0500 Orbital Way Pacoima, California 91331 U.S.A. MODEL 307 POWER SUPPLY OPERATOR TRAINING GUIDELINES Document No. 740096 Doc. Rev.
HEADQUARTERS Arc Machines, Inc. 10500 Orbital Way Pacoima, CA 91331 U.S.A. Tel.: 1- 818 896-9556 Fax: 1-818 890-3724 sales@arcmachines.com GERMAN OFFICE Arc Machines GmbH Markelsbach 2 D-53804 Much, Germany Tel.: 02245 / 91680 Fax: 02245 / 916868 sales@arcmachines.de EUROPEAN OFFICE Arc Machines, Inc. Chemin du Lavasson 2 CH-1196 Gland Switzerland Tel.: +41 / 22 / 995.00.51 Fax: +41 / 22/ 995.00.59 sales@arcmachines.
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™-basedModel 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™ environment makes the Model 307 uniquely suited for weld logging and weld documentation.
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.
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.
Table of Contents 1 INTRODUCTION 2 SAFE OPERATION 3 ICONS, BUTTONS, SYMBOLS 4 MODEL 307 INSTALLATION 5 SEQUENCE OF EVENTS/ WELD PARAMETERS 6 POWER SUPPLY OPERATION & FUNCTIONS 7 MODEL 307 LIBRARY 8 AUTOGENERATION OF WELD SCHEDULES MODEL 307 9 MANUAL CREATION OF WELD SCHEDULES OPERATOR TRAINING GUIDELINES 10 ASSOCIATED DATA 11 WELDING WITH THE 307 12 WELD PROCEDURE OPTIMIZATION 13 WELD HEAD CALIBRATION & OPERATION 14 END-PREPARATION FOR ORBITAL WELDING 15 TUNGSTEN SPECIFICATIO
Arc Machines, Inc. Model 307 Orbital Tube Welder Training Chapter 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-welding functions it also has wire feed capabilities.
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.
Arc Machines, Inc. Model 307 Orbital Tube Welder Training record of each weld, so that if quality questions arise, the process of tracing 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 factoryapproved Arc Machines, Inc. Instructor. IT IS NOT A SUBSTITUTE FOR THAT TRAINING.
Arc Machines, Inc. Model 307 Orbital Tube Welder Training Chapter 2. Safe Operating Procedure Safety Precautions for Model 307 Operation AVOID ALL CONTACT WITH THE WELDING WORK (GROUND) OR ELECTRODE DURING ARC START Electrode installation in a Model 8 weld head. 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.
Arc Machines, Inc. Model 307 Orbital Tube Welder Training Model 307 Do’s and Don’ts Safe Use of Orbital Welding Equipment DO’s 1. Do VERIFY correct AC Power Source (100 or 240 VAC single phase) before plugging in the Model 307. 2. Do Autocal weld head (or select Manual Option) each time the Model 307 is connected to a different weld head. The weld head must be calibrated to the power supply it is connected to. 3.
Arc Machines, Inc. Model 307 Orbital Tube Welder Training DON’TS 1. Don’t GRIND near the Weld Head or Power Supply without protecting them. 2. Don’t use acid or other corrosives on or near the Weld Head. A LIGHT APPLICATION OF ISOPROPYL ALCOHOL (IPA) is the only approved liquid for cleaning of weld heads or the Model 307. 3. Don’t attempt to weld without a secure BARE METAL WORK (GROUND) CONNECTION when using the Manual TIG Torch. 4.
Arc Machines, Inc. Model 307 Orbital Tube Welder Training Don’ts 9. Don’t attempt to move tube end into position using the Weld Head as an alignment tool. USE PIPE STANDS, CLAMPS, ALIGNMENT TOOLS, etc. to hold the tube or pipe in position for welding. Tack welding of components with a weld head or a manual torch prior to orbital welding may be necessary in some applications. 10. Don’t add oil or grease to the weld head. 11.
Arc Machines, Inc. Model 307 Orbital Welder Training Model 307 Warnings WARNINGS! Safety Precautions This section, concerning safe operating procedures for the Model 307, should be read and understood before proceeding to other sections of the training manual. It also contains precautions and warnings for the operation of welding equipment in general. In addition, users should reference and become familiar with “ANSI-49.
Arc Machines, Inc. Model 307 Orbital Welder Training MODEL 307 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 protective clothing, footwear and head gear. WARNING: Never weld on sealed containers or pipes. This may result in an EXPLOSION.
Arc Machines, Inc. Model 307 Orbital Welder Training MODEL 307 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 WITHOUT PROPER VENTILATION OR RESPIRATORS. WARNING: AMI factory training is essential for all Welding Operators and Maintenance Technicians who operate AMI equipment. Consult factory for dates of training classes and other training information.
Arc Machines, Inc. Model 307 Orbital Tube Welder Training Chapter 3. Model 307 Icons, Buttons, and Symbols Symbols and Icons have been used throughout this manual to illustrate key points. It is hoped that this will make the manual easier to understand and to translate for non-English-speaking people. The Windows™ operating system uses icons as buttons that must be touched or clicked on with a mouse to perform certain functions. Table 1. Toolbar Icons. USER Table 2.
Arc Machines, Inc. Model 307 Orbital Tube Welder Training The TOOL BAR at the top of the Model 307 Touch Screen displays icons which have a variety of functions which are listed below. When an icon is greyed out, this means that the icon’s function is not available from that screen. Table I. Model 307 TOOLBAR ICONS ICON FUNCTION Touching the Home icon will return the user to the Model 307 Home (Opening) Screen.
Arc Machines, Inc. Model 307 Orbital Tube Welder Training Table I. Model 307 TOOLBAR ICONS ICON FUNCTION Touching the Faults icon on the toolbar displays fault settings. Touching the Calibration icon brings up a screen with directions for calibrating the weld head to the Model 307 Power Supply. The Icon will be greyed out if there is no weld head connected to the power supply. Touching the Help icon brings up the 307 Help information. The Stop USB icon is visible from the Weld Schedule Library screen.
Arc Machines, Inc. Model 307 Orbital Tube Welder Training Table 2. Buttons used on the Model 307 Power Supply Pressing Single Entry displays the Weld Schedule - Single Entry screen on which weld parameters which apply to all levels of a weld program are entered. Pressing the Levels button displays the Weld Schedule - Weld Levels screen on which weld parameters that can be changed for each level, such as amperages and pulse times, are entered.
Arc Machines, Inc. Model 307 Orbital Tube Welder Training Table 2. Buttons used on the Model 307 Power Supply Pressing the Test button on the Weld Schedule Weld Screen puts the Model 307 into Weld Mode. Pressing the red WELD button on the Weld Schedule Weld screen puts the Model 307 into Test Mode. Touching the Data Acquistion button opens the Weld Identification Information screen. Weld Data Recording may be enabled or disabled from this screen.
Arc Machines, Inc. Model 307 Orbital Tube Welder Training Table 2. Buttons used on the Model 307 Power Supply Paste Schedule inserts a copied schedule into another folder of the same power supply or into a folder in a Library in remote power supply. Rename Schedule allows the user to change the name of a selected schedule by typing in the new name from the keyboard. Level Advance.
Arc Machines, Inc. Model 307 Orbital Tube Welder Training Table 3. Computer Icons used on Model 307 NO.
Arc Machines, Inc. Model 307 Orbital Tube Welder Training Table 3. Computer Icons used on Model 307 14 Users To Signify Users (or Classification of User such as Supervisor, etc.
Arc Machines, Inc. Model 307 Orbital Tube Welder Training Table 4. Graphical Symbols used in this Manual NO.
Arc Machines, Inc. Model 307 Orbital Tube Welder Training Table 4.
Arc Machines, Inc. Model 307 Orbital Tube Welder Training Table 4.
Arc Machines, Inc. Model 307 Orbital Tube Welder Training Table 4.
Arc Machines, Inc. Model 307 Orbital Tube Welder Training Table 4.
Arc Machines, Inc. Model 307 Orbital Tube Welder Training Table 4.
Arc Machines, Inc. Model 307 Orbital Tube Welder Training Table 4.
Arc Machines, Inc. Model 307 Orbital Tube Welder Training Table 4.
Arc Machines, Inc. Model 307 Orbital Tube Welder Training Table 4. Graphical Symbols used in this Manual 91 Wirefeed Stop Delay Time To Signify when the wire stops feeding in relation to the end of the last level.
Arc Machines, Inc. Model 307 Orbital Tube Welder Training Table 4. Graphical Symbols used in this Manual 101 Weld Head Symbol To Signify a generic Orbital Weld Head 102 Downslope Time Symbol Signifies the amount of time to ramp the current from the end of the last level to arc extinction Document No. 740096 Rev. A Chapter 3. Page 18 Arc Machines, Inc.
Arc Machines, Inc. Model 307 Orbital Tube Welder Training Chapter 4. Model 307 Power Supply Installation EQUIPMENT INSTALLATION The basic Model 307 orbital welding power supply is part of a complete welding system intended for autogenous welding of metal tubes, pipes and fittings.
Arc Machines, Inc. Model 307 Orbital Tube Welder Training electrical performance is based on a maximum weld head distance of 50 feet (15.4 m) from the Model 307. A System Stop Button is located on the front of the Power Supply and on the Operator Pendant. Pressing System Stop shuts down welding operations. Weld Current Output. Current type is continuous or pulsed output DC Straight Polarity for GTAW (TIG) welding only. The programmable range is from 3 to 200 amperes (± 1% of programmed setting or ± 1.
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Arc Machines, Inc. Model 307 Orbital Tube Welder Training supply. From the Home screen touch "Shutdown". Wait for "It’s now safe to turn off your computer" to appear on the screen before turning the circuit breaker OFF. MODEL 307 POWER SUPPLY ADAPTER CABLE CONNECTIONS WELD HEAD MOTOR CONTROL GROUND GROUND ELECTRODE ARC GAS OUTPUT Weld head or adapter cable connections to the Model 307 Power Supply for Weld Head Motor Control, Electrode, Ground and Arc Gas.
Arc Machines, Inc. Model 307 Orbital Tube Welder Training Weld Head Motor Control Cable Remove dust cap on cable and insert weld head CONTROL connector into the Model 307 WELD HEAD connector identified by the weld head symbol. Note positioning keyway. Hand tighten connecting ring after pins are seated. Do not force. (See figure on page 4.) Welding Gas Connections Gas Hoses. The gas hoses supplied with the Model 307 are selected for suitability for high-purity orbital welding.
Arc Machines, Inc. Model 307 Orbital Tube Welder Training WELD HEAD INSTALLATION TO ADAPTER CABLE The weld head cable connects to the adapter cable, except for the Model 9-500 and Model 9-250 which plug into the power supply or extension cable using a pigtail. Insert the adapter cable GROUND, ELECTRODE, and GAS connectors into the mating weld head cable connectors. Pull back the collar of the female quick-disconnect fitting of the electrode and ground connectors and twist the male connector into place.
Arc Machines, Inc. Model 307 Orbital Tube Welder Training MODEL 307-CW INSTALLATION The Model 307-CW mounts beneath the 307 power supply and circulates water and coolant through the weld heads and cables to prevent overheating. The CW is recommended for welding heavy-walled materials or for bench welding where high productivity is required. Most AMI weld heads are water-cooled but the Model 9-500 and 9-250 weld heads are not.
Arc Machines, Inc. Model 307 Orbital Tube Welder Training replacement pump if required). Flow/no flow indicators are of both visual and electronic design. The 307 CW is filled from a spout on the top of the unit. A Fill Indicator on the front panel indicates the fill level, while a flow indicator rotates to indicate coolant flow. Fill spout Fill Level Flow Indicator Model 307-CW (front) Note: Pump does not self- prime well. Monitor Fill Level after cables have filled with coolant.
Arc Machines, Inc. Model 307 Orbital Tube Welder Training MANUAL TORCH INSTALLATION Tack welding with a manual GTAW torch in a high-purity application. Photo courtesy of the Murray Company Mechanical Contractors. Ground Foot Controller OR The optional manual TIG (GTAW) torch (307-MT), ground cable and foot control is available for use with the Model 307 Power Supply for tack welding or manual TIG welding. (See diagram on page 10.
Arc Machines, Inc. Model 307 Orbital Tube Welder Training M-307 to MANUAL TORCH HOOK-UP M-307 POWER SUPPLY CONNECT PANEL WELD HEAD M307-FC MANUAL TORCH FOOT CONTROLLER ARC GAS ARC GAS IN AC INPUT GROUND ELECTRODE ID PURGE LINE CONNECT TO REGULATOR/FLOWMETER (OPTIONAL) AIR-COOLED. MANUAL TORCH WORK GROUND M307-FS FOOT SWITCH Document No. 740096 Rev. A Chapter 4. Page 10.
Arc Machines, Inc. Model 307 Orbital Tube Welder Training Model 307 Remote Pendant Pendant The Model 307 Remote Pendant is used to initiate the weld sequence at a distance of up to 25 feet from the power supply. Extension cables up to 100 feet are available. The pendant keys have the same function as the similar buttons on the 307 Power Supply. The remote pendant plugs into the remote connector on the side of the Model 307.
Arc Machines, Inc. Model 307 Orbital Tube Welder Training Model 307 Accessory Connections The Model 307 Power Supply features several types of connectors for optional accessories with control or communication functions. DATA RS 232 AUXILIARY PLUG O2 Analyzer or other device Streaming Data PENDANT FOOT CONTROL/ FOOT SWITCH 307-RP Data. The RS-232 Communications Port outputs streaming digital data to an external device during the weld sequence.
Arc Machines, Inc. Model 307 Orbital Tube Welder Training Pendant. A remote pendant may be connected to the Model 307 to initiate weld sequence at a distance from the power supply. See page 11. Foot Control. A Foot Control or Foot Switch may be connected to the Model 307 for use with a manual torch. I/O Devices: (Memory Capacity 20 GB) The Model 307 Floppy Disk Drive The Model 307 has a floppy disk drive that can be used for downloading Weld Data Records or for loading software onto the 307.
Arc Machines, Inc. Model 307 Orbital Tube Welder Training Installing Printer Paper in the Model 307 Internal Printer. Remove paper cover from the front of the Model 307 by pressing the release button. Be careful not to drop the cover. Paper may be installed manually or with Automatic Paper Load. To load paper by hand, lift the head up/down lever until it clicks. With the thermal head in the up position, insert the paper straight into the printer.
Arc Machines, Inc. Model 307 Orbital Tube Welder Training diagonally as shown below. Insert the paper straight into the printer until the auto-paper feeder engages the thermal paper. If the paper becomes misaligned during loading, raise the head and reset the paper. WRONG RIGHT Cut paper edge as shown before loading printer paper. Note that sensors for automatic paper feed are on the same side as the head up lever. If the paper is not cut as shown, the paper will not feed.
Arc Machines, Inc. Model 307 Orbital Tube Welder Training Chapter 5. Model 307 Weld Parameters/ Sequence of Events LEVEL 1 LEVEL 2 LEVEL 3 LEVEL 4 OPE NSL DOW SEQUENCE START PREPURGE POSTPURGE This chapter will explain the Sequence of Events that takes place during a weld.
Arc Machines, Inc. Model 307 Orbital Tube Welder Training the starting level to full primary Amps in a timed Upslope. However, There is usually no upslope programmed for autogenous welds and the initial welding current will be equal to primary amps. If Pulse Mode is "On" the current will pulse between a higher Primary Amps and a lower Background Amps with pulsation beginning at arc initiation.
Arc Machines, Inc. Model 307 Orbital Tube Welder Training Programmable Variables Single Entry Parameters The programmable variables which are controlled by the Power Supply are divided into two categories on the Model 307 and are shown on different screens. Single Entry parameters are those that are entered only once and remain the same for all levels of a schedule. Level/Segment parameters may be changed from level-tolevel.
Arc Machines, Inc. Model 307 Orbital Tube Welder Training Start Level - This is the amperage at which the 307 initiates the arc if upslope is used. When upslope is set to zero, the start level current is equal to Level 1 primary amps. Level Advance - Use the pull-down menu to set the Level Advance to Manual, Auto or External. In Auto Mode the levels advance from one level to the next as the level timers time out and/or according to preset level positions.
Arc Machines, Inc. Model 307 Orbital Tube Welder Training Start Position - The Start Position documents the start location of the electrode (when the tube is in the horizontal 5G position). The default position is 3 O’clock. Selection of a different start location requires the operator to position the weld head accordingly. Since most thin-wall tube welding applications are not significantly affected by the Start Position, this information is normally used only for heavywall applications.
Arc Machines, Inc. Model 307 Orbital Tube Welder Training Primary Travel (speed) - Background Travel (speed). If Travel Mode is set to CONT (continuous) the electrode rotation will remain at the Primary Travel (RPM) setting. If the Travel Mode is set to STEP the electrode rotation (RPM) will alternate between the Primary and Background travel (RPM) settings. Pulse Mode - Pulse Mode is selectable by a pull-down menu in each level.
Arc Machines, Inc. Model 307 Orbital Tube Welder Training Level Time - Level Time is the time the electrode will travel during a particular level. If Level Position is programmed, Level Time will be automatically adjusted accordingly. For auto-generated weld schedules, Travel Start Delay time is added to Level 1 time while overlap (tiein) is added to Level 4 time. Document No. 740096 Rev. A Chapter 5. Page 7.
Arc Machines, Inc. Model 307 Orbital Tube Welder Training Chapter 6. Power Supply Functions and Operations Opening (Home) Screen: When the 307 Circuit Breaker is turned to the ON position, the Home Page (below) will appear. From the Opening Screen, users may do one of the following by touching one of the buttons on the Touch Screen: Button Function OPEN LAST SCHEDULE. Opens the previously used weld program (schedule). The WELD SCHEDULE - MAIN screen will appear.
Arc Machines, Inc. Model 307 Orbital Tube Welder Training Button Function SYSTEM SETUP FUNCTIONS. This button provides access to numerous functions such as printer and report setup, security administration and time/date set, etc. SHUTDOWN. Exits the 307 Software. Wait for “It’s now safe to shut down your computer” before turning the Circuit Breaker to OFF. LOGON ( LOG OFF). Where LOGON is required you must enter your LOGON NAME and PASSWORD to operate the Model 307. TOOLS.
Arc Machines, Inc. Model 307 Orbital Tube Welder Training Open Last Schedule Weld Schedules may be opened from the Model 307 Library or the Last Schedule used on the 307 may be opened directly by touching the OPEN LAST SCHEDULE button on the Opening Screen. The WELD SCHEDULE - MAIN screen will appear. Weld Schedule Name To weld with this schedule, touch the WELD button to bring up the WELD SCREEN.
Arc Machines, Inc. Model 307 Orbital Tube Welder Training In TEST MODE pressing Start initiates a Weld Sequence without an arc. Pressing TEST will put the Model 307 into WELD MODE. In WELD MODE pressing Start on the Weld Screen will initiate the weld sequence with an arc. Pressing Weld will return the M307 to Test Mode. Press START to begin welding. Refer to Chapter 11. Welding with the 307 for more complete welding instructions. Document No. 740096 Rev. A Chapter 6.
Arc Machines, Inc. Model 307 Orbital Tube Welder Training System Setup Functions Touching the SYSTEM SETUP FUNCTIONS button on the M 307 Opening Screen displays the System Setup screen shown below. Your security classification determines which setup functions you can access. Touching the In-sequence Display button on the System Setup screen brings up the In-sequence Display Selection screen. These choices determine the screen or function that is displayed during the weld sequence. Document No.
Arc Machines, Inc. Model 307 Orbital Tube Welder Training Displays Weld Schedule - Main screen of active weld schedule during weld sequence. Displays program Levels screen and displays a graph showing progress of weld levels. Displays values of amps, volts, and travel speed as digital streaming data during weld. Plots numerical data as a linear graph after the end of weld sequence.
Arc Machines, Inc. Model 307 Orbital Tube Welder Training Security Administration permits the classification of users as Operators, Supervisors and Programmers with defined access to M 307 functions. Users may be added, removed, or their classification changed. Enabled Touching the Faults button from the System Setup Functions brings up the Faults Setup Screen. Fault functions are enabled by selecting the button for Stubout, Input AC, High Arc, Gas, Coolant or external faults.
Arc Machines, Inc. Model 307 Orbital Tube Welder Training The Keyboard button on the System Setup screen opens the Keyboard Setup screen which enables users to enable or disable the on-screen keyboard or to clear the keyboard history. The Printer Setup button on the System Setup screen allows the user to select Report or Label as print options. Touch the Install Printer button to connect the Model 307 to a printer to print.
Arc Machines, Inc. Model 307 Orbital Tube Welder Training If Label Setup is selected from the Printer Setup screen, the Label Printer Print Items screen is displayed. The items selected will appear on the printed label for each weld. The Printer Setup button on the above screen brings up the Label Printer Selection Screen from which the user may select the Printer device and choose a Logo (or no logo) to print on the Label. Label Printer Document No. 740096 Rev. A Chapter 6.
Arc Machines, Inc. Model 307 Orbital Tube Welder Training Touching the Language button from the System Setup screen brings up the Language Selection screen. Highlight the Language to be shown on Model 307 screens. A language may be Imported, Exported to a remote machine or deleted. Touching the Screen List button from the System Setup Functions screen displays 307 screens. Pressing Next brings up additional screens. Each screen is identified by a number in the upper right hand corner. Document No.
Arc Machines, Inc. Model 307 Orbital Tube Welder Training The Weld Head Data button displays the Weld Head Wizard Screen. This screen permits 307 Programmers to write definitions for new weld heads and export or import weld head information from other sources. See Chapter on Advanced Functions for more complete information. Touching the Total Welds Counter Reset button from the System Setup Functions Screen displays the Total Welds Counter Reset screen.
Arc Machines, Inc. Model 307 Orbital Tube Welder Training 24 Hr From System Setup Functions screen touch the Date Time set button. Use pull-down menus to set date and time of day. Select 24 hour clock if desired. The Model 307 Touch Screen may be calibrated by touching the Touch Screen calibration button on the System Setup Function screen and then clicking on the targets shown on the screen. Document No. 740096 Rev. A Chapter 6.
Arc Machines, Inc. Model 307 Orbital Tube Welder Training The Power Supply Information screen provides information including Serial Number, Arc and System Hours, Total number of welds done by the Power Supply (since the last reset) and a Unique Machine ID number used for software upgrades and machine identification by AMI service. ∑t ∑t ∑n # Document No. 740096 Rev. A Chapter 6.
Arc Machines, Inc. Model 307 Orbital Tube Welder Training Model 307 Tools Functions Touching the Tools button on the Model 307 Opening Screen, or the Tools Icon on the Toolbar opens the Tools screen and displays the Tools menu. Tools functions consist of Conversions and Calculators as well as access to Weld Data Records. in.
Arc Machines, Inc. Model 307 Orbital Tube Welder Training The Tools Backup Gas Pressure Conversions calculator converts inches of water to Millimeters of water or Millibar of pressure to Pascal or vice-versa when one of the items is typed in. The Tools Electrode Rotation calculator will calculate the RPM when the Travel speed (IPM or mm/min.) is entered.
Arc Machines, Inc. Model 307 Orbital Tube Welder Training ∑t 360° Tools - Weld Time Calculator Entering the RPM from the Tools - Electrode Rotation screen and pressing the Total Time for 360° degree revolution will display the time for one revolution. To calculate Total Weld (arc) Time, add the time for Rotation Delay and Overlap to the time for 1 revolution. Tools - Electrode Calculator Select the weld head you wish to use or enter the Rotor Diameter. Enter the tube diameter and wall thickness.
Arc Machines, Inc. Model 307 Orbital Tube Welder Training Tools - AMI Calculator The AMI Calculator is a regular calculator that performs standard arithmatic functions when numbers and symbols are entered from the keyboard. Selecting the Weld Data Records button from the Tools menu opens the Weld Data Records screen which lists weld records that can be searched by various criteria. See Chapters on Associated Data and Data Acquisition/ Advanced functions for more detailed information on weld records.
Arc Machines, Inc. Model 307 Orbital Tube Welder Training Touch OK when Logon and Password have been entered. LOGON/LOG OFF. The Model 307 can be set up to require operator logon names and passwords and set to one of 3 security levels (Operator, Supervisor, or Programmer). The M 307 comes with the default set to not require log-in and is set to the Supervisor Level. If the M 307 is set up to require Log-In, Log-In is accomplished by touching the LOGON button from the M 307 Opening Screen.
Arc Machines, Inc. Model 307 Orbital Tube Welder Training Screens Accessible from Weld Schedule - Main Screen: Opening Screen Weld Schedule -Overrides Weld Schedule - Single entry Weld Schedule Main Screen Associated Data - Comments Weld Schedule - Levels Weld Schedule - Weld Screen Weld Schedule - Library Associated Data - Main Weld Schedule - Weld Screen Counter/Alert Indicator Document No. 740096 Rev. A TEST/WELD changes operating Mode.
Arc Machines, Inc. Model 307 Orbital Tube Welder Training Chapter 7. Model 307 Library Pressing the SELECT FROM LIBRARY Button from the Opening Screen or the Library Icon on the Toolbar opens the Weld Schedule Library. Weld schedules may be stored in and accessed from either Local (307) or Remote (laptop) Libraries or a Floppy, USB Memory Stick or other External Device. A device must be connected in order to access the particular library.
Arc Machines, Inc. Model 307 Orbital Tube Welder Training Once the Schedule name has been highlighted, the Folder functions change to Schedule buttons and the Open Schedule button appears. Touching the Open Schedule button displays the Weld Schedule Main Screen. See Chapters 6 and 11 to follow guidelines for welding. Select Schedule Selecting schedule displays schedule functions Touch to OPEN SCHEDULE Opening a Weld Schedule from the Library displays the Weld Schedule-Main Screen.
Arc Machines, Inc. Model 307 Orbital Tube Welder Training Library Folder Functions The Create Folder button brings up a space to enter the Folder Name. Enter the new folder name as shown from the keyboard screen that will appear. Select Library where you want the folder to reside Touch OK when name has been typed. Type in Folder Name from keyboard Create Folder Keyboard: To enter a number or letter shown on one of the keys, touch the key rapidly for the number of times required to display that character.
Arc Machines, Inc. Model 307 Orbital Tube Welder Training Folders may be Renamed, Deleted, or Copied and Pasted into the Model 307 Library or the Library of a remote machine, floppy disk, or an external device such as a USB memory stick. To Rename a Folder, select local or other library, then highlight the folder you wish to rename and touch the Rename Folder button. Type the Renamed Folder name using the keyboard and touch OK. The new folder name will appear.
Arc Machines, Inc. Model 307 Orbital Tube Welder Training To Copy a Folder from a Local Machine to a Remote Machine or laptop the 307 must be connected to the remote machine. First select the Local Library then touch to highlight the folder you wish to copy. Then touch the Copy Folder button. Select Library by touching Highlight folder by touching Paste Folder.
Arc Machines, Inc. Model 307 Orbital Tube Welder Training Copying a Folder from the Local Library to a Floppy Drive A floppy disk must be installed in the Model 307 to access the floppy library. Select Local Library Highlight Folder to be copied Touch the Copy Folder Button Select Floppy Library Touch the Paste Folder Button Touch the Paste Folder button The folder you copied and all the weld schedules in the folder are displayed in the Floppy Library Document No. 740096 Rev.A Chapter 7. Page 6.
Arc Machines, Inc. Model 307 Orbital Tube Welder Training Library Weld Schedule Functions When a Weld Schedule is selected by touching, the Folder Buttons at the bottom of the Weld Schedule Library Screen change to Schedule Buttons to Create, Rename, Delete or Copy schedules.
Arc Machines, Inc. Model 307 Orbital Tube Welder Training To Rename a Weld Schedule, first select the Library and then the Folder in which the schedule you wish to rename resides. Highlight the schedule name and touch the Rename Schedule button. A screen will appear with a blank in which to enter the new name. Type in and Enter the new name using the 307 keyboard. Then Press OK. The new weld schedule name should appear in the selected folder in the selected library.
Arc Machines, Inc. Model 307 Orbital Tube Welder Training To Delete a Weld Schedule from a M307 Library, first select the library, then the folder in which the schedule resides, then highlight by touching the Weld Schedule Name, then press the Delete Schedule button. Press to Delete selected weld schedule Press Yes to Delete Weld Schedule. Document No. 740096 Rev. A Chapter 7. Page 9.
Arc Machines, Inc. Model 307 Orbital Tube Welder Training To Copy a Weld Schedule and Paste it into another location: First select the Library (Local, Remote or External Device) in which the schedule resides, then select the Folder which contains the schedule, then touch the schedule name to highlight. Press Copy Schedule to copy.
Arc Machines, Inc. Model 307 Orbital Tube Welder Training To Paste a Weld Schedule to a USB Memory Stick Install a Memory Stick into the 307 USB port. Its software must be activated. Copy a weld schedule from the local or other library and select the External Device library. The Choose Folder screen will appear. Locate using the pull-down menu and select the icon for the Memory Stick then touch select. The External Device Library will appear.
Arc Machines, Inc. Model 307 Orbital Tube Welder Training Select folder to highlight and touch Paste Schedule Press Paste Schedule to paste copied schedule into selected folder. The schedule is pasted into the USB memory stick Don’t forget to touch the Stop USB button before removing the Memory Stick Document No. 740096 Rev. A Chapter 7. Page 12.
Arc Machines, Inc. Model 307 Orbital Tube Welder Training Screens Accessible from the Model 307 Library Close Library Opening Screen Weld schedule Library - Weld Schedule Library Folder selected - folder buttons displayed Weld Schedule Main Weld schedule Library - Weld Schedule Library Weld Schedule selected buttons change to schedule Weld schedule Library Weld schedule Library - Weld schedule Library Weld Schedule Library Weld schedule Library - Weld Schedule Library Document No. 740096 Rev.
Arc Machines, Inc. Model 307 Orbital Tube Welder Training Chapter 8. Autogeneration of New 307 Weld Schedules Autogeneration of a Continuous Weld Schedule To Create a New Weld Schedule on the Model 307 touch the Create New Schedule button on the 307 Opening screen. Then select the Folder from the pull down menu on the Weld Schedule Wizard screen, type in Schedule Name, and select the weld head you wish to use from the menu. Select English or Metric units of measure and then press Next.
Arc Machines, Inc. Model 307 Orbital Tube Welder Training Weld Schedule Name: Type in schedule name To type in the weld schedule name from the keyboard, touch character key once for the number shown on the key or rapidly in succession until the desired letter appears, i.e. two times for a “d” and three times for an “e”, etc. Selecting the Shift key will result in capital letters. Press Enter when name is complete. Caution: Do not use illegal characters: \/’!@#*&%?: as characters in schedule names.
Arc Machines, Inc. Model 307 Orbital Tube Welder Training Weld head selection. Select weld head from menu. Use scroll bar to view entire list. Select units of measure. Press Next when done. Select weld head from menu Use scroll bar to view complete list of weld heads Press Next when all complete Enter Library information. Touching the field you wish to complete will open the keyboard for typing in the information. Type in information for Tube 1. Fields with an asterisk* are mandatory.
Arc Machines, Inc. Model 307 Orbital Tube Welder Training Type in the information for each field and press Enter. Repeat until all the mandatory and desired information for Tube 1 has been entered. Then touch Next. The Dialog screen for entering Tube 2 information will appear. Tube 1 Dialog screen. If the information for Tube 2 is identical to that of Tube 1, press the Same as Tube 1 button. If not, fill in information for tube, fitting or other weld component from the keyboard.
Arc Machines, Inc. Model 307 Orbital Tube Welder Training Automatic Weld Schedule Generation: Select Continuous, Step or Tack to generate a schedule. Autogeneration of a Continuous Weld Program This section illustrates a new Continuous weld schedule that has been generated automatically. Programs for Step and Tack are shown on pages 8 and 13. For directions on how to enter weld parameters manually, see Chapter 9. The first Weld Schedule screen is the Weld Schedule - Main screen shown below.
Arc Machines, Inc. Model 307 Orbital Tube Welder Training Weld Schedule - Single Entry. This screen shows autogenerated weld parameters for those items that are entered only once for the entire schedule. To modify a parameter, select it by touching and use the keyboard to enter the new value. Use the Scroll Bar to view additional parameters Weld Schedule - Weld Levels Screen. Weld parameters which may be changed in any level. Use scroll bar to view additional weld parameters.
Arc Machines, Inc. Model 307 Orbital Tube Welder Training Weld Schedule- Weld Levels scrolled down to view Level Time Scroll bar moved down to view or adjust Level Times To Add or Delete a Level. The default for automatically generated schedules is 4 Levels. If you wish to add a level, select the level you wish to copy and touch the Level bar to display the pull-down menu. Select Copy this level to create another level indentical in all parameters to the level selected.
Arc Machines, Inc. Model 307 Orbital Tube Welder Training Autogeneration of a STEP Program STEP (or SYNCHRO) rotation mode is used for fusion welds on thinwalled pipe up to about 0.154” wall, or tubing where extra penetration or margin of error is required. Wall thicknesses of 0.080” or greater may require STEP mode, and thinner materials such as 0.065” wall pharmaceutical type fittings, short sanitary ferrules or valves, may benefit.
Arc Machines, Inc. Model 307 Orbital Tube Welder Training Enter Library Information You must enter the diameter and wall thickness at the weld joint and the material. Heat number and a description of the weld are optional. Square butt is the default end prep. Press Next when finished. Enter the correct prep if it is not a square butt joint. Select welding position from the pull-down menu. If the second weld component is identical to the first, press the Same as Tube 1 button.
Arc Machines, Inc. Model 307 Orbital Tube Welder Training Weld Schedule - Main Screen Weld parameters for the autogenerated program can be viewed and/or modified by touching the Single Entry and Levels buttons from this screen. Overrides for this program can be modified by touching Overrides. Data related to the weld schedule can be entered via the Associated Data and Comments Screens. The display that will appear during welding can be selected from In Seq. Display.
Arc Machines, Inc. Model 307 Orbital Tube Welder Training Weld Schedule - Weld Levels screen Scroll down to view Primary and Background Pulse Times and Level Times. Primary and Background Amps can be adjusted by touching the +1% or -1% buttons. Adjust other parameters by touching and typing in new value from the keyboard. Touch OK to return to the Weld Schedule - Main screen. Scroll down to view the Primary and Background Pulse Times.
Arc Machines, Inc. Model 307 Orbital Tube Welder Training Creating an Orbital Tack Weld Program Tack welding is often required for holding parts in place for orbital welding. This can be done either with a manual torch (Chap. 4 pages 9 -10; Chap. 9) or an Orbital Tack Weld program can be generated automatically for use with the Model 307 and AMI tube welding heads. An example Orbital Tack Weld program follows: Begin by selecting a folder for the program, unit of measure, and weld head then touch Next.
Arc Machines, Inc. Model 307 Orbital Tube Welder Training When the Library Information for the tubes have been entered the Weld Schedule Wizard - Finished screen appears. Touch the Tack Icon to generate the Orbital Tack Program. Touch Tack icon to generate Tack weld schedule The Weld Schedule Tacking Values screen provides options for orbital tack welds. The amount of weld bead penetration is adjusted by moving the slide switch and the percent of penetration is shown in the window.
Arc Machines, Inc. Model 307 Orbital Tube Welder Training Weld Schedule Main Screen Weld Schedule Single Entry - For the Orbital Tack Weld program the preand postpurge times are set at 20 seconds, there is no Downslope, Level Advance is Auto, Stubout Mode is ON, and there is no Travel Start Delay time. Document No. 740096 Rev. A Chapter 8. Page 14.
Arc Machines, Inc. Model 307 Orbital Tube Welder Training Weld Schedule Weld Levels This weld schedule has 8 levels. Travel Mode changes from Off to Cont in each successive level with Level Times corresponding to travel mode. The Primary Amps changes from 35 pulsing to 6 Amps to achieve penetration in levels with Travel Mode Off and is reduced to a constant 6 amps in levels where Travel Mode is Cont. This produces a series of tack welds around the tube circumference.
Arc Machines, Inc. Model 307 Orbital Tube Welder Training Levels 4 through 7 are shown on the screen below. Note Level Position at each level. Travel speed is fast during the time that travel is CONT and stopped when Travel Mode is Off. Pulse times are the same in each level. To weld with this schedule press OK to return to the Weld Schedule Main Screen and then Press Weld to get to the Weld Schedule - Weld screen.
Arc Machines, Inc. Model 307 Orbital Tube Welder Training Chapter 9. Manual Creation of 307 Weld Schedules This section is for those programmers and supervisors who wish to develop their own weld schedules manually. It explains the basis of weld parameters such as welding currents and RPM and provides formulas for their calculation. The example of 0.500 in. O.D., 0.049 in. wall (12. mm, 1.
Arc Machines, Inc. Model 307 Orbital Tube Welder Training To complete the program manually, touch the Manual button on the Weld Schedule Wizard-FINISHED screen . Touching the Manual button opens the Weld Schedule Main Screen. Touch the Single Entry button to display the Single entry parameters. Document No. 740096 Rev. A Chapter 9. Page 2.
Arc Machines, Inc. Model 307 Orbital Tube Welder Training Programming Single Entry Weld Parameters When Manual is selected, default or zero values for weld parameters will be shown. The programmer must select each parameter and enter a value from the keyboard. Prepurge: The Prepurge time will default to the minimum recommended setting for the specific weld head selected. Using longer prepurge times will result in cleaner welds and longer electrode life.
Arc Machines, Inc. Model 307 Orbital Tube Welder Training Level Advance: For all autogenous tube and pipe welds select Auto mode. Auto, Manual and External Level Advance are available from the pull-down menu. Stubout Mode - Stubout Mode is typically turned ON for autogenous orbital welding. It must be OFF when using the manual torch. Pulse Mode - Select ON for all autogenous welding. Travel Mode - Use the Pull-down menu to select Travel Mode. Cont is typically used for autogenous tube welding.
Arc Machines, Inc. Model 307 Orbital Tube Welder Training The Weld Schedule - Single Entry screen values for parameters (shown as icons) that have been changed and entered are shown with a blue highlight. Scroll down to select start position Scroll down to select other weld parameters Use pulldown menu to select start position Document No. 740096 Rev. A Chapter 9. Page 5.
Arc Machines, Inc. Model 307 Orbital Tube Welder Training Programming Levels/Segments Parameters The Weld Schedule - Weld Levels screen displays weld parameters that may be changed for each level. Once parameters for Level 1 have been entered, touch OK to save. Touching Add a Level will create another level identical to the previous level. Select those parameters you wish to change and enter the value from the keyboard.
Arc Machines, Inc. Model 307 Orbital Tube Welder Training Primary Amps/Wall Thickness 120 100 Amps 80 60 40 1 Amp per 0.001” Correction 20 0 0.035 0.049 0.065 0.083 0.109 0.12 Wall Thickness - Inches Level Amps: Typically, the heat required to achieve penetration at the beginning of a weld will need to be reduced during the weld to avoid overpenetration. There are several methods of calculating intermediate level Primary Amps. 1.The first method works for any number of levels.
Arc Machines, Inc. Model 307 Orbital Tube Welder Training Example: (Refer to chart at the bottom page 7). Based on 1 amp per 0.001” of tube wall thickness, Level 1 primary amps for an 0.049” wall thickness would be 49 amps. Add the 10% correction (5 amps) = 54 amps for level 1. The last level primary amps is typically 20% less than Level 1 primary amps. (43 amps). Decrease Intermediate Level Primary amps equally. Note: Variations in materials will require minor amperage adjustments.
Arc Machines, Inc. Model 307 Orbital Tube Welder Training LEVEL 1 LEVEL 2 LEVEL 3 LEVEL 4 54 52 50 49 16 16 16 16 Level Time: To calculate Level time, add the time for one complete 360° revolution (60 sec divided by the RPM), add time for Travel Start delay and tie-in. Divide the sum by the number of levels to get the time per level. Time for 360° = 60 sec. ÷ RPM Total Time = Time for 360° + Travel Start Delay + Tie-In Time per Level = Total Time ÷ Number of Levels Example: If RPM = 3.
Arc Machines, Inc. Model 307 Orbital Tube Welder Training Finished Levels/Segments Parameters for .500 in O.D. 0.049 in tube by manual programming Use scroll bar to view level times See Chapter 10. Associated Data for entering important information for the weld record. Document No. 740096 Rev. A Chapter 9. Page 10.
Arc Machines, Inc. Model 307 Orbital Tube Welder Training Creation of a Weld Program in Travel (Rotation) Step Mode The simplest way to create a STEP rotation weld schedule is to use the 307 autogeneration feature described on pages 7 through 10 of this chapter. The program can easily be modified from the Levels/Segments screen. There are several approaches to writing a STEP program, but only the easiest and quickest will be presented here.
Arc Machines, Inc. Model 307 Orbital Tube Welder Training primary RPM is set to 1/2 the calculated RPM (based on 5 IPM) and the background RPM is set to the calculated RPM may be effective in increasing penetration without reducing the time per weld as much as setting the primary RPM to 0.0. STEP RPM may be based on 4 IPM instead of 5 IPM. Actual travel speed is slower in STEP mode. Size Considerations Orbital fusion welds are practical on diameters from 1/8” to 7.0” and wall thickness from about 0.
Arc Machines, Inc. Model 307 Orbital Tube Welder Training Example Weld Schedule for the AMI Manual Torch For welding with the AMI Hand Torch, whether air-cooled or water cooled, there must be a weld schedule open with parameters for amps and time entered. Touch Create New Schedule and select Hand Torch from the weld head menu. Touch Next when Folder, Schedule name and weld head have been entered. Select Manual from the Weld Schedule Wizard FINISHED screen. Document No. 740096 Rev. A Chapter 9. Page 13.
Arc Machines, Inc. Model 307 Orbital Tube Welder Training The screen below shows the Main Weld Screen for a weld schedule for the AMI Manual GTAW torch. The wall thickness entered is 0.065 in. (1.65 mm). The current will need adjusting, less current for thinner walls and more current for heavier walls. Touch Single Entry to view weld parameters Weld Schedule- Single Entry Note: Once a parameter has been modified it will be highlighted.
Arc Machines, Inc. Model 307 Orbital Tube Welder Training Hand Torch Weld Schedule - Weld Levels The Weld Levels screen has parmeters that may be changed for each level of a weld sequence. For a manual torch program, one level is usually sufficient. Pulse Mode is ON for this program but some users may prefer constant current for tack welds. Primary and Background Amps (current) may be adjusted to provide more heat for heavier wall thickness. Tack welds should not penetrate to the I.D.
Arc Machines, Inc. Model 307 Orbital Tube Welder Training Save Changes? As you close your weld schedule, you will be asked if you wish to save your changes. Select Save to save the changes you have made. Document No. 740096 Rev. A Chapter 9. Page 16.
Arc Machines, Inc. Model 307 Orbital Tube Welder Training Chapter 10. Associated Data - Electrode Gas Materials Equipment Weld record keeping is an important part of the welding operation for many industries. The Model 307 is designed to collect data for each weld stored as weld records that may be useful information at a later date. Associated Data - Pressing the Associated Data button from the Weld Schedule - Main Screen brings up the Associated Data - Main Screen (shown on the next page).
Arc Machines, Inc. Model 307 Orbital Tube Welder Training Associated Data - Main Screen Pressing the Tube button on the Associated Data - Main Screen opens the Associated Data - Tube screen shown below. This screen is filled in prior to generation of a weld program and may be modified at any time. Recording the outside diameter (Tube 1) of the weld joint, wall thickness, and material type is mandatory information.
Arc Machines, Inc. Model 307 Orbital Tube Welder Training Associated Data - Tube 2 To enter or view additional data touch Next or Data Main. Associated Data - Equipment Power supply serial number and date of calibration are already entered. Enter weld head serial number from the keyboard if this information is desired. Document No. 740096 Rev.A Chapter 10. Page 3.
Arc Machines, Inc. Model 307 Orbital Tube Welder Training Associated Data - Gas Type in Arc Gas Type or Mixture, Flow rates and gas source information for the Arc Gas and Backup Gas (I.D. purge). Vent diameter (exit orifice) and I.D. pressure should also be recorded if applicable. Touch the AMI recommended Arc Gas flow rates button for factory-recommended flow rates. Associated Data - Electrode Enter Electrode Type, Diameter, length, grind angle,tip diameter and arc gap.
Arc Machines, Inc. Model 307 Orbital Tube Welder Training Weld Schedule Counter and Alert Reset From the Main Weld Schedule screen touching the Counter Reset button will bring up the Counter/Alert Indicator screen that allows the user to either reset the alert counter to a new number, reset the weld counter to zero, change the alert message and/or disable the alert.
Arc Machines, Inc. Model 307 Orbital Tube Welder Training Chapter 11. Welding with the Model 307 In order to weld with the Model 307, you must have an open weld schedule for the size of tube or pipe you intend to weld and the Weld Schedule-Weld screen for that schedule must be displayed in weld mode on the 307 touch screen. 3 Ways To Open a Weld Schedule: 1. Weld Schedules may be opened from the Model 307 Library. Touch Library on the 307 Opening Screen. (see Chapter 7). 2.
Arc Machines, Inc. Model 307 Orbital Tube Welder Training Pressing WELD on the Weld Schedule-Main screen (previous page) will bring up the Weld Schedule - Weld Screen. In Test Mode (green Test button displayed) touching Start initiates a weld sequence without striking an arc. The rotor will turn at the programmed speed for the programmed amount of time. Touch START to make a Test run. Touch Test to enter Weld Mode Pressing TEST on the screen above will put the Model 307 into WELD MODE.
Arc Machines, Inc. Model 307 Orbital Tube Welder Training BEFORE YOU WELD: This is a check list for things that must be done correctly or set up properly in order to get consistently good welds. Anyone doing an orbital welding installation or other orbital welding project should establish their own written SOPs (Standard Operating Procedures) for all activities related to orbital welding that must be followed by welding personnel. Verify that the Weld Schedule Name is correct.
Arc Machines, Inc. Model 307 Orbital Tube Welder Training Model 307 Functions that may be set for security, viewing or data recording during welding: Is Logon required? Programmer enters passwords for welding personnel. Touch System Set-up from the 307 Opening Screem and select Security Administration. Have you selected the In-Sequence display? From the 307 Opening Screen select System Setup Functions and from the Setup Screen select In-Sequence Display.
Arc Machines, Inc. Model 307 Orbital Tube Welder Training Chapter 12. Weld Procedure Optimization Weld coupon on 1.500 inch O.D. 316L stainless steel cut open for evaluation of the I.D. surface for a bioprocess application. Photo courtesy of ProTech Process, Inc. H eat-to-heat variations in stainless steel may make it necessary to adjust weld parameters, particularly amperes, for individual heats of material.
Arc Machines, Inc. Model 307 Orbital Tube Welder Training To make a Test Run of a weld schedule, open the schedule and from the Weld Schedule - Main screen, touch the grey Single Entry button. Set downslope to 0.0 and touch OK. From the Weld Schedule - Main Screen, touch the grey Weld button to show the Weld Schedule - Weld screen with the green Test button. To make the Test Run, touch the red Start button. Verify that the electrode travels 360° plus the desired overlap or tie-in.
Arc Machines, Inc. Model 307 Orbital Tube Welder Training The Radial Graph (pie chart) feature of the Model 307 can be used to detemine the location of level changes on the weld circumference. To display the pie chart during test runs or welds, touch the System Setup button on the 307 Opening Screen and then select the gray In-Sequence Display button, Select Radial Graph.
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Arc Machines, Inc. Model 307 Orbital Tube Welder Training Chapter 13. Weld Head Calibration and Operation Weld heads must be calibrated for rotational speed to the power supplies with which they are to be used. With the weld head plugged into the power supply touch the calibration icon on the tool bar. For manual calibration you must use a manual calibration program in Test Mode with the correct amount of time for the RPM used and adjust the rotational speed using the weld head potentiometer.
Arc Machines, Inc. Model 307 Orbital Tube Welder Training For Automatic calibration to the power supply select Automatic. The screen will indicate when the calibration is in progress and when the calibration has been completed. If the potentiometer is out of range the weld head will not calibrate, and the 307 will indicate “Calibration Failed.” Adjust the potentiometer CW to increase speed or CCW to decrease speed.
Arc Machines, Inc. Model 307 Orbital Tube Welder Training Manual Weld Head Calibration To calibrate a weld head manually, touch the Calibration Icon , select Manual and then use a program with appropriate RPM and time for the weld head as shown in Table 1. At a rotational speed of 1 RPM, the rotor should complete one Revolution (360°) in 60 seconds. The manual calibration program should have no travel start delay (0.0 sec) and no Downslope time (0.0 sec).
Arc Machines, Inc. Model 307 Orbital Tube Welder Training Manual Calibration of Weld Heads For Manual Calibration of Weld Heads use the RPM and Times shown in Table 1 to write schedules for calibration of each individual weld head.
Arc Machines, Inc. Model 307 Orbital Tube Welder Training Weld Head Templates. When a weld schedule is open, a template for the specified weld head may be displayed by touching the Templates Icon on the Tool Bar.
Arc Machines, Inc. Model 307 Orbital Tube Welder Training Tungsten Electrode Installation in Weld Head Electrodes are machined to a specific length for each weld head/weld O.D. combination. It is thus very important to install the electrode properly in order to achieve the correct arc gap. For rotors which have a through hole, including most Model 9 weld heads, the electrode must be installed flush to the rotor O.D.
Arc Machines, Inc. Model 307 Orbital Tube Welder Training Installation of Tube Clamp Inserts Tube clamp inserts (TCIs) are used to hold the tubes or other weld components in place for welding. Each tubing diameter welded in a particular head must have two sets of TCIs or fitting clamp inserts, one set on each side of the head. The 9-500 and 9-250 type weld heads use clamp assemblies for this purpose. Adapters are available for TCIs of the large heads so they may be used in more than one size of weld head.
Arc Machines, Inc. Model 307 Orbital Tube Welder Training Tube Installation to the weld head Arc Machines Model 8 and Model 9 weld heads have a window that opens for viewing the electrode line-up to the weld joint. Install tube on one side of the head and before locking the housing clamps completely, position the second weld component, confirm alignment, lock clamps and close window. The electrode should be centered on the weld joint with no discernable gap between the weld components.
Arc Machines, Inc. Model 307 Orbital Tube Welder Training Tungsten Extenders - E type heads and “mushroom” tungsten extenders An important feature of weld heads is the minimum length a weld component must be in order to be welded in a particular type or configuration of weld head. Standard Model 9 weld heads (9-1500 and larger) can be converted to the “E” configuration in which the electrode is moved to one side of the head.
Arc Machines, Inc. Model 307 Orbital Tube Welder Training Table 2. Size Range and Minimum Weld End Stick-Out AMI Weld Head Model Number O.D. Range Min. “A” dim. 4-500 0.093” - 0.500” 2,4 - 12,7mm 0.25” 6,3mm 9-250 0.093” - 0.250” 2,3 - 6,3mm 0.25” 6,3mm 9-500 0.093” - 0.500” 2,2 -12,7mm 0.25” 6,3mm 9-750 0.125” - 0.750” 3,2 - 19,0mm 0.70” 17,8mm 9-1500 0.250” - 1.500” 6,3 -38,1mm 1.41” 35,8mm 9AF-1500 0.250” - 1.000” 6,3 - 25.4mm .85” - .96” 21,6 - 24,4mm 9AFM-1500 0.250” - 1.
Arc Machines, Inc. Model 307 Orbital Tube Welder Training 8-2000 0.250” - 2.000” 6,35 - 50,79mm 0.87 22,09mm 8-4000 0.250” - 4.000” 6,35 - 101.59mm 0.87 22,09mm 8-6625 2.000” - 6.000” 50,79mm - 152,39mm 0.87 22,09mm Brochures and additional information on Arc Machines’ weld heads may be found on the Arc Machines, Inc. web site at www.arcmachines.com. Document No. 740096 Rev. A Chapter 13.
Arc Machines, Inc. Model 307 Orbital Tube Welder Training Chapter 14. End-Preparation for Orbital Welding Preparing tube ends in a cleanroom with a machine that cuts and faces in one operation. Photo courtesy of Murray Company Proper and consistent end preparation is an essential requirement for repeatable high-quality orbital welding results.
Arc Machines, Inc. Model 307 Orbital Tube Welder Training Drawing for Table DT-5 Final Tolerances for Mechanically Polished Fittings and Process Components from ASME BPE-2002. Reprinted with permission from the ASME In the drawing from Table DT-5 of the BPE Standard, the B dimension is the Squareness face to Tangent which increases with tubing size. The Tangent length (T) is defined as the straight length measured from the welding end. T varies from 1.50 in on 1/4 inch O.D. tubing to 2.
Arc Machines, Inc. Model 307 Orbital Tube Welder Training Orbital type saw is used to cut tubing while producing a square end. Photo courtesy of George Fiscsher GmbH. Prepping Equipment Equipment is available for cutting, for facing, or for a combination of cutting and facing. Orbital type saws in which the saw blade moves around a stationary tube are commonly used.
Arc Machines, Inc. Model 307 Orbital Tube Welder Training Chapter 15. Tungsten Electrode Specifications for Orbital Fusion Welding Tungsten electrode length for orbital welding is controlled to the thousandth of an inch + 0.003 inches ( + .08 mm). The use of tungsten electrodes is an essential component of the GTAW (TIG) process.
Arc Machines, Inc. Model 307 Orbital Tube Welder Training Tungsten Type - AWS color code Pure Tungsten 1.5% Lanthanated 2% Ceriated Zirconiated 2% Thoriated 1% Thoriated W 2% Ce TUNGSTEN GEOMETRY Tungsten length determines the Arc Gap tains a sharper tip and exhibits substantially longer lifetime than other types and has excellent arc ignition characteristics. Ceriated tungsten is non-radioactive. Tungsten is supplied as rods to be cut and machined into electrodes.
Arc Machines, Inc. Model 307 Orbital Tube Welder Training Table 1: TUNGSTEN LENGTH AND GEOMETRY Wall Thickness Arc Gap Tip Dia. Tung. Dia. .020”-.035” .030” .020” .040” .049” -.083” .050” .030” .062” .091” -.154” .070” .040” .093” Arc Gap The tungsten length is used to set the arc gap for fusion tube welding.The ARC GAP at a particular current value determines the voltage and thus the power applied to the weld. The arc gap will remain constant as long as the tube is perfectly round.
Arc Machines, Inc. Model 307 Orbital Tube Welder Training Formula for calculation of Tungsten Length and diagram of relationship of Tungsten Length to Rotor Diameter and Arc Gap. Taper Angle and Tip Shape TAPER ANGLE AND TIP SHAPE Taper 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.
Arc Machines, Inc. Model 307 Orbital Tube Welder Training Model 307 Electrode Calculator Electrode Length and Tip Diameter. To find the correct electrode length for a particular weld schedule, touch the Tools Icon from the schedule or the Tools button from the 307 Opening Screen. Then select Electrode from the Tools menu. On the Tools - Electrode Calculator Screen, select the weld head (or enter rotor O.D.). Enter tube diameter, wall thickness, and Arc Gap (or select AMI recommended Arc Gap).
Arc Machines, Inc. Model 307 Orbital Tube Welder Training Electrode Diameter Electrode diameters differ in relation to the amount of amperage being conducted. A weld head’s specific electrode diameter(s) can be found in the weld head template. Touch the Templates Icon on the toolbar. Electrode diameters for the weld head are shown. Touch the Help Icon on the Toolbar for additional electrode information. Electrode Data may be saved as part of a weld record.
Arc Machines, Inc. Model 307 Orbital Tube Welder Training Chapter 16. Purging Requirements for Orbital Welding M etals 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 atmosphere, may have detrimental effects on some metals. In the GTAW process an inert shielding gas is supplied to the weld head to protect the electrode, the molten weld puddle and adjacent areas from oxidation.
Arc Machines, Inc. Model 307 Orbital Tube Welder Training Hydrogen mixtures Additions of hydrogen to the shielding gas produces a reducing atmosphere which inhibits the formation of oxides, reduces slag formation, and for this reason is often used for welding nickel-based alloys. The argon/hydrogen mixture produces a cleaner-appearing weld on stainless steel at similar levels of oxygen contamination than pure argon. It has also been used as an I.D.
Arc Machines, Inc. Model 307 Orbital Tube Welder Training DISCOLORATION/HEAT TINT Left: A semiconductor quality weld on electropolished 316L stainless steel. There is no discernable discoloration of the weld or HAZ. Right: A badly oxidized or "sugared" weld on 316L stainless steel. Even slight amounts of discoloration have been shown to have a negative effect on the corrosion resistance of stainless steel. Nitrogen Nitrogen is not an inert gas. It is sometimes used as an I.D.
Arc Machines, Inc. Model 307 Orbital Tube Welder Training Purity requirements Orbital welding equipment does not require gas of higher purity than manual 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. In order to meet the stringent specification for discoloration Semi Standard F79-0703 requires I.D.
Arc Machines, Inc. Model 307 Orbital Tube Welder Training Prior to welding the flow rate to the weld head (O.D.) is set by touching the Manual Purge button on the Weld Schedule Weld Screen screen and setting the flow from the regulator/ flowmeter. I.D. (Back) Purge The purge supplied to the inside diameter of the weld joint must be measured and controlled. Separate flow indicators are recommended for the shield and purge gas lines. Prepurge and postpurge times for the I.D.
Arc Machines, Inc. Model 307 Orbital Tube Welder Training is sometimes used to flush out volatilized materials from the weld area before they can be deposited in order to prevent the "blue halo." I.D. Pressure Caution must be exercised to avoid overpressurizing the weld. If a high flow rate is used, a larger exit orifice for the purge gas is required to prevent I.D. concavity ("suck-back") or a blow-out. The exit orifice diameter should be measured and recorded for each different size of tubing.
Arc Machines, Inc. Model 307 Orbital Tube Welder Training Use Adequate Ventilation. Welding should be done with good ventilation to avoid breathing harmful materials that may be produced during welding. Gas hose connections to the purge plugs must be leak-free. Use the chart on page 8 to determine the flow rate and minimum purge times required for the weld head being used. Coupon welds should be made with the same shield and purge gas as the production welds.
Arc Machines, Inc. Model 307 Orbital Tube Welder Training Table 1. GAS FLOW RATES AND PREPURGE/POSTPURGE TIMES Recommended Flow Rate Prepurge and Postpurge Weld Head Head Number liters/min.
Arc Machines, Inc. Model 307 Orbital Tube Welder Training Chapter 17. Weld Criteria/QA-QC A welding inspector from a third party QA company inspects an orbital weld in a pharmaceutical plant with a borescope. Photos courtesy of Purity Systems, Inc. A s the use of Orbital Welding has advanced during the past decade or so, so has the demand for improved weld quality. Industry standards writing groups have produced several new standards based on the use of orbital welding.
Arc Machines, Inc. Model 307 Orbital Tube Welder Training For certification of orbital welds to ASME Sect. IX and B31.3, there must be a Q.A. manual and a Q.A. program in effect and a set of generalized weld standards which may reference any other standard, such as SEMI or ASME BPE-2002. Qualified weld procedures must be developed, preferably on the actual heats of material being installed.
Arc Machines, Inc. Model 307 Orbital Tube Welder Training Any weld bead in which the narrowest part of the OD weld bead is less than 50% of the widest part, is not acceptable. Excessive weld bead meander where a weld bead has less than 25% of its width over the centerline of the OD weld bead is not acceptable. Concavity and convexity. An autogenous orbital weld should be flush on the ID and OD surfaces.
Arc Machines, Inc. Model 307 Orbital Tube Welder Training Photo from AWS D18.1/D18.2 standard which shows a series of orbital welds on the ID of a 316L SS tube. Welds were purged with argon containing oxygen as a contaminant at levels from 10 ppm (1) to 25,000 ppm (10). Discoloration While the semiconductor industry demands color-free welds, the pharmaceutical and food and dairy industries are generally willing to accept some light blue or straw color of the ID.
Arc Machines, Inc. Model 307 Orbital Tube Welder Training with defined qualifications who represents the owner. It is important that welding operators examine their welds and be able to recognize when there may be a problem with the weld parameters or with purging, electrodes, or fit-up and be able to take corrective action. Most owners hire third-party QA inspectors for weld inspection in high-purity applications.
Arc Machines, Inc. Model 307 Orbital Tube Welder Training duplicate samples cut at opposite orientations to the start of the weld should be made. The ASME BPE-2002 standard allows one rewelding of a weld with incomplete penetration only. Welds with other types of defects must be repaired or replaced at the owner’s discretion. Bead-on-plate (BOP), welds that are done directly on the tube without a weld joint, are not acceptable for QC purposes.
Arc Machines, Inc. Model 307 Orbital Tube Welder Training Chapter 18. Data Acquisition/Advanced Functions A rc Machines’ Model 307 Project Data Acquisition is designed for collecting relevant digital data for each weld and storing the data as weld records on the power supply for use in quality assurance documentation. Project Data Acquisition consists of three elements. These are: 1. Weld data records. 2. Digital Data Streaming output. 3. Performance Monitoring.
Arc Machines, Inc. Model 307 Orbital Tube Welder Training Entering a Weld Identification Number To enter a Weld Identification number, select Data Acquisition from the Weld Schedule - Weld Screen to display the Weld Identification Information Screen. Information that can be entered on the Weld Identification Information screen from the keyboard includes Weld Identification (ID number), Project Name, Building, Drawing Number (or ISO number) and a space for entering Additional Information.
Arc Machines, Inc. Model 307 Orbital Tube Welder Training Searching for existing Weld Data Records (WDRs). Touch the Tools Icon on the 307 Toolbar to display the Tools Screen. Touch the Weld Data Records button to display the list of Weld Data Records already stored in the machine. Weld records matching the search criteria will be displayed in a list on the power supply. WDRs are listed by Weld ID, Project Name and Operator (Logon) Name.
Arc Machines, Inc. Model 307 Orbital Tube Welder Training Weld ID Printing and Exporting Weld Data Records Once a Weld Data Record or group of records has been selected, they can be printed out on any printer connected to the Power Supply. The records can also be exported to any storage device connected to the power supply; this includes network computers and the internet. See Chapter 6 Page 8 for additional information on printing. Note: Weld Data Records CAN NOT be viewed on the Power Supply.
Arc Machines, Inc. Model 307 Orbital Tube Welder Training Report Setup From the Home Screen touch System Setup Functions, then Printer Setup. Touch Report Setup to select the fields to be printed in a report or touch Label Setup to select the fields of data to be printed on an adhesive-backed label. Note: The label will always print the Weld I.D. Number and the Power Supply Serial Number as a minimum. Printer Setup - Report Items Selected items for Report or Label are highlighted with green light.
Arc Machines, Inc. Model 307 Orbital Tube Welder Training Streaming Data Digital Data Streaming refers to a serial (RS232) output of welding feedback parameters monitored in real-time (i.e. while the weld is being made). To collect digital streaming data, select Data Acquisition from the Weld Schedule - Weld Screen and Enable Weld Data Recording as shown on page 2 of this Chapter. Select Data Stream from the Associated Data Main screen for the weld schedule for which you intend to record data.
Arc Machines, Inc. Model 307 Orbital Tube Welder Training Selectable Outputs include: 1) Operator Info: Operator (Logon) Name and security classification if logged on will appear as text. 2) Project Data: Text will be added to the output for all items entered on the Weld Identification Information screen.
Arc Machines, Inc. Model 307 Orbital Tube Welder Training Weld Schedule -Linear graph If Linear graph is selected for In Sequence Display and Data Acquisition is active, streaming data for amps, volts and travel speed will be displayed as moving data points during the weld sequence. After the end of the weld, the data will be assembled into a Linear Graph as shown below. Touch the Close button to return to the weld schedule. Touch the Close button to return to the weld schedule. Document No. 740096 Rev.
Arc Machines, Inc. Model 307 Orbital Tube Welder Training Performance Monitoring Performance Monitoring describes monitoring the feedback values and comparing them to programmed values. Should a deviation exceed the selected tolerance percentage a fault will be generated. Selectable values for the performance monitoring are 2%, 5%, and 10%. Open (or create) a weld schedule. From the Weld Schedule - Main screen touch Weld.
Arc Machines, Inc. Model 307 Orbital Tube Welder Training Model 307 Advanced Functions The Model 307 Power Supply has several advanced features which require the user to be logged on to the system at the Programmer level. Screens requiring higher security levels are grayed out for other users. Weld Head Wizard Weld head definitions for AMI weld heads shown on Templates are read-only files and can not be changed by the user.
Arc Machines, Inc. Model 307 Orbital Tube Welder Training Weld Head Wizard The Weld Head Wizard allows the user to specify or modify factors which affect the operation of the new weld head. These include ground fault enabled or disabled, electrode and tube diameters, rotor diameter, gas flow rates and purge times, size range of tubing and/or pipe that the head can accommodate, the amperage at which coolant may be required, and weld head position enabled for weld heads with encoders.
Arc Machines, Inc. Model 307 Orbital Tube Welder Training Manage Weld Heads Touching the Manage Icon on the Tool Bar of the Weld Head Wizard (screen 102) opens the Manage Weld Heads Screen. The new weld head will be shown and the data can be modified by the user by clicking on or touching the Weld Head Name. Factory installed templates are Read-Only. Touching Open opens the Weld Head Wizard for the selected weld head.
Arc Machines, Inc. Model 307 Orbital Tube Welder Training Edit Servo Definitions Only qualified personnel are permitted to change weld head definitions Editing functions include, but are not limited to, changes in the Servo Name, Servo Slot, Servo Function, English or Metric metrics, Feedback device type, motor and program limits, jog speed and jog direction. Only qualified personnel logged onto the 307 at the Programmer level are permitted to make changes in Servo Definitions. Document No. 740096 Rev.
Appendix 1. ARC MACHINES, INC. Model 307 Weld Schedule Development Sheet Value Level 1 Document No. 740096 Rev. A Level 2 Level 3 Level 4 Chapter 19. Appendix Page 1.
Arc Machines, Inc. Model 307 Orbital Tube Welder Training Document No. 740096 Rev. A Chapter 19. Appendix Page 2.
Arc Machines, Inc. Model 307 Orbital Tube Welder Training Appendix 3. Welding Operator Qualification to ASME Section IX of the BPVC Several orbital welding standards including ASME BPE 2002 and SEMI require qualification of welding operators to Section IX of the ASME Boiler and Pressure Vessel Code. The following steps are required for qualification: A. A Q.A. manual and program must be in effect. B. A set of general weld standards must exist. C. Qualified procedures must be completed and documented. 1.
Arc Machines, Inc. Model 307 Orbital Tube Welder Training Appendix 4. Weld and Examination/Inspection Log for welding to the ASME Bioprocessing Equipment Standard (BPE) 2005 Appendix Reprinted with permission of the ASME. Document No. 740096 Rev. A Chapter 19. Appendix Page 4.
Appendix 5. Example ASME Welding Operator Performance Qualification Form Reprinted with permission of the ASME. Document No. 740096 Rev. A Chapter 19. Appendix Page 5.
Arc Machines, Inc. Model 307 Orbital Tube Welder Training Index A adapter cable, 4.3 Add a Level button, 8.7 Add Servo, 18.12 Adding or Deleting a Servo, 18.12 Advanced Functions, 18.1 alignment alignment tools, 2.4 AMI calculator, 6.17 AMI service, 6.13 Amps amperage in Step Mode, 9.11 Background Amps, 5.5, 9.8 background amps, 5.2 Level Amps, 9.7 Primary Amps, 5.5, 9.6 primary amps, 5.2 An Example Group, 7.1 Appendices Appendix 1. M-307 Weld Schedule Sheet, 19.1 Appendix 2.
Arc Machines, Inc. Model 307 Orbital Tube Welder Training Index continued: D data acquisition, 18.1 Building, 18.2 Disable, 18.2 Enable, 18.2 Operator (Logon) Name, 18.3 Project Data Acquisition, 18.1 Project Name, 18.3 (ISO) Drawing Number, 18.2 Data Stream, 18.6 Date Time set, 6.12 Delete Servo, 18.12 dewar, 16.1 diffuser, 16.6 discoloration, 16.3, 16.4 documentation, 17.2 Downslope, 5.3, 9.3 Do’s and Don’ts, 2.2 dust covers, 4.6 G gas E Edit Servo, 18.12 Edit Servo Definitions, 18.
Arc Machines, Inc. Orbital Tube Welder Training Index continued: K Keyboard, 6.8, 7.3 L Label Setup, 6.9 Language selection, 6.10 levels Add a Level, 9.6 Level Advance, 5.4, 9.4 Level Position, 5.5, 9.6 Level Time, 5.7 Levels/Segments Parameters (manual), 9.10 Weld Levels screen, 9.6 Library Folder functions, 7.3 Library Information, 8.9, 9.1 Local Library, 7.1 Remote Library, 7.1 Weld Schedule Functions, 7.7 Local machine, 7.5 LOG OFF, 6.2, 6.18 LOGON, 6.2 Logon Name, 6.18 LOGON/LOG OFF, 6.
Arc Machines, Inc. Orbital Tube Welder Training Index continued: report items, 18.5 RF, 2.1, 2.4 rotor return to home position, 5.2 rotor diameter, 15.4 RPM Background RPM, 8.8 Calculation of RPM, 9.8 Primary RPM, 8.8 Primary RPM Step Mode, 9.11 S Save changes, 9.16 Schedule Buttons, 7.7 screens Screen list/Weld Data Records, 6.10 Screens accessible from Weld Schedule - Main screen, 6.19 Screens assessible from the 307 Library, 7.7 Security Administration, 6.7, 6.18 Select from Library, 6.
Arc Machines, Inc. Orbital Tube Welder Training Index continued: U Upslope, 5.3, 9.3 USB memory stick, 3.3, 7.1 V ventilation, 16.7 W Warnings Disconnect the input power, 2.1 Do not weld in enclosed areas, 2.3 emission of toxic fumes, 2.2 energized electrical parts, 2.1 factory training is essential, 2.3 fires or explosions, 2.2 High Frequency Radio Wave, 2.1 Magnetic fields, 2.1 non-flammable protective clothing, 2.2 severe burns from touching newly welded components, 2.
