassis ground) of minimum 1 megohm input impedance. Battery operated

devices are recommended.

2. Screwdriver, Calibration, small slot with 6” shaft and a 3/32 Allen Wrench

3. Any Weld Head rated for 100 amps or more pipe that will not melt away with

100 amperes or a manual torch set up on flat plate.

4. External Shunt, 1 mv/amp, PN 13B272504-01 (optional)

5. Dial Calipers

7.1

Summary of Contents for 227

Page 1: ...10500 Orbital Way Pacoima California 91331 U S A MODEL 227 POWER SUPPLY OPERATION MANUAL Document No 740063 ...

Page 2: ... international safety regulations the EXCLAMATION SYMBOL indicates that this equipment is considered HAZARDOUS until an operator has been made aware of these POTENTIAL HAZARDS by READING THIS MANUAL The LIGHTNING FLASH SYMBOL indicates that there are potential electrical hazards The use and display of these symbols make it the OPERATOR S RESPONSIBILITY TO INSURE THAT HE HAS READ AND OR BEEN MADE A...

Page 3: ...n the latest STANDARD version of SOFTWARE at the time of last revision see revision page Some deviations in actual operation from this document are possible depending on the software version of a particular machine Please feel free to contact Arc Machines Service Department for documentation or information on how software updates effect this document ii ...

Page 4: ...ture Ranges 2 4 2 6 Cable Operating Distance Limits 2 4 SECTION III INSTALLATION 3 0 Inspection 3 1 3 1 Power Connection 3 1 3 2 Welding Gas Connections 3 2 3 3 Adapter Cable to M 227 Installation 3 3 3 4 Weld Head Installation 3 7 3 5 Ground Work Cable Installation 3 7 3 6 Remote Pendant Installation 3 8 SECTION IV SYSTEM FUNCTIONS 4 0 Introduction 4 1 4 1 Functional Description General 4 1 4 2 W...

Page 5: ... Operation 5 17 5 13 Printer Operation 5 18 SECTION VI PROGRAMMING 6 0 Introduction 6 1 6 1 Create a Weld Schedule 6 1 6 2 Modify a Weld Schedule 6 4 6 3 Copy a Weld Schedule 6 5 6 4 Transfer Receive a Weld Schedule 6 5 6 5 Delete a Weld Schedule 6 6 6 6 Program Select Function 6 6 SECTION VII CALIBRATION 7 0 Introduction 7 1 7 1 Equipment Required 7 1 7 2 Current Servo 7 2 7 3 AVC Servo 7 4 7 4 O...

Page 6: ... CONFIGURATION 1 7 FIGURE 2 INSTALLATION LOCATIONS 3 4 FIGURE 3 AC POWER SET UP 3 5 FIGURE 4 CABLE CONNECTIONS 3 6 FIGURE 5 SEQUENCE TIMING CHART 4 7 FIGURE 6 PANEL KEY LOCATIONS 4 8 FIGURE 7 USE OF NEXT PREV KEYS 5 5 FIGURE 8 STANDARD REMOTE PENDANT 5 10 FIGURE 9 M227 207 CW or M207 CW INSTALLATION 8 4 v ...

Page 7: ... Torch Weave Steering Oscillation and automatic timing functions Another version is available without the AVC and Oscillator functions The M 227 includes a Remote Operators Pendant and comes ready to weld Users need only to supply input AC power regulated gas source with flow meter and the appropriate weld head or manual torch Some operation conditions may require optional components such as the M...

Page 8: ...ard WARNING This equipment is authorized to use a type of arc starter that produces a High Frequency Radio Wave sometimes called HF and or RF Starting It can cause interference and sometimes even damage to nearby electronic equipment such as computers that are un protected or poorly protected against such interference WARNING Magnetic Fields from High Currents can affect pacemakers PACEMAKER WEARE...

Page 9: ...ld gives off infra red IR Both can burn eyes and skin if unprotected Suitable eye and skin protection must be worn WARNING Weld materials can emit toxic fumes during welding WELD ONLY IN AREAS WITH ADEQUATE VENTILATION WARNING Most GTAW gases like Argon are non toxic however Argon is heavier than air and will displace the normal atmosphere in enclosed areas DO NOT WELD IN ENCLOSED AREAS WITH OUT P...

Page 10: ...roper operation and handling 1 TOO AVOID severe equipment damage VERIFY that the M 227 is connected to the correct Input AC power see section 3 1 2 Before operating check all fittings and connectors for proper seating and that all protective boots are in place If not properly seated or protected short circuits poor connections or inert gas leaks could occur 3 The M 227 is intended for typical GTAW...

Page 11: ... 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 12 Do not attempt to move tube end into position using the weld head as a lever 13 Do not add any lubrication like graphite oil or grease to the weld heads or power supply unless it is specified in the operation ...

Page 12: ...esign and produce equipment that is functional but at the same time design this equipment to keep electromagnetic radiation at a minimum The user has the responsibility to install and use the power source per the instructions of the manufacturer Through this practice it is reasonable to assume that the probability of electromagnetic disturbances will be significantly reduced However if some electr...

Page 13: ...MODEL 227 OPERATION MANUAL Doc 740063 Rev E SYSTEM CONFIGURATON 1 7 ...

Page 14: ... aborted or bad arc start attempt However these circuits take a few seconds to operate or COULD FAIL THE ELECTRODE SHOULD ALWAYS BE CONSIDERED A POSSIBLE SHOCK HAZARD This is especially true when ever the system is in weld sequence ready to weld is welding or has just finished welding However equipment component failure system abuse or improper maintenance could result in electrical potential at t...

Page 15: ...rigin 3 Model Number Rating Plate applies to 4 Serial Number located on M 227 Center Plate not on rating plate 6 International and USA Standards that the equipment meets 8 Weld Process symbol for GTAW welding 9 Rated MIN and MAX Outputs at Continuous Current with no pulsation Rated MIN and MAX Outputs when current is pulsing MAX current output using 110 VAC input is 100 Amperes 10 Symbol that outp...

Page 16: ... 30 amperes 208 VAC 27 13 50 60 Hz 30 amperes 220 VAC 20 18 50 60 Hz 30 amperes 230 VAC 15 22 50 60 Hz 30 amperes 240 VAC 10 25 50 60 Hz 30 amperes indicates the allowable input voltage change to maintain performance as specified Maximum input current is based on maximum output current at maximum arc voltage See section 3 1 for installation 3 OUTPUT POWER Straight polarity constant current DC regu...

Page 17: ...M WIRE FEED START DELAY 00 0 99 9 seconds PRIMARY WIRE FEED SPEED 000 200 IPM BACKGROUND WIRE FEED SPEED 000 200 IPM WIRE FEED STOP DELAY 00 0 99 9 seconds WIRE FEED RETRACT TIME 0 0 1 0 seconds PRIMARY AVC 5 0 20 0 volts BACKGROUND AVC 5 0 20 0 volts AVC START DELAY TIME 00 0 99 9 seconds AVC STOP DELAY TIME 00 0 99 9 seconds AVC MODE SETTINGS CONT SAMPLE OFF OSCILLATION MODE ON OFF TORCH OSCILLA...

Page 18: ...9 levels PRIMARY AVC 1 to 99 levels BACKGROUND AVC 1 to 99 levels OSC AMPLITUDE 1 to 99 levels OSC DWELL and EXCURSION TIMES 1 to 99 levels 2 4 NON PROGRAMMABLE FUNCTIONS WIRE FEED MODE SWITCH ON OFF SYSTEM MODE KEY SWITCH PROGRAM OPERATE LOCK MANUAL PURGE ON OFF 2 5 AMBIENT TEMPERATURE RANGE 32 F 0 C to 110 F 45 C 2 6 CABLE OPERATING DISTANCE LIMITS Standard 50 ft 15 2 m Maximum 100 ft 30 5 m The...

Page 19: ... WARNING Do not connect the M 227 power supply to any AC power other than the ones listed in section 2 0 2 The M 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 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 ...

Page 20: ...s see figure 3 and remove the cover Set the switch to the alternate position and install the cover plate It must be flipped over so the hole in the plate will fit over the switch handle in the new position This will automatically expose the alternate voltage label on the other side 3 2 WELDING GAS CONNECTIONS 1 An Arc Input Gas Hose is supplied with the M 227 This hose is made of material selected...

Page 21: ...eld Head Adapter Cable consists of a 40 ft Control Adapter Cable and a 40 ft Service Adapter Cable The two cables are not tied together as a unit WARNING Always turn the power supply off before making any cable or connection changes to the M 227 power supply 1 One end of an adapter cable ALWAYS connects to the weld head The other end connects to the M 227 or to a weld head extension cable The conn...

Page 22: ...MODEL 227 OPERATION MANUAL Doc 740063 Rev E INSTALLATON LOCATONS 3 4 ...

Page 23: ...MODEL 227 OPERATION MANUAL Doc 740063 Rev E AC POWER SET UP 3 5 ...

Page 24: ...MODEL 227 OPERATION MANUAL Doc 740063 Rev E CABLE CONNECTIONS 3 6 ...

Page 25: ...ates on the Weld Head Cable 3 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 4 Unscrew the CONTROL connector dust caps on both cables just before installing Insert t...

Page 26: ...or into the M 227 Panel connector labeled REMOTE 2 If a M 227 RP extension is used it is installed between the M 227 and the RP 3 If required the M 227 can be operated without the RP Unit CAUTION Installation is now complete but before proceeding with POWER ON it is EXTREMELY important to have a basic understanding of SYSTEM FUNCTIONS Read section IV system functions before proceeding with OPERATI...

Page 27: ...erator can locate it in the WELD SCHEDULE LIBRARY by description or by weld schedule number 2 WELD SEQUENCE AND LEVELS Selected weld schedules are started by manually initiating the SEQUENCE START Once the sequence is started the system operation can be totally automatic In addition to functions to start and stop the weld the weld sequence includes the ability to preset changes in function values ...

Page 28: ...used to maintain the desired Arc Gap between the Electrode and the weld puddle 7 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 8 PULSATION The system...

Page 29: ...d and displayed when selected with the following information 1 Individual WELD SCHEDULE NUMBER from 001 to 100 2 OD Outside diameter in inches or mm of the weld 3 WALL Wall thickness in inches or mm of the weld 4 MAT Uses abbreviations to identify the base material the schedule is programmed to run 5 HEAD Uses Weld Head Model number to identify what AMI Head the schedule is programmed to run 6 PAS...

Page 30: ...ally advances or ends the sequence 2 WELD CURRENT START LEVEL As the arc is established the weld current will jump to a small value This current is used to stabilize the arc and is called the START LEVEL Its value is programmable and may need to be changed depending on certain conditions However it is not a multi level function and it is only used to help initiate the arc 3 WELD CURRENT UPSLOPE So...

Page 31: ...mplitude by the end of current Upslope 9 OSCILLATOR DWELL and EXCURSION TIMERS The Oscillator movement is based on time The Level 1 Dwell and Excursion Timers start counting at the beginning of Event 3 if OSC MODE is set to ON 4 EVENT 4 FULL LEVEL FUNCTIONS Sometime after the arc is established depending on the weld schedule the current UPSLOPE OSC UPSLOPE and all START DELAYS Travel Wire AVC will...

Page 32: ...se programmable modes OFF Will prevent rotation from occurring CONT Runs the travel at the PRIMARY RPM speed only regardless of PULSE MODE STEP Will pulse the travel between the PRIMARY RPM and BACKGROUND RPM speed If the TRAVEL MODE is in STEP but the PULSE MODE is in OFF then only PRIMARY will occur without pulsing there are no background functions 8 LEVEL 1 PRIMARY RPM After the Travel Start De...

Page 33: ...MODEL 227 OPERATION MANUAL Doc 740063 Rev E SEQUENCE TIMING CHART 4 7 ...

Page 34: ...MODEL 227 OPERATION MANUAL Doc 740063 Rev E PANEL KEY LOCATIONS 4 8 ...

Page 35: ...only the Primary AVC value The AVC position will not move during Background SAMP BCK Allows the AVC to work only during the BACKGROUND current using only the Background AVC value The AVC position will not move during Primary 13 LEVEL 1 PRIMARY AVC After the AVC START DELAY time is complete and the AVC MODE is in CONT or SAMP PRI the AVC will maintain this value during the Primary current 14 LEVEL ...

Page 36: ...VEL PRIMARY AMP value and BACKGROUND AMP value if pulsed and OSC AMPLITUDE will start to decrease towards 0 The time it takes to reach arc cutoff about 3 amps is called the DOWNSLOPE time and it is programmable 2 WIRE STOP DELAY TIMER At the end of the last Level the WIRE STOP DELAY time will start counting The WIRE will continue to feed until this time is complete When the wire quits feeding the ...

Page 37: ...keys before the ENTER key is pressed Use this key when a mistake is make using the numeric keys 4 ENTER KEY Used at the end of each step to indicate completion and to move to the next step or screen 5 F KEYS These are function keys numbered 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 diff...

Page 38: ...e previous parameters used for the previous pass 16 PREV SCREEN KEY Same as NEXT SCREEN but screens appear in reverse order 17 PRINT KEY If pressed when the status screen is displayed a copy of system hours and software revision will be printed If pressed during the library screen a copy of the entire library will be printed If pressed while displaying a weld schedule the entire weld schedule will...

Page 39: ...e TEST mode 25 WIRE JOG FWD KEY 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 installation 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 ...

Page 40: ...TE In order to CREATE MODIFY TRANSFER COPY or DELETE a weld schedule in the system memory the mode switch must be set to this position All system operations such as weld sequence can also be performed in this mode CAUTION Authorization and access to the OPERATE MODE KEY should be controlled When the switch is set to the PROGRAM mode the operator may permanently MODIFY change or DELETE weld schedul...

Page 41: ...ect this and prevent arc start 11 OSC LIMIT On Heads with OSC limit switches if they are engaged the system will create an ALL STOP 12 AVC LIMIT On Heads with AVC limit switches if they are engaged the system will create an ALL STOP 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...

Page 42: ... is connected 4 REV Used to display the SOFTWARE REVISION of a particular M 227 Depending on intended use M 227 s may have different software revisions 5 PRINT EMM Used to print a copy of the EMM memory 6 AMP TIME Used to change the last significant digit of Level Current or Level Time from whole numbers to tenths 000 to 000 0 7 ARC V FLT Used to de activate STUB OUT and HIGH VOLT faults These fau...

Page 43: ... programmed weld schedules LVL Level or levels LVPS Low voltage DC power supply check MAT Material MNL Monel OD Outside diameter OK Mean monitored function is operating properly PRE PURGE POST PREPURGE postpurge columns PRI Primary function value PRI AMP BCK Primary amp background amp columns PRI PULSE BCK Primary time background time columns PRI RPM BCK Primary speed background speed columns PRO ...

Page 44: ...ETE Used to delete a weld schedule from memory INVALID NUMBER Can appear by attempting to CREATE a weld schedule that already exists or by Selecting a weld schedule that does not exist MODE LOCK Screen cannot be changed Weld schedule if selected will be locked in MODIFY Used to permanently change a weld schedule OPERATE Operate mode only cannot program OVERRIDES Ability to change a value temporari...

Page 45: ...POWER ON STATUS SCREEN 1 Before connecting or energizing the AC power verify that all input power set up requirements of Section III have been complied with WARNING Applying 200 VAC or greater input power to a M 227 set up for 110 VAC operation WILL CAUSE THE INPUT VARISTERS TO FAIL MAKE SURE THE INPUT POWER SET UP IS CORRECT FOR THE POWER BEING USED 2 The M 227 can be turned on without the adapte...

Page 46: ... is more data on another screen or level a flashing will appear in the appropriate corner s to indicate that more information is available Screen Level keys are used in selection of a weld schedule and all weld schedules use 8 basic Lower Screen Displays that appear in the following order 1 PROMPT SCREEN Appears when a weld schedule is called up from memory Gives instructions in lower display and ...

Page 47: ...2 3 4 or 5 the operator can press the NEXT LEVEL key to view the values for the next level for those same functions if programmed When displaying level 2 or greater pressing the PREV LEVEL key will then display the previous level Pressing the NEXT SCREEN or PREV SCREEN key after using the NEXT LEVEL or PREV LEVEL key will display the NEXT SCREEN for that LEVEL except if the next screen is 1 6 7 or...

Page 48: ...NEXT SCREEN key The next weld schedule in memory will be displayed Continue pressing the NEXT SCREEN key until the desired weld schedule appears When the desired schedule appears press the ENTER key After a few seconds your selected weld schedule will appear on the display 5 When the weld schedule is called up from memory it will appear on the screens like this OD WALL MAT HEAD PASS READY 001 1 50...

Page 49: ...MODEL 227 OPERATION MANUAL Doc 740063 Rev E USE OF NEXT PREVIOUS KEYS 5 5 ...

Page 50: ...e 5 6 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 1 Use the NEXT SCREEN and or NEXT LEVEL keys until the function value to be changed appears on the screen 2 Directly above and below each ...

Page 51: ...SCREEN or WELD SCREEN with the System Mode set to OPERATE will access the first of three SET UP screens that contain the following functions 1 CALCULATE Pressing the F key under this choice will access a prompt screen for calculating Tungsten Length or RPM or Weld Time Follow the instruction on the screen to make these calculations These features can be very helpful when creating new weld procedur...

Page 52: ...ammed for 87 7 amperes and this is changed to whole numbers the WELD when accessed will then call for 87 amperes it will drop the digit not round off 7 ARC V FAULT This feature can turn this FAULT ON or OFF When ON a STUB OUT will be created if the ARC VOLTAGE goes below 5 V or a HIGH VOLTS fault if the VOLTAGE goes over 20 V These conditions only occur in automatic welding if something is wrong H...

Page 53: ...he 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 NOTE The following SET UP functions are accessed by pressing the NEXT SCREEN key from the fourth SET UP screen 3 OSC JOG Use this feature to set the OSC STEERING speed Weld Head models with an OSC function can very...

Page 54: ...MODEL 227 OPERATION MANUAL Doc 740063 Rev E STANDARD REMOTE PENDANT 5 10 ...

Page 55: ...y 28 Background AVC Override key 29 Osc Amplitude Override key 30 Excursion Time Override key 31 IN Dwell time Override key 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...

Page 56: ...p 5 for more details Using the Override Keys only OVERRIDES the function value in the LEVEL displayed During Sequence you cannot Override a value in another LEVEL Before Sequence it can be done by use of the MAN ADV special Function See Special Function Key operation step 5 for more details 5 SPECIAL FUNCTION KEY The Pendant Special Function key allows access and manipulation of many additional fu...

Page 57: ...time before starting sequence 7 SET Used in conjunction with a M 6 Weld Head to move the Torch to a pre set arc gap prior to arc starting 8 OSC MAN Used to engage the OSC function and perform the same movement out of sequence that it will perform in sequence Used to check Amplitude value 9 MAN ADV For OVERRIDE purposes all weld schedule passes when called up from memory or reset after welding are ...

Page 58: ...sed 3 A MANUAL calibration schedule will always be run in TEST Mode and usually contains the following PRE PURGE POST UP SLOPE DOWN ROT DLY 000 000 00 0 00 0 CCW 00 0 STR WFDY STP RETRACT T MODE 00 0 00 0 0 0 AUTO LVL TIME PRI AMP BCK PRI PULSE BCK 1 000 000 0 00 0 00 LVL PULSE ROT PRI RPM BCK 1 OFF CONT LVL PRI WF BCK 1 000 000 LVL TIME PRI AMP BCK PRI PULSE BCK 2 005 000 000 0 00 0 00 LVL PULSE ...

Page 59: ...upply it is connected to If weld heads are switched they must be re calibrated on that system before welding commences 1 Insure that the weld head is connected per section III and the Weld Head manual Wire Feed calibration is done by feeding the wire and measuring actual speed Before proceeding CHECK THAT THE HEAD IS FREE TO FEED WIRE SAFELY 2 To manually calibrate the user will need to have a Wel...

Page 60: ...Press Sequence Start Wire should feed out 60 seconds When Sequence is over cut the wire flush with the nozzle and measure It should be whatever value was programmed If it is not adjust the Wire Feed Cal Potentiometer on the Weld Head Repeat step 6 and 7 until the wire is calibrated 5 11 MANUAL ADVANCE FUNCTION All of the previous calibrations were based on the TIMER MODE being in the AUTO position...

Page 61: ...al and weld head manual 4 Turn on the gas source at the regulator flowmeter Engage MANUAL PURGE and set the required flow rate for the weld and weld head being used Continue Manual purge until all lines are filled with the gas and all moisture and impurities have been removed How long this takes depends on the conditions When this is done dis engage the Manual Purge function 5 When the weld schedu...

Page 62: ...ther weld 5 13 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 3 The printer will produce a copy of t...

Page 63: ...LL PARAMETERS PERFORMED AS PROGRAMMED the last key is pressed after each weld is made a hard copy record of performance can be kept The DATE is also included on each print out 4 An Auto print function can also be set up to have the system automatically make a print out after each Weld Sequence in Weld Mode If this mode is selected the printer will automatically print out a copy of the complete wel...

Page 64: ...S FROM MEMORY IS ALSO A FEATURE OF THIS MODE To CREATE a schedule the OPERATE mode switch must be in the PROGRAM position All programming starts from the 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 6 1 CREATE A...

Page 65: ...TER KEY PRESS C KEY TO CANCEL PROGRAMMING MODE OD WALL MAT HEAD 001 0 000 0 00 NOTE The weld description and all values for LEVEL 1 of the weld schedule must be entered They cannot be skipped you must enter a number even if it is 0 for each item before progressing to the next item 4 Enter the O D in inches or millimeters using the numeric keys Verify the correct number on the screen and then press...

Page 66: ...tem follows an exact sequence through LEVEL 1 When the last LEVEL 1 values is entered the screen will ask if you want to create LEVEL 2 if so press the NEXT LEVEL key If you are done press the PRO key and go to step 9 If the NEXT LEVEL is used the system will copy all values of level 1 and switch to the MODIFY mode In the MODIFY mode you only have to make changes to level 2 functions that are diff...

Page 67: ...he system will then ask you what weld schedule number you wish to MODIFY Use the numeric keys to enter the number verify and then press the ENTER key 2 Modifying a weld schedule works similar to reviewing a weld schedule in the operate mode see section V Use the NEXT PREV SCREEN and EXT PREV LEVEL keys to find the function and level to be modified 3 When the function values or mode to be modified ...

Page 68: ...he CE key and try again 6 4 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 then taking the M 227 EMM to another M 227 and TRANSFERRING a COPY of it into that M 227 For single system users it will also be important to have a security...

Page 69: ...TION USE OF THIS FUNCTION WILL RESULT IN THE LOSS OF A WELD SCHEDULE IN MEMORY 1 The DELETE function must start from the STATUS screen and the OPERATE mode switch must be in the PROGRAM position 2 Press the PRO key then press the F key above or below the word DELETE Use the numeric keys to enter the weld schedule number to be DELETED A WARNING will appear that pressing ENTER will DELETE this Sched...

Page 70: ...creen will then ask what WELD should be in position 1 Then position 2 3 and 4 You do not have to select all 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 6 7 ...

Page 71: ...t sinks etc and must employ safety precautions when working with a welding machine Any testing or recording instruments connected to any points in the machine or to the welding head may be exposed to extremely high transient voltage at the time the arc starter operates ENSURE THAT ALL TEST EQUIPMENT IS DISCONNECTED DURING ARC START NOTE Wire Feed and Rotation Travel Calibration in conjunction with...

Page 72: ...as a place for writing in the Weld when it is created Six levels shall be programmed odd numbered levels 1 3 5 shall be set to 100 amps and even number level 2 4 6 settings will be at 10 amps 1 Select Weld Schedule Number ____ and verify that it is programmed as follows LVL 1 6 PULSE OFF ROT OFF PRI RPM BCK 0 00 0 00 LEVEL 1 LVL 1 3 5 TIME 20 PRI AMP BCK 100 0 PRI PULSE BCK 0 00 0 00 LVL 2 4 6 TIM...

Page 73: ...he system should return to your calibration weld procedure Set the Weld Test Mode to WELD 6 Set up the DMM to read on the 200 mv DC scale if you are using the external shunt Set it up to read on the 20 VDC scale if you are using the center plate test points 7 If you are using the external shunt prepare to insert them into the red and black test point on the shunt 8 If you are using the center plat...

Page 74: ... ARC VOLTAGE CONTROLLER AVC CALIBRATION A weld schedule is required for AVC calibration The first time calibration is performed this schedule will have to be CREATED Step 1 next page has a place for writing in the Weld after it has been created NOTE The adjustment for AVC Calibration is located on the Center Plate under the computer cover front panel housing Turn the Power OFF and unscrew the two ...

Page 75: ...o WELD 6 Press SEQUENCE START After the arc is established and meter is connected the DMM should read 10 0 VDC 0 1 VDC 7 If out of Tolerance adjust TR 3 on the center plate until the reading is correct 8 When Arc Voltage is correct press Sequence Stop 7 4 TORCH OSCILLATION OSC AMPLITUDE CALIBRATION A weld schedule is required for OSC calibration The first time calibration is performed this schedul...

Page 76: ...ETRACT 0 0 T MODE MAN STLV 25 OSC OFF STR AVDLY STP 1 0 0 0 STR MODE TOUCH RESPONSE 3 2 Insure that the Torch is free to Oscillate without obstructions 3 Set the WELD TEST mode RP or Panel to TEST Using Jog Keys center Torch in the middle of its stroke 4 Using the Dial Caliper prepare to measure the total movement of the Torch from its furthest IN position toward the Head to its furthest OUT posit...

Page 77: ...Fill the tank per instructions of Section VIII 3 Cleaning exterior and interior surfaces Prolonged use in dusty shop or outside environments may cause the outside surfaces to accumulate a coating of dirt and dust Do not use shop air usually too wet to blow dust particles away from panels Either wipe it off with a damp cloth or use a vacuum cleaner with a soft brush Where a vacuum brush cannot reac...

Page 78: ...he fault occurred 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 circulation fan failure or component failure within the Power Supply OR THE SYSTEM IS BEING OPERATED IN AN AMBIENT AIR TEMPERATURE BEYOND ITS RATED 110 DEGREES F This Fault should only occur during an actual weld sequence If...

Page 79: ...eville representative 5 COOL Monitors the coolant flow out of the M227 207 CW or M207 CW cooling unit If it is not at least 0 2 GPM a fault will occur This fault will only exist if the CW unit is turned ON IF it is off no fault will occur Check the hoses and flow path of coolant to and from the weld head this is usually the problem If all looks good then an internal failure of theCW pump or flow s...

Page 80: ...itted from the M 227 to the electrode if anything creates resistance or an alternate path for the RF the start can be weak When a BAD START occurs check the electrode connection and electrode condition first Also check to insure that CERRIATED electrodes are being used They have proven to be much more effective than THORIATED electrodes for RF transmission and longer life BAD STARTS can also be ca...

Page 81: ... 7 ERROR MESSAGES 1 MEMORY CHECK At Power On the weld schedule memory storage is checked for any type of corruption If any of the checks fail the system will display the following LIBRARY MEMORY ERROR RELOAD FROM EMM PRESS PRINT FOR MEMORY STATUS REPORT NOTE When the print key is pressed any weld schedule with a directory or link error will automatically be DELETED Any schedule with a sum check er...

Page 82: ... increments for Amps and Level Time will reset to whole 6 Operators Name will clear 7 Power Supply Serial Number will clear Replacing the BATRAM requires accessing the inside of the M 227 A complete replacement procedure is available in the M 227 Maintenance Manual 2 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 ca...

Page 83: ...led 3 Pump Both M227 207 CW M207 CW water pumps have a built in pressure regulators set at 60 PSI along with an external flow rate FAULT detect switches 4 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 In are...

Page 84: ... coolant flow path is created turn the M 227 ON and set the CW ON OFF switch to ON The pump should start circulating coolant WARNING DO NOT OPERATE the water cooling unit WITHOUT coolant in the tank OR WITHOUT a water flow path water OUT to IN through a weld head 2 Both CW units contain a flow sensor If the Set Up Screen Coolant Fault Mode is ON the M 227 will look to see if the Cooling Unit is co...

Page 85: ...ANSFER or RECEIVE functions as described in Section VI of this manual 3 When finished with the EMM it should be stored in a secure dry location away from any large magnetic or electrical sources 4 The EMM uses a type of memory that does not require batteries and has an unlimited shelf life However it does have a limited number of erase cycles Erasing occurs anytime you are COPYING from a M 227 to ...

Page 86: ...MODEL 227 OPERATION MANUAL Doc 740063 Rev E SECTION VIII OPTIONS M227 207 CW OR M207 CW INSTALLATION 8 4 ...

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