Chapter - Arc Machines, Inc.

10500 Orbital Way 

Pacoima, California 91331 U.S.A. 

MODEL 307 POWER SUPPLY 

OPERATOR TRAINING GUIDELINES 

Document No. 740096 

Doc. Rev. A

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 

EUROPEAN OFFICE 


Chemin du Lavasson 2 

CH-1196 Gland 

Switzerland 

Tel.: +41 / 22 / 995.00.51 

Fax: +41 / 22/ 995.00.59 

sales@arcmachines.ch 


Rev. A 

www.arcmachines.com 

GERMAN OFFICE 

Arc Machines GmbH 

Markelsbach 2 

D-53804 Much, Germany 

Tel.: 02245 / 91680 

Fax: 02245 / 916868 

sales@arcmachines.de 

UK OFFICE 

Arc Machines UK Limited 

Unit 4, Raynesway Park Drive 

Derby, DE21 7BH England 

Tel.: 01332 / 574000 

Fax: 01332 / 757757 

sales@arcmachines.co.uk

Effective Date: September 1, 2004 

Copyright 2005, Arc Machines, Inc. 

MODEL 307 

Operator Training Guidelines 


General Guidelines for Orbital Tube and Pipe Welding 

The Arc Machines Model 307 is designed to be a versatile orbital 

welding control and power supply system. The Windows-based- 

Model 307 features the absolute latest state-of-the art technology, 

from its 200 ampere second-generation solid state power supply to 

its color VGA display with touch screen. The Windows environment 

makes the Model 307 uniquely suited for weld logging and 

weld documentation. The basic Model 307 features a complete complement 

of controls including gas flow and available water cooling 

necessary to operate AMI orbital weld heads for in-place field welding 

tasks ranging from small diameter fusion tube welds to welding 

thin-wall piping with filler wire addition.

Arc Machines, Inc. Model 307 Orbital Welder Training 

Model 307 Operator Training Guidelines 

Notice 

This document and the information contained herein is the property of Arc 

Machines, Inc. It is proprietary and submitted and received in confidence. It 

shall be used only for the purpose for which it is submitted and shall not be 

copied in whole or in part without the prior express written permission of Arc 

Machines, Inc. 

The information in this document has been carefully reviewed and is believed 

to be accurate. However, no responsibility is assumed for inaccuracies. 

Information and instructions in this document are subject to change and Arc 

Machines, Inc. reserves the right to change specifications and data without 

notice. 

WARNING! 

The nature of the GTAW process creates some POTENTIAL HAZARDS. In 

accordance with international safety regulations the EXCLAMATION SYMBOL 

indicates that this equipment is considered HAZARDOUS until an operator has 

been made aware of these POTENTIAL HAZARDS by READING THIS MAN- 

UAL. The LIGHTNING FLASH SYMBOL indicates that there are potential 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 

AWARE OF ALL SAFETY-RELATED ITEMS CONTAINED IN THIS MANUAL. 

Publication date: First Edition - September 2004 

Copyright 2005 by Arc Machines, Inc. 

All rights reserved. 

REV DCO# CHANGE DESCRIPTION DATE APR 

Document No. 740096 i. 

Rev. A


MODEL 307 OPERATOR TRAINING GUIDELINES 

EFFECTIVITY 

Features and operation of the Model 307 are derived mostly from SOFTWARE. 

This document is based on the latest STANDARD version of SOFTWARE at the 

time of last revision (see revision page). 

Some deviations in actual operation, from this document, are possible 

depending on the software version of a particular machine. Please feel free to 

contact Arc Machines Service Department for documentataion or information 

on how software updates effect this document. 

Document No. 740096 ii. 

Rev. A

Table of Contents 

MODEL 307 

OPERATOR TRAINING 

GUIDELINES 

General Guidelines for 

Orbital Welding of Tube 

& Thin-Wall Pipe 


Effective Date: September 1, 2004 

Draft May 2005 

1 

2 

3 

4 

5 

6 

7 

8 

9 

10 

11 

12 

13 

14 

15 

16 

17 

18 

19 

20 

INTRODUCTION 

SAFE OPERATION 

ICONS, BUTTONS, SYMBOLS 

MODEL 307 INSTALLATION 

SEQUENCE OF EVENTS/ 

WELD PARAMETERS 

POWER SUPPLY OPERATION 

& FUNCTIONS 

MODEL 307 LIBRARY 

AUTOGENERATION OF WELD 

SCHEDULES 

MANUAL CREATION OF 

WELD SCHEDULES 

ASSOCIATED DATA 

WELDING WITH THE 307 

WELD PROCEDURE 

OPTIMIZATION 

WELD HEAD CALIBRATION 

& OPERATION 

END-PREPARATION FOR 

ORBITAL WELDING 

TUNGSTEN 

SPECIFICATIONS 

PURGE GASES AND PURGE 

PARAMETERS 

WELD CRITERIA/WELD 

QUALIFICATION 

DATA ACQUISITION/ 

ADVANCED FUNCTIONS 

APPENDICES 

INDEX

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 Windowsbased 

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. 

The Model 307 was 

developed for economy 

and ease of use and will 

automatically generate a 

weld schedule or program 

when the Arc 

Machines weld head and 

weld component dimensions 

are entered. To 

meet the Industry’s demands for quality assurance (QA) and weld data 

collection, the Model 307 has extensive capabilities to store and transmit 

detailed weld documentation and historical data. 

Welding personnel can program the Model 307 in time per level or simply 

enter the desired weld head position in rotational degrees for the end of 

each level, and time required to complete the level will be entered automatically. 

Weld parameters are clearly visible on the 307’s touch screen 

and can easily be modified by the operator if changes should be necessary. 

Input Power. The Model 307 Power Supply operates on 110 to 240 VAC, 

50/60 Hz, single phase only, without reconnection. 

Weld Current. The Model 307 has a programmable range of 5 to 200 

amperes of primary welding current, while average current is software-limited 

to 150 amps or less. The Model 307 will warn users if programmed 

current values exceed recommendations for particular weld heads. 

Weld Heads. The Model 307 operates all standard AMI fusion weld heads 

including the Model 8 and Model 9 series, Model 4, Model 85, and Model 96. 

It can also operate the Model 95 series of wire-feed weld heads. The motor 

controls can accept DC tachometer velocity feedback, or quadrature-encoder 

position and velocity information. 

Document No. 740096 Chapter 1. Page 1. 

Rev. A 

Arc Machines’ Model 307 Power Supply and Model 8-2000 weld 

head on a cleanroom bench at the WELDEX show in the UK.


Left and above: Welding in a dairy plant with a Model 8-4000 weld head. 

Right: A Model 4-500 bench mount weld head. 

Real-time digital data acquisition. The Model 307 captures and displays 

real-time streaming data for welding current, pulsation, arc voltage and 

travel speed during the weld and displays the data in graphical form on the 

Model 307 screen at the end of the weld. The power supply can compare 

the actual data gathered during the weld and report whether the weld 

parameters were performed within pre-set acceptance limits. 

Weld Logging. The Model 307’s Intel ® Pentium ® processor makes this 

power supply uniquely suited for weld logging and weld documentation. 

Weld records are created by the Model 307 when a weld identification (ID) 

number is assigned to the weld. Users can select from a variety of fields of 

Associated Data which include weld head and power supply serial numbers; 

material type and heat numbers of tubing, fittings or other weld components; 

gas type, flow rates to weld head and weld I.D., dewar serial 

number; and electrode type and geometry. 

Project management. Rapid retrieval of weld records is important for 

users who may be subject to audits from the FDA or other regulatory 

agency. Weld records stored in the Model 307 memory can be retrieved by 

project, weld identification number, date, welding operator, or other field. 

Weld records can be downloaded onto electronic 

media or to a computer for compilation 

of records for a particular job thus avoiding 

the necessity of re-entering this data manually. 

Weld I.D. numbers as well as other identifying 

data may also be printed onto an 

adhesive-backed plastic label that can be 

used for weld identification purposes. 

It should be understood that no welding 

machine can unequivocally detect and indicate 

the quality of a particular weld. The 

Model 307 can, however, provide a detailed 


Rev. A 

Model 95-6625 Weld Head with wire- 

Feed capabilities welding a flange to a 

pipe in Guatemala. Photo courtesy of 

Alimentos Maravilla S.A.


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 factory- 

approved Arc Machines, Inc. Instructor. IT IS NOT A SUBSTITUTE FOR 

THAT TRAINING. The purpose of such a class is to enable welding personnel 

to quickly and easily understand the basic functions and safe operation 

of the Model 307 Power Supply and appropriate weld head(s) and to use this 

equipment successfully in their application. 

Students must be able to correctly set up the power supply and be able to 

calibrate and install the weld head with correct tube-clamp inserts and the 

correct tungsten type, diameter and length. They must understand the 

basics of purging and know how to set the correct flow rates for the weld 

head they are using. 

Hands-On. Students are given sufficient hands-on training to enable them 

to generate weld programs, to make welds, and to evaluate the welds. 

Trainees should also be familiar with the end-preparation requirements for 

orbital welding. They are expected to recognize an acceptable weld for 

their industry or application and be able to make adjustments in the weld 

program or procedures in order to produce welds that comply with the 

standards of their industry. 

Upon successful completion of this course, which is typically comprised of 

two 8-hour days and, at the discretion of the instructor, students will 

be awarded an Arc Machines, Inc. Certificate of Completion. 


Rev. A


Chapter 2. Safe Operating Procedure - 

Safety Precautions for Model 307 Operation 

AVOID ALL 

CONTACT 

WITH THE 

WELDING 

WORK 

(GROUND) OR 

ELECTRODE 

DURING ARC 

START 

THE ELECTRODE SHOULD ALWAYS BE 

CONSIDERED A POSSIBLE SHOCK HAZARD. 

This is especially true whenever the system is: 

• IN SEQUENCE 

• READY TO WELD, 

• IS WELDING, 

• OR HAS JUST FINISHED WELDING. 

When replacing or adjusting the electrode: 

• Set power supply to “TEST” mode 

Most AMI Power Supplies feature RF (radio frequency) Arc 

Starting. This is a High Voltage/High Frequency electrical transmission 

process. The GTAW process requires electrical potential 

(high voltage) to be present on the electrode and on exposed 

internal terminals during arc starting and during welding. ALL 

AMI Power Supplies contain a “bleeder” circuit to ground any 

residuals or potential after welding or after an aborted or bad 

“arc start” attempt. However, these circuits take a few seconds 

to operate or could fail. 


Rev. A 

Electrode installation 

in a Model 8 

weld head.


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. Do CHECK ALL CABLE AND QUICK-DISCONNECT 

FITTINGS to insure proper seating and that protective 

boots are in place. 

4. Do check for GAS LEAKS on all external Gas fittings. 

5. Do PROTECT WELD HEADS by storing in shipping 

container (or otherwise suitably protected) when not in 

use. 

6. Do KEEP PROTECTIVE COVERS ON THE MOTOR CABLE CON- 

NECTORS when not in use. 

7. Do insure that the PROPER ELECTRODE is installed in 

the weld head. 

8. Do use a REGULATOR AND FLOWMETER designed for the 

gas that is being used and suitable for the purity 

requirements of the application. 


Rev. A


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. Don’t attempt to weld without PROPER FACING AND 

CLEANING OF THE MATERIAL to be welded. Use only 

approved cleaning products. 

5. Don’t drop the Weld Head, Remote Pendant, 

Cables, or Power Supply. Precautions should be taken 

to secure this equipment in production situations. 

6. Don’t route the cables where they will be SUBJECT TO 

DAMAGE from traffic or equipment. 

7. Don’t expose the Weld Head, Remote Pendant, 

Cables, or Power Supply to RAIN OR STANDING WATER DUR- 

ING OPERATION. Do not operate equipment when wet. 

8. Don’t pull on cables. This will result in 

DAMAGE TO THE EQUIPMENT. 


Rev. A


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. Don’t increase GAS FLOW RATE (CFH) beyond levels 

specified for each particular weld head. 

12. Don’t allow TUNGSTEN OR OTHER METAL PARTICLES to 

enter the gear train of the weld heads. This will cause 

serious (and expensive) damage. 

13. Don’t switch the Model 307 Power Supply ON and 

OFF rapidly with circuit breaker (CB-1). To do so may 

result in loss of stored information or resetting of system 

functions. 

RF and EMI Emissions 

Arc Machines’ policy is to comply with the IEC and FCC regulation. Every 

effort has been made to reduce RF emissions from our power supplies to 

the absolute minimum. 

Document No. 740096 Chapter 2. Page 4 

Rev. A


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-49.1 Safety in Welding and Cutting” published by the 

American National Standards Institute. 

WARNING: Touching energized electrical parts can cause fatal 

shocks and burns. When in weld sequence the electrode and work 

are electrically energized. Incorrectly installed or improperly 

grounded equipment is a hazard. 

WARNING: This equipment is authorized to use a type of arc starter 

that produces a High Frequency Radio Wave (sometimes called 

HF or RF Starting). It can cause interference and sometimes even 

damage to nearby electronic equipment (such as computers) that 

are unprotected or poorly protected against such interference. 

WARNING: Magnetic fields from High Currents can affect pacemakers. 

Pacemaker wearers should avoid being in close proximity 

to welding systems. 

WARNING: Disconnect the input power to the machine before 

opening or servicing. Discharge all circuits that store high voltage 

such as capacitor packs. Only QUALIFIED service personnel should 

open this equipment. 


Rev. A


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. 

WARNING: Welding produces high temperatures in both the 

welded components and the welding equipment. Both can cause 

severe burns. Do not touch recently welded components. Avoid 

touching internal components of the welding system soon after use. 

Avoid touching torch components and welding fixtures soon after 

welding. 

WARNING: The welding arc emits ultra-violet (UV) radiation and the 

molten weld gives off infra-red. Both can burn eyes and skin if 

unprotected. Suitable eye and skin protection must be worn. 

WARNING: Weld materials can emit toxic fumes during welding. 

HEXAVALENT CHROMIUM, which is given off when stainless steel is 

welded, causes lung cancer in humans. See Semi F79-0703 

Appendix- HEXAVALENT CHROMIUM ALERT. WELD ONLY IN 

AREAS WITH ADEQUATE VENTILATION. 


Rev. A


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 WITH- 

OUT 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. 

WARNING: Some systems, such as the M-307 Power Supply are 

intended solely for indoor use and must be kept dry. Before operating, 

storing, or handling, always make sure that the M-307, M-307- 

RP Pendant, weld heads and cables are not exposed to rain or 

standing water. SYSTEM COMPONENTS ARE NOT WATER 

PROOF. 

WARNING: Keep hands and fingers clear from moving parts such 

as fans, gears, rotors, and Rotation Mechanisms. 


Rev. A


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. 

USER 

FAST 

SLOW 

RUN/IDLE 

OR SPEED 

ELECTRODE 

ELECTRODE 

TRAVEL SPEED 

ELECTRODE 

TRAVEL 

DIRECTION 

Table 1. Toolbar Icons. 

Table 2. Computer buttons which appear on the touch 

screen and open screens or perform functions on the Model 

307 are shown in Table 2. 

Table 3. Windows- based Computer Icons used on 

the Model 307 Power Supply. 

Table 4. Graphic symbols used in this manual. (Symbols 

related to Safety are shown in Chapter 2.) The source of the 

original symbols are listed when known. When symbols 

have been used in previously unpublished combinations, the 

source of the original symbols are given as well as the 

designation AMI to show that they have been modified in 

some way by Arc Machines, Inc. 

Graphic Symbols. Graphic symbols designed for use on 

arc welding and cutting apparatus have been published 

(1999 revision) by the National Electric Manufacturers 

Association (NEMA). While many of these symbols were 

shown alone, suggestions for using them in combination to 

describe combined functions were presented. In this manual 

several of the Graphic symbols have been combined in new 

ways. For example, the rabbit is the symbol for fast, while 

the tortoise is the symbol for slow or idle. Together they can 

mean run/ idle or speed. When combined with the symbol 

for electrode, the combined symbols can be used to signify 

electrode travel speed. The addition of the curved arrow, 

which is the symbol for direction of rotation, creates a 

symbol for the direction of electrode travel. 


Rev. A


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. 

Touching the Tools icon displays a menu for 307 functions 

for English/Metric conversions, Electrode rotation 

IPM/RPM conversions, Backup Gas Pressure conversions, 

a Weld Time calculator, an Electrode Calculator and a 

regular Calculator. 

The Setup icon displays the System Setup screen which 

has functions for Backup or Transfer of weld schedules, 

Security, Fault Setup, In-Sequence Display, Printer 

Setup, Language, Keyboard, Weld Head Data, reset Total 

Weld counter, a list of 307 screens, setting of Date or 

Time, and Power Supply information. 

Touching the Print icon prints a weld schedule or report 

if the user is connected to a printer. 

Touching the Library icon displays the list of weld programs 

(schedules) stored in the 307 Memory, external 

data storage device, or remote M307 power supply. 

Touching the Templates icon from a Weld Schedule 

Screen brings up a screen with important data regarding 

the weld head specified for the schedule being used. 


Rev. A


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. Press the Stop USB icon prior to removing 

a USB memory stick from the Model 307 or saved files 

may be lost. 

Touching the Continuous Icon initiates the autogeneration 

of a weld schedule in which the rotation is continuous 

(Primary RPM only). 

Touching the Step icon initiates the autogeneration of a 

weld schedule with STEP rotation mode in which the electrode 

moves only during the background current pulse. 

Touching the Tack icon initiates the autogeneration of a 

weld schedule for making orbital tack welds. 


Rev. A


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. 

Pressing Overrides opens the Weld Schedule - Overrides screen on 

which upper and lower limits for weld schedule parameters may be set. 

Pressing Associated Data opens the Associated Data Main Screen 

from which other screens are accessible for entering data on Tube, 

Equipment, Gas, Electrodes and Comments. 

Pressing Comments opens the Associated Data Comments screen 

which is a blank screen for writing comments about a particular weld 

schedule. 

Pressing Library opens the Model 307 Weld Schedule Library in 

which weld schedules stored in the Model 307 Library are listed and may 

be opened for welding. 

Pressing Counter Reset opens the Counter/Alert Indicator screen. 

From this screen you may enable, disable, or reset the alert indicator 

and weld counter. 

Pressing Weld opens the Weld Schedule Weld Screen from which the 

weld sequence (welding) can be initiated when in Weld Mode. 

Pressing In Seq. Display opens the In-Sequence Display Selection 

Screen which allows the user to select data for display during the weld 

sequence. 

Pressing Home returns the user to the Model 307 Opening Screen (1). 

Pressing the Start button in Weld Mode initiates the Weld Sequence. 

Pressing Start from Test Mode initiates a weld sequence in which an arc 

is not struck. 


Rev. A



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. 

Touching the Weld Main button opens the Weld Schedule Main screen 

of the open weld schedule. 

Library Buttons 

Create Folder opens a screen on which the name of the new folder is 

entered. This folder may be used for storing a user-defined group of 

weld schedules. 

Rename Folder opens a screen on which the name of a specified folder 

appears. A new name may be assigned to the folder. 

Delete Folder opens a screen asking whether the user truly wants to 

delete the selected folder. To delete the folder touch YES. To cancel 

choose NO. 

Paste Folder will paste a folder that has been copied into the selected 

Library. 

Copy Folder copies the selected folder which may then be pasted into a 

remote machine. 

Open Schedule. When a weld schedule is selected in the Library, this 

button will open the schedule to the Main Weld Schedule Screen. 

Copy Schedule copies the selected schedule so that it may be pasted 

into another folder or to the Library of a remote machine. 

Delete Schedule will ask the user if he truly wishes to delete a selected 

schedule. When the user touches YES, the schedule will be deleted. 


Rev. A



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. Touching the Level Advance button on the touch screen 

or on the remote pendant during the weld sequence advances the 

program to the next level. 

Add Level. When the Levels screen of a weld schedule is visible additional 

Levels may be added to the schedule by touching this button. 

Plus or Minus 1%. Both Primary and Background Amps of a weld 

schedule are changed 1% up or down by touching one of these buttons. 


Rev. A


Table 3. Computer Icons used on Model 307 

NO. Symbol Function, Keyword 

or Phrase 

1 

Close - At upper 

right of screen 


Rev. A 

Application Source 

To Signify Closing of a 

Computer file 

2 Open To Signify Opening of a 

Computer File 

3 

Fault Status 

Indicator - Red or 

Green 

Red Signifies a 307 Fault 

Condition - Green is OK 

4 New To Signify Creating a 

New File 

Microsoft 

Microsoft 

AMI 

Microsoft 

5 Save To Signify Saving a File Microsoft 

6 Keyboard To Signify a Computer 

Keyboard 

7 307 RP Symbol To Signify the 307 

Remote Pendant 

8 Copy To Signify Copying or 

Duplicating a File 

Microsoft 

AMI 

Microsoft 

9 Delete To Signify Deleting a File Microsoft 

10 ENT Button used to Signify 

the Enter Key on a Keyboard 

11 Folder To Signify File Folder for 

Weld Schedules 

12 Mouse To Signify use of a 

Mouse, Mouse Click, or 

Software 

13 Password To Signify use of a 

Password to Access a 

Program or System 

Microsoft 

Microsoft 

AMI 

Microsoft 

Microsoft


14 Users To Signify Users (or 

Classification of User 

such as Supervisor, etc.) 

15 Printer To Signify a Printer or to 

Print a File 

16 Floppy disk To Signify a File or Data 

such as a Weld 

Record(s) 

17 Display To Signify a Computer 

Monitor Screen 

18 Streaming Data To Signify Real Time 

Digital Data Output 

1 Touch 

Screen 

Windows ® Functions and Definitions 


Rev. A 

Microsoft 

Microsoft 

Microsoft/AMI 

Microsoft 

AMI 

A Computer Screen that Accepts Commands by Touch 

2 Toolbar Windows ® places toolbars across the tops of programs with buttons 

for various tasks such as copy, cut, paste, etc. 

3 Pull-Down 

Menu 

4 Left or Right 

Click 

Table 3. Computer Icons used on Model 307 

A list of options that appears when choosing a selection from the 

Menu Bar or other feature. 

To push and release the right or left button on the mouse. These 

have separate functions. 

5 Double Click To push and release the left mouse button twice in rapid succession. 

6 Check Boxes Clicking in a box next to an option places a check in the box and 

changes its setting. 

Scroll Bar 

Drag 

Drop 

Box at right hand side of screen that when moved vertically up or 

down moves the viewing window up or down. A similar scroll bar at 

the bottom of the screen moves the view from side to side. 

A four-step process that moves an object across your desktop. 

First touch the object and drag the object to the new location. 

(Used after Drag) Letting go of the mouse (or releasing your finger) 

allows the object to remain at the new location.


Table 4. Graphical Symbols used in this Manual 

NO. Symbol Function, Keyword 

or 

Phrase 

1 


Rev. A 

Application Source 

Line To Signify a Power Line or 

Cord 

ANSI/NEMA 

2 Single Phase To Signify Single Phase IEC 974 

3 

4 

5 

6 

7 

8 

9 

10 

11 

12 

Three Phase To Signify Three Phase IEC 974 

Three Phase 

Transformer 

Line Connection 

(Three Phase at 

50 to 60 Hertz) 

Signifies Three Phase 

Transformer 

To Signify a Line Connection 

Circuit Breaker To Signify a Circuit 

Breaker in an Electrical 

Circuit 

Direct Current 

(DC) 

Water 

Coolant Input 

Water Coolant 

Output 

IEC 

974 

IEC 974 

ANSI/NEMA 

Signifies Direct Current IEC 417 

5031 

To Signify Water 

(Coolant) Input 

To Signify Water 

(Coolant) Output 

Earth (Ground) To Signify the Earth 

(Ground) Connection 

Work Connection 

Electrode Negative 

To Signify a Work Piece 

Connection 

To Signify Electrode Negative 

Connection or 

Switch Position 

ANSI/NEMA 

ANSI/NEMA 

IEC 417 

5017 

ISO 7000-0453 

ANSI/NEMA


13 Electrode To Signify an Electrode ANSI/NEMA 

14 

15 

16 

Electrode 

generic 


Rev. A 

Signifies a generic electrode 

Gas Type To Signify the Type of 

Gas Such As Argon, CO 2 

ANSI/NEMA 

ANSI/NEMA 

Gas Supply To Signify a Gas Supply ANSI/NEMA 

17 Gas Input To Signify Gas Input ANSI/NEMA 

18 

Ventilating and 

Air Circulating 

Fan 

To Signify a Ventilating 

Fan or Air Circulating 

19 Grinder To Signify not to grind in 

certain areas - contamination 

caused by grinding 

20 

21 


Protective Boots 

over Cable 

Connector 

Exclamation 

Point 

To Signify Secure Connection 

with Protective 

Boots 

To Signify Warning, Danger, 

Caution 

ISO 7000-0089 

AMI 

AMI 

IEC 417 

5036A


22 Lightning Symbol for Severe Electrical 

Shock Hazard 

23 

24 

Dangerous Voltage 

Read Operator’s 

Manual 

To Signify Dangerous 

Voltage 


Rev.A 

To Signify that the Operator’s 

Manual Should be 

Read 

25 Torch Signifies a Welding or 

Cutting Torch 

26 

27 

28 

Arc Gap or Arc 

Voltage Control 

(AVC) 

Gas Tungsten 

Arc Welding 

(GTAW) Torch 

Tack Welding 

(GTAW) 

Signifies Arc Gap or Arc 

Voltage Control (AVC) 

IEC 417 

5036A 

IEC 417 

5036A 

SAE 

ANSI/NEMA 

ANSI/NEMA 

AMI 

To Signify a GTAW Torch ISO 7000-0465 

To Signify Tack Welds 

with a GTAW Torch 

29 Orbital GTAW To Signify the Orbital 

GTAW Process 

30 

V 


Input Voltage/ 

Power 

To Signify Input Voltage 

(Power) 

31 Pipestand To Signify use of a 

Pipestand 

ISO 7000-0465 

ISO 7000-0465 

AMI 

IEC 417 

5034 

ANSI/NEMA 

AMI


32 Stop of Action To Signify the Stop (of 

Action) Function or Control 

33 Start To Signify the Start (of 

Action) Function or Control 

34 Process Cycle To Signify One Complete 

Process Cycle 

(Weld Sequence) 

35 Weld Current To Signify Welding Amps 

During Process Cycle 

36 Arc Volts To Signify Arc Volts During 

Process Cycle 

37 Pulse Signifies Pulse Function 

or Control 

38 

39 

40 


Sequence 

Advance 

Sequence 

Deadvance 

Air (Gas) Pressure 


Rev. A 

To Signify Advancing to 

the Next Sequence Event 

(Level) 

To Signify Returning to 

the Previous Sequence 

Event (Level) 

To Signify Air (or Gas) 

Pressure Function or Control 

41 Purge by Gas To Signify Purging of Air 

(by Gas) 

42 Gas Preflow To Signify Gas Preflow 

Time (PREPURGE) 

ANSI/NEMA 

ANSI/NEMA 

ANSI/NEMA 

ANSI/NEMA 

ANSI/NEMA 

ANSI/NEMA 

ANSI/NEMA 

ANSI/NEMA 

ANSI/NEMA 

ISO 

7000-0474 

ISO 7000-0474 

ANSI/NEMA


43 Gas Postflow To Signify Gas Postflow 

(POSTPURGE) Flow 

44 Remote Signifies Remote Operation 

or Control 

45 Pushbutton To Signify a Pushbutton 

Switch used to Start or 

Stop a Function 

46 Panel/LOCAL To Signify Panel/Local 

Function or Switch such 

as a Switch to Change 

Between a Local Control 

and a Remote Control 

47 ON-OFF Switch To Signify an ON-OFF 

Switch 

48 Receptacle To Signify a Receptacle 

Type Connector 

49 

50 


ON 

(Enable) 

OFF 

(Disable) 

To Signify the ON or 

Enabled State of a 

Function 


Rev. A 

To Signify the OFF or Disabled 

State of a Function 

51 Hand To Signify Manual 

Control of a Function or 

Tool 

52 Foot Control To Signify a Foot Control 

Device, Function, Connection 

or Control 

ISO 7000-0474 

ANSI/NEMA 

ANSI/NEMA 

ANSI/NEMA 

ANSI/NEMA 

ANSI/NEMA 

ANSI/NEMA 

ANSI/NEMA 

ANSI/NEMA 

ANSI/NEMA 

ANSI/NEMA


53 

Disturbance (or 

change) 


Rev.A 

To Signify a Disturbance 

in the Proper Run of a 

Procedure, or Fault Condition 

54 Fast To Signify Fast Action or 

Operation 

55 Slow To Signify Slow Action or 

Operation 

56 Travel Speed To Signify Travel or Run 

Speed 

57 

58 

59 

Electrode Travel 

Speed 

Direction of 

electrode travel 


Start Delay 

To Signify Travel Speed 

of the Electrode or Torch 

To Signify Direction of 


To Signify the Time after 

Arc Start that the Electrode 

Begins to Move 

60 ALL STOP To Signify shut down of 

Power Supply 

61 Sequence STOP To Signify stopping of the 

weld sequence 

62 

63 


START 

Sequence 

Start Delay 

Time 

To Signify initiation of 

weld sequence 

To Signify a Timed Delay 

in Starting a Function 

64 Stop Delay Time To Signify a Timed Delay 

in Stopping a Function 

ISO 7000-0228 

SAE 

SAE 

SAE 

SAE 

ANSI/NEMA 

AMI 

ANSI/NEMA 

/AMI 

ANSI/NEMA 

/AMI 

ANSI/NEMA 

AMI 

ANSI/NEMA 

AMI 

ANSI/NEMA 

AMI 

ANSI/NEMA 

AMI 

ANSI/NEMA 

AMI


65 Rotating Switch To Signify Increase or 

Decrease of a Quantity by 

Rotating 

66 

Weld Head Position 


Rev. A 

To Signify Position of the 

Weld Head with Respect 

to the Pipe 

67 Automatic Cycle To Signify an Automatic 

Sequence of Machine 

Functions Repeated Continuously 

without Manual 

Intervention 

68 

69 

70 


Single Cycle (or 

Pass of Welding 

Sequence) 

Auto-Manual 

Switch 

Rotating Switch 

with Set Positions 

71 A Amperage (control) 

72 V Voltage (control) 

Signify a Process that is 

Completed in One Cycle, 

(i.e. a Pass) 

To Signify a Switch 

between an automatic 

and manual function 

Signifies an increase/ 

decrease of quantity with 

a rotary control in steps 

To Signify Amperage or 

Amperage Control 

To Signify Voltage or 

Voltage Control 

ANSI/NEMA 

AMI 

ISO 7000-0026 

ISO 7000-0426 

ISO 7000-0096 

ISO 7000-0026 

ANSI/NEMA 

ISO 

N95 31 

73 t Time To Signify Time S1 

74 s Seconds To Signify Seconds S1 

75 HF High Frequency S1 

76 f Frequency S1 

77 HZ HERTZ To Signify Cycles per Second 

78 5G 5G Welding 

Position 

To Signify Pipe Horizontal 

Position 

S1 

S1 

S1


79 # Number To Signify a Quantity or 

Number 

80 -(((((((((- Stringer Bead To Signify Welding without 

Torch Oscillations 

81 _( ( ( ( ( ( ( ( ( ( (_ Weave Bead To Signify Welding with 

Torch Oscillation 

82 Tri-Foil To Signify Radioactive 

Materials 


Rev. A 

ISI 700 0831 

AMI 

AMI 

USA EPA 

83 Material Type To Signify Material Type ANSI/NEMA 

84 Wall Thickness To Signify the Wall Thickness 

of the Weld Joint or 

tube 

85 Wire Feed To Signify a Wirefeed Unit 

or Wirefeed Function 

86 

87 

88 

89 

90 


Wirefeed Manual 

Advance 

Wirefeed 

Retract 

Manual 

Wirefeed 

Advance 

Wirefeed 

Retract 

Wirefeed Start 

Delay Time 

Cold Jog (Inch) Towards 

Workpiece 

Cold Jog (Inch) Away 

From Workpiece 

To Signify the Feeding of 

Wire Forward Towards 

the Workpiece 

To Signify the Feeding of 

Wire Away from the 

Workpiece 

Signifies the Time after 

Arc Start that wire begins 

to feed 

ANSI/NEMA/AMI 

ANSI/NEMA 

ANSI/NEMA 

ANSI/NEMA 

ANSI/NEMA 

ANSI/NEMA 

ANSI/NEMA/AMI


91 

Wirefeed Stop 

Delay Time 


Rev. A 

To Signify when the wire 

stops feeding in relation 

to the end of the last 

level. 

92 Wire Diameter To Signify the Diameter 

of the Welding Wire 

93 

Wire Manipulator 

Position 

To Signify the Position or 

Position Control of the 

Wire Manipulator 

94 Diameter Signifies diameter such 

as the diameter of wire or 

electrode (or pipe) 

95 

96 


Leading Wire 

Entry 

Trailing Wire 

Entry 

To Signify Wire Entry into 

the Leading Edge of the 

Weld Pool 

To Signify Wire Entry into 

the Trailing Edge of the 

Weld Pool 

97 Input Memory Signifies a Saving to 

Memory Function or Control 

98 Output Memory Signifies a Recall from 

Memory Function or 

Control 

99 Pass One Signifies One Cycle - AMI 

used to Signify the First 

Pass of a Weld Schedule 

100 Pass Two To Signify the Second 

Pass of a Weld Schedule 

ANSI/NEMA/AMI 

ANSI/NEMA 

ANSI/NEMA 

AMI 

ANSI 

Y14.5 M 

1982 

ANSI/NEMA 

AMI 

ANSI/NEMA 

AMI 

ANSI/NEMA 

ANSI/NEMA 

ISO 7000-0426 

AMI 

ISO 7000-0426 

AMI


101 

102 


Weld Head 

Symbol 

Downslope Time 

Symbol 

To Signify a generic 

Orbital Weld Head 


Rev. A 

Signifies the amount of 

time to ramp the current 

from the end of the last 

level to arc extinction 

Arc Machines, 

Inc. 

ANSI/NEMA


Chapter 4. Model 307 Power Supply Installation 

EQUIPMENT INSTALLATION 

Arc Machines, Inc. Windows-Based 

Microprocessor-Controlled GTA Welding 

Power Supply Model 307 


Rev. A 

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. 

The complete system consists of 

the Model 307, adapter cable 

(when required), gas hoses, and 

any of the AMI Model 9 series of 

tube welding heads, the Model 8 

series narrow weld heads, the 

Model 4-500 bench-mount head, 

or the M-96 fusion tube-totubesheet 

welding head. The 

Model 307 power supply provides 

GTAW current with pulsation 

controls, high-frequency arc 

starting, purge gas controls, 

weld head arc rotation, and 

automatic timing functions. A source of input AC Power, regulated gas 

source (usually argon), with a flow-meter must be supplied by the user. 

Weight: 62 lbs (28 Kg) 

Optional accessories include a Remote Operating Pendant (M-307-RP), 

extension cables, and a water cooling unit (307-CW). Additional options 

such as chart recorders and oxygen analyzers may be used with the 

Model 307 as part of a Quality Assurance/Quality Control program. The 

system can also be used as a manual welding power source using an 

optional manual torch and a variable foot controller or foot switch. 

POWER CONNECTION 

or 

The Model 307 input power requirements are from 100 to 240 VAC single 

phase at 50/60 Hz. Maximum welding current output is 150 Amps. A 35 

ampere service is required to obtain 150 Ampere output on 115 VAC. The 

maximum 150 amperes is obtainable with 30 ampere service on 230 

VAC. The Model 307 has an attached 15 foot (4.6m) Power Cable. All


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 ± 1.0 ampere, whichever is greater) while 

maintaining a maximum average current of 150 amps at 100% 

duty cycle. Programmable increments can be user-defined in the 

weld program in units of 1 or 0.1 AP. Maximum recommended 

amps (from a weld head template) can be programmed after a 

warning of the "recommended limit" is displayed on the screen. 

Note: Not all circuits are capable of delivering the rated 

amperage. When possible, use a 220 VAC power source, or a 

dedicated circuit for 110 VAC to avoid fluctuations in power. 

Manual 

purge 

indicator 

Touch 

screen 

Power 

ON 

indicator 

Printer 

307-CW 

307-CW 

connector 

Input Gas 

AC Input 

307-CW 

power input 

connector 

307 Front 

System 

Stop button 

Accessory 

connectors 

Paper door 

release 

Adapter 

cable 

connectors 

Coolant in 

and out 

Floppy 

disk drive 

USB Port 

PS2 

Keyboard 

connector 

Circuit 

breaker 

(Power 

ON/OFF) 


Rev. A 

307 Right Side 

307 Back 307 Left Side


M-307 TO MODEL 8, 9 or MODEL 4 WELD HEAD 

M-307-RP 

REMOTE PENDANT 

(OPTIONAL) 

WATER OUT WATER IN GROUND ELECTRODE ARC GAS WELD HEAD 

M307 ADAPTER CABLE 

REMOTE PENDANT EXTENSION 

(OPTIONAL) 

EXTENSION CABLE 

(OPTIONAL) 

GROUND/WATER ARC GAS WELD HEAD ELECTRODE/WATER 

ACCESSORY 

CONNECTIONS 

WELD HEAD 

Connections for Model 8, 9, and 4 Weld Heads to the Model 307 Power Supply. Note 

that connections shown are for weld heads using the Model 307 Adapter Cable with the 

optional water cooling unit (Model 307-CW). The Model 9-250 and Model 9-500 weld heads 

plug into the power supply without the use of the adapter cable but require pigtails. The I.D. 

purge connects directly to the flowmeter/regulator. 

ADAPTER CABLE TO MODEL 307 INSTALLATION 

The Model 307 Adapter Cable has a larger weld head motor connector 

from those used on the Model 207 Adapter Cable. Thus an adapter (pigtail) 

is required to use the older 207/107 cables with the Model 307. 

Adapter cables are not required for Model 9-500 or Model-250 which have 

no provision for water cooling but a pigtail connector is required to plug 

these heads into the power supply. The 307/Model 9 Adapter cable is 

used with the other Model 9 and Model 8 weld heads which do have 

provisions for water cooling. One end of the adapter cable connects to the 

weld head. The other end connects to the Model 307 or to a weld head 

extension cable. (Refer to figure above). 

Always turn the power supply off before making any 

cable or connection changes to the Model 307 power 


Rev. A 

Weld Head 

Connector 

M-307 POWER SUPPLY CONNECT PANEL 

Arc gas ground electrode 

WATER IN WATER OUT 

WATER COOLING UNIT 

(OPTIONAL FOR M-307 ONLY) 

ID PURGE LINE 

MODEL 8, MODEL 9, OR MODEL 4 

WELD HEAD


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 

ARC GAS OUTPUT 

WELD HEAD 

MOTOR CONTROL 

GROUND 

To connect the ELECTRODE and GROUND connectors to their respective 

terminals on the Model 307, align the keyways, push in and twist 

clockwise until fully locked. 


Rev. A 

GROUND 

ELECTRODE 

Weld head or adapter cable connections to the Model 307 Power Supply for Weld Head 

Motor Control, Electrode, Ground and Arc Gas. 

ELECTRODE AND GROUND CABLES WELD HEAD CONTROL CABLE 

Plug cables in with keyways up and turn 

clockwise until locked. 

WELD HEAD CONTROL CABLE 

Insert motor connector with keyway aligned 

and tighten locking rings.


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. Plastic materials which may be 

used for high-purity welding differ with respect to permeability to moisture 

and oxygen and resistance to heat and to particulation. None are 

perfect. Gas hoses made from rubber or nylon are not suitable. Do not 

use hoses that are longer than necessary. 

CAUTION: The Model 307 arc gas solenoid valve is rated at 50 psi 

(345KPa) maximum pressure, DO NOT EXCEED THIS RATING. 

Use the Manual Purge button on the Model 307 Weld Schedule-Weld 

Screen to set gas flow rate for the weld head. The Manual Purge must 

be On with the gas input and gas output hoses plugged in for gas to flow. 

Adjust flow rate to weld head from flowmeter on gas source. 

Touch the Templates icon for factory recommended flow rates 

for the weld head used in a particular weld schedule. 

The ID purge must be supplied directly from the flow-meter/ 

regulator on the argon source. 

Arc gas input 

AC input 

Arc Gas Input to the 307 is on 

the back of the power supply 

above the AC connector. 


Rev.A 

Arc gas output 

Arc gas output from 307 to the 

Adapter Cable. Once seated, tighten 

screw to hold connector in place.


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. 

Adapter cable 

electrode and 

ground 

connectors 

to weld head 

cable 

Slide the rubber boots together (male boot should cover connection 

first) and secure them in place, being careful not to dislodge 

the connectors. The boots protect the connectors and prevent 

shorting to ground. 

Remove dust covers from CONTROL cables, and insert the 

adapter cable connector into the head connector. Tighten by 

hand and screw dust caps together. 

WELD HEAD MOTOR ELECTRODE / 

GROUND 


Rev. A 

Pull back on the collar of the 

female connector. Make connection 

with collar pulled back. 

Weld Head Motor Connector to 307 307 Adapter Cable to Weld Head 

Connector 

COOLANT CIRCULATES THROUGH HOSES IN THE ADAPTER CABLE. 

WELD HEAD GAS CONNECTION


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. Heads without water cooling may be cooled between welds by 

placing in front of a fan. 

Note: The 9-500C weld head is a water-cooled version of the 9-500. 

Model 307 Power Supply 

Model 307 Power Supply and Optional 307-CW 

Input power The Input Power cable is attached to the back of the Model 

307-CW and connected to the back of the Model 307 power supply. 

The 307 Adapter cable has two water fittings that connect into the optional 

307-CW. Water circulates from the CW through those hoses to the 

weld head and back to the CW. 

The maximum flowrate for the 307-CW is 2 liters per minute (.5 gallons) 

at 35 PSI. The maximum delivery pressure is 45 PSI with a bypass 

relief valve. Total 307-CW water capacity is 0.75 Gallons U.S. (2.8 liters). 

A glycol coolant-water mixture is recommended. The M307-CW unit operates 

on 12 volts DC at 2.6 Amps (4 AMP indicated rating is for 


Rev. A 

307-CW 

coolant IN 

coolant OUT


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 

Model 307-CW (front) 

Note: Pump does not self- prime well. Monitor Fill Level after 

cables have filled with coolant. 

CAUTION: Remove Coolant before shipping the 307-CW. 


Rev.A 

Flow Indicator 

The Coolant Fault must be turned on when the 

M307-CW is in use. 

The Fault Setup Screen is accessed from the System Setup Functions 

button on the Opening screen which opens the System Setup Screen; select 

Faults which opens the Fault Setup Screen (shown below) and 

touch the Coolant button. A Green light is ON when fault is enabled. 

Green light 

shows fault 

enabled


MANUAL TORCH INSTALLATION 

Ground 

Foot Controller 

OR 

Foot Switch 

Tack welding with a manual GTAW torch in a high-purity 

application. Photo courtesy of the Murray Company Mechanical 

Contractors. 

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.) Optional 

extension cables are available for both the torch and 

foot controller. 

Important: Stubout Mode must be set to "OFF". 


Rev. A


M307-FC 

MANUAL TORCH 

FOOT CONTROLLER 

(OPTIONAL) 

M307-FS 

FOOT SWITCH 

M-307 to MANUAL TORCH HOOK-UP 

ARC GAS 

M-307 POWER SUPPLY CONNECT PANEL 

WELD HEAD 

GROUND ELECTRODE 

AIR-COOLED. 

MANUAL TORCH 


Rev. A 

ARC GAS IN 

AC INPUT 

ID PURGE LINE 

CONNECT TO 

REGULATOR/FLOWMETER 

WORK GROUND


Model 307 Remote 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. 

STOP - Shuts 

down Model 307 

Welding Operations 

Weld/Test changes 

307 from weld 

mode to test mode 

and vice-versa 

Start - Initiates 

the Weld or Test 

sequence 

Downslope - 

Initiates 

programmed 

Downslope from 

weld sequence 

Travel Counter 

Clockwise Jog - 

jogs rotor counterclockwise 


Rev. A 

Pendant 

Stop Weld turns 

off the arc and 

stops rotation. 

Manual Purge 

starts the flow of 

gas to the weld 

head. 

Clear Fault resets 

function 

Travel Clockwise 

Jog - Turns rotor 

clockwise


Model 307 Accessory Connections 

The Model 307 Power Supply features several types of connectors for 

optional accessories with control or communication functions. 

Streaming 

Data 

307-RP 

Data. The RS-232 Communications Port outputs streaming digital 

data to an external device during the weld sequence. The output 

is in ASCII format and a standard RS-232 cable is required. 

The Auxiliary Plug may be used to connect an external device such as an 

oxygen analyzer to give a fault condition unless certain conditions are met. 

Connect device to the Auxiliary pin connector, enable External Fault on the 

307 Fault screen. Select if device to Trigger on High. Select action on pulldown 

menu to give a Warning, Start Downslope or Stop the Weld when fault 

is detected. Type in device name from the keyboard. 

Type in 

device 

name from 

keyboard 

DATA RS 232 

PENDANT 


Rev.A 

AUXILIARY PLUG 

FOOT CONTROL/ 

FOOT SWITCH 

O2 Analyzer 

or other 

device 

Select 

action from 

pull-down 

menu


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. 

Floppy disk 

drive 

USB 

Connector 

PS2 Keyboard 

connector 

Model 307 USB Connector 

The Model 307 USB connector can accept input 

from any USB device including a USB keyboard, 

USB mouse, or USB hub. A USB hub can accept 

input from several USB devices simultaneously. 

USB 

memory 

stick 

PS2 

keyboard 

PS2 Keyboard Connector 

The PS2 Keyboard connector may be used to connect a 

standard PS2 keyboard to the Model 307. 


Rev. A


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. When the edge of the paper emerges from 

between the thermal head and the platen, pull the paper out making sure 

that it is correctly aligned. Return the thermal head to the down position. 

Unload the paper with the thermal head in the up position. Pull the 

paper straight up by hand in the direction in which the paper is normally 

fed. If the paper is bonded on the core of the paper roll, separate the paper 

from the roll and then pull the paper out. 

Automatic paper loading. Load the paper with the thermal 

head in the down position. Cut the end of the paper 


Rev. A 

Head up/down lever


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. 

Cleaning Printer Head 

Do not clean the head immediately after printing. Allow enough time for 

the head and pressure unit to cool. Do not use rough materials such as 

sandpaper for cleaning. 

To clean the print head lift the head up/down lever. Clean the heat elements 

with a cotton swab moistened with isopropyl alcohol. Allow the 

alcohol to evaporate before lowering the print head. 


Rev. A


Chapter 5. Model 307 Weld Parameters/ 

Sequence of Events 

SEQUENCE START 

PREPURGE 

LEVEL 1 

LEVEL 2 

LEVEL 3 

This chapter will explain the Sequence of Events that 

takes place during a weld. Every size of tube, pipe, fitting, 

or other component to be welded must have a written 

weld schedule or weld program that defines what each 

of the various weld parameters controlled by the power 

supply will be at each phase or level of the sequence. The 

effect that each parameter has on the weld will be explained. 

The weld sequence or "sequence of events" begins 

when the operator presses the Start button on the Model 

307 touch screen from the Weld Schedule - Weld Screen in 

Weld Mode. This initiates a timed Prepurge during which 

an inert shield gas is supplied to the weld head. Gas continues 

to flow throughout the weld sequence and during a 

timed Postpurge which begins at the end of Downslope. 

At the end of prepurge the arc is initiated. The current at 

which the arc is struck will be the value set for Start Level. 

Current (amps) may be programmed to advance from 


Rev. May 2005 

LEVEL 4 

DOWNSLOPE 

POSTPURGE


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. 

A weld schedule consists of a series of timed levels so that 

weld parameters (usually amperage) may be changed from 

one level to the next, i.e., Level 1 Time, Level 2 Time, etc. 

In general, four levels of current is typical but any number of 

levels may be programmed. The power supply can also be 

programmed to make a weld with two or more passes. At the 

end of the last level the current is gradually reduced in a 

timed Down-slope. Electrode travel (rotation) is delayed after 

arc start for a programmed period of time called Travel 

Start delay. Travel stops at the end of downslope and the 

weld head rotor returns to home at the end of Postpurge. 

Radial graphs generated by the Model 307 during the welding 

sequence show position of electrode on the tube during the weld and 

at the end of each level. Left: electrode in the middle of Level 4. Right: 

electrode near the end of Downslope. Start position was 3 o’clock. 

The Model 307 Power Supply may be used to automatically 

develop weld schedules after the weld head number and 

the diameter (O.D.) and wall thickness of the material to be 

welded are entered. In generating weld schedules the Model 

307 offers a choice of: auto-generated continuous rotation 

(CONT), step rotation (STEP), or tack weld (TACK), or 

manual generation which can be any of the preceding. 


Rev. A


Programmable Variables 

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. 

Non-programmable variables are 

not controlled by the power supply but 

are an essential part of the program 

and must be controlled as well. Data, 

such as electrode length and purge 

flow rates may be entered from the 

Associated Data screens entered 

from the Weld Schedule - Main Screen. 

This information will not be acted on 

by the power supply but becomes a 

part of the weld record for documentation 

purposes. 

PROGRAMMABLE VARIABLES: Single Entry 

Prepurge time: Inert gas must be supplied to the weld 

head for the entire weld sequence to minimize oxidation 

of the weld O.D. The Prepurge time is the amount of 

time the shield gas flows to the weld head between the 

start of sequence and arc initiation. 

Postpurge is the amount of time the gas is allowed to 

flow after the arc is extinguished. See chart for recommended 

flow rates and purge times for the different AMI 

weld heads. 

Upslope: Upslope is the time programmed for the current 

to reach the full value after striking an arc. It is normally 

set to zero (0.0 sec.) for autogenous welds. 

Downslope: is the time set for the arc to extinguish after 

the end of the last programmed level. Typically this 

should be from 4 to 15 seconds depending on tube diameter. 


Rev. A 

Single Entry Parameters


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. In 

manual mode, the levels advance by using the Level 

Advance button on the touch screens or remote pendant. 

External advance requires input from an external device. 

Stubout Mode - Stubout Mode On means that if the electrode 

contacts the weld pool or work, a fault will occur and 

power will be shut down. Stubout Mode must be Off for 

manual welding. Use the pull-down menu to select mode. 

Travel Start Delay - Travel Start (Rotation) Delay is the 

time allowed for the rotor to remain stationary after arc 

start. Time should be just sufficient to achieve full penetration 

before the rotor starts to move. 

Travel Direction - The default travel direction for weld 

heads is clockwise (CW). Other options, selectable from 

the pull-down menu on the Single Level screen are counterclockwise 

(CCW) and OFF. 


Rev. A


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 heavy- 

wall applications. 

PROGRAMMABLE VARIABLES: 

Level/Segment Parameters - 

Level parameters are parameters 

that may be changed during the weld 

sequence. 

Level Position - Level Position is 

the location of the electrode at 

the end of a particular level. If 

Level Time is changed, position 

values will be adjusted accordingly. 

Primary Amps - Background 

Amps. When Pulse Mode is ON, 

amperage is pulsed between the 

Primary (high) amp setting and 

the Background (low) amp setting. 

Primary Pulse (Time) - Background Pulse (Time). 

The Primary and Background pulse timers indicate the 

duration of Primary and Background Amps. 


Rev. A 

Scroll down 

to view 

other options 

Level/Segment


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. Pulse Mode ON pulses the current 

between the primary and background amps by enabling the 

pulse timers and background amps. Pulse Mode OFF provides 

full primary amps. Pulse Mode External allows the 

pulse to be triggered by an external source. 

Travel Mode - Electrode travel mode can be selected from 

the pull-down menu in each level. In Travel Mode CONT 

the electrode travels at a constant speed; in Step the electrode 

may travel at different speeds during the primary and 

background pulse times, typically primary travel is set to 

zero in step mode; in OFF the electrode does not move; in 

External travel may be triggered by an external device. 

Travel Mode: Weld bead appearance in CONT Travel mode (Left) and 

STEP Travel mode (Right). STEP mode is typically used on wall thicknesses 

greater than 0.083 in. 


Rev. A


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. 


Rev. A


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. Before welding, verify that the Weld 

Schedule Name corresponds to the weld program you 

wish to use. 

SELECT FROM LIBRARY. Displays the list of folders 

and the weld schedules stored within them. 

CREATE NEW SCHEDULE. Brings up screens for 

creation of a new weld program. 


Rev.A


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. The TOOLS button brings up the Calculator 

functions, English/Metric and Backup Gas pressure conversions 

as well as other tools for calculating gas flow, 

electrode lengths, rotation speed and weld time. 

REMOTE CONNECT. Establishes connection with a 

remote Power Supply (Only seen on Remote Software). 

HELP. Displays Model 307 “TERMS” help screen as well 

as the entire Model 307 Operator Training manual. 


Rev. A


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 

Pressing WELD on the Weld Schedule-Main screen (above) will bring up the 

Weld Schedule Weld Screen shown below. The green Test button 

indicates Test Mode. 


Rev. A 

To weld with this 

schedule, touch the 

WELD button to bring 

up the WELD SCREEN.


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. 

Refer to Chapter 11. Welding with the 307 for more complete welding 

instructions. 


Rev. A 

Press START to 

begin welding.


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. 


Rev. A


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. 

Displays a radial graph showing 

electrode position and location of level 

changes on weld circumference during 

Weld and Test sequences. 

Displays the calibration values for 

travel speed, wire feed, and other 

functions. Caution - these settings 

should not be modified by untrained 

personnel. 

Permits modification of selected weld 

parameters during the weld sequence. 

Use buttons to increase or decrease 

Amps, Pulse Rate, or RPM (IPM). 


Rev. A


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. 

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. The green light 

indicates that the fault is enabled. Pulldown menus on the External Faults 

offer the choice of a Warning Only if a fault is detected, or the 307 will enter 

Downslope or Stop the Weld sequence immediately if the selected fault 

occurs. 

Downslope Stop Weld 


Rev. A 

Enabled


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. With Report enabled, touching 

Report Setup brings up the Printer Setup - Report Items screen. This 

allows the user to select those items to be included as part of the weld 

records. 


Rev. A 

Enabled


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. 


Rev. A 

Label Printer


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. 


Rev. A


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. Touching 

“yes” will reset the count of all weld schedules in the Model 307 to zero. 


Rev. A


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. 


Rev. A 

24 Hr


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. 


Rev. A 

∑t 

∑t 

∑n 

#


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./mm 

English/Metric Conversions 

Typing in any of the parameters: inches, milimeters, cubic feet per hour or 

liters per minute from the keyboard will convert to the corresponding 

parameter. 

in./mm 

CFH/LPM 


Rev. A


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. When the diameter and wall thickness 

of the weld joint is entered, the recommended travel speed will be 

shown when the AMI Recommendation button is touched. Touching the Weld 

Time button brings up the AMI Tools calculator to calculate Time for one 360° 

revolution. 

IPM/RPM 


Rev. A 

360°


∑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. Enter the Arc Gap or press the AMI 

Recommended Arc Gap screen buttton to find the arc gap. The Electrode 

Length and Tip diameter will be shown at the right of the screen. 


Rev. A


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. 


Rev. A


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. Users who have entered 

their Logon Name and Password from the Security Administration 

screen in System Setup Functions are qualified to log on to the M307. 

Users are classified as Programmer (highest level) with access to all the 

screens, Supervisor, which has more limited screen access, or Operator 

which has access to weld screens and can make adjustments within the Override 

limits but can not make permanent schedule changes. 

Note that the Logon Name is the Welding Operator I.D. used for weld 

documentation and weld logging. 

Shutting Down the Model 307 Power Supply: 

Close any open screens with the Close button. 

Close the Weld Schedule you are using. 

If a USB device is in use, touch Stop USB 

prior to ejecting the device. 

Use the Home button to return to the Home Screen. 

Log OFF if Logon was required. 

Touch “Shutdown” and wait for the message 

“It is now safe to turn off your computer” before 

turning the M 307 circuit breaker to the OFF position. 


Rev. A 

Touch OK 

when Logon 

and Password 

have been 

entered.


Screens Accessible from Weld Schedule - Main Screen: 

Weld Schedule - Single entry 

Weld Schedule - Levels 

Weld Schedule - Library 

Opening Screen 

Weld Schedule Main Screen 

Weld Schedule - Weld Screen 

Counter/Alert Indicator 

Weld Schedule - Weld Screen 

TEST/WELD changes 

operating Mode. 

Touching SEQUENCE START 

from this screen initiates 

the Weld. 

In-Sequence Display Selelction 


Rev. A 

Weld Schedule -Overrides 

Associated Data - Comments 

Associated Data - Main


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. 

In the Model 307 Libraries, groups of weld schedules are kept together in 

Folders. Touching (or clicking) on the name of a Folder such as An Example 

Group will display the list of weld schedules in that folder. The Libraries have 

both Folder and Schedule functions which are displayed on the buttons at the 

bottom of the library screens. To select or activate Folder functions, touch the 

area in the Folders column. To select or activate schedule functions, touch 

the area under Schedule Name. 

Opening an Existing Weld Schedule 

To Open an existing Weld Schedule, select the library where the schedule 

resides (Local, Remote, Floppy, External Device) by touching (or mouse) 

select folder, highlight schedule name by touching then touch the OPEN 

SCHEDULE button. 

Select Library: 

Local, Remote, 

External or 

Floppy 

Select Folder 

by touching 

Folder 

functions 

displayed 


Rev. A 

Touch 

schedule 

name to 

highlight


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. 

Selecting 

schedule 

displays 

schedule 

functions 

Opening a Weld Schedule from the Library displays the Weld 

Schedule-Main Screen. The Weld Schedule Name or Number is shown 

as well as the Folder Name, Outside Diameter, Wall Thickness, Weld 

Head Number, Date Created, and Date the weld program was modified. 

To weld with an open schedule consult Chapters 6 and 11. 

NAME 

To Weld - 

touch the 

WELD key to 

open the Weld 

Schedule Weld 

Screen. See 

Chapters 6 

and 11 for 

more details. 


Rev.A 

Select 

Schedule 

Touch to 

OPEN 

SCHEDULE 

Folder


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. 

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. For 

example, to type an “a”, touch the 2abc key twice in succession and the “a” 

will appear. Touching the 2abc key 3 times in succession will produce a “b” 

and so forth. Selecting the Shift Key will make a capital letter “A” or “B”, 

etc. Press Enter to add the new folder to the Library. Press Cancel to 

return to the Library screen without entering. 

New Folder 

Name 


Rev. A 

Select 

Library 

where you 

want the 

folder to 

reside 

Touch OK 

when name 

has been 

typed. 

Press 

Enter 

when 

name is 

correct


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. 

Select 

Library by 

touching 

To Delete a Folder from the Library, first select the library (local, etc.) then 

touch the folder you wish to delete. When the folder is highlighted, touch the 

Delete Folder button. A screen will appear asking if you want to delete the 

folder with all its weld schedules. Touch Yes to delete the folder. 

Select 

folder to 

be deleted 


Rev. A 

Touch OK 

when new 

name has 

been typed 

Press “Yes” to 

Delete Folder 

or “No” to 

cancel.


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. To Paste Selected Folder into a remote machine select the 

Remote library, touch the folder area on the left side of the screen, then 

touch the Paste Folder button to enter the schedule into the Remote 

Machine Library. Folders can also be copied from a Remote Machine to a Local 

Machine by the same process. 

i 


Rev. A


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 


Rev.A


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. 

Touch 

Create 

Schedule 

button to 

generate a 

new weld 

schedule 

Touching the Create Schedule button opens the Weld Schedule Wizard 

Screen for creating a new weld schedule. See Chapter 8 for Autogeneration 

of weld schedules. 


Rev. A 

Select a 

schedule to 

access 

schedule 

functions 

Touch Open 

Schedule to 

open 

selected 

schedule


Type in weld 

schedule 

name from 

keyboard 

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. 


Rev. A 

Touch OK 

when done


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. 


Rev. A


To paste to a 

floppy first 

highlight the 

floppy icon, 

then touch 

Select 

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. 

To Paste the schedule you have copied to a new location, first 

select the Library (Local, Remote, Floppy or External Device), 

then select the Folder in which you want to paste the schedule. 

If there is no folder, you must first create a folder. 

T 


Rev. A 

Press Copy 

Schedule to 

Copy 

Touch Select 

when desired 

folder is highlighted 

Touch Paste 

Schedule 

when library 

appears a


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. 

If no folder exists in the library, you must use the Create Folder button to 

create one. Then select the folder to highlight and the screen background 

will turn green. The Paste Schedule Button will change from grey to black. 

Touch the green background (or put your cursor there) and press Paste 

Schedule to paste the schedule into the new location. The schedule name 

will appear and the green background will change back to grey. 

If no folder 

exists, type 

in new 

folder name 

from keyboard 

and 

touch 

Create 

Folder 


Rev. A 

Select 

Memory 

Stick Icon - 

note USB 

Icons differ 

with manufacturer 

Touch Select 

to Choose 

USB folder 

Touch OK 

when done


Select folder 

to highlight 

and touch 

Paste 

Schedule 

Don’t forget 

to touch the 

Stop USB 

button before 

removing the 

Memory Stick 


Rev. A 

Press Paste 

Schedule to 

paste copied 

schedule into 

selected folder. 

The schedule 

is pasted into 

the USB 

memory stick


Screens Accessible from the Model 307 Library 

Weld schedule Library - 




Weld Schedule Library 


Folder selected - folder buttons 

displayed 


Weld Schedule selected - 

buttons change to schedule 


Weld Schedule Wizard 


Rev.A 

Close 

Library 

Opening Screen 

Weld Schedule Main 



Weld Schedule Library


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. 

Select units by touching 


Rev. A 

Select 

Folder from 

pull-down 

menu


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. The 307 will not accept these characters. 

Type in the optional Description from the keyboard as shown below. 


Rev. A 

Press Enter 

when name 

is complete


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 

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. 


Rev. A 

Press Next 

when all 

complete 

Select weld 

position from 

pull-down 

menu 

Press Next when Library 

Information is complete


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. Press Next when Library 

Information has been completed. 

Tube 2 


Rev. A


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. To weld with this schedule press WELD. Other screens accessible from 

this screen are shown in Chapter 6 on page 19. 


Rev. A 

Touch to 

display 

WELD 

screen


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. 

Weld Schedule - Weld Levels Screen. Weld parameters which may be 

changed in any level. Use scroll bar to view additional weld parameters. To 

modify a weld parameter, touch the parameter you wish to change and enter 

the modified parameter from the keyboard. 

Level 

Position/Time 


Rev. A 

Use the 

Scroll Bar 

to view 

additional 

parameters 

Use pull- 

down menu 

in each level 

to copy or 

delete that 

level 

Scroll Bar- 

scroll down 

to see other 

weld 

parameters 

Touch OK 

when done


Weld Schedule- Weld Levels scrolled down to view Level Time 

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. Select Delete Level to 

delete the level. You will be prompted with “Do you want to delete level?” 

Touch “Yes” to delete the level. 

Copy this level 

Delete Level 

Add Level button. Selecting the Add Level button creates 

a new level identical to the last level to the right of the last 

level. You must scroll horizontally with the scroll bar to view 

the added level. 

Note that if changes are made to Level Position the Level Time is automatically 

adjusted, and vice-versa. However, if a new level is added, you must 

enter either time or a new position in the new level in order for the electrode 

to advance past the previous last level. 


Rev. A 

Scroll bar 

moved 

down to 

view or 

adjust Level 

Times


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. STEP may also be 

useful for welding materials of dissimilar heats or with slight differences in wall 

thicknesses. STEP welds take more time than welds done with continuous rotation, 

but provide a wider bead and greater repeatability for field conditions. 

In STEP mode the weld head rotor movement is synchronized with the current 

pulses so that the Primary RPM takes place during the Primary Current 

Pulse, and the Background RPM at the Background Current Pulse. The 

stopping or slowing of the rotor during the high current pulse allows for greater 

penetration without a change in amperage, and provides cooling for the weld 

puddle during the background pulse. 

Example Step Program 

Press Create New Schedule on the 307 Opening Screen and begin by selecting 

the folder for the program from the pull-down menu. Then enter the program 

name from the keyboard and the optional description. Select the weld 

head by highlighting from the list of weld heads. In the following example, the 

weld will be on 4 inch pipe (4.5 inches or 114.29 mm O.D.) which has a wall 

thickness of 0.120 inches or 3.04 mm. Press Next when finished. 


Rev. AA


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. 

If the second weld component is identical to the first, press the Same as 

Tube 1 button. Otherwise enter Library information for second component. 

Touch STEP on the Weld Schedule Wizard Screen. 


Rev. A 

Select 

welding 

position 

from the 

pull-down 

menu.


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. To weld with this program touch the WELD button. 

Weld Schedule - Single Entry This screen displays the weld parameters 

that remain unchanged for the entire weld sequence. 


Rev. A 

To Weld 

touch the 

WELD 

button to 

display the 

Weld 

Screens


Weld Schedule - Weld Levels screen 

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. 

Weld Schedule - Weld Levels screen showing Primary and Background 

Pulse times. 

In STEP 

mode, 

Primary 

Travel is zero 

and travel 

takes place 

during the 

Background 

Amps pulse 


Rev.A 

Scroll down to 

view Primary 

and Background 

Pulse Times 

and Level Times.


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. This example uses a 9-1500 weld head and 1 inch O.D. tube. 

Enter Library Information for Tube 1 and Tube 2. 


Rev. A


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. 

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. The number of 

tacks can be changed from the keyboard. The Tacking Pattern can be 

Sequential in which the tacks are done in order, or a Balanced pattern where 

tacks are placed on opposite sides of the joint and then the electrode is moved 

90° and the process repeated. The balanced procedure is done to minimize 

distortion. 

Adjust slide 

switch to 

set percent 

(%) tack 

penetration 


Rev. A 

Touch Tack 

icon to 

generate 

Tack weld 

schedule 

% 

Select 

Tacking 

Pattern


Weld Schedule Main Screen 

Weld Schedule Single Entry - For the Orbital Tack Weld program the pre- 

and 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. 


Rev. A


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. Scroll down the Levels screen to view the pulse times 

and level times. 

Scroll across to view other 

Levels 


Rev. A 

Scroll 

down to 

view pulse 

times and 

level times


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. 

Amps can be adjusted by touching the plus or minus amps buttons to get 

the desired tack penetration. 


Rev. A


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, 1.24 mm ) tubing 

used for the autogenerated (CONT) schedule in Chapter 8 will be used to 

illustrate manual weld schedule development. 

From the Opening Screen select the Create New 

Schedule button. The weld head selection menu will 

appear on the Weld Schedule Wizard Screen. Select 

the Units of Measure. Select the folder from the pull-down menu, 

type in the weld schedule name from the keyboard and select the 

9AF-750 weld head. Press Next and enter the Library information 

from the keyboard as shown on pages 1 to 6 of Chapter 8. 


Rev. A


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. 


Rev. A


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. See Chapter 16 for recommended minimum prepurge 

times. 

Postpurge: The Postpurge time will default to the minimum 

recommended setting for the specific weld head selected. Using 

longer postpurge times will result in cleaner welds and longer 

electrode life. See Chapter 16 for recommended minimum postpurge 

times. 

Upslope: The Upslope time is typically set for 0.0 for autogenous 

welds. Upslope may be programmed for wire feed applications. 

Downslope: Downslope time must be sufficient to prevent a crater 

or crack, no less than 2 seconds, typically from 4 to 15 sec. 

Longer times are recommended for larger diameters. Enter 5 

seconds for the 0.500 O.D. tube. 

Start Level: - Start Level 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. 


Rev. A


CW 

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. 

Travel Start Delay - Electrode Travel Start (Rotation) 

Delay. This must be long enough to achieve full penetration 

before beginning rotation. Typically 1 to 2 sec. 

Travel Direction - The default Travel Direction for Arc 

Machines’ weld heads is clockwise (CW). Other choices on 

the pull-down menu are Counterclockwise (CCW) or travel 

OFF. Select OFF for use with manual torches. 

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, the default Start Position is normally used. 


Rev. A


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 


Rev. A 

Scroll down 

to select 

other weld 

parameters 

Use pulldown 

menu to 

select start 

position


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. 

Add the number 

of levels 

needed 

Symbols for each parameter are shown at the left of the screen. 

Level Position: Enter the position of the electrode at the end of 

the level. The time to arrive at that position will be entered automatically 

once the travel speed has been entered. 

Determination of Welding Currents 

Primary Amps: Primary amps will essentially determine the 

amount of weld penetration. Calculation of Primary Amps for Level 

1 is based on wall thickness. The amount of primary amperage 

needed will vary somewhat from heat-to-heat of stainless steel. 

One Amp per 0.001” is a rough approximation. However, more 

realistic amperage values are obtained using the corrections 

shown in the table on the next page. Values are based on a travel 

speed of 5 IPM. 


Rev. A


Amps 

120 

100 

80 

60 

40 

20 

0 

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. If the 

amperage is reduced by 20% from Level 1 to the Last Level, 

then the Last Level will be equal to 80% of Level 1. To calculate 

the amount of primary amp reduction for each level, subtract 

the Last Level amps from Level 1 amps and divide the 

difference by the number of levels you are creating minus 1 

level. 

“Real World” Level 1 Primary Amperage Calculations 

Wall Thickness 

(in). 

Primary Level 1 

Amps based on 1 

amp per 0.001” 


Rev. A 

Primary Amps/Wall Thickness 

1 Amp per 0.001” 

Correction 

0.035 0.049 0.065 0.083 0.109 0.12 

Wall Thickness - Inches 

% Correction Primary 

Amps based 

on 

correction 

0.035 35 Amps 0 35 Amps 

0.049 49 Amps +10 54 Amps 

0.065 65 Amps +15 75 Amps 

0.083 83 Amps +15 96 Amps


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. 

Background Amps: Background amps are set at approximately 

30% of Level 1 amps and generally remain the same throughout 

the weld sequence. Example: Level 1 amps = 54. 30% of 54 = 

16.2. If using whole numbers, round off to 16. 

Example Amperage calculation for .500 in. O.D. tube with 

0.049 in wall: 

Primary Travel - Primary Travel speed is typically based on 5 

inches per minute (IPM). Some customers prefer travel speeds 

based on 4 IPM for larger sizes and/or heavier wall thicknesses. 

Arc Machines recommends 8 RPM (6.28 IPM) for 0.250 in. O.D., 

0.035 in. wall tubing. 

Calculation of RPM: Circumference = π x O.D. = 3.141 x .500 = 1.57 in. 

RPM = IPM ÷ circumference = 5 IPM ÷ 1.57 = 3.18 RPM 

Background Travel - Background travel is only active when 

Travel Mode is Step. That is when the RPM has a different value 

during the Primary and Background current pulse times. In STEP 

mode, the Primary Travel (RPM) is typically set to zero (0.0) while 

the Background RPM is calculated for 4 or 5 IPM (non-step). 

Primary Pulse Time - Primary Pulse time is the time that the 

amperage remains at the Primary Amps. Increasing the 

Primary Pulse Time will increase the heat input into the weld. 

Background Pulse Time - Background Pulse time is the time 

that the amperage remains at the Background amperage. Pulse 

times are typically “balanced” or kept equal. Short pulse durations 

result in weld beads that are close together while increasing 

the pulse times results in weld beads spaced further apart. 

((((( or ( ( ( ( (. 


Rev.A


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 = 3.18, 60 sec. ÷ RPM = 60 sec ÷ 3.18 RPM = 18.9 sec. 

Total Time = 18.9 sec. + 1.5 sec. delay + 1.5 sec. tie-in = 22 sec. 

Time per level = 22 ÷ 4 = 5.5 sec per level. 

If Level Position is changed, the Level Time will be automatically 

recalculted. If Level Time is changed, the Level Position will be 

automatically recalculated. 


Rev. A 

LEVEL 1 LEVEL 2 LEVEL 3 LEVEL 4 

54 52 50 49 

16 16 16 16


Finished Levels/Segments Parameters for .500 in O.D. 0.049 in tube 

by manual programming 

See Chapter 10. Associated Data for entering important information for 

the weld record. 


Rev. A 

Use scroll bar 

to view level 

times


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. 

STEP Weld Bead: ( ( ( ( ( ( ( CONT Weld Bead: (((((((((( 

• The current ( amperage) should be set at the values for the preliminary 

weld schedule, i.e., primary amps for level 1 set at 1 amp per thousanth of 

wall thickness. (Note: for heavier-wall pipe from 0.109” to 0.154” wall, use 

the STEP Weld Development Work Sheet. (See Chap. 19. Appendix 2.). 

• Rotation (Travel Stop Delay) Delay time should be sufficient 

to achieve penetration of the first weld bead. Typically 1 

second for each 0.010 inch or 10 seconds per 0.100 inch wall. 

• Primary RPM set to 0.0 

• Background RPM set to calculated value for 5 IPM (or 4 IPM if heavier 

wall) 

• Double Pulse times - if pulse times for the CONT program were set at 0.2 

and 0.2 sec, try 0.4 and 0.4 or 0.5 and 0.5 sec. Longer pulse times will be 

needed for heavier wall. The rotor movement during the background pulse 

should be equal to about 65% of the wall thickness. (Balanced pulse times 

are not necessary. Greater penetration can be achieved when the PRIMARY 

PULSE TIME is greater than the BACKGROUND PULSE TIME.) 

• Double all level times and downslope time from Continuous program. 

• Verify Total Time by doing a TEST RUN. Make sure there is adequate 

TIE-IN with DOWNSLOPE set at 0.0. (Reset downslope time after test 

weld.) ∑t 

• Make a trial (partial) weld for about 1 Level to make adjustments in 

penetration if necessary. Make sure there is adequate TRAVEL START 

DELAY. When the first part of the weld looks good, add another Level or 

two and try again until a complete weld schedule has been determined. 

Test for repeatability. 

STEP Program with Primary RPM Greater than 

Zero. STEP programs typically are programmed with 

0.0 Primary RPM, but a STEP procedure in which the 


Rev. A 

RPM>0


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 0.010” to 0.154” wall with standard fusion welding 

equipment. Orbital equipment with AVC (automatic voltage control) which 

maintains a constant arc gap extends the range for autogenous welding to 

schedule 10 pipe up to 10, 12, or 14 inches IPS. However, not all welding 

techniques are applicable to all sizes. STEP rotation mode and mixed gas are 

often used to increase penetration on heavier-walled pipe. 

1/8” OD tubing can be orbitally welded either with single or multi-pass techniques, 

with or without pulsation. At a travel speed of 5 IPM, the RPM would 

be 12.7. At 7 IPM, the RPM would be 17.8 or 18 RPM which is approaching the 

maximum RPM of the 9-250 and 9-500 weld heads which is 20 RPM and is out 

of range of the other weld heads. It takes the right equipment and “know-how” 

to properly cut and face tubing of this size for orbital welding without damaging 

the tubing. Furthermore, inspection of the ID for penetration is virtually 

impossible without destroying the weld. Thus frequent test coupons are recommended. 

1/4” OD tubing is typically welded at 8 RPM for a single-pass weld with 

pulsation which is a travel speed of 6.28 IPM. This is slightly faster than the 

usual 5 IPM. Although some users have made successful welds using 5 IPM, 

or 9 IPM, the 6.28 IPM has been widely used with consistent results using the 

1 amp per 0.001” wall formula. 

5 IPM is recommended as a travel speed for sizes from 3/8 inch to 3.5 inch 

O.D. tube. Faster travel speeds are possible with very thin-walled materials. 

5 IPM 


Rev. A


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. 


Rev. A


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. PREPURGE 

and POSTPURGE times are held to a minimum, but should be long enough 

to produce a clean tack or weld bead. Level Advance is set to Manual so 

the torch will operate without interruption. Stubout Mode is set to Off from 

the pull down menu. Pulse mode may be set to ON or Off on the pull down 

menu. No travel time is specified. 


Rev. A


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. Tack welds must be fully consumed by the orbital 

weld on the I.D. and O.D. 

On the screen below Primary Amps have arbitrarily been set to 50 and 

Background Amps to 20. Adjust penetration using the + Amps button. An I.D. 

purge IS STRONGLY RECOMMENDED for manual tack welding to prevent 

I.D. oxidation. 


Rev. A 

I.D.


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. 


Rev. A


Chapter 10. Associated Data - 

Gas 

Materials 

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). Collectively, buttons on this screen open screens 

which provide a way to input important information about the weld schedule. 

This information can be stored and retrieved as part of the weld record. 

Information on the tubing or other weld component, equipment, gas, 

electrode, comments about the weld, data stream, and optional wire may 

be entered. These weld parameters are not acted upon by the power supply, 

but have an effect on the weld and are considered to be non-programmable 

variables. Additional information such as ISO drawing number, Operator 

name, date and time of weld may also be documented by the Model 307. 


Rev. A 

Electrode 

Equipment 

ISO Drawing Number Name of welder 

Date 

Time


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. Material heat numbers and brief 

description of the weld components, Tube 1 and Tube 2, which may be tubes 

or other types of components, is optional information. Touch the Tube 2 Tab 

to view Tube 2 data. 

Associated Data -Tube 

Tube 2 


Rev. A 

Touch the Tube 2 Tab 

to view Tube 2 data.


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. 


Rev.A


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. Use the Tools Icon from the toolbar to locate electrode 

information. 


Rev. A


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. 

Selecting either option from the above screen brings up the 

Weld Counter Reset Setup screen which can be customized to weld schedule 

that is currently open. For example, an alarm may be set to tell the user 

to change the electrode after 15 welds or to make a test coupon. Type in 

alarm message from the keyboard. 

Type in 

message 


Rev. A


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. The Last Schedule used on the 307 may be opened 

directly by touching the OPEN LAST SCHEDULE button 

on the Opening Screen. (See Chapter 6, page 3.) 

3.If no schedule exists for the size of tube or pipe you 

are welding, select the Create New Schedule button 

from the 307 Opening Screen to create a new weld 

schedule. (See Chapters 8 and 9). 

When a schedule is opened, the WELD SCHEDULE - MAIN screen for that 

schedule will appear: 

Weld Schedule Name 


Rev. A 

To weld with this 

schedule, touch the 

WELD button to 

bring up the WELD 

SCHEDULE - WELD 

SCREEN.


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. Pressing Weld will return the M307 to Test Mode. In WELD MODE 

pressing Start on the Weld Screen will start the sequence and the arc. 

TO WELD: Press Start on the Weld Schedule-Weld Screen in Weld 

Mode. 

Press 

Weld to 

enter Test 

Mode 


Rev. A 

Press START to 

begin welding.


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. 

� Is the material type, heat number, OD, and wall thickness 

shown on the schedule correct? 

� Do the weld components have the proper end preparation? 

Have they been properly cleaned? (See Chapter 14). 

� Is the 307 Power Supply set up and properly installed with the 

correct line voltage? (Refer to Chapter 4). 

� Is the weld head set up with correct clamp inserts, electrode 

of the correct length? (See Chapter 15). 

� Is the weld head calibrated to the power supply? (See 

Chapter 13 for weld head calibration instructions). 

� Is the purge gas of the correct type and purity grade 

(certification required?) See Chapter 16 for purging 

information. 

� Is the purge gas flow rate correct for the weld head? ID 

purge set for correct flow rate and pressure? Touch the 

Template icon on the Tool Bar for recommended flow rates. 

� Are the components correctly aligned and fit up in the weld 

head? (See Chapter 17. page 3 for permissible misalignment). 

� Is the electrode length correct and is it lined up to the weld 

joint? (See Chapter 15). 

� Are the necesssary faults activated? (Don’t forget to turn off 

the Stubout Fault when using a manual torch). On the 307 

Opening Screen choose System Set-up and then Faults. 


Rev. A


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. 

� Has the Weld Counter been reset? From the Weld 

Schedule-Main screen of your weld schedule select 

Counter Reset and reset the counter. 

� Do you require Data Acquisition? From the Weld 

Schedule-Weld screen of your program select Data 

Acquisition. The Weld Identification Information screen 

will appear on which the Weld ID number and other items 

may be entered. (See Chapter 18). 

� Associated Data fields. From the Weld Schedule-Main 

screen of your weld schedule, touch Associated Data. In 

formation about the gas, equipment, tube, electrode and 

data stream may be entered and items selected to appear 

on the weld record. 

� Printer set-up. If a print-out is required set the 307 to 

print a label or weld record. From the Opening Screen 

select System Setup Functions and choose Printer Set-up. 

(See Chapter 6, pages 8-9.) 


Rev. A


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. 

Heat-to-heat variations in stainless steel may make it necessary to adjust 

weld parameters, particularly amperes, for individual heats of material. The 

objective of this chapter is to guide the operator to achieve an optimized 

weld program from one that is untried. The weld should have complete 

uniform penetration around the entire circumference, have good alignment 

of weld components and be well purged on the ID and OD. See Chapter 17 

Weld Criteria for more specific industry requirements. 

Making a Test Run 

Before attempting to weld with an untried weld schedule, make a Test Run. 

In a Test Run, the weld head rotor rotates at the programmed RPM without 

striking an arc. 

A Test Run is done to make sure that the Total Time in all levels (excluding 

Downslope) is adequate to achieve a complete revolution (360°) plus 

tie-in. Downslope must be set to zero for the Test Run and 

re-entered for the actual weld. 

Total Time includes Time for One Revolution (360°), plus Travel Start 

Delay time, plus time for the proper amount of overlap or tie-in which 

should be equal to time to travel a distance of at least 2 wall thicknesses. 

∑ 

Total Time 

= t 


Rev. A 

360° + + 2Xt


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. Adjust time and or level position as 

necessary. 

At the end of the TEST RUN, re-enter the DOWNSLOPE TIME. 


Rev.A


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. 

Radial Graphs generated by the Model 307 during the welding sequence show 

position of electrode on the tube during the weld and at the end of each level. 

Left: electrode in the middle of Level 4. Right: electrode near the end of 

Downslope. Start position was 3 o’clock. 

Make a Trial Weld. With the power supply properly installed, 

and weld head calibrated, install weld coupons in weld 

head and connect an appropriate purge. From the Weld Schedule 

- Weld Screen with the green Test button, touch the green 

button to show the red Weld button then touch Sequence Start. 

Examine each section of the Trial Weld and adjust parameters 

in each level. Examine weld for discoloration, misalignment, 

cracks and porosity. Make changes in weld procedure to 

achieve repeatable consistent high-quality welds. 

Trial Weld - determine the direction of electrode travel, the location of level 

changes and make modifications as needed. Note- the tip of the Downslope 

points in the direction of electrode travel. 


Rev.A


Weld Defect Troubleshooting Chart 

Weld Problem Probable cause(s) Remedy 

Lack of penetration to the ID 1) Insufficient amperage 

2) tungsten offset 

3) different heat number 

4) sulfur mismatch 

5) variable wall thickness 

6) Fluctuations in power 

source 

OD Concavity 1) Too much amperage 

2) Gravity (heavy-walled 

material) 

3) Very low sulfur content 

ID Concavity 1) Excessive ID purge 

pressure 

Discoloration of ID (Oxidation) 1) Excessive oxygen and/ 

or moisture in ID purge 

gas 

2) Moisture and/or oxygen 

in or on tubing - 

chemical residue from EP 

3) Leak in purging set-up 

4) Pinched gas hose 

Misalignment 1) Dimensional tolerances 

- out-of-round 

2) Wall thickness mismatch 

3) Worn out TCIs 

4) Poor workmanship 

Porosity 1) Moisture in purge gas 

2) Moisture or dirt on 

weld components 

Excessive slagging 1) Impurities in base 

material especially oxides 

of aluminum, calcium, 

silicon 


Rev. A 

1) Increase amps for 

affected level(s) 

2) verify electrode centering 

3) verify heat number 

4) make two passes 

5) verify wall thickness - 

6) Use dedicated circuit 

1) Reduce amperage for 

affected level(s) 

2) Reduce heat for that 

level 3) Increase ID purge 

pressure (thin-walled tubing) 

2) Reduce ID purge flowrate 

or increase size of exit 

orifice (restrictor) 

1) Verify gas purity - 

check condition of purifier 

2) Clean and dry tubing - 

heating may be necessary 

3) Check purge system for 

leaks - replace fittings 

4) Check gas hose 

1) Verify components 

meet specified tolerances 

2) Check wall thicknesses 

3) Replace TCIs 

4) Tack weld components 

and/or use alignment tools 

1) Purify gas 

2) Clean and dry weld 

components 

1) Increase amperage 

2) Vary pulse times 

3) Try argon/hydrogen 

mix 

4) Change material


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. 


Rev. A 

Advanced 

Calibration to 

be used by 

Programmers 

only


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. On the Model 8 Series weld heads 

the calibration screw is on the bottom of the weld head handle. 

Typical Model 9 potentiometer location. 


Rev. A 

CW 

CCW


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). Calibration programs must be run 

in Test Mode Only. If the weld head goes too far or comes up short, adjust 

the screw on the calibration pot counter clockwise (CCW) to slow it down or 

clockwise (CW) to speed up the rotation. Repeat as necessary. 


Rev. A 

Schedule for 

weld heads 

calibrated at 4 

RPM for 15 sec. 

If the travel 

speed is 

correct and 

degrees set 

to 360°, time 

will be 

entered 

automatically


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. 

Table 1: RPM and Times for Manual Calibration of Weld Heads 

Model 9-250 6 RPM 10 Seconds 

Model 9-500C 6 RPM 10 Seconds 

Model 9AF-750 4 RPM 15 Seconds 





Model 9-7500 10 RPM (10 = 1) 60 Seconds 





Important: Calibration (automatic or manual) must be performed each time 

a different weld head is connected to the Model 307 Power Supply. 


Rev. A


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. Templates contain 

information pertaining to particular weld heads such as the Maximum amps 

recommended for the head, the Maximum Travel Speed, the Minimum recommended 

prepurge time, the recommended Arc Gas flow rate, electrode 

diameters, water cooling requirements, size range (capacity) of the weld 

head and Rotor Diameter which is used to calculate the correct electrode 

length for a particular tubing O.D. 

The weld head template recommendations are used to alert the operator of 

any recommended maximum amperage or minimum prepurge time, but will 

allow programming of values outside the recommended limits. 


Rev. A


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. Note that some rotors have different diameter holes to accommodate 

the different electrode diameters. 

Electrode in the Model 9-1500 weld head is installed 

from the O.D. and must be flush with the rotor O.D.. 

The Model 8 weld heads and Model 9-500 and 9-250 series weld heads have 

electrode holes that only go part way through the rotor. Electrodes in these 

heads must be installed from the I.D. and be fully seated in the hole. 

Electrode is installed from the I.D. on the Model 8 

series weld heads and must go all the way in. 


Rev. A


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. 

Two sets of TCIs are installed in the 9-1500 weld head. Here the 

operator installs a TCI by securing the single screw with an Allen 

wrench. Each set of TCIs has a unique marking and members of a 

set should be installed on the same side of the head. 

The 9-750 weld head has solid TCIs. 

The outside of the TCI is marked OUT 

and should be oriented to the outside 

of the head. 


Rev. A 

Top TCI 

Bottom TCI


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. For longer weld components use a pipe stand 

or other support. Do not use the weld head as an alignment tool. 


Rev. A


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. 

The housing on the electrode side of the head is removed and replaced by a 

gas seal to retain the purge inside the head. Table 2 gives the “A” dimension 

which is the minimum length or “stickout” needed to weld components in a 

particular head. Welding in “E” heads usually requires tack welding to hold 

the components in place for orbital welding. Tungsten extenders, some of 

which are called “mushrooms” because of their shape, may be used to locate 

the electrode off the centerline and thus reduce the length required to reach 

the centerline on that side. 

Model 8 weld heads were introduced in 1997 to provide a narrower head with 

a shorter stickout requirement. This distance is 0.87 in (22.9 mm) from 

either side of the weld head. The Model 8 weld heads can be used for fittingto-fitting 

welds which are not practical in the standard weld heads. Smaller 

sized weld heads require less stickout. For example, the required stickout for 

the Model 9-500 is 0.250 inches (6.35 mm). 


Rev. A 

Model 8 Weld Head


Table 2. Size Range and Minimum Weld End Stick-Out 

AMI Weld Head O.D. Range Min. “A” dim. 

Model Number 

4-500 0.093” - 0.500” 

2,4 - 12,7mm 

9-250 0.093” - 0.250” 

2,3 - 6,3mm 

9-500 0.093” - 0.500” 

2,2 -12,7mm 

9-750 0.125” - 0.750” 

3,2 - 19,0mm 

9-1500 0.250” - 1.500” 

6,3 -38,1mm 

9AF-1500 0.250” - 1.000” 

6,3 - 25.4mm 

9AFM-1500 0.250” - 1.000” 

6,3 - 25.4mm 

9E-1500 0.250” - 1.315” 

6,3 - 33,4mm 

9-2500 0.750” - 2.500” 

19,0 - 63,6mm 

9AF-2500 0.750 - 2.000” 

19,0 - 50,8mm 

9E-2500 0.750” - 2.375” 

19,0 - 60,3mm 

9-3500 1.000” -3.500” 

25,4 -88,9mm 

9E-3500 1.000” - 3.250” 

25,4 - 82,5mm 

9-4500 1.500” - 4.500” 

38,1 - 114,3mm 

9E-4500 1.500” - 4.000” 

38,1 - 101,6mm 

9ER-4500 1.500” - 4.500” 

38,1 - 114,3mm 

9-7500 2.875” - 7.500” 

73,0 -190.5mm 

9E-7500 2.875” - 6.625” 

73.0 - 168,3mm 


Rev. A 

0.25” 

6,3mm 

0.25” 

6,3mm 

0.25” 

6,3mm 

0.70” 

17,8mm 

1.41” 

35,8mm 

.85” - .96” 

21,6 - 24,4mm 

0.25” 

6,3mm 

0.37” 

9,4mm 

1.72” 

43,7mm 

.89” - 1.12” 

22,7 -28,4mm 

0.37” 

9,4mm 

1.72” 

43,7mm 

0.37” 

9,4mm 

2.00” 

50,8mm 

0.37” 

9,4mm 

0.37” 

9,4mm 

2.16 

54,8mm 

0.53 

13.4


8-2000 0.250” - 2.000” 

6,35 - 50,79mm 

8-4000 0.250” - 4.000” 

6,35 - 101.59mm 

8-6625 2.000” - 6.000” 

50,79mm - 152,39mm 

Brochures and additional information on Arc Machines’ weld heads may be 

found on the Arc Machines, Inc. web site at www.arcmachines.com. 


Rev. A 

0.87 

22,09mm 

0.87 

22,09mm 

0.87 

22,09mm


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. The most commonly used end 

preparation for orbital GTA fusion 

welding is the Square Butt preparation 

in which the ends of the tubing 

are faced square with no bevel so 

that they mate together in the weld 

head with no discernable gap. 

Tube ends must be faced square without burrs 

or breaks to fit up snugly in the weld head. 


Rev. A 

The ASME Bioprocessing Equipment 

Standard (BPE-2002) has defined 

the acceptance criteria for ends of 

fittings and weld components for 

orbital welding in biopharmaceutical 

applications.


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 2.50 inches on 6 inch O.D. 

tube. The Control portion, C, is defined as the length from the welding end 

over which tolerances for wall thickness and O.D. are maintained. The length 

of the control portion is fixed for all sizes at 0.75 in. (19 mm). 

Cleaning/Surface Condition 

Weld components must be clean in order to achieve good weld results. Cleaning 

procedures vary with industry and application, but the BPE standard in 

part DT-12 Surface Condition states that 

“Internal and external surfaces of fittings and 

process components furnished to this Standard 

shall be cleaned to remove oils, grease, 

particulates, and grinding componds or electrolytes”. 

When such fittings are packaged, 

the ends are protected with end caps and fittings 

are sealed in plastic bags or shrink 

wrapped. The installer is responsible for 

maintaining cleanliness of components during 

the installation and for the condition of 

tubing that is cut and prepped on site. 


Rev. A 

A facing tool used to produce 

machined ends on small diameter 

tubing.


Orbital type saw is used to cut tubing while 

producing a square end. Photo courtesy of 

George Fiscsher GmbH. 


Rev. A 

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. Orbital 

type saws can produce weld ends 

square enough for some orbital welding 

applications, but if the blades are 

not kept sharp, the edges may 

become rough and burrs may occur. 

Burrs produced by cutting and facing 

must be removed before welding. 

Tube cutters may be used for cutting 

small diameter tubing, but this procedure compresses the tubing ends and 

the ends must be faced back to the uncompressed part. An I.D. purge is 

often used to prevent particles generated during cutting and facing operations 

from entering the interior of the tubing. Gloves must be worn when 

handling unwrapped tubing and components in high-purity applications. 

Insert rings may be used as filler material 

for fusion welding of some materials. Rings 

must be tacked in place prior to orbital 

welding. 

End preparation equipment for facing 

heavier wall thicknesses


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. Consistency of tungsten electrode properties 

such as type, length, diameter, tip configuration and grind is 

important for maintaining the repeatability and quality of orbital 

welds and these must be controlled for optimal weld performance. 

The GTAW process in which the electrode conducts 

current for the arc but is not consumed by the heat of welding 

depends upon the high melting point of tungsten which has the 

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

to the melting point of iron which is 2800 o F (1538 o C). 

Tungsten Type 

Tungsten properties are improved by the addition of 2% thoria 

or ceria which improve the arc strike characteristics and arc stability. 

Pure tungsten is seldom used for GTAW because thoriated 

and ceriated tungstens have superior properties, especially for 

orbital GTAW applications. For tube welding applications, ceriated 

tungsten is always recommended, as this type main- 


Rev. A 

TUNGSTEN 

IN GTAW 

PROCESS 

THORIATED, 

CERIATED 

TUNGSTEN 

2% Th


2% Ce 

W 

TUNGSTEN 

GEOMETRY 

Tungsten length 

determines the 

Arc Gap 

Tungsten Type - AWS color code 

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. The unprocessed rods are color-coded as to 

type: green for pure tungsten, orange for 2% ceriated, 

red for 2% thoriated, etc. according to AWS Specification 

A5.12/A5.12M as shown in the figure on this page. The 

ISO International Standard 6848 has a comparable 

tungsten type identification system. 

Importance of Tungsten Geometry 

Electrodes with a ground finish are dimensionally more 

uniform. A smooth finish is always preferable to rough or 

inconsistent finish, since consistency in electrode geometry 

is essential for consistent weld results. Electrons 

emitted from the tip (DCEN) transfer heat from the tungsten 

tip to the weld. A finer tip permits the current density 

to be maintained at a very high level but may result 

in shorter tungsten life. For orbital tube or pipe welding, 

it is important for the electrode tip to be machine ground 

to assure repeatability of the tungsten geometry and 

thus, the welds. 


Rev. A 

Tungsten Dimensions that are controlled 

for orbital welding 

Pure Tungsten 

1.5% Lanthanated 

2% Ceriated 

Zirconiated 

2% Thoriated 

1% Thoriated


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. Pipe is never perfectly round and the 

arc gap must be controlled to maintain a constant arc 

gap around the entire weld circumference. The Model 

95 wire feed weld head has a mechanical arc gap 

controller. 

Tungsten Diameters 

Tungsten diameters for fusion welding are based on 

wall thicknesses. Model 9 weld heads, except for the 

Model 9-250 and Model 9-500 which only accept 0.040” 

tungsten, accept two different tungsten diameters. For 

the Model 9AF-750, the Model 9-900, and the Model 

9/AF-900 weld heads, 1/16” diameters are used for 

most applications. For the larger heads, the use of 

either 1/16” or 3/32” diameters is based on wall thickness. 

The use of 1/16” tungsten for wall thicknesses up 

to 0.093”, and 3/32” tungsten for heavier wall thicknesses 

is recommended. 


Rev. A 

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”


TAPER ANGLE 

AND TIP SHAPE 

TUNGSTEN TIP 

DIAMETERS 

TUNGSTEN LIFE 

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 18 o included angle for 

the electrode tip for all tungsten diameters used in the 

orbital tube and pipe weld heads. The tip shape has a controlling 

effect on the shape of the arc and on the amount 

and depth of weld penetration. A flat tip extends electrode 

life and increases weld repeatability. 

Tip Diameters 

The Tip Diameters are specified for orbital fusion tube 

welding. Tip diameters are typically based on wall thickness 

with a finer tip used for thinner-walled materials. Tungstens 

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

diameter specifications. 

Tungsten Life 

Tungsten Life will vary with the application, quality of the 

gas, and cleanliness of the metal. A great many more welds 

per tungsten are possible on 1/4 inch tube than on larger 

pipe. However, factors such as moisture or oxygen in the 

shielding gas can have a serious detrimental effect on tungsten 

life. The use of mixed gases such as 95%Ar/5%H2 or 

75%He/25%Ar, may also limit tungsten life. Similarly, oxidation 

or other surface contaminants on the metal can 

adversely affect tungsten wear. The rule of thumb is to 

change the tungsten if the weld quality deteriorates. For 

high-purity tube welds, tungsten is often changed after a 

set number of welds for that particular application. 


Rev. A 

Formula for calculation 

of Tungsten Length 

and diagram of relationship 

of Tungsten Length 

to Rotor Diameter and 

Arc Gap.


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). Electrode Length and tip diameter are displayed. 


Rev. A


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. From the Main Weld 

Schedule screen select Associated Data. Enter electrode information from 

the keyboard. 


Rev. A


Chapter 16. Purging Requirements 

for Orbital Welding 

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. For autogenous orbital 

welding in enclosed weld heads, the head 

forms a chamber of inert gas providing 

protection of the entire O.D. weld joint. 

M 

A backing or purge gas is applied to the 

I.D. of the weld joint to prevent the formation 

of oxides or other detrimental 

surface substances and to provide pressure 

for the weld profile. Backing gas is 

required for high-purity orbital welding 

and for tack welding (if tack welds are 

permitted). 

Gas type 

Ar 

He/Ar 

Ar/H2 Argon 

Argon is the most commonly used gas for both shield and backing during 

GTA welding of 316L stainless steels in the biotechnology and pharmaceutical 

industries, while a gas mixture containing 1 to 5% hydrogen is often 

used in the semiconductor industry. The type of gas used as a shield gas 

has a profound effect on the character of the arc and the depth of weld penetration. 

Gas mixtures of helium and argon (75% helium/25% argon), as 

well as argon and hydrogen (95% argon/5% hydrogen), provide a hotter 

arc than pure argon and deeper penetration at the same current settings. 

The gas type is considered to be an essential variable for weld procedure 

qualifications and a change from one gas type to another or to a gas mixture 

requires requalification of the welding procedure. Welding operators must 

also be requalified when there is a change of gas type or gas mixture. 


Rev. A 

Large argon dewar outside a cleanroom is used 

for purging welds on high-purity semiconductor 

and pharmaceutical piping assemblies. Photo 

courtesy of Murray Company.


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. purge for HP and UHP semiconductor applications 

to reduce discoloration. However, hydrogen and hydrogen mixes from cylinders 

typically contain higher amounts of oxygen and moisture than argon 

supplied in dewars and thus oxygen contamination may outweigh any benefits 

of using hydrogen additions to prevent discoloration. 

Hydrogen mixes produce smoother weld beads as the wetting characteristics 

are improved by the reduced surface tension of the weld metal. The 

weld bead is typically narrower, but may not be narrower on very low-sulfur 

materials. However, the arc is less stable with a tendency towards arc wander, 

and tungsten life is severely 

affected. Since the 

addition of hydrogen affects 

penetration, precise control of 

the gas mixture is essential to 

maintain the consistency of 

the weld, especially for thinwalled 

materials. Hydrogen is 

detrimental to the properties 

of some metals. It may cause 

hydrogen induced cracking, 

porosity, etc. Hydrogen gas 

is flammable and 

potentially explosive. Mixtures 

greater than 5% total 

volume are not recommended 

for safety reasons. 

Verify that the gas type or 

mixture is compatible with the 

alloy being welded. For example 

gas mixtures containing 

hydrogen should never be 

used on carbon steel or titanium. 

The helium/argon mixture 

is the preferred gas for 

welding carbon steel. 


Rev. A 

Cleanroom orbital welding operator adjusts flowrate 

for purging. For high-purity applications separate 

flowmeters are used for I.D. and O.D. purges. 

Magnehelic ® gauges are mounted on the wall. Photo 

courtesy of Murray Co.


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. purge gas but is 

typically supplied in cylinders with levels of oxygen contamination unsuitable 

for high-purity applications. 

Heat tint/discoloration 

Discoloration, or heat tint, resulting from oxygen and/or moisture in the purge 

gas forms in colors ranging from a pale straw color to dark brown, or dark 

brown and black (sugared), and from a pale gray or bluish haze to a deep intense 

blue, with the deeper colors indicative of higher oxygen concentrations. 

Oxidation (heat tint) is formed when elements and compounds in the base 

metal diffuse or vaporize from the base metal in the heat of welding, form oxides, 

and are deposited on the surface of the weld and heat-affected zone 

(HAZ). Sometimes deposits, particularly of manganese which vaporizes at 

lower temperatures than the other elements, are seen on the downstream side 

of the weld only. The light blue color that results is sometimes referred to as 

a "blue halo." 

A direct relationship has been demonstrated between oxygen levels in the 

purge gas, heat tint, and loss of corrosion resistance of stainless steel and 

duplex materials after welding. Welds on reactive materials, such as titanium, 

also show severe detrimental effects on mechanical strength resulting from 

oxidation and benefits are obtained from improved purity of the purge gas and 

effective shielding. 


Rev. A


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. purge gas to be certified to less than 3 ppm total moisture, 

oxygen and other contaminants. The ASME BPE Standard, widely used in 

the biopharmaceutical industry, requires that the I.D. of welds be free of color 

while a slight amount of blue or straw color in the HAZ may be acceptable. The 

BPE does not specify gas type or purity levels, but bioprocess piping contractors 

generally use argon dewars with impurity levels of less than 20 ppm or a 

purity of 99.998% to achieve the specified color-free weld bead. Purge gas purity 

specifications are usually more relaxed for pipe welding applications for 

which argon gas of 99.99% purity is generally considered adequate. 

Purging techniques 

O.D. Purge 

The 307 Power Supply supplies a constant gas shield to the weld head for the 

entire weld sequence. Prepurge and Postpurge times are programmable. Table 

1. on page 8 lists minimum prepurge and postpurge times for the various 

weld heads, but the purge should continue for as long as necessary to avoid 

unacceptable weld discoloration. Recommended flow rates for Model 8 and 9 

weld heads are also shown in Table 1. Precise control and consistency of the 

flow rate to the weld head (O.D.), is important for weld repeatability. Insufficient 

flow can result in a poor purge and discoloration of the weld and the HAZ. 

Excessive flow to the weld O.D. can disturb the arc, causing arc-out or arcwander. 


Rev. A


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. purge are 

not controlled by the 

power supply but the 

purge is turned on 

before beginning the 

weld sequence and 

turned off after the 

end of postpurge by 

the welding operator. 

These times must be 

adequate to prevent 

excessive discoloration 

of the weld I.D. 

Insufficient purge 

gas flow will result in 

discoloration of the 

weld and/or HAZ of 

the I.D. weld. A high 

I.D. purge flow rate 

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. 

A pressure gauge inserted at the weld joint that measures gas 

pressure in inches of water column is often used in high-purity 

process piping applications to assure that the I.D. purge pressure 

is correct before beginning to weld. The gauge is removed 

for welding. 


Rev. A


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. A pressure gauge 

(Magnehelic ® or equivalent) connected to a tee inserted at the weld joint is 

used in high purity applications to adjust the flow rate (or orifice size) that 

will result in the amount of I.D. pressure necessary to produce a flat, fully 

penetrated I.D. weld bead. The tee is then removed from the joint and the 

weld head installed on the joint to make the weld using the predetermined 

flow rate (orifice diameter). Flow rates, purge times, orifice sizes and internal 

pressure should all be documented as part of the Standard Operating 

Procedures (SOPs) and, once established, followed routinely by all welding 

personnel. See SEMI Standard F79-0703 Table 1. for suggested I.D.purge 

settings for high-purity applications. 

Purging techniques 

Sound purging procedures are an essential component of a successful orbital 

welding program. Successful purging requires gas of appropriate quality 

for the application and maintaining the gas purity up to the point of use, i.e., 

the O.D. and I.D. of the weld puddle and HAZ. This requires air-tight hoses 

and connectors. Welded stainless steel tubing with face seal fittings are 

used for the highest purity semiconductor applications so that only stainless 

steel comes into contact with the weldment. All types of plastic tubing are 

permeable to atmosphere to some degree. The Polyflow ® (polyethylene) 

tubing supplied with the Arc Machines equipment is very good. The SEMI 

specification recommends PFA plastic tubing, but in either case the plastic 

tubing should be restricted to less than 10 feet in length. Specifications for 

the various types of plastic tubing listing permeability to oxygen and moisture 

can be obtained from the plastic tubing manufacturers. The use of rubber 

or similar type purge hoses is not consistent with high-quality welding. 

Some type of diffuser may be used to disperse the argon flow to assure 

that the entire weld joint is covered. A diffuser at the connection of the gas 

hose to end cap can be used to disperse the argon stream entering the tube 

or pipe ID. This can also be accomplished by a filter. Contractors have developed 

a variety of devices and techniques to assure that the entire I.D. 

weld joint is adequately covered by purge gas. 

Analytical equipment such as oxygen and moisture analyzers can be 

used to verify that purge gas exiting the I.D. of the tube or pipe being welded 

has approximately the same level of purity as the source gas. If it does 

not, the location of the leak(s) must be found. 


Rev. A


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. 

Welding tubing in a cleanroom 

with a Model 9-500. 


Rev. A


Table 1. GAS FLOW RATES AND PREPURGE/POSTPURGE TIMES 

Weld Head 

Head Number liters/min. CFH Minimum Purge Time (seconds) 

9-250 2 - 5 7 - 10 ---------------------------------- 20 

9-500 2 - 6 8 - 12 ---------------------------------- 20 

9-500C 2 - 6 8 - 12 --------------------------------- 20 

9-750 5 - 7 10 - 14 ---------------------------------- 20 

9-1500 7 - 12 15 - 25 ---------------------------------- 20 

9AF-1500 7 - 12 15 - 25 ---------------------------------- 20 

9-2500 12 -14 25 - 30 ---------------------------------- 30 

9-3500 12 - 14 25 - 30 ---------------------------------- 30 

9-4500 14 - 19 30 - 40 ---------------------------------- 60 

9-7500 14 - 19 30 - 40 ---------------------------------- 60 

8-2000 7 - 12 15 - 30 ---------------------------------- 30 

8-4000 7 - 12 15 - 30 ---------------------------------- 30 

8-6625 7 - 12 15 - 30 ---------------------------------- 60 

4-500 2 - 6 8 - 12 ---------------------------------- 20 

‘E’ TYPE WELD HEADS 

Recommended Flow Rate 

9E-1500 12 - 17 25 - 35 ---------------------------------- 30 

9E-2500 12 - 19 25 - 40 ---------------------------------- 30 

9E-3500 14 - 21 30 - 40 ---------------------------------- 30 

9E-4500 17 - 24 35 - 50 ---------------------------------- 60 

9E-7500 19 - 28 40 - 60 ---------------------------------- 60 

Note: The same gas flow rates apply to both standard and AF type weld heads 


Rev. A 

Prepurge and Postpurge


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. 

As 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. The ASME Bioprocessing Equipment Standard (BPE-2002) now applies 

to the Personal Care industry as well as Bioprocessing and Pharmaceutical 

applications. SEMI, the organization that writes standards for the 

semiconductor industry has introduced two new standards in 2003 that apply 

to orbital welding. SEMI F79-0703 is a practice that offers guidelines for 

proper welding procedures for installing gas distribution systems and SEMI 

F81-1103 is a specification for visual inspection and acceptance of GTA 

welds in semiconductor gas distribution systems. AWS published a new 

standard in 1999, AWS D18.1:1999 Specification for Welding of Austenitic 

Stainless Steel Tube and Pipe Systems in Sanitary (Hygienic) Applications, 

to be used for sanitary food, dairy and beverage installations. 

Both SEMI F79-0703, SEMI F81-1103, and BPE-2002 state that all welding 

performed according to those standards must conform to ASME Sect. IX and 

B31.3 including full documentation. SEMI permits qualification to AWS 

D10.9 as an alternative. AWS D18.1 requires a WPS according to ANSI/AWS 

B2.1 and bend and tensile tests in accord with ANSI/AWS B4.0 Standard 

Methods for Mechanical Testing of Welds. 


Rev. A


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. The orbital weld schedule which lists 

weld parameters such as welding currents, pulse times, rotational speed, 

and times is frequently used as part of the PQR. 

To verify the structural integrity of welds, tube samples are welded, submitted 

to a testing facility, and subjected to bend tests to assure that the weld 

is ductile, and tensile tests to show that the weld meets the minimal tensile 

strength of the base material. The weldment typically breaks in the HAZ, but 

if it should break in the weld but still meet the minimal tensile strength of 

the material, it is acceptable. ((No grinding of autogenous (fusion) orbital 

welds in preparation of the test specimens is required.)) 

Documentation of welding procedures includes a WPS (Weld Procedure 

Specification, form QW-482) and PQR (Procedure Qualification Record, form 

QW-483). If the welder performing the welds is to be qualified as well, a 

WOPQR (Welding Operator Performance Qualification Record, form QW- 

484B) must be also be filled out. 

Types of Defects that are Disallowed 

Weld qualification to ASME Sect. IX and B31.3 does not permit discontinuities 

such as cracks, porosity, lack of penetration of the weld bead to the ID, 

undercut or excessive OD reinforcement, which would affect the structural 

integrity of the weldments. 

Visual Weld Criteria 

Weld bead smoothness. Standards for the semiconductor and bioprocess 

industries are concerned with internal weld bead smoothness, surface finish, 

and cleanliness of the product contact surfaces. Smoothness is important 

for semiconductor applications because a smoother surface takes less 

time to dry down and to get the particle count down to specified levels. Weld 

surfaces in bioprocessing and food and dairy equipment must be smooth in 

order to discourage microbial growth and contamination of the product. 


Rev. A 

Full penetration welds. Virtually all 

applications of orbital fusion welding insist 

upon welds in which the weld bead 

is fully penetrated around the entire ID 

weld joint circumference. ASME BPE- 

2002 requires that all welds be fullypenetrated, 

with a straight, uniform 

weld bead.


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. The ASME BPE-2002 standard 

provides a set of weld profiles showing acceptable 

limits for OD and ID concavity and 

convexity and specifies that the weld joint thickness 

must not be less than the minimum specified 

wall thickness for the material. The D18.1 

standard also sets limits on concavity and convexity since these discontinuities 

could affect the drainability and cleanability of sanitary piping systems. 

Misalignment 


Rev. A 

Limits on misalignment are also specified by SEMI, 

ASME BPE-2002, and AWS D18.1 since this could 

affect the drainability of fluid systems or affect flow 

in gas distribution systems. 

Tack welds 

ASME BPE-2002 requires that tack welds be fully consumed. Unconsumed 

tack welds have been identified as a major cause of weld rejection. The photos 

below illustrate the importance of proper purging of tack welds. 

The weld sample on the left was purged during tacking. Purged tacks are easily consumed 

by the orbital weld. The center sample shows unpurged tacks. The orbital weld on the right 

has unconsumed tacks as the arc deflected around the oxidized (unpurged) tacks.


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. The ASME BPE standard provides for 

ID discoloration to be held to a minimum, with the ID weld bead free from 

color, but with the level of discoloration to be permitted in the HAZ to be 

determined in advance by the owner and contractor. The allowance of some 

discoloration is in recognition that zero discoloration is quite difficult to 

achieve unless additional gas purification is available and that oxygen, manganese, 

moisture, etc. that contribute to discoloration may originate from 

the weld components themselves, and are thus difficult to control. AWS 

D18.1 and AWS D18.2 contain a colored photo which allows owners and 

contractors to agree to a level of discoloration appropriate for their application. 

Slag islands 

Certain heats of material are especially prone to slagging or oxide islands 

that form on either ID or OD of the weld. AWS D18.1 prohibits oxide islands 

greater than 1/16” (1.6 mm) and limits the number of islands to 4 in the 

size range from 1/64” up to but not including 1/16” in any weld. The small 

silicon dioxide spot at the end of downslope on 316L tubing is generally considered 

to be acceptable. Testing materials for weldability prior to acceptance 

should help to eliminate difficult heats. 

Company Weld Specifications 

Qualification to ASME Sect. IX of the Boiler and Pressure Vessel Code requires 

that there be an In-House Quality Assurance Manual in-place. Individual 

companies frequently write their own specifications in full compliance 

with specifications for their industry, but with additional details. 

Inspection Techniques and Requirements 

Both SEMI specifications and ASME BPE-2002 (in accord with B31.3) 

recommend 100% visual inspection of the weld OD. B31.3 makes the 

distinction between Inspection and Examination. Weld examination is done 

by the operator or the installing contractor while the Inspector is someone 


Rev. A


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. The BPE requires a minimum of 20% of welds to be randomly 

selected for ID inspection which would typically be done with a borescope. 

A borescope, or fiberscope, is a fiber optic instrument with a monitor (TV 

screen and optional video tape recorder) used for inspecting the weld on the 

tube or pipe ID. Some borescopes can measure concavity or convexity of 

the inner weld bead, but it is difficult to detect light oxidation with a borescope. 

For SEMI the percent of welds inspected is subject to agreement as 

part of the purchase order for services. 

Use of Test Coupons 

The 3-A Sanitary Standards written by the dairy industry in the 1950s recommended 

the use of preproduction weld samples to determine that the 

manual welder had the necessary skills to make a sanitary weld and so that 

the owner and installing contractor could agree on quality standards in advance 

of a job. For orbital welding, test coupons help to establish quality 

standards in advance of an installation, and the repeatability of the process 

offers assurance that if the test weld is good, previous welds done with the 

same weld parameters and conditions should also be acceptable. 

Test coupons should be made: 

• at the beginning and end of each shift 

• after a change in welding procedure 

• change in material heat 

• change in tubing size 

• change in gas supply 

• change of welding equipment 

• change of power supply location 

• test coupons should be made any time there is a concern about 

deterioration of weld quality. 

Since 100% inspection of the ID of orbital welds is not always possible or 

practical, the use of test coupons is the next best thing. To be meaningful, 

test coupons should be done on the actual material with the same heat 

number as that being used on the job. They should be cut open to expose 

the entire weld bead for viewing. If the test coupon is found to be defective, 

the weld is rejected and all welds made since the previously accepted test 

weld must be cut out and replaced. Note that with smaller tube sizes, the 

cut will remove a significant part of the weld. For small diameter tubes, 


Rev. A


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. 

Note: Welding operators should be aware of the welding criteria and 

specifications for their particular application. 

See Chapter 18. Data Acquisition/Advanced Functions for additional information 

on Weld Documentation and Weld Logging. 


Rev.A


Chapter 18. Data Acquisition/Advanced Functions 

Arc 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. 

Weld Data Records 

A Weld Data Record consists of a file created at the time the weld was made. 

This file contains information about the Weld Schedule, Operator Info, Performance 

Log, Project Info, Power Supply Info, and Fault Setup Information. 

Weld Data Records will only be saved for welds with a valid weld ID number. 

Existing weld data records will be stored on the power supply. Weld Data 

Records can be printed on the internal power supply printer, or exported from 

the power supply. 


Rev. A


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. 

Use the pull-down menu to specify the performance monitoring tolerances. 

Touch Enable to activate Weld Data Recording or Disable to end WDR. 


Rev. A 

Type in Weld 

Identification 

number from 

the keyboard 

Touch Enable 

to activate 

Weld Data 

Recording


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. From this list the user can select any one or all of 

the WDRs for Viewing or Exporting. 


Rev. A


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. Nor can 

they be imported from another Power Supply. 


Rev. A


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. 

Print to internal printer Print to external printer Print Label 


Rev. A


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. The rate at which the data is 

sampled is selectable from the Streaming Data screen. 


Rev. A 

Use Pull- 

Down menu 

to select 

Data 

Acquisition 

sampling 

Rate.


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. 

3) Level Time (if selected) 

4) Current (if selected) 

5) Voltage (if selected), 

6) Travel (Motor Servo 1, if selected) 

7) Wire feed (Motor Servo 2, if selected) 

8) Head position (if selected) 

9) Events: i) Elapsed Time, Event message ii) Events will be printed on 

a separate Line 

10) The Start and Stop times of the streaming data output can also be 

selected. Start of the data stream can be: Start Output At: Start of 

Prepurge, at arc start, or at the end of upslope. 

Stop of the data stream - Stop Output At: Start of Downslope, end of 

Downslope, or at end of Postpurge. 

Sampling of the Data 

Primary values and background values will both be sampled separately with 

sampling delays built-in to prevent sampling the feedback data during the 

transition periods. When a deviation occurs during the weld sequence, the 

event will be logged with the following information: time the event 

occurred, expected value, and the actual value. These events will be 

stored as part of the Weld Data Record, and included in the “end of 

sequence” report. 


Rev. A


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. 


Rev. A 

Touch the 

Close 

button to 

return to 

the weld 

schedule.


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. Choose Data Acquisition from the Weld Schedule - Weld 

screen then select value for Performance Monitoring tolerance for the 

weld parameters from the pull-down menu on the Weld Identification 

Information screen. Choose an appropriate value for the application. 


Rev.A 

Select 

Performance 

monitoring 

tolerance 

from the 

pull-down 

menu 

% 

Touch Enable 

to activate 

WDR


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. The Weld Head Wizard allows the 

user to create a new weld head definition by either copying and modifying an 

existing definition or to create a new one from scratch. Touch Weld Head 

Data on the System Setup screen and then touch New on the Weld Head 

Wizard screen. 

Select 

weld head 

type 


Rev. A 

Type in new 

or modified 

weld head 

name then 

touch OK


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. 

Weld head notes 

Weld head notes provides a screen on which the user can write information 

about the weld head. This information is stored with other information 

pertaining to the weld head. 


Rev. A


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. 

Name of 

the new 

weld head 

is shown on 

the list 

Adding or Deleting a Servo to a Weld Head Template 

Touching (or clicking) on the Weld Head Name opens the Weld Head Wizard 

for that weld head. Add Servo, Delete Servo, and Edit Servo are selectable 

from the Weld Head Wizard Tool Bar. 


Rev. A 

Touching 

Open opens 

the Weld 

Head 

Wizard for 

the selected 

weld head. 

Select the 

Servo you 

wish to edit 

and touch or 

click to open 

the Edit Servo 

screen


Edit Servo Definitions 

Only qualifiedpersonnel 

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. 


Rev. A

Appendix 1. 

ARC MACHINES, INC. 

Model 307 Weld Schedule Development Sheet 

Value 

Level 1 Level 2 Level 3 Level 4 Level 5 Level 6 

Document No. 740096 Chapter 19. Appendix Page 1. 

Rev. A



Rev. A


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. Test coupons that satisfy your visual criteria and/or those out- 

lined in ANSI/ASME B31.1 Code for Pressure Piping or B31.3 

Process Piping (or other applicable code such as ASME BPE-2002) 

must be generated and sent to a qualified test lab for destructive 

testing (bends and tensiles). 

2. Bend tests are predetermined over a certain sized radius. Two 

each root, and face bends must be performed. The weld zone area 

(heat affected zone - HAZ) must be carefully inspected for 

cracking. 

3. Tensile testing must be done to examine for the following: 

a. PSI at which the specimen breaks must equal or exceed the 

minimum specified tensile stress of the materials being joined. 

Forms for the Weld Procedure Specification (QW-482)* and 

the Procedure Qualification Record (QW-483)* must be filled 

out. 

b. Should the specimen break on the weld, as opposed to 

being adjacent, (but still meet the base criteria in PSI) the sample 

is good. 

c. The welder performing the test and creating the weld 

samples has now become certified (Form QW-484B for Welding 

Operator Performance Qualification (WOPQ)* or equivalent 

must be filled out.) 

4. Welder Certification: Each welder must submit 6 inches of linear 

weld for certification, or multiple coupons, but no more than 4. 

5. By ASME Code you have now proven that the process and 

techniques used meet the ASME criteria for procedure 

qualification. 

*Forms E00006, E00007,and E0008B may be obtained from the Order Dept., ASME, 22 Law 

Drive, Box 2300, Fairfield, NJ 07007-2300. 


Rev. A


Appendix 4. Weld and Examination/Inspection Log for welding to 

the ASME Bioprocessing Equipment Standard (BPE) 2005 Appendix 

Reprinted with permission of the ASME. 


Rev. A

Appendix 5. Example ASME Welding Operator Performance Qualification 

Form 

Reprinted with permission of the ASME. 


Rev. A


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. Step/(Synchro) Weld 

Schedule Development, 19.2 

Appendix 3. Welding Operator Qualification 

to ASME Sect. IX BPVC, 

19.3 

Appendix 4. Proposed Weld and Examination/Inspection 

Log for 

weldilng to the ASME BPE Standard, 

19.4 

Appendix 5. Example ASME Welding 

Operator Performance Qualification 

Form, 19.5 

Appendix 1. M-307 Weld Schedule Development 

Sheet, 19.1 

arc 

arc gap, 15.3, 15.4 

arc gas solonoid, 4.5 

Arc Machines, Inc. Certificate of Completion, 

1.3 

argon 

argon/hydrogen mixture, 16.2 

see also gas, 16.1 

ASME Bioprocessing Equipment Standard 

(BPE-2002), 17.1, 17.2 

weld criteria, 17.3 

ASME Section IX, 17.1 

BPVC, 17.4 

PQR Procedure Qualification Record, 

17.2 

Document No. 740096 Index. Page 1 

Rev. A 

WOPQR welder qualification form, 

17.2 

WPS Weld Procedure Specification 

form, 17.2 

Associated Data 

Electrode, 10.4 

Equipment, 10.3 

Gas, 10.4 

Main Screen, 10.1, 10.2 

Tube, 10.2 

Tube 2, 10.3 

autocal, 2.2 

Autogeneration 

automatic weld schedule generation, 

8.5 

of a Continuous weld schedule, 8.1 

of a STEP Program, 8.7 

of an orbital tack weld schedule, 8.12 

AWS 

AWS D18.1 

1999, 17.1 

AWS D18.1 and AWS D18.2, 17.4 

B 

backing or purge gas, 16.1 

backup gas pressure conversions calculator, 

6.15 

bend test, 17.2 

bleeder circuit, 2.1 

bluish haze. See also Discoloration. 

BOP welds, 17.6 

borescope, 17.5 

C 

chart recorder, 4.1 

circuit breaker, 6.1, 6.2, 6.18 

Cleaning/Surface Condition., 14.2 

cleanliness, 17.2 

Close button, 6.18, 18.8 

Continuous travel mode, 8.5 

contractor, 17.4 

corrosion resistance, 16.3 

Counter reset button, 10.5 

Create 

Create a New Weld Schedule, 6.1, 

8.1, 8.8 

Create New Schedule button., 9.1 

current - Step mode, 9.11 

Currents, determination of (see also 

amps), 9.6


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 

E 

Edit Servo, 18.12 

Edit Servo Definitions, 18.13 

electric shock, 2.1 

electrode, 2.2, 4.4 

electrode calculator, 6.16, 15.5 

electrode data, 15.6 

electrode diameter (see also tungsten), 

15.6 

electrode rotation calculator, 6.15 

shock hazard, 2.1 

enclosed weld heads, 16.1 

End-Preparation for Orbital Welding, 14.1 

English/Metric Conversions, 6.14 

Enter Library information, 8.3 

equipment installation, 4.1 

External Device, 7.1 

F 

facing, 2.3 

Faults, 6.7 

floppy disk, 7.1 

Folder 

Copy folder, 7.5 

create a folder, 7.10 

Create Folder, 7.3 

Delete a folder, 7.4 

Folder Buttons, 7.7 

Folder Name, 7.2, 7.3 

groups of weld schedules in M-307 Library, 

7.1 

new folder, 7.3 

Paste folder, 7.5 


Rev. A 

Paste selected folder, 7.5 

rename folder, 7.4 

G 

gas 

back-up gas, 16.1 

gas flow rate, 2.4 

gas hoses, 4.5 

gas leaks, 2.2 

gas type, 16.1 

hydrogen mixes, 16.2 

purge gas purity specifications, 16.3 

recommended flow rates for model 9 

weld heads, 16.7 

shield gas, 16.1 

Gloves, 14.3 

Graphical Symbols, 3.1 

green Test button, 12.2 

grinding, 2.3, 17.2 

ground finish, 15.2 

ground (work) connection, 2.3, 4.4 

GTAW 

GTAW current, 4.1 

GTAW process, 2.1, 15.1 

H 

Hands-On, 1.3 

HAZ, 17.4 

heat number, 17.5 

heat tint 

discoloration., 16.3 

oxidation, 16.3 

heats of materials, 17.2 

Help, 6.2 

high voltage, 2.1 

Home, 6.18 

Home Page, 6.1 

hydrogen induced cracking, 16.2 

I 

Icons, 3.1 

In Sequence Display, 6.5, 6.6 

inert gas (see also gas), 16.1 

Input power, 1.1, 4.7 

Inspection techniques and requirements, 

17.4 

Installation of Tube Clamp Inserts, 13.7 

Intel® Pentium® processor, 1.2 

ISO International Standard 6848, 15.2 

isopropyl alcohol (IPA), 2.3 

I.D. purge 

back purge, 16.5 

pressure, 16.6

Arc Machines, Inc. Orbital Tube Welder Training 


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, 6.18 

M 

Manage Weld Heads, 18.12 

manual 

Level Advance, 5.4 

manual button, 9.2 

manual creation of 307 weld schedules, 

9.1 

manual purge, 4.5 

manual torch, 4.1, 4.9, 4.10 

manual weld head calibration, 13.1, 

13.4 

manual welding, 4.1 

misalignment, 17.3 

Model 307 to Model 9 weld head hook up, 

4.3 

Model 307CW 

installation, 4.7 

moisture, 16.1 

moisture analyzers, 16.6 

N 

National Electric Manufacturers Association 

(NEMA), 3.1 

newlink data, 18.1 

nitrogen and nitrogen mixtures, 16.1, 

16.3 

O 

Open a weld schedule, 7.1, 11.1 

Open Last Schedule, 6.1 


Rev. A 

Open Schedule, 7.2 

Opening Screen, 6.1 

Operator (Logon) Name, 18.7 

Orbital type saws, 14.3 

owner, 17.4 

oxygen analyzer, 4.1, 16.6 

oxygen contamination, 16.2 

P 

passes, 5.2 

Password, 6.18 

Paste a Weld Schedule to a USB Memory 

Stick, 7.11 

Personal Care industry, 17.1 

plastic tubing, 16.6 

Postpurge, 5.3 

power connection, 4.1 

Power supply information, 6.13 

PQR, 17.2 

Prepurge, 5.3 

prepurge and postpurge times, 16.4 

Primary Amps (manual torch), 9.15 

Printer paper installation, 4.14 

Procedure Qualification Record (QW-483), 

19.3 

programming 

Levels/Segments Parameters, 9.6 

single entry weld parameters, 9.3 

protective covers, 2.2 

Pulse 

Background Pulse Time, 9.8 

Primary Pulse Time, 5.5, 9.8 

Pulse Mode, 5.5, 9.4 

pulse mode, 5.2 

purge 

ID purge source, 4.5 

manual, 4.5 

postpurge, 9.3 

prepurge, 9.3 

purging techniques, 16.4, 16.6 

purity requirements, 16.4 

Q 

Quality Assurance manual, 17.2, 17.4 

quick-disconnect, 2.2 

R 

radial graph, 5.2, 12.3 

rain, 2.3 

Real-time digital data acquisition, 1.2 

recommended arc gap, 6.16 

regulator/flowmeter, 2.2 

Remedy (for weld problems), 12.4 

Remote Connect, 6.2 

Remote machine, 7.5 

remote pendant, 4.1



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, 6.1 

Selectable Outputs, 18.7 

SEMI, 17.2, 17.6 

SEMI F79-0703, 2.2, 17.1 

SEMI F81-1103, 17.1 

SEMI Standard F79-0703, 16.4 

sequence, 2.1 

Shutdown, 6.2, 6.18 

Shutting down the 307, 6.18 

Size range, 9.12 

Square Butt preparation, 14.1 

Start 

Start button, 12.2 

Start Level, 5.4, 9.3 

Start Position, 5.5, 9.4 

start weld sequence, 6.4 

Statement of purpose, 1.3 

STEP 

Step procedure, 9.11 

STEP Program with Primary RPM Greater 

than Zero, 9.11 

STEP rotation, 8.8 

Stop USB, 3.3, 6.18 

storage of weld heads, 2.2 

Streaming Data, 18.6 

Stubout mode, 5.4, 9.4 

surface finish, 17.2 

switch position, 2.2 

Symbols, 3.1 

System, 6.5 

System Setup Functions, 6.2, 6.5, 12.3 

T 

Tack welds, 17.3 

balanced, 8.13 


Rev. A 

orbital tack welding, 

8.12 

percent (%) penetration, 

8.13 

Sequential, 8.13 

Tack Icon, 8.13 

templates icon, 4.5 

tensile tests, 17.2 

Test coupons, 17.5 

Test Mode, 2.1, 6.4, 13.1 

TEST RUN, 12.1 

time 

Time for One Revolution, 12.1 

Total Time, 12.1 

total weld time, 9.11 

titanium, 16.3 

Tool bar, 3.2 

Tools, 6.2 

Tools - Electrode Calculator, 15.5 

Tools button, 6.14 

Total Time, 12.1 

Total Welds Counter Reset, 6.11 

Touch screen calibration, 6.12 

Travel 

Background Travel, 5.6, 9.8 

continuous, 8.5 

Primary Travel, 5.6, 9.8 

Travel Direction, 5.4, 9.4 

Travel Mode, 5.6 

travel speed/RPM, 9.8 

Travel start delay, 5.4, 9.4 

travel start delay - Step mode, 9.11 

Travel (Rotation) Step Mode, 9.11 

5 IPM is standard, 9.12 

travel speed (see RPM), 5.4 

Trial Weld, 12.3 

Tube cutters, 14.3 

Tube Installation to the weld head, 13.7 

Tube 1, 8.4 

Tube 2, 8.4 

Tungsten, 2.4 

ceriated, 15.1 

diameters, 15.3 

length calculation, 15.5 

melting point, 15.1 

Specifications, 15.1 

Taper angle, 15.4 

Tip Diameters, 15.4 

tungsten geometry, 15.2 

Tungsten Length and Geometry Table, 

15.3 

tungsten life, 15.4 

tungsten type, 15.1 

2% thoria, 15.1



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, 2.2 

System components are not waterproof, 

2.3 

welding arc emits ultra-violet (UV) radiation, 

2.2 

welding on sealed containers or pipes, 

2.2 

weld 

Weld Counter Reset, 10.5 

Weld Current., 1.1 

Weld ID, 18.3 

weld identification number, 18.2 

Weld Mode, 6.4, 11.2 

weld bead smoothness, 17.2 

weld data records, 6.17, 18.1, 18.3 

printing and exporting, 18.4 

Viewing or Exporting, 18.3 

Weld head notes, 18.11 

Weld Head Wizard, 18.11 

Weld heads 

automatic calibration, 13.2 

manual calibrataion, 13.3 

Model 8 weld heads, 13.6 

water-cooled version of the 9-500, 4.7 

Weld Head Data button, 6.11 

weld head installation, 4.6 

weld head selection., 8.3 

Weld heads operated by Model 307, 

1.1 

Weld Logging, 1.2 

Weld Problems, 12.4 

Weld Procedure Specification (QW-482), 

19.3 

weld record keeping, 10.1 


Rev.A 

weld schedule, 5.1, 17.2 

Copy and Paste a schedule, 

7.10 

delete schedule, 7.9 

example Step program, 8.8 

Main Weld Screen manual torch, 9.14 

paste schedule, 7.11 

rename schedule, 7.8 

Single Entry Manual, continuous, 9.5 

weld parameters, 17.2 

Weld Schedule - Main screen, 8.5, 11.1 

Weld Schedule - Single Entry, 8.6 

Weld Schedule - Weld Levels screen., 

8.6 

weld schedule counter and alert reset, 

10.5 

Weld Schedule Main Screen, 7.2 

Weld Schedule Main Screen (Tack 

weld), 8.14 

weld schedule name, 7.2, 8.2 

Weld Schedule- Single Entry (manual 

torch), 9.14 

Weld Schedule Single Entry, tack weld, 

8.14 

Weld Schedule Tacking Values, 8.13 

Weld Schedule Weld Levels (tack weld), 

8.15 

Weld Schedule Weld screen, 6.3, 11.2 

Weld Schedule Library, 7.1 

Weld Schedule Wizard, 7.7, 8.1 

Weld Time calculator, 6.16 

weldability, 17.4 

Welding Operator I.D. (see Logon name), 

6.18 

Welding Operator Performance Qualification 

(WOPQ), 19.3 

Welding Operator Qualification to ASME IX 

BPVC, 19.3 

Welding with the Model 307 

Open Last Schedule, 6.3, 11.1 

welds 

full penetration welds, 17.2 

test coupons, 10.5 

trial (partial) weld, 9.11 

weld criteria, 17.2 

weld defects, 17.2 

Numerics 

1/4” OD tubing, 9.12 

1/8” OD tubing, 9.12 

307 weld schedule sheet, 19.1

Chapter - Arc Machines, Inc.

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