Swagelok CWS-D100-1B, CWS-D100-2B User Manual

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WELDING SYSTEM

USER’S MANUAL

CWS-D100-1B CWS-D100-2B

The Swagelok Limited

Lifetime Warranty

Swagelok hereby warrants to the purchaser of this Product that the non-electrical components of the Product shall be free from defects in material and workmanship for the life of the Product. All electrical components installed in or on the Product are warranted to be free from defects in material and workmanship for twelve months from the date of purchase.

The purchaser’s remedies shall be limited to replacement and installation of any parts that fail through a defect in material or workmanship.

MANUFACTURER SPECIFICALLY DISAVOWS ANY OTHER REPRESENTATION, EXPRESS OR IMPLIED, WARRANTY, OR LIABILITY RELATING TO THE CONDITION OF USE OF THE PRODUCT, AND IN NO EVENT SHALL SWAGELOK BE LIABLE TO PURCHASER, OR ANY THIRD PARTY, FOR ANY DIRECT OR INDIRECT CONSEQUENTIAL OR INCIDENTAL DAMAGES.

Table of Contents

Foreword

Registration Information i. . . . . . . . . . . . . . . . . . . . . . . .

Safety Summary iii. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Statements iii. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Symbols iii. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Safe Practices and Safety Precautions vii. . . . . . . .

User Precautions ix. . . . . . . . . . . . . . . . . . . . . . . . . .

Power Supply Warning Label x . . . . . . . . . . . . . . . .

Referenced Specifications xi. . . . . . . . . . . . . . . . . . .

Section 1 Introduction SWS D100

Gas Tungsten Arc Welding 1-2. . . . . . . . . . . . . . . . . . . . . .

Principles of the GTAW Process 1-2. . . . . . . . . . . . .

GTAW Process Advantages 1-2. . . . . . . . . . . . . . . . .

Process Variables 1-3. . . . . . . . . . . . . . . . . . . . . . . . . .

System Components 1-4. . . . . . . . . . . . . . . . . . . . . . . . . . .

The SWS D100 Power Supply 1-4. . . . . . . . . . . . . . .

The Weld Head 1-5. . . . . . . . . . . . . . . . . . . . . . . . . . . .

Fixture Blocks 1-6. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Overview of SWS Operation 1-7. . . . . . . . . . . . . . . . . . . .

Specifications 1-9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Section 2 Installation

Introduction 2-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Tools and Accessory Requirements 2-2. . . . . . . . . . . . . .

Electrical Requirements 2-3. . . . . . . . . . . . . . . . . . . . . . . .

Input Voltage 2-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Using an Extension Cord 2-3. . . . . . . . . . . . . . . . . . . .

Unpacking and Inspecting System Components 2-4. . .

Unpacking the Power Supply 2-4. . . . . . . . . . . . . . . .

Unpacking the Weld Head Cable Assembly

and Related Components 2-5. . . . . . . . . . . . . . . . . . .

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Table of Contents

CWS−D100−B Welding System

Installing the SWS 2-6. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Installing the Power Supply 2-6. . . . . . . . . . . . . . . . . .

Installing the Weld Head 2-7. . . . . . . . . . . . . . . . . . . .

Installing the Gas Delivery System 2-9. . . . . . . . . . . . . . .

Introduction 2-9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Installing the Typical Shielding/Purge Gas

Delivery System 2-10. . . . . . . . . . . . . . . . . . . . . . . . . . .

Installing the Optional Gas Delivery System 2-12. . .

Preliminary Check 2-14. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Section 3 Operation

Introduction 3-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Front Panel Controls 3-2. . . . . . . . . . . . . . . . . . . . . . . . . . .

Current Control Switches 3-3. . . . . . . . . . . . . . . . . . . .

Timing Control Switches 3-4. . . . . . . . . . . . . . . . . . . .

Pushbuttons 3-6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Status Indicator Lights 3-8. . . . . . . . . . . . . . . . . . . . . .

Digital Displays 3-9. . . . . . . . . . . . . . . . . . . . . . . . . . . .

SWS Modes of Operation 3-9. . . . . . . . . . . . . . . . . . . . . . .

Operational Mode 3-12. . . . . . . . . . . . . . . . . . . . . . . . . .

Program Mode 3-17. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Test Mode 3-22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Installing the Electrode in the Series 5/10/20

Weld Head 3-26. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Selecting the Proper Electrode 3-26. . . . . . . . . . . . . . .

Inserting the Electrode into a Rotor 3-26. . . . . . . . . . .

Setting the Arc Gap 3-27. . . . . . . . . . . . . . . . . . . . . . . . . . . .

Setting the Arc Gap Gage 3-27. . . . . . . . . . . . . . . . . . .

Setting the Arc Gap 3-27. . . . . . . . . . . . . . . . . . . . . . . .

Preparing the Work 3-28. . . . . . . . . . . . . . . . . . . . . . . . . . . .

Fixturing the Work 3-29. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Selecting the Fixture Block and Collets 3-29. . . . . . . .

Installing the Collets in a Tube Fixture Block 3-29. . .

Aligning the Work Pieces in the Tube

Fixture Block 3-30. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Connecting the Purge Gas Line 3-32. . . . . . . . . . . . . .

Connecting the Weld Head to the Fixture Block 3-33. . . .

Safety Interlock 3-33. . . . . . . . . . . . . . . . . . . . . . . . . . . .

Mating the Weld Head to the Fixture Block 3-34. . . .

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CWS−D100−B Welding System

Entering the Weld Parameters 3-35. . . . . . . . . . . . . . . . . . .

Using a Weld Procedure Guideline 3-35. . . . . . . . . . .

Effects of Weld Parameters 3-36. . . . . . . . . . . . . . . . .

Setting the Shield Gas Flow 3-37. . . . . . . . . . . . . . . . . . . . .

Starting and Completing the Weld 3-37. . . . . . . . . . . . . . .

Display Indications During Welding 3-38. . . . . . . . . . .

After the Weld is Complete 3-39. . . . . . . . . . . . . . . . . .

Operation Summary 3-40. . . . . . . . . . . . . . . . . . . . . . . . . . .

Section 4 Micro Weld Heads CWS-4MRH-A,

CWS-4MFH-A, CWS-8MRH

Introduction 4-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Using the Micro Fixture Tool 4-3. . . . . . . . . . . . . . . . . . . . .

Installing the Motor Module 4-3. . . . . . . . . . . . . . . . . . . . .

Installing the Micro Weld Head 4-4. . . . . . . . . . . . . . . . . .

Installing/Replacing the Electrode 4-6. . . . . . . . . . . . . . . .

Setting the Arc Gap 4-8. . . . . . . . . . . . . . . . . . . . . . . . . . . .

Fixturing the Work 4-9. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Connecting the Micro Weld Head to the Fixture 4-11. . . .

Considerations During Welding 4-13. . . . . . . . . . . . . . . . . .

Using the Optional Bench Mounting Bracket 4-14. . . . . . .

Series 4 Bench Mount Bracket 4-14. . . . . . . . . . . . . . .

Series 8 Bench Mount Bracket 4-15. . . . . . . . . . . . . . .

Table of Contents

Section 5 Weld Parameter Adjustment

Introduction 5-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Developing a Weld Procedure Guideline 5-1. . . . . . . . . .

Determining the Work Specifications 5-2. . . . . . . . . .

Setting the Front Panel Switches 5-3. . . . . . . . . . . . .

Example Weld Procedure Guideline Worksheet 5-9

Weld Procedure Guideline Worksheet 5-10. . . . . . . .

Evaluating the Weld 5-16. . . . . . . . . . . . . . . . . . . . . . . . . . . .

Identifying Typical Weld Discontinuities 5-16. . . . . . .

Identifying Proper Welds 5-17. . . . . . . . . . . . . . . . . . . .

Adjusting Controls for Weld Quality 5-22. . . . . . . . . . . . . .

Section 6 Maintenance

Introduction 6-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Series 5/10/20 Fixture Blocks 6-2. . . . . . . . . . . . . . . . . . .

Daily Maintenance 6-2. . . . . . . . . . . . . . . . . . . . . . . . .

Forty-Hour Maintenance 6-2. . . . . . . . . . . . . . . . . . . .

Micro Weld Head Fixture Blocks 6-3. . . . . . . . . . . . . . . . .

Daily Maintenance 6-3. . . . . . . . . . . . . . . . . . . . . . . . .

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CWS−D100−B Welding System

Series 5/10/20 Weld Head 6-4. . . . . . . . . . . . . . . . . . . . . .

Daily Maintenance 6-4. . . . . . . . . . . . . . . . . . . . . . . . .

Forty-Hour Maintenance 6-4. . . . . . . . . . . . . . . . . . . .

Series 5/10/20 Weld Head Disassembly

and Cleaning 6-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Series 5/10/20 Weld Head Assembly 6-9. . . . . . . . .

Micro Weld Heads 6-10. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Daily Maintenance 6-10. . . . . . . . . . . . . . . . . . . . . . . . .

Eight-Hour Maintenance 6-11. . . . . . . . . . . . . . . . . . . .

Micro Weld Head Assembly 6-15. . . . . . . . . . . . . . . . .

Power Supply 6-15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Fuse Inspection and Replacement 6-15. . . . . . . . . . .

Section 7 Troubleshooting

Introduction 7-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Swagelok Welding System (SWS) Repair Procedure 7-1

Repair/Replacement Instructions 7-2. . . . . . . . . . . . .

Appendix A Glossary

Appendix B Optional Equipment

SWS Remote Pendant B-2. . . . . . . . . . . . . . . . . . . . . . . . .

Weld Head Extension Cables B-3. . . . . . . . . . . . . . . . . . .

Data Logging/Monitoring B-4. . . . . . . . . . . . . . . . . . . . . . . .

Data Recording Printer B-6. . . . . . . . . . . . . . . . . . . . . . . . .

Introduction B-6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Unpacking and Inspection B-6. . . . . . . . . . . . . . . . . . .

Installation B-6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Operating the Printer B-9. . . . . . . . . . . . . . . . . . . . . . .

Maintenance B-15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Using a Standard RS-232 Printer B-16. . . . . . . . . . . . .

Appendix C Electrode Selection Tables

and Geometry

CWS-4MRH-A, CWS-4MFH-A

Micro Weld Heads C-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CWS-8MRH Micro Weld Head C-1. . . . . . . . . . . . . . . . . . .

CWS-5H-B Weld Head C-2. . . . . . . . . . . . . . . . . . . . . . . . .

CWS-10H-A Weld Head C-2. . . . . . . . . . . . . . . . . . . . . . . .

CWS-20H-A/B Weld Head C-3. . . . . . . . . . . . . . . . . . . . . .

Electrode Geometry C-3. . . . . . . . . . . . . . . . . . . . . . . . . . . .

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September 2005

CWS−D100−B Welding System

Appendix D Weld Head Information

MICRO WELD HEAD − TUBE WELDING D-2 . . . . . . . . .

SERIES 5 WELD HEAD − TUBE WELDING D-2 . . . . . . .

SERIES 10 WELD HEAD − TUBE WELDING D-3 . . . . .

SERIES 20 WELD HEAD − TUBE WELDING D-3 . . . . .

SERIES 20 WELD HEAD − PIPE WELDING D-4 . . . . . .

MICRO WELD HEAD − TUBE WELDING D-4 . . . . . . . . .

SERIES 5 WELD HEAD − TUBE WELDING D-5 . . . . . . .

SERIES 10 WELD HEAD − TUBE WELDING D-5. . . . .

SERIES 20 WELD HEAD − TUBE WELDING D-6. . . . .

Appendix E Arc Gap Gage Setting Tables

Wall Thickness and Arc Gap E-1. . . . . . . . . . . . . . . . . . . .

Weld Head Arc Gap Gage Setting Tables E-2. . . . . . . . .

Arc Gap Gage Setting Tables

for Swagelok ATW Fittings E-11. . . . . . . . . . . . . . . . . . . . . .

Arc Gap Gage Setting Formula E-12. . . . . . . . . . . . . . . . . .

Table of Contents

Appendix F Parts Drawings

Appendix G Gas Flow Rate Tables

Purge Rate and Pressure Tables G-1. . . . . . . . . . . . . . . .

Purge Rate and Pressure Tables Continued G-2. . . . . . .

General Suggested Shielding

Gas Flow Rates (Argon) G-2. . . . . . . . . . . . . . . . . . . . . . . .

Appendix H Fixture Block Alignment

Series 5 Fixture Block H-1. . . . . . . . . . . . . . . . . . . . . .

Series 20H-B Fixture Block H-5. . . . . . . . . . . . . . . . . .

Series 8 Micro Weld Head Fixture H-6. . . . . . . . . . . .

Appendix I Weld Procedure Guidelines

Index

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Table of Contents

CWS−D100−B Welding System

TOC−6

September 2005

Foreword

Registration Information

Your Swagelok representative can provide support and service of your Swagelok Welding System (SWS) as well as local stock of precision fittings and valves.

Please take a moment to fill out the warranty information form as well as the information listed below. Keep this information available in case you need to contact your Swagelok representative.

Power Supply:

Model Number*: Serial Number*: Delivery Date:

* See rating label on the rear of the unit, shown in Figure 1.

Weld Head(s): Weld Head:

Model Number: Serial Number: Delivery Date:

Model Number:

Figure 1 Rating Label

Serial Number: Delivery Date:

Foreword

CWS−D100−B Welding System

September 2005

CWS−D100−B Welding System

Safety Summary

The safety information presented here pertains to both

the Swagelok Gas Tungsten Arc Welding (GTAW).

Read Operating Instructions

Read all of the instructions in this manual prior to operating the SWS.

Statements

Welding System (SWS) and the process of

Foreword

Caution!

Statements identify conditions or practices that could result in damage to the equipment or other property.

WARNING!

Statements identify conditions or practices that could result in personal injuries or loss of life.

Symbols

The following symbols are used in this manual and on the equipment to visually identify where warning or caution information is found. Consult symbols and related instructions below for necessary actions to avoid the hazards.

WARNING or Caution

This symbol identifies the location of all other types of warning or caution information which don’t have specific symbols. Accompanying text will identify the specific nature of the condition and if the condition is a warning or caution.

iii

Foreword

CWS−D100−B Welding System

ELECTRIC SHOCK can kill.

Touching live electrical parts can cause fatal shocks and severe burns. Incorrectly installed or improperly grounded equipment is a hazard.

D Do not touch live electrical parts D No user serviceable parts in the power supply other

than a fuse. Refer all other power supply servicing to your Authorized Swagelok representative.

D Keep all panels and covers securely in place. Do

not touch electrode connector, electrode, or rotor after pressing start. The electrode is live during the weld cycle.

D Verify that the power supply is properly grounded

before use. Make sure the power cord is plugged into a properly wired and grounded receptacle.

D Follow local electrical codes and the guidelines in

the manual when installing the SWS. Failure to do so may create an electrical shock hazard. Shock hazards can exist even when equipment is properly installed, so it is important that the operator be trained in the proper use of the equipment and follow established safety practices.

D Frequently inspect input power cord for damage or

bare wiring – replace immediately if damaged.

D Properly unplug the power cord. Grasp the plug to

remove it from the receptacle.

D Do not use extension cords that are in poor physical

condition or have insufficient current capacity. Failure to do so can pose fire and shock hazards.

September 2005

CWS−D100−B Welding System

FUMES AND GASES can be hazardous.

Welding produces fumes and gases. Breathing these fumes and gases can be hazardous to your health. Build−up of gases can displace oxygen and cause injury or death.

D Do not breathe fumes or gases. D If inside, ventilate the area and/or use exhaust at the

arc to remove welding fumes and gases.

D If ventilation is poor, use an approved air-supplied

respirator.

D Read the Material Safety Data Sheets (MSDSs) and

the manufacturer’s instructions for metals, consumables, coatings, cleaners, and degreasers.

D Work in a confined space only if it is well

ventilated or while wearing an air−supplied respirator. Always have a trained watch−person nearby. Welding fumes and gases can displace air and lower the oxygen level causing injury or death. Be sure the breathing air is safe.

Foreword

D Do not weld in locations near degreasing, cleaning,

or spraying operations. The heat and rays of the arc can react with vapors to form highly toxic and irritating gases.

D Do not weld on coated metals, such as galvanized,

lead, or cadmium plated steel, unless the coating is removed from the weld area, the area is well ventilated, and if necessary, while wearing an air−supplied respirator. The coatings and any metals containing these elements can give off toxic fumes if welded.

D The ultraviolet light emitted by the welding arc acts

on the oxygen in the surrounding atmosphere to produce ozone. Test results1 , based upon present sampling methods, indicate the average concentration of ozone generated in GTAW process does not constitute a hazard under conditions of good ventilation and welding practice.

1 WELDING HANDBOOK, VOLUME 2, 8TH EDITION,

AMERICAN WELDING SOCIETY.

D Shut off shielding gas supply when not in use.

Foreword

CWS−D100−B Welding System

ARC RAYS can burn eyes. NOISE can damage hearing.

Arc rays from the welding process produce intense visible and invisible (ultraviolet and infrared) rays that can burn eyes. The SWS is meant for use only with enclosed weld heads which minimize exposure to these harmful rays.

D Do not look at welding arc. D Use protective screens or barriers to protect

others from flash and glare; warn others not to watch the arc.

D Wear approved ear protection if noise level

is high.

WELDING can cause fire or explosion.

Welding on closed containers, such as tanks, drums, or pipes, can cause them to blow up. The hot work piece and hot equipment can cause fires and burns. Check and be sure the area is safe before doing any welding.

D Protect yourself and others from the

hot work piece.

D Watch for fire, and keep a fire

extinguisher nearby.

D Do not weld on closed containers such as tanks,

drums, or pipes, unless they are properly prepared according to AWS F4.1.

D Do not use welder to thaw frozen pipes. D Do not use extension cords that are in poor physical

condition or have insufficient current capacity. Failure to do so can pose fire and shock hazards.

September 2005

CWS−D100−B Welding System

Safe Practices and Safety Precautions

READ ANSI Z49.1

Safety and safe practices in welding, cutting and allied processes are covered in ANSI Z49.1, SAFETY IN WELDING AND CUTTING. When using the SWS, follow all basic safety practices.

CYLINDERS can explode if damaged.

Shielding gas cylinders contain gas under high pressure. If damaged, a cylinder can explode. Since gas cylinders are normally part of the welding process, be sure to treat them carefully.

D Protect compressed gas cylinders from excessive

heat, mechanical shocks, slag, open flames, sparks, and arcs.

Foreword

WARNING! SHIELDING GAS CYLINDERS

CAN EXPLODE IF DAMAGED OR IMPROPERLY TREATED.

D Install cylinders in an upright position by securing

to a stationary support or cylinder rack to prevent falling or tipping.

D Keep cylinders away from any welding or other

electrical circuits.

D Never weld on a pressurized cylinder − explosion

will result.

D Use only correct shielding gas cylinders, regulators,

hoses, and fittings designed for the specific application; maintain them and associated parts in good condition.

D Turn face away from valve outlet when opening

cylinder valve.

D Keep protective cap in place over valve except

when cylinder is in use or connected for use.

D Read and follow instructions on compressed gas

cylinders, associated equipment, and CGA publication P−1 listed in Safety Standards.

vii

Foreword

CWS−D100−B Welding System

WARNING! SHIELDING GAS CYLINDERS

CAN EXPLODE IF DAMAGED OR IMPROPERLY TREATED.

WARNING! PACEMAKER WEARERS

KEEP AWAY.

HOT PARTS can cause severe burns.

After welding, the work piece, weld head, and electrode can be extremely hot and may cause burns.

MAGNETIC FIELDS can affect pacemakers.

D Pacemaker wearers keep away. D Wearers should consult their doctor before going

near welding operations.

viii

September 2005

CWS−D100−B Welding System

User Precautions

Foreword

D Power Supply Grounding

The power supply is grounded through the ground connector of the power cord. Avoid electrical shock by making sure the power cord is plugged into a properly wired and grounded receptacle before turning the unit on.

D Water and Moisture

System components are not waterproof. Do not expose the SWS equipment to water.

D Proper Use and Storage

Do not store or use near hazardous materials. Store indoors and cover the system when not in use.

D Weld Heads

Disconnect the weld head completely from the power supply prior to servicing.

WARNING! VERIFY THAT THE SYSTEM

IS PROPERLY GROUNDED BEFORE USE.

User service, including cleaning or component replacement, is limited to those operations identified in this manual.

D Fixture Blocks

Disconnect the fixture block from the weld head prior to servicing. User service, including cleaning or component replacement, is limited to those operations identified in this manual.

D Power Supply Service

There are no user serviceable parts in the power supply other than a fuse. Refer all other servicing to your Authorized Swagelok sales and service representative.

WARNING! USERS SHOULD NOT

SERVICE THE POWER SUPPLY.

Foreword

CWS−D100−B Welding System

Power Supply Warning Label

This warning label is affixed to the power supply.

September 2005

CWS−D100−B Welding System

Referenced Specifications

1. AWS F4.1, Recommended Safe Practices for the Preparation

for Welding and Cutting of Containers and Piping.

American Welding Society, 550 N.W. LeJeune Rd, Miami, FL 33126 (www.aws.org

2. ANSI Z49.1, Safety in Welding Cutting, and Allied Processes.

American Welding Society, 550 N.W. LeJeune Rd, Miami, FL 33126 (www.aws.org

3. CGA Publication P−1, Safe Handling of Compressed Gases

in Cylinders.

Compressed Gas Association, 4221 Walney Road, 5th Floor, Chantilly VA 20151−2923, ( www.cganet.com

Foreword

4. OSHA 29CFR 1910 Subpart Q, Welding Cutting, and Brazing.

Acquire from U.S. Government Printing Office, Superintendent of Documents, P.O. Box 371954, Pittsburgh, PA 15250 (www.osha.gov

5. OSHA 29CFR 1926 Subpart J, Welding and Cutting.

Acquire from U.S. Government Printing Office, Superintendent of Documents, P.O. Box 371954, Pittsburgh, PA 15250 (www.osha.gov

Foreword

CWS−D100−B Welding System

xii

September 2005

Section 1 Introduction SWS D100

The Swagelok Welding System (SWS) is a versatile, portable and easy to use orbital welding system. This section includes

D gas tungsten arc welding D system components D overview of SWS operation D specifications.

Figure 1-1 Swagelok Welding System

1-1

Introduction

CWS−D100−B Welding System

The purpose of this manual is to familiarize you with the SWS and to provide the reference information needed to produce high-quality, repeatable welds.

While reading, you may encounter unfamiliar terminology. Some terms are common to the welding industry and others particular to the SWS. Refer to Appendix A, Glossary, if necessary.

Gas Tungsten Arc Welding

Principles of the GTAW Process

Gas Tungsten Arc Welding (GTAW) is a welding process that creates an arc between a nonconsumable tungsten (or tungsten alloy) electrode and the work. The electrode is held in a torch, rotor, or other device. GTAW uses a shielding gas, most commonly Argon, that is delivered to the weld area. The shielding gas envelops the weld joint and electrode, protecting both from contamination by the atmosphere.

The electric arc which creates the weld is produced by the passage of current through the conductive ionized shielding gas. The arc is established between the tip of the electrode and the work. Heat generated by the arc melts the base metal. Once the arc and weld puddle are established, the electrode moves along the joint and the arc progressively melts the joint surface. Filler wire, if used, is added to the leading edge of the weld puddle to fill the joint.

GTAW provides precise control of heat input to the weld joint. For this reason, it is preferred for joining thin gage metals and for making welds close to heat sensitive components. The process offers advantages to many industries, ranging from the high purity required in the semiconductor industry to autogenous manual welds of the process industry.

The process can be used to weld almost all metals. GTAW can be used to weld all types of joint geometries in tubing, pipe, or other structural shapes. It is particularly appropriate for welding wall sections less than 3/8 in. (9,5 mm) thick.

GTAW Process Advantages

The GTAW process has the following advantages:

D produces superior quality welds D allows excellent control of weld penetration D welds almost all metals D produces autogenous welds at high speeds D allows precise control of the welding variables D welds with or without filler metal D eliminates spatter

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September 2005

CWS−D100−B Welding System

Process Variables

The major process variables in GTAW are arc current, arc voltage, and travel speed.

D Arc Current − The current measured between the tungsten electrode and the work.

Generally stated, arc current controls the weld penetration. Direct Current Electrode Negative (DCEN) is common for GTAW. It offers the

advantages of deep penetration and fast welding speeds because most of the heat generated in the welding process is transferred to the work.

D Arc Voltage − The voltage measured between the tungsten electrode and the work.

Arc voltage is affected by the following:

D arc current D shape of the tungsten electrode tip D type and purity of shielding gas

Introduction

D arc length (distance between the electrode and the work)

Arc length is important with this process because it affects the width of the weld puddle; puddle width is proportional to arc length. The desired arc length is as short as possible.

D Travel Speed − The speed that the electrode moves over the work while welding.

Travel speed affects both the width and weld penetration of GTAW. Its effect on width is more pronounced than on penetration. Increasing travel speed decreases the width of the weld.

Travel speed generally is fixed in mechanized welding. Other variables such as current or voltage are varied to maintain control of the weld.

1-3

Introduction

CWS−D100−B Welding System

System Components

The SWS D100 Power Supply

The power supply features microcontroller electronics and closed-loop circuitry to precisely control output current. Simplified controls and displays provide efficient programming and monitoring of the welding process.

See Table 1-1 on page 1-9 for the power supply specifications.

Figure 1-2 SWS D100 Power Supply

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September 2005

CWS−D100−B Welding System

The Weld Head

The SWS weld heads deliver consistent, precise welds for outside diameters from 1/16 in. to 2 in. (3 mm to 52 mm). There are six weld heads to choose from, depending on the size of the work pieces. See Figure 1-3.

A dc motor in the weld head drives a rotor which carries the tungsten electrode around the weld joint. Optical circuitry in the weld head sends precise feedback to the power supply to control the speed of the rotor.

All moving parts in the weld head mount in low-friction devices to provide smooth, consistent operation.

A spring-loaded, floating brush continuously contacts approximately one-third of the circumference of the rotor at all times. This configuration ensures consistent, uniform electrical conductance to the rotor and electrode.

Introduction

See Table 1-5 on page 1-10 for the weld head specifications.

Series Micro Motor Module

Series 4 Micro (Rigid)

Series 4 Micro (Flexible)

Series 5Series 20 Series 10

Series Micro Motor Module

Series 8 Micro

Figure 1-3 Weld Heads

1-5

Introduction

CWS−D100−B Welding System

Fixture Blocks

The SWS fixture blocks accurately align and hold tubing, fittings, and valve bodies. The modular design allows you to select different side plates and create the configuration needed for the job.

The fixture block is separate from the weld head, allowing work pieces to be easily aligned and fixtured before welding. The use of multiple fixture blocks offers increased productivity.

Each fixture block is designed to accommodate a range of work piece sizes. A unique and patented Universal Collet Insert (UCI) fits into the fixture block to match the diameter of the work piece. The collet design firmly holds tubing and fittings that vary ± 0.005 in. (0,13 mm) from nominal outside diameter. Collets are also available for thin wall pipe. The collets exchange quickly, making the fixture block very adaptable to changing work requirements. Tables 1-6, 1-7, and 1-8 list the available fixtures and collets.

Series 20-A Series 10

Series 20-B

Series 8

Series 4

Series 5

1-6

Figure 1-4 Standard Fixtures

September 2005

CWS−D100−B Welding System

Overview of SWS Operation

GTAW Orbital welding is a proven method for welding cylindrical shapes such as tubes, fittings, and pipe. The SWS design makes the orbital welding process efficient and effective.

The SWS provides an advanced method of autogenous GTAW. The system uses a fixture block and associated weld head to provide precise fixturing of the work pieces. The welding parameters are controlled by the SWS power supply and are programmed by the operator.

Operating the SWS is uncomplicated. The work piece sizes define the fixture block configuration, collets, and weld head to be used.

The fixture block quickly clamps onto the work pieces. The weld joint is centered in the fixture block using a centering gage. Since the fixture block is not part of the weld head, multiple fixture blocks can be used to maximize weld setup efficiency.

Introduction

The weld head cable assembly attaches quickly to the power supply. Setup of the weld head is limited to the selection of an electrode and setting the arc gap. The arc gap setting depends on the characteristics of the work pieces. A gage is provided with the weld head to assist in setting the arc gap. After the arc gap is set, the weld head attaches to the fixture block and is secured with a locking ring.

The power supply uses rotary switches for weld parameter control. See Figure 1-5. The appropriate switch settings are generally defined by the work pieces to be welded and are refined using test welds. The correct settings used for a specific job are developed into a weld procedure guideline. The guideline is used to maintain repeatability and quality control for subsequent jobs of the same type.

1-7

Introduction

CWS−D100−B Welding System

Figure 1-5 SWS D100 Front Panel Controls

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September 2005

CWS−D100−B Welding System

Specifications

Table 1-1 Power Supply

Model Supply Voltage* Service Amps Output Current (dc)

CWS-D100-1B 115 V (ac) 20 A 2 to 100 A CWS-D100-1B 115 V (ac) 15 A 2 to 70 A CWS-D100-2B 230 V (ac) 15 A 2 to 100 A

* 10% input voltage tolerance, frequency range 50 Hz to 60 Hz

Table 1-2 Duty Cycle

Model 6.25 % 60 % 100 %

CWS-D100-1B 100 Amps

14 Volts

CWS-D100-2B 100 Amps

14 Volts

32.3 Amps

11.3 Volts

32.3 Amps

11.3 Volts

25 Amps

11 Volts

25 Amps

11 Volts

Introduction

Duty cycle is the ratio of time the power supply can weld to the time the power supply must remain idle to cool. The 10 minute cycle is a recognized welding industry standard. It represents the maximum weld time allowed, with the balance of the 10 minute cycle required for cooling.

Table 1-3 10 Minute Cycle Times

Maximum Weld TIme

Duty Cycle Rating

30 % 3 7 60 % 6 4

100 % 10 0

(Minutes)

Required Idle Time

(Minutes)

Continually exceeding the duty cycle may activate an internal thermal protector that will disable the power supply and display message code 50. Refer to pages 3-13 and 3-15.

Table 1-4 Power Supply Dimensions and Weight

Model Dimensions (overall) Weight

CWS-D100-1B 15 1/2 in. (39 cm) wide

20 in. (51 cm) deep

9 in. (23 cm) high (without handle)

CWS-D100-2B 15 1/2 in. (39 cm) wide

20 in. (51 cm) deep

9 in. (23 cm) high (without handle)

42 lbs (19 kg)

45 lbs (20.4 kg)

1-9

Introduction

CWS−D100−B Welding System

Table 1-5 Weld Heads

Series Model OD Capacity

4 Micro* CWS-4MRH-A

CWS-4MFH-A

8 Micro* CWS-8MRH 1/4 to 1/2 in.

5 CWS-5H-B 1/8 to 5/8 in.

10 CWS-10H-A 1/4 to 1 in.

20 SWS-20H-B** 1/2 to 2 in.

* Requires CWS-M-MTR-A motor module ** Requires SWS-20TFB-A

1/16 to 1/4 in.

(3 to 6 mm)

(6 to 12 mm)

(3 to 16 mm)

(6 to 25 mm)

(12 to 52 mm)

Table 1-6 Standard Fixture Blocks

Minimum Weld

Model OD Capacity

CWS-4MFA-** 1/16 to 1/4 in.

(3 to 6 mm)

SWS-8MFA-** 1/4 to 1/2 in.

(6 to 12 mm)

CWS-5TFB 1/8 to 5/8 in.

(3 to 16 mm)

CWS-10TFB 1/4 to 1 in.

(6 to 25 mm)

CWS-20TFB 1/2 to 2 in.

(12 to 52 mm)

SWS-20TFB-A 1/2 to 2 in.

(12 to 52 mm)

** Designates size in 1/16ths or mm; 4MFA- includes sizes 01, 02, 04, 3

mm, and 6 mm. 8MF- includes sizes 04, 06, 08, 6 mm, 8 mm, 10 mm, and 12 mm

Extension Length

1/4 in. (6 mm)

3/4 in. (19 mm)

(recessed)

15/16 in. (24 mm)

(no recess)

1 3/8 in. (35 mm)

1.45 in. (37 mm)

1-10

September 2005

CWS−D100−B Welding System

Table 1-7 Special Purpose Fixture Side Plates

Model Used for Comments

CWS-5FSP1

CWS-5FSP2

CWS-5HBDA-BW4 CWS-5HBDA-BW6 CWS-5HBDA-BW6MM

SWS-20FSP1L tubular weld fittings

SWS-20FSP1R tubular weld fittings

* DA − manual actuator only



VCR

, S Type

, VCO



VCR

B Type VCO fittings,

and tubing

Micro-Fit fittings

and tubing

BN, DL, DS,

HD, HB, DA* style

valve bodies

and tubing

Introduction

weld extension length must be less than 0.75 in. (19 mm)

requires adapter inserts

requires Micro-Fit fitting collets

1/4 in., 3/8 in., or 6 mm tubular weld fittings and tubing butt weld ends

0.80 in. (20 mm) weld extension length

requires SWS-20UCI-XXTN collets

0.80 in. (20 mm) weld extension length

requires SWS-20UCI-XXTN collets

Table 1-8 Collets

Model OD Capacity Comments

CWS-5UCI-** 1/8 in. to 5/8 in.

(3 mm to 16 mm)

CWS-5UFCI-.95 n/a fixture collets to hold adapter inserts for

CWS-5UFCI-** 1/8 in. to 5/8 in.

(3 mm to 16 mm) CWS-5MWCI-04 1/8 in., 1/4 in., 6 mm for Micro-Fit fittings CWS-5MWCI-06 3/8 in., 8 mm, 10 mm for Micro-Fit fittings CWS-5MWCI-08 1/2 in., 12 mm for Micro-Fit fittings CWS-10UCI-** 1/4 in. to 1 in.

(6 mm to 25 mm) CWS-20UCI-** 1/2 in. to 2 in.

(12 mm to 52 mm)

CWS-20UCI-**P 1/4 in. to 1 1/2 in.

(10.2 mm to 48.3 mm)

SWS-20UCI-**TN 1/2 in. to 2 in.

(12 mm to 52 mm)

SWS-20UCI-MC n/a collet to hold ferrule mandrels for

** − Identifies the collet size in 1/16ths or metric (MM suffix)

tubing add “mm” suffix for metric sizes.

CWS-5FSP1 side plate tube collet for special purpose side plates

tubing

pipe add J suffix for JIS pipe (-**PJ) add MMP suffix for metric pipe (-**MMP)

tubular weld fitting collet for SWS-20FSP1L and SWS-20FSP1R

add MM (MMTN) suffix for metric sizes

SWS-20TFB-A fixture block

1-11

Introduction

CWS−D100−B Welding System

Table 1-9 Adapter Inserts for CWS-5FSP1

Model Used for Comments

CWS-5MBVCO-04 316L-4-BVCO-1

316L-4-VCO-1-4TB2

1/4 in. VCR weld glands

CWS-5FVCR-04 1/4 in. VCR

weld glands

CWS-5FBVCO-04 316L-4-BVCO-3

1/4 in. VCR weld glands

CWS-5MSVCR-04 6LV-4-SVCR-3 with captured male

CWS-5FSVCR-04 6LV-4-SVCR-3S

6LV-4-SVCR-3

glands must have overall length of

1.12 in. (28 mm) or less with captured male nut SS-4-SVCR-4

glands must have overall length of

0.72 in. (18 mm) or less with captured female nut SS-4-VCR-1

glands must have overall length of

0.77 in. (20 mm) or less with captured female nut SS-4-VCR-1

nut SS-4-SVCR-4 with captured female

nut SS-4-SVCR-1

WARNING! DO NOT USE EXTENSION

CORDS THAT ARE IN POOR PHYSICAL CONDITION OR HAVE INSUFFICIENT CURRENT CAPACITY. FAILURE TO DO SO CAN POSE FIRE AND SHOCK HAZARDS.

Table 1-10 Extension Cords

Wire gauge 0 ft to 50 ft

Model Supply Voltage

CWS-D100-1B 115 V (ac) #12 AWG

CWS-D100-2B 230 V (ac) #12 AWG

Some power loss will occur, depending on the length of the extension cord. See Table 1-10 to determine the minimum wire size to use.

(0 m to 15 m)

(2,5 mm)

Wire gauge

50 ft to 100 ft

(15 m to 30 m)

#10 AWG

(4,0 mm)

#10 AWG

(4,0 mm)

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September 2005

Section 2 Installation

Introduction

This section describes the procedures necessary for installing the Swagelok Welding System (SWS). This section includes:

D tools and accessory requirements D electrical requirements D unpacking and inspecting system components D installing the SWS D installing the gas delivery system D preliminary check.

2-1

Installation

CWS−D100−B Welding System

Tools and Accessory Requirements

You need the following tools and accessories to install and operate your SWS.

Tool/Accessory Included? Provided With

Hex Wrenches (0.050 in. to 5/32 in.) Yes Weld Head Electrode Package Yes Weld Head Arc Gap Gage Yes Weld Head Flat Blade Screw Driver Yes Weld Head Centering Gage Yes Fixture Block Quick−Connect Stem Yes Power Supply Secondary Solenoid Bypass Plug Yes Power Supply Dial/Digital Calipers or Micrometer No − Purge Connector(s) No −

(3)

(1)

(2)

No − No − No −

Shielding/Purge gas lines Shielding/Purge Gas Source Pressure Regulator Internal Purge Gas Flow Meter No − Shielding Gas Flow Meter No −

(1)

All lines used for shielding/purge gas should be the low moisture

absorption type.

(2)

A compressed gas bottle or liquid Dewar source can be used.

Argon is the gas most frequently used.

(3)

A two-stage gas regulator is suggested. The regulator should

reduce the source pressure to 25 psig to 50 psig (1.9 bar to

3.5 bar) for the arc shielding and internal (backing) purge flow meters.

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September 2005

CWS−D100−B Welding System

Electrical Requirements

Input Voltage

Table 2-1 lists the electrical requirements for the power supply.

Table 2-1 Power Supply Electrical Requirements

Installation

Power Supply

Model

CWS-D100-1B 115 V* (ac) 20 A CWS-D100-2B 230 V (ac) 15 A * If the input voltage is 100 V or less, the output power

capabilities may be reduced.

Voltage

Requirement

Service Current

Ensure that the following guidelines are adhered to when considering the electrical requirements for the power supply:

D All wiring and related components must

be installed according to local and National Electrical Codes.

D The power supply must be grounded. D A dedicated electrical circuit must be used.

Using an Extension Cord

WARNING! THE POWER SUPPLY MUST

BE GROUNDED. IF IT IS NOT GROUNDED, ELECTRIC SHOCK CAN OCCUR.

If it is necessary to use an extension cord, follow these guidelines:

D The wire size must meet the specifications

indicated in Table 1-10, located in Section 1, Introduction.

D If the length of the cord is greater than 100 ft,

call your Swagelok representative for recommended guidelines.

Note: The voltage drop in an extension cord 100 ft long may affect the output performance of the SWS.

2-3

Installation

CWS−D100−B Welding System

Unpacking and Inspecting System Components

Unpacking the Power Supply

The SWS power supply is packaged in a wooden shipping container. See Figure 2-1. The power supply part number and serial number are located on a label on the outside of the container.

Note: Keep the shipping container and the foam inserts for storing and/or shipping.

Table 2-2 lists the contents of the shipping container.

Table 2-2 Shipping Container Contents

Part Description Part No. Qty.

Welder Power Supply CWS-D100-*B 1 Power Cord CWS-CORD-* 1 1/4 in. Male QC SS-QC4-S-400 1 Secondary Solenoid Bypass Plug − 1 Swagelok Welding System

User’s Manual

* Denotes Model ** Denotes Language

CWS-MANUAL-D100B-** 1

Remove the contents of the shipping container by performing the following steps:

1. Remove the following items:

D Swagelok Welding System User’s Manual D Swagelok Quick-Connect stem D secondary solenoid bypass plug D power cord

Figure 2-1 Shipping Container

2-4

2. Remove the power supply by lifting it by the handle. Remove the side foam inserts. Place the power supply on a stable cart, platform, or table.

3. Check the power supply and accessories for damage.

4. Check that the serial number on the rear panel of the power supply matches the serial number on the shipping container label.

5. Record the model and serial numbers, and the delivery dates on page i of the Forward section of this user’s manual.

September 2005

CWS−D100−B Welding System

Unpacking the Weld Head Cable Assembly and Related Components

The following weld head components are packaged in a foam-lined shipping container:

D weld head assembly D arc gap gage D electrode package D tool package

1. Inspect the container for damage.

2. Remove the components from the container.

Installation

3. Check the items for any damage.

4. Verify that the weld head serial number matches the serial number on the shipping container.

5. Record the model and serial numbers, and the delivery dates on page i of the Forward section of this user’s manual.

2-5

Installation

CWS−D100−B Welding System

Installing the SWS

To get the maximum performance and reliability from your SWS, it must be set up and installed properly.

Figure 2-2 Power Cord Receptacle

This section describes how to

D install the power supply D install the weld head.

Installing the Power Supply

To install the power supply, follow these steps:

1. Place the power supply in a position such that the front and rear panel controls are easily accessible.

2. Locate the power cord. Insert the cord into the polarized receptacle on the rear of the power supply. See Figure 2-2.

3. Tighten the connector lock at the base of the receptacle to secure the cord in the receptacle.

Figure 2-3 Power Supply Circuit

Breaker in the OFF Position

4. Ensure that the power cord reaches an electrical outlet. Do not connect the power cord to the outlet at this time.

5. Turn off the circuit breaker. Refer to Figure 2-3.

2-6

September 2005

CWS−D100−B Welding System

Installation

Installing the Weld Head

The weld head assembly has four connectors that plug into the power supply. See Figure 2-4.

The four connectors on the cable are

D fixture D electrode (red) D work (green) D weld head shielding gas.

Connect the four connectors to the rear panel of the power supply by performing the following steps (see Figure 2-5):

1. Locate the weld head assembly.

Fixture

Electrode

Work

Weld Head

Shielding Gas

Figure 2-4 Weld Head Assembly

Figure 2-5 Weld Head Connectors

2-7

Installation

CWS−D100−B Welding System

Caution! Ensure that the fixture

connector is fully seated in the mating socket and the threaded sleeve is tight.

Note: The weld head shielding gas connector must be a single-end shut-off (SESO) Swagelok Quick-Connect stem (SS-QC4-S-400).

2. Align the notch on the multi-pin connector with the small tab in the mating socket on the rear panel labelled

FIXTURE. Insert the connector in the socket. Turn the

connector sleeve clockwise by hand until it is tight. This connection provides the control signals to drive the weld head.

3. Insert and fully seat the red connector into the socket on the rear panel labelled

ELECTRODE. Twist the

connector 1/4-turn clockwise to lock it into place. This connection is the negative (−) output terminal of the weld head.

4. Insert the green connector into the socket on the rear panel labelled

WORK. Twist the connector 1/4-turn

clockwise to lock it into place. This connection is the positive (+) output terminal of the weld head.

5. Insert the weld head shielding gas connector into the Swagelok Quick-Connect stem labelled

TO WELD HEAD. Ensure that the connector is firmly

attached. This connection provides shielding gas to the weld head through a solenoid valve in the power supply.

2-8

September 2005

CWS−D100−B Welding System

Installing the Gas Delivery System

Introduction

The Gas Delivery System reduces oxidation or contamination to the weld puddle, tungsten electrode, and Heat Affected Zone (HAZ).

There are two types of gas delivery systems commonly used:

D typical Gas Delivery System

Refer to the installation procedure beginning on page 2-10.

Installation

D gas delivery system using a secondary shielding

gas solenoid valve Refer to the installation procedure beginning on

page 2-12.

2-9

Installation

CWS−D100−B Welding System

Installing the Typical Shielding/Purge Gas Delivery System

Install the Shielding/Purge Gas Delivery System. Figure 2-6 shows a typical system. Be sure to adhere to the following precautions:

D Ensure that the gas storage container(s) are secured

before using them.

D Ensure all connections are tight and do not leak. D Use only a Swagelok single-ended shut-off

Quick-Connect stem on the shield/purge line for the shielding gas connector.

D Adjust the low-pressure regulator gage to reduce

the gas storage container source pressure to 25 psig to 50 psig.

When complete, continue to the Preliminary Check procedure beginning on page 2-14.

2-10

September 2005

CWS−D100−B Welding System

Installation

High Pressure Gage (0 psig to 3000 psig)

Inert

Gas Cylinder

Purge Fitting (Swagelok Union or Reducing Union with Nylon Ferrules or Ultra-Torr

2-stage Regulator

Tubing to be Welded

Low Pressure Gage (0 psig to 150 psig)

Internal Purge

Gas Shut-Off Valve



)

SWS Fixture Block

Flow Meter for Internal Purge Gas (Range

0 std ft

/h to 30 std ft3/h)

Supply

Manifold

Purge Fitting (Swagelok Union or Reducing Union with Nylon Ferrules or Ultra-Torr for Purge Gas Restriction)

Flow Meter for Shielding Gas (Range 0 std ft

/h to 50 std ft3/h)

Shielding Gas Supply Inlet

SWS Power Supply

Figure 2-6 Typical Gas Delivery System

2-11

Installation

CWS−D100−B Welding System

Installing the Optional Gas Delivery System

The optional gas delivery system is generally used in Ultra High Purity (UHP) gas systems where quick connects are not permitted. This type of system uses an external 12 V (dc) secondary solenoid valve instead of using the solenoid valve located inside the power supply. If necessary, the secondary solenoid valve may be the high purity type.

Caution! Do not insert the secondary

solenoid bypass plug into the connector unless you are using a secondary solenoid. Inserting the plug disables the power supply solenoid.

A secondary solenoid bypass plug is inserted in the

EXT GAS CONTROL connector on the rear panel to disable

the solenoid inside the power supply and provide +12 V to control the secondary solenoid.

For the gas delivery system using a secondary shielding gas solenoid valve, locate the:

D secondary solenoid bypass plug D secondary shielding gas solenoid valve D 1/4-turn internal purge gas shut-off valve.

Refer to Figure 2-7. Install the optional gas delivery system. Be sure to adhere to the following precautions:

D Ensure that the gas storage container(s) are secured

before using them.

D Ensure all connections are tight and do not leak.

2-12

D Observe correct polarity on the secondary solenoid

bypass plug.

D Adjust the low pressure regulator gage to reduce

the gas storage container source pressure to 25 psig to 50 psig.

September 2005

CWS−D100−B Welding System

Installation

SWS Fixture Block

SWS Power Supply

Weld Head

Internal Purge Gas

Shut-Off Valve

Shielding Gas

Flow Meter

Secondary

Solenoid

Valve

Secondary Solenoid Bypass Plug

2-stage Regulator

Supply

Manifold

Inert Gas

Cylinder

Internal Purge Gas Flow Meter

Figure 2-7 Optional Gas Delivery System

Secondary Solenoid

Bypass Plug

2-13

Installation

CWS−D100−B Welding System

Preliminary Check

Before placing the SWS into operation, you should check that the power supply is operating correctly.

To check the system, follow these steps:

1. Connect the power supply power cord to an electrical outlet.

2. Turn on the power supply circuit breaker. After a 2 second to 4 second delay, the following is displayed:

D Blinking decimal point followed by a zero in

the Average Current and Average Voltage displays on the power supply front panel. See Figure 2-8.

Figure 2-8 Average Current and

Voltage Displays

D The amber-colored Fixture indicator light is

on indicating that the fixture block is not attached to the weld head. See Figure 2-9.

If the power supply does not come on, refer to Section 7, Troubleshooting, for a list of possible causes and corrective actions.

Figure 2-9 Weld Status

Indicator Lights

2-14

September 2005

CWS−D100−B Welding System

3. Position the weld head such that the rotor can be easily seen. See Figure 2-10.

Installation

4. Press

STOP/RESET on the front panel.

D For series 5, 10, and 20 Weld Heads, the

rotor should make one-half of a rotation (180° position) in the head. See Figure 2-11.

D For the micro head, the rotor should make one

complete rotation in the head.

5. Press

STOP/RESET on the front panel to return the rotor

to its home position.

6. Turn off the power supply.

If problems occur, refer to Section 7, Troubleshooting, for a list of possible causes and corrective actions.

Rotor

Figure 2-10 Positioning the Weld

Head to View the Rotor Rotation

Note: The rotor must be returned to its home position before welding.

Figure 2-11 Checking the

Rotor Rotation

2-15

Installation

CWS−D100−B Welding System

2-16

September 2005

Section 3 Operation

Introduction

This section describes the basic operation of the Swagelok Welding System (SWS). This section includes

D front panel controls D SWS modes of operation D installing the electrode in the

Series 5/10/20 Weld Head

D setting the arc gap D preparing the work D fixturing the work D connecting the weld head

to the fixture block

D entering the weld parameters D setting the shield gas flow D starting and completing the weld.

The description of the welding process in this section uses a weld procedure guideline based on tubing with a 1/2 in. OD and 0.049 in. wall thickness. Remember that a weld procedure guideline is a list of weld parameter settings that have been determined for a particular job. Keep in mind that the weld parameters listed in this section may not produce an optimum weld since the purpose of this section is to demonstrate the operation of the SWS. Section 5, Weld Parameter Adjustment, describes how to optimize welding parameters.

3-1

Operation

CWS−D100−B Welding System

Front Panel Controls

7 8

1. Impulse rotary switch

2. Maintenance rotary switch

3. Impulse Rate rotary switch

4. Impulse Width rotary switch

5. Arc Start rotary switch

6. Duration rotary switch

7. Prepurge rotary switch

1 2 3 4 5 6

16 17 18 1914

8. Weld Time rotary switch

9. Downslope rotary switch

10. Postpurge rotary switch

11. Rotor Speed rotary switch

12. Average Current display

13. Average Voltage display

14. Start pushbutton

15. Downslope pushbutton

16. Purge pushbutton

17. Rotor Jog pushbutton

18. Print pushbutton

19. Stop/Reset pushbutton

20. Status indicator lights

21. Remote Pendant connector

3-2

Figure 3-1 Front Panel Controls

You operate the SWS by using pushbuttons and rotary switches on the front panel of the power supply. The values you program into the rotary switches are determined by the weld procedure guidelines.

The front panel digital displays monitor the welding process and show message code information. Message codes are numbers that indicate weld parameter setup errors, power supply status, etc.

The status indicator lights on the front panel show the welding process sequence or flash a warning if the power supply detects that a weld parameter is set incorrectly.

September 2005

CWS−D100−B Welding System

Current Control Switches

The current control switch group determines the characteristics of the current output of the power supply during a weld cycle. See Figure 3-2. The controls function as follows:

D IMPULSE (High Amps) sets the maximum current output

used during the weld cycle. The impulse setting affects the depth of penetration of the weld profile.

D MAINTENANCE (Low Amps) sets the minimum current

output used during the weld cycle. This is the current level required to

D maintain the arc D provide enough background heat to maintain the

weld puddle.

Operation

D IMPULSE RATE (Pulses/Sec) sets the number of changes

per second between the Impulse and Maintenance current levels during the weld cycle.

D IMPULSE WIDTH (% of Impulse) sets the percentage of

time the current is at the Impulse current level for each Impulse/Maintenance cycle.

D ARC START (Amps) sets the output current during the

duration period. This current level

D helps stabilize the initiated arc D develops the weld puddle.

Figure 3-2 Current Controls

3-3

Operation

CWS−D100−B Welding System

Timing Control Switches

The timing control switch group determines the weld cycle timing. See Figure 3-3. The controls function as follows:

D PREPURGE (Seconds) is the time in which shielding gas

flows through the weld head and around the weld joint before the arc is initiated.

D DURATION (Seconds) is the length of time between

the arc start period and the beginning of the weld time cycle.

D The current specified on the arc start rotary switch

is maintained during this time.

D The rotor does not move during this time.

D WELD TIME (Seconds) is the actual welding time at the

average current. During the weld time, the output current cycles between the impulse and maintenance levels at the impulse rate and impulse width entered.

Figure 3-3 Timing Controls

D During this time, the rotor moves at the speed

specified by the rotor speed rotary switch.

D The weld time cycle forms the main body of

the weld.

D DOWNSLOPE (Seconds) is the time during which the

average weld current uniformly decreases until the arc is extinguished.

D During this time, the rotor continues to move at the

speed specified by the rotor speed rotary switch.

D The downslope cycle reduces the chance of

weld cracking.

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September 2005

CWS−D100−B Welding System

D POSTPURGE (Seconds) is the amount of time the

shielding gas continues to flow through the weld head and around the weld joint after the arc is extinguished. This gas flow prevents oxidation and contamination of the weld bead and electrode while the work is cooling.

D ROTOR SPEED (% of Max Speed) is expressed as a

percentage of the maximum RPM that the rotor can attain. A rotor speed setting of 99 gives the maximum RPM for the weld head. See Table 3-1.

Table 3-1 Maximum Rotor Speed by

Weld Head Model

Maximum

Rotor Speed

Weld Head Model

Micro Weld Head 24 2.5 Series 5/10 Weld Head 12 5 Series 20 Weld Head 6 10

(RPM)

Seconds/

Revolution

Operation

Note: A minimum of 10 seconds

PREPURGE is recommended for all

SWS Weld Head models. If Weld Head extension cables are used, add one second for each foot of cable added.

3-5

Operation

CWS−D100−B Welding System

Pushbuttons

The front panel pushbuttons control the welding operation and provide some manual control functions for the weld head. See Figure 3-4. The pushbutton functions are as follows:

D START initiates the welding sequence. D DOWNSLOPE initiates the downslope cycle when pressed

during the weld time cycle. The downslope cycle reduces the output current levels from the weld time levels to zero during the time specified.

D STOP/RESET aborts the weld and halts the rotor if

pressed during the weld cycle. Push to return the rotor to its home position as shown in Figure 3-5 on page 3-7. The rotor will move at maximum speed when traveling to the home position, regardless of the programmed rotor speed. When not welding, pushing

STOP/RESET causes the rotor to rotate

as shown in Table 3-2.

STOP/RESET again

Figure 3-4 Pushbuttons

Note: The external gas solenoid referenced here may be used in place of the internal solenoid at the user’s option. See Section 2, Installation, for installation information.

Table 3-2 Stop/Reset Rotor Travel

Weld Head Model Rotor Travel

Micro Weld Head 1 Revolution Series 5, 10, 20 1/2 Revolution

(no Fixture Block connected) 1 Revolution

(with Fixture Block connected)

D PURGE activates the internal solenoid valve or the

optional external gas solenoid valve and starts the flow of shielding gas to the weld head. See Note. When

PURGE is depressed, shielding gas flows to the weld

head until you press the pushbutton again. The pushbutton overrides the prepurge and postpurge timers and allows shielding gas to continuously flow through the weld head.

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September 2005

CWS−D100−B Welding System

D ROTOR JOG advances the rotor manually. Press

and hold the pushbutton to move the rotor. Release the pushbutton to stop the rotor.

ROTOR JOG can be

used to position the rotor for electrode replacement or adjustment. The rotor will move at the speed defined by the

D PRINT causes the power supply controller to transmit

ROTOR SPEED rotary switches.

weld data to the printer port on the rear of the unit. The optional CWS-DRP printer accepts the data and prints the record.

Operation

Figure 3-5 Rotor Home Position

3-7

Operation

Figure 3-6 Status Indicator Lights

CWS−D100−B Welding System

Status Indicator Lights

The status indicator lights monitor certain elements of the power supply operation. See Figure 3-6.

The conditions monitored by some of the indicators are independent of the welding process. Most of the indicators light during the welding process to show the control sequence executed by the power supply. The control sequence is affected by the values entered into the timing control switches.

The lights also notify you if any weld parameter settings exceed pre-defined limits. See Figure 3-8 for an example.

D Fixture indicates whether or not the weld head is

properly attached to the fixture block. If it is not connected, the indicator light is on. The power supply will not start a weld cycle when this indicator light is on.

Caution! DO NOT try to remove the

fixture block from the weld head until all status indicator lights are off.

D Prepurge indicates the prepurge cycle is active. The

Prepurge cycle occurs prior to arc start. This light indicates that the shielding gas solenoid valve in the power supply is energized, allowing the shielding gas to flow to the weld head prior to starting the welding cycle.

D Start indicates the power supply is in the arc start

portion of the weld cycle.

D Weld time indicates the weld cycle is in progress. D Downslope indicates the downslope cycle is

in progress.

D Postpurge indicates the postpurge cycle is in progress.

The shielding gas continues to flow to the weld head, and the rotor moves to the home position.

D Rotor indicates the rotor is in motion.

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September 2005

CWS−D100−B Welding System

Digital Displays

The digital displays monitor system operation during welding and provide message code information. See Figure 3-7. The display functions are as follows:

D Average Current indicates the average arc current

measured during the weld sequence.

D Average Voltage indicates the average arc voltage

measured during the weld sequence. The average voltage displayed during a weld cycle

varies with the arc gap, type of shielding gas, current output, etc., but typically is in the 5 V to 15 V range.

The Average Current and Average Voltage displays are also used for programming and displaying message codes. See SWS Modes of Operation.

Operation

SWS Modes of Operation

The front panel controls serve two purposes. In addition to controlling the weld parameters and weld sequences, the controls are used to access the modes of the power supply.

The power supply has three modes of operation:

D operational D program D test

Each mode uses message codes to perform a variety of functions. Generally, the message codes are grouped by mode. Operational mode uses codes 1 to 11, 41, 42, 50, and 51. Program mode uses 20 to 23, 30 to 35, 60 to 63, and 99. Test mode uses 97 and 98.

The message codes are explained in detail later in this section.

Figure 3-7 Digital Displays

Table 3-3 shows all the message codes used by the power supply. Note that certain code ranges are marked Factory Use. These codes, except for 64 to 96, are normally not used, which is noted in the table.

3-9

Operation

CWS−D100−B Welding System

Table 3-3 SWS Message Codes

Code No. Name

Normal

Operating

Range

Mode or

Setting to

Activate

Code Type

01 Impulse 2 A to 99.9 A < 2 Disable* 02 Maintenance 2 A to 99.9 A < 2 Disable* 03 Impulse Rate 1 Hz to 99 Hz < 1 Caution 04 Impulse Width 5 % to 95 % < 5 or > 95 Disable* 05 Arc Start 2 A to 99 A < 2 Disable* 06 Duration 0.0 to 5.0 > 5.0 Disable* 07 Prepurge 1 s to 99 s < 1 Caution 08 Weld Time 1 s to 99 s < 1 Disable* 09 Downslope 1 s to 99 s < 1 Disable* 10 Postpurge 1 s to 99 s < 1 Caution 11 Rotor Speed 5 % to 99 %

≥ 1 or < 5

Caution

< 1 Disable*

12 to 19 Factory use Not used

20 Resettable weld

counter

21 Automatic print

counter

0 to 9999 Program

mode

0 to 99 Program

mode

Programmable

22 Enable signal

polarity

23 Arc Start power 0=low

0=low

1=high

1=normal

Program

mode

Program

mode

Programmable

24 to 29 Factory use Not used

30 Time - hours 0 to 24 Program

Programmable

mode

31 Time - minutes 0 to 59 Program

Programmable

mode

32 Date - month 1 to 12 Program

Programmable

mode

33 Date - day 1 to 31 Program

Programmable

mode

34 Date - year 2 digit

00=2000

35 Date printing

format

0=mm/dd/yy 1=dd/mm/yy

Program

mode

Program

mode

Programmable

36 to 40 Factory use Not used

41 Paper out No paper

Caution

installed with

printer

power on

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September 2005

CWS−D100−B Welding System

Operation

Normal

Operating

Code No. Name

Range

42 Printing Data is

Mode or

Setting to

Activate

Code Type

Information only

transferred

to printer

port

43 to 49 Factory use Not used

50 Hi-temp Excessive

Disable*

internal

power

supply

temperature

51 Old head type No weld

Disable*

head or

non-safety

interlocked

weld head connected

52 Rotor jam Rotor motion

impeded

Disable*

See Note (A)

53 to 59 Factory use Not used

60 Non-resettable

weld counter

61 Arc start

attempts

62 System serial

number

63 System

software

Program

mode

Program

mode

Program

mode

Program

mode

Information only

version

64 to 96 Factory use See Note (B)

97 Test switches/

Test mode

pushbuttons

98 Test indicator

Test mode

lights/displays

99 Print user

parameters

Program

mode

* The Prepurge, Start, Weld Time, Downslope, and Postpurge status indicator lights are flashing.

Note (A): Press again unless

STOP/RESET to clear the error. Rotor will not move

STOP/RESET is pressed a second time.

Note (B): Service may be necessary. Call your Swagelok representative.

3-11

Operation

CWS−D100−B Welding System

Operational Mode

When the power supply is turned on it enters the operational mode. The Average Current and Average Voltage displays show a blinking decimal point and a zero. If the weld head is not attached to a fixture block, Fixture is on. The power supply is ready to be used.

Weld Parameter Limits (Message codes 1 to 11)

Each front panel rotary switch controls a part of the welding process. The power supply operates normally as long as each switch setting is within certain limits. If the limits are exceeded, the power supply reacts to the condition and shows a message code on the front panel displays. If the code display is accompanied by flashing status indicator lights, a “disable” condition exists. If not, the code display indicates a “caution” condition.

Message codes 1 to 11 refer to the front panel rotary switches by number. See Table 3-4. See Figure 3-1 to cross reference the switch position numbers.

Table 3-4 Weld Parameter Limit Message Codes

Normal

Operating

Code No. Name

01 Impulse 2 A to 99.9 A < 2 Disable* 02 Maintenance 2 A to 99.9 A < 2 Disable* 03 Impulse Rate 1 Hz to 99 Hz < 1 Caution 04 Impulse Width 5 % to 95 % < 5 or > 95 Disable* 05 Arc Start 2 A to 99 A < 2 Disable* 06 Duration 0.0 to 5.0 > 5 Disable* 07 Prepurge 1 s to 99 s < 1 Caution 08 Weld Time 1 s to 99 s < 1 Disable* 09 Downslope 1 s to 99 s < 1 Disable* 10 Postpurge 1 s to 99 s < 1 Caution 11 Rotor Speed 5 % to 99 %

Range

Mode or

Setting to

Activate

≥ 1 or < 5

< 1 Disable*

Code Type

Caution

3-12

* The Prepurge, Start, Weld Time, Downslope, and Postpurge status

indicator lights are flashing.

September 2005

CWS−D100−B Welding System

Disable Condition

The power supply enters a “disable” condition when a serious fault exists or a front panel control is set to a value that could damage the system. The power supply will not start in a “disable” condition. The rotor can still be moved while the “disable” condition exists, using

ROTOR JOG. The power supply shows the “disable”

STOP/RESET or

condition by flashing the status indicator lights shown in Figure 3-8 and flashing a message code on the Average Current and Average Voltage displays. The code shows you what rotary switch is misprogrammed.

Caution Condition

A “caution” condition indicates that a front panel parameter setting is questionable. The power supply is not disabled and can weld if a “caution” exists. The front panel indicates a “caution” condition by flashing a message code on the Average Current and Average Voltage displays. The code shows you which rotary switch has the questionable value.

Interpreting the Message Codes

Operation

Figure 3-8 Disable Condition

The power supply shows the switch setting problem by displaying the switch code on the Average Voltage display. Codes 1 to 11 use the Average Current display to show the limit for the switch identified by the Average Voltage display. Code numbers 41 and above in the Average Voltage display are system status information or errors detected by the power supply.

See Figure 3-9. The Average Voltage display shows that rotary switch position 04 has an incorrect value. Refer to Figure 3-1 and note that the switch labeled 04 is the

switch. The position of the dash indicates which limit

WIDTH

IMPULSE

is exceeded, minimum or maximum. Figure 3-9(A) shows the dash on the left, indicating that the setting is too low. Figure 3-9(B) shows the dash on the right, indicating the setting is too high.

The Average Current display shows the limit for the parameter. Whether the limit displayed is a minimum or maximum depends on the position of the dash in the other display. Figure 3-9(A) shows the low limit for

is 5. Figure 3-9(B) shows the high limit for IMPULSE

WIDTH

is 95.

WIDTH

IMPULSE

3-13

Operation

CWS−D100−B Welding System

Dash on left indicates below minimum

Figure 3-9 Digital Display Examples for the Operator/Machine Interface

Dash on right indicates above maximum

Multiple Disable or Caution Conditions

The power supply displays multiple errors on the digital displays one after another. Each message code is displayed for a moment, followed by the next, until all are shown. The sequence repeats continuously until the errors are cleared.

If the message code is caused by a “disable” condition, the status indicator lights blink as the code is displayed.

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September 2005

CWS−D100−B Welding System

System Status/Faults (Message codes 41 to 52)

41 Paper out

Code 41 indicates that the optional printer is out of paper. See Appendix B, Optional Equipment, for information on the printer.

42 Printing

Code 42 appears when a print cycle is started. The power supply outputs data to the optional printer. This code only shows that the data is being sent to the printer. The power supply does not monitor the printer operation.

50 Hi-temp

Operation

Code 50 is a “disable” condition that is not resettable. The condition occurs when a temperature sensor inside the power supply detects a buildup of heat that exceeds a predefined limit. The power supply is disabled until the internal temperature drops to a safe level. Allow the power supply to cool. After the condition clears, welding can resume.

51 Old head type

Code 51 is a “disable” condition. The code is displayed if the power supply does not detect a safety interlocked weld head. The code is displayed if no weld head is connected or if a nonsafety interlocked weld head is connected.

52 Rotor jam

Code 52 is a “disable” condition. The condition occurs if the power supply senses that the rotor motion is impeded. The power supply monitors the rotor when a move command is given. If no motion is detected, the code is displayed, and the system is disabled.

3-15

Operation

Figure 3-10 Display Readout for

Example 1

CWS−D100−B Welding System

Let’s look at two examples:

EXAMPLE 1 − Disable Condition

Suppose a weld procedure guideline is keyed in and

IMPULSE is set to 1 A. The minimum allowable Impulse

setting (message code 01) is 2 A, so the power supply is disabled and the status indicator lights begin to flash. Pressing moved with

ST ART has no effect. The rotor can still be

ROTOR JOG or STOP/RESET.

The digital displays read as shown in Figure 3-10. The Average Voltage display shows that switch one (Impulse) is below its minimum allowable setting (dash on left). The Average Current display shows the minimum limit is 2 A.

By changing the value of the Impulse switch to 2 A or greater, the condition is corrected and the operation can proceed. The correct Impulse value can only be determined by developing a proper weld procedure guideline.

Figure 3-11 Display Readout for

Example 2

EXAMPLE 2 − Caution Condition

A weld procedure guideline is keyed in and Prepurge is set to zero seconds. You may wish to use a continuous purge, so the prepurge timer is not needed. The minimum prepurge setting (message code 07) is one second. According to Table 3-3, code 07 will not disable the power supply, so entering zero creates a “caution” condition.

The digital displays read as shown in Figure 3-11. The Average Voltage display shows that switch 7 (Prepurge) is below its normal limit (dash on left). The Average Current display shows the minimum limit is one.

The unit is still functional. This condition only serves to show that there is a questionable setting. If

ST ART is

pushed, the system begins welding, and the weld current and voltage are displayed. After completing the weld, the digital displays again indicate the caution condition. When Prepurge is changed to one second or greater, the displays return to normal.

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September 2005

CWS−D100−B Welding System

Program Mode

The program mode accesses setup parameters for the power supply and the optional printer. The program mode also serves as an access path for the test mode. See “Test Mode” on page 3-22.

Entering Program Mode

Refer to Figure 3-12. Do the following to enter program mode:

Operation

1. Press and hold

2. Press and hold

DOWNSLOPE. ROTOR JOG.

3. Release both pushbuttons at the same time.

The status indicator lights begin to sequence up and down, indicating that the program mode has been successfully entered.

Selecting Program Items

In program mode, the

ROTOR SPEED rotary switch is the

code number selector. Enter a number into the switch, and the code number is shown on the Average Voltage display. Data associated with the code number will be displayed on the Average Current display.

Figure 3-12 Entering Program Mode

3-17

Operation

CWS−D100−B Welding System

Codes selected by the ROTOR SPEED switch may be able to be programmed, such as time and date information, or be a read-only parameter, such as the system serial number. See Table 3-5 for a list of all code numbers.

Table 3-5 Program Mode Code Numbers

Code No. Description Programmable

20 Resettable weld counter Yes 21 Automatic print counter Yes 22 Enable signal polarity Yes 23 Arc Start power Yes 30 Time − hours Yes 31 Time − minutes Yes 32 Date − month Yes 33 Date − day Yes 34 Date − year Yes 35 Date printing format Yes 60 Nonresettable weld counter No 61 Arc start attempts No 62 System serial number No 63 System software version No 99 Print user parameters No

Code Number Descriptions

20 Resettable weld counter

The resettable weld counter counts the number of valid weld cycles completed. The counter can be preset to any number from 0 to 9999. The controller increments the counter each time a valid weld cycle occurs. A weld cycle must last longer than 1.5 seconds to be considered valid. The counter number will be printed on the weld data record. See the description of the optional printer in Appendix B, Optional Equipment.

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September 2005

CWS−D100−B Welding System

21 Automatic print counter The print counter allows the power supply to automatically

print a weld data record at regular intervals. The interval is set by the value entered in the counter. Entering a value of ten, for example, causes the power supply to print a weld data record for weld cycle 10, 20, 30, and so on. The power supply stores the weld count in memory. The weld count will be reset if a new print count value is entered. The weld count is also reset when the power supply is turned off.

The default print counter value is zero. Zero in the counter disables the feature.

A weld data record printout can be accomplished at any time by pushing

PRINT on the front panel. See the printer

description in Appendix B, Optional Equipment, for an example of the printout.

Operation

22 Enable signal polarity The Enable signal, one of the BNC data recording outputs

described in Appendix B, Optional Equipment, has a selectable polarity. Set item 22 to a value of 1 to make the signal active HIGH. A value of 0 in item 22 causes the signal to be active LOW. See Appendix B, Optional Equipment, for more information on data recording.

23 Arc Start power The Arc Start power setting changes the Arc Start

power level. The default setting for Arc Start power is one (normal

power). This setting is recommended for all tubing with an OD greater than 1/16 in. (1,5 mm) or a wall thickness greater than 0.020 in. (0,5 mm).

Set the Arc Start power to zero (low power) for tubing with a 1/16 in. (1,5 mm) OD or wall thickness under

0.020 in. (0,5 mm). Using the normal power setting for

work of this size can affect the integrity of the weld. The

ARC START and DURATION rotary switch settings may have

to be increased when Arc Start power is set to zero.

3-19

Operation

CWS−D100−B Welding System

30-35 Time and date

The controller in the power supply keeps track of the time and date. Display or change the current settings using items 30 through 35.

Code 30 is the hour, using the 24-hour format. Code 31 is the minutes, 32 is the month, 33 is the day, and 34 is the year. Each item is a two-digit value. A 00 entered for the year indicates the year 2000.

Code 35 sets the date format for a printout. A value of zero, which is the default, sets the date to the mm/dd/yy format. A value of one sets the format to dd/mm/yy.

60-63 Weld system information

Note: The controller does not check the state of the printer during execution of a print cycle. The user parameters are sent to the printer port when

ROTOR JOG is pressed.

Code 60 is a non-resettable weld counter. This counter tracks any weld cycle lasting longer than 1.5 seconds. Its maximum value is 999 999.

Code 61 is a counter tracking arc start attempts. Any attempt to start an arc will increment the counter. This counter is also not resettable. The value will be greater than or equal to the weld count in item 60.

Code 62 displays the serial number of the power supply. The value is set at the factory and cannot be changed.

Code 63 displays the version of the controller software. A value of 400 means version 4.00.

99 Print user parameters

Code 99 causes the system to output all user parameters to the optional printer. See the description in Appendix B, Optional Equipment, for an example of the printout. After entry, press

ROTOR JOG to start the print cycle. Average

Voltage will show the number 42 while data is being sent

to the printer.

3-20

September 2005

CWS−D100−B Welding System

Changing Program Mode Items

ARC START and DURATION switches are used for

The programming values into the power supply. If a code number requires a two-digit value, only the

DURATION

switch is used to input values. If a data value has more than two digits, digits and

ARC START is used to set the most-significant two

DURATION sets the least-significant two digits.

See Figure 3-13. The Average Current display shows the current value of

the item. After a new value is entered, the display changes to reflect the new value.

The following example uses the resettable weld counter, code 20, to illustrate how a code value is changed. The example shows how to set the weld counter to a value of

1000. Do the following to modify the value:

Operation

1. Press and hold

2. Press and hold

DOWNSLOPE. ROTOR JOG.

3. Release both pushbuttons at the same time. The SWS is now in program mode.

4. Enter 20 into

5. Enter 10 into

6. Press and hold

ROTOR SPEED. ARC START. Enter 00 into DURATION.

ROTOR JOG for 2 seconds to 3 seconds to

enter the new value. When the status indicator lights begin to flash, release the pushbutton.

When

ROTOR JOG is pressed, all the status indicator

lights will turn on. After a small delay, the lights start to flash, indicating the change has been completed. The Average Current display now shows the new value.

Since the Average Current display is limited to three digits, values greater than 999 must be displayed in two parts. First, the most-significant digits are displayed. After a moment, the three least-significant digits are displayed, with a decimal point by the last digit. For this example, 1 would be displayed first, followed by 000., to show the value of

1000. See Figure 3-14.

Figure 3-13 Data Entry Switches

Figure 3-14 Data Display for Values

Above 999

3-21

Operation

CWS−D100−B Welding System

Exiting Program Mode

Caution! Return the rotary switch

settings to normal welding values after exiting program mode.

Exit the program mode by pressing

STOP/RESET.

The system returns to operational mode. See Caution.

Test Mode

The power supply can be switched from the program mode to the test mode. When selected, the test mode is used to test the front panel controls, displays, and the optional remote operator pendant.

Table 3-6 Test Mode Code Numbers

Code No. Description Programmable

97 Test switches/pushbuttons n/a 98 Test indicator lights/displays n/a

Test Descriptions

97 to 98 Front panel tests

Code 97 is the front panel switch test code. Use this test to verify the operation of all front panel rotary switches and pushbuttons.

Code 98 is the front panel light test. Use this test to verify all front panel status indicator lights and LED displays.

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September 2005

CWS−D100−B Welding System

Entering Test Mode

Refer to Figure 3-15. Enter the test mode using the following steps:

Operation

1. Press and hold

2. Press

ROTOR JOG and then release both buttons at the

DOWNSLOPE.

same time. The SWS is now in program mode.

3. Enter 97 into

ROTOR SPEED.

Code 97 tests front panel switches and pushbuttons.

4. Press

ROTOR JOG.

The controller changes from the program mode to the test mode.

Testing Rotary Switches

Review the rotary switch numbers. See Figure 3-1 on page 3-2. Switch one is Impulse, and switch two is Maintenance, etc.

Test code 97 displays the first switch that has a non-zero value. When the power supply is switched to the test mode, the digital displays indicate the value keyed into

IMPULSE.

Figure 3-15 Entering Test Mode

For example, if

IMPULSE is set to 45.0, the display appears as

shown in Figure 3-16. Average Voltage shows that switch one (Impulse) is being tested and Average Current shows its present setting of 45.0.

At this point

IMPULSE can be rotated, and the numerical

values of each switch position are displayed in Average Current. This exercise shows that the switches are

working properly. Once the operation of

IMPULSE is verified, the switch

must be set to zero to allow the diagnostic to look to the next switch.

IMPULSE set to 0, the unit displays the values in switch

With

MAINTENANCE. Use the same method described earlier

two, to verify the operation of this switch.

Figure 3-16 LED Test Display

3-23

Operation

CWS−D100−B Welding System

After verification of MAINTENANCE, set its value to zero and move to switch three, and so on.

If a switch displays an incorrect value, it may be damaged or defective. Contact your Swagelok representative for service.

Testing Pushbuttons and Status Indicator Lights

Note: The remote pendant is an optional feature. See Appendix B, Optional Equipment, for more information.

In Test code 97, the pushbuttons and status indicator lights can also be functionally tested on both the front panel of the power supply and on the remote pendant.

When the pushbuttons are pressed, a specific status indicator light turns on. Pressing a pushbutton and seeing an indicator light turn on checks both for proper operation. The pushbuttons and corresponding status indicator lights are shown in Table 3-7.

Table 3-7 Pushbutton Test Reference

Pushbutton Lights Illuminated

Start Fixture and Rotor

Downslope Prepurge

Purge Start

Rotor Jog Weld Time

Print Downslope

Stop/Reset Postpurge

Note: The postpurge and rotor indicator lights are not tested on the remote pendant.

3-24

The remote pendant pushbuttons and status indicator lights can also be tested. Plug in the remote pendant and follow the same procedure as before. Note that the

pushbutton is not on the remote pendant. When testing the remote pendant pushbuttons, the status indicator light that turns on may not be adjacent to the pushbutton. The order is established by the button positions on the power supply front panel. See Table 3-7 for all pushbutton/indicator light pairings.

September 2005

CWS−D100−B Welding System

Testing Front Panel Lights/Displays

The tests executed in Test code 97 assume that the front panel status indicator lights and LED displays are functional. If you are in doubt, Test code 98 tests the lights and displays.

Operation

1. Exit Test code 97 by pressing

DOWNSLOPE

and STOP/RESET simultaneously, then release both pushbuttons.

2. Enter 98 into

ROTOR SPEED.

Test code 98 verifies the front panel lights and displays. All front panel status indicator lights and all segments of the LED displays are turned on.

Exiting Test Mode

1. To return to the program mode, press

STOP/RESET simultaneously.

DOWNSLOPE and

After releasing the pushbuttons, the system will return to program mode.

2. Press

STOP/RESET to exit program mode and return to

operational mode.

3-25

Operation

CWS−D100−B Welding System

Installing the Electrode in the Series 5/10/20 Weld Head

Each Swagelok weld head comes with a selection of electrodes. The following instructions show how to properly install the electrode in the Series 5/10/20 weld head. See Section 4, Micro Weld Head, for the micro weld head instructions.

Selecting the Proper Electrode

Electrode length and diameter depend on your weld head model and the outside diameter of the work piece being welded. To select the correct electrode, use the Electrode Selection Table in Appendix C, Electrode Selection Tables and Geometry, of this manual, or the appropriate weld procedure guideline.

Electrode

Clamping Screws

Figure 3-17 Electrode Installation

WARNING! TURN THE CIRCUIT

BREAKER OFF WHILE INSTALLING THE ELECTRODE.

Caution! Do not jog or move the rotor

unless the electrode is clamped in place.

Inserting the Electrode into a Rotor

1. Press STOP/RESET. The rotor makes one half of a revolution (180°) for the

Series 5, 10, and 20 weld head, assuming that the weld head is not attached to a fixture block.

2. Verify that the rotor is in the correct position to install the electrode. See Figure 3-17. If the rotor position is not as shown, press

The micro weld head setup is different. The procedures are covered in Section 4, Micro Weld Head.

3. On the rear panel, turn off the circuit breaker.

4. Loosen the two electrode clamping screws. If you are replacing the electrode, remove the electrode.

5. Insert the new electrode with the sharp tip pointing out. Tighten the electrode clamping screws slightly to temporarily hold in place.

STOP/RESET again.

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September 2005

CWS−D100−B Welding System

Operation

Setting the Arc Gap

The proper arc gap setting facilitates control of the weld and improves consistency. The following steps cover how to set the arc gap.

The arc gap is set by using the arc gap gage provided with the weld head. The gage is adjusted for the desired arc gap and then installed in the rotor aperture. With the gage in place, the electrode can be positioned with reasonable accuracy.

Setting the Arc Gap Gage

1. Measure the outside diameters of the work pieces being welded using a caliper or micrometer. See Figure 3-18(A).

2. Refer to the tables for your weld head model in Appendix E, Arc Gap Gage Setting Tables. Find the “actual” outside diameter nearest to your measurement.

Figure 3-18 Setting the Arc Gap gage

3. Adjust the arc gap gage to match the setting from the table or weld procedure guideline. See Figure 3-18(B).

4. To calculate arc gap gage settings for other arc gaps, see the arc gap gage setting formula in Appendix E, Arc Gap Gage Setting Tables.

5. Gage settings for Swagelok ATW fittings are in the tables in Appendix E, Arc Gap Gage Setting Tables.

Setting the Arc Gap

1. Insert the arc gap gage into the rotor. See Figure 3-19(A).

2. Tilt the weld head upward. Loosen the electrode screw allowing the electrode to drop onto the gage surface. See Figure 3-19(B).

3. Tighten the electrode clamping screws just enough to secure the electrode. Remove the arc gap gage.

A B

Figure 3-19 Setting the Arc Gap

Caution! Do not jog or move the rotor

unless the electrode is clamped in place.

3-27

Operation

CWS−D100−B Welding System

4. Restore power to the SWS by turning the circuit breaker on.

Hack Saw Cut

Method

End Roller in by Cutter

Blade and Roller

5. Press

STOP/RESET to return the rotor to the

home position and visually inspect the rotor smooth rotation.

Preparing the Work

Refer to Figure 3-20. Prepare the tube pieces to be welded.

Result

Burrs

Irregular Wall

Thickness

Burrs in Flow Path

Gap

Tube Cutter

Tube Facing Tool

Burrs Reduced Flow Area

Face Perpendicular

Square Corners

Figure 3-20 Tube Preparation

Smooth Transition

at Wall Facesto Axis

No Gaps

Tubing must be square and burr-free to ensure repeatable, high-quality autogenous fusion welds. Cut the tubing to length with a hacksaw or tube cutter. Face the tube ends with a lathe or a portable facing tool. Deburr the ends, making sure that both the inside and outside diameters are square and burr-free. Clean the tube ends using an appropriate solvent.

3-28

September 2005

CWS−D100−B Welding System

Minimize the chance of a poor quality weld by following these guidelines:

D Tube ends must be square. D Tube ends must be burr-free. D Tube ends must not have a wall thickness variation

exceeding ±15 % of nominal.

D Tube ends must be free of any rust, grease, oil,

paint, or other surface contaminates.

Fixturing the Work

Select or configure the appropriate fixture block. Select the collets to match the work outside diameter.

Operation

Figure 3-21 Opening the Fixture Block

Selecting the Fixture Block and Collets

1. Select the fixture block that accepts the outside diameter of the tube to be welded. See Table 1-6 in Section 1, Introduction.

2. Select the proper collets for the diameter of the parts being welded. See Table 1-8 in Section 1, Introduction.

Installing the Collets in a Tube Fixture Block

1. Release both levers and open the tube fixture block. See Figure 3-21.

2. Install the collet halves in both the top and bottom side plates and tighten the collet screws. Make sure the collet shoulder is flush against the fixture side plate. See Figure 3-22.

Fixture Side Plate

Collet Shoulder

Figure 3-22 Installing Collets

3-29

Operation

Figure 3-23 Place the Centering Gage

CWS−D100−B Welding System

Aligning the Work Pieces in the Tube Fixture Block

1. Place the centering gage in one side of the tube fixture block. The centering gage must span the width of the collet. See Figure 3-23.

2. Butt one work piece against the centering gage. See Figure 3-24(A).

3. Lock down the top side plate. See Figure 3-24(B).

4. Remove the centering gage.

Note: When welding a Swagelok ATW fitting to tubing, butt the tubing against the centering gage first.

Figure 3-24 Placing First Work Piece in the Fixture Block

3-30

September 2005

CWS−D100−B Welding System

5. Butt the second work piece against the first work piece, and lock down the top side plate. See Figure 3-25.

6. Inspect 360° around the weld joint for fit and alignment. If the alignment is not correct, proceed to the Appendix H, Fixture Block Alignment.

Operation

Figure 3-25 Placing Second

Work Piece

3-31

Operation

CWS−D100−B Welding System

Connecting the Purge Gas Line

Refer to Figure 2-6 in Section 2, Installation. Connect the internal purge gas line to the work pieces.

1. Set the internal purge gas flow meter depending on the inside diameter of the work pieces. See Appendix G, Gas Flow Rate Tables.

2. Open the shut-off valve in the purge gas line. The length of time for internal purge before welding

depends on the internal volume and length of the work piece to be welded.

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September 2005

CWS−D100−B Welding System

Connecting the Weld Head to the Fixture Block

The instructions that follow refer to a Series 5/10/20 style weld head. See Section 4, Micro Weld Head, for instructions for using a micro weld head.

Safety Interlock

Operation

This feature disables the power supply when the weld head is not attached to the fixture block. On the front panel, Fixture remains on until the weld head is properly attached.

A sensor in the weld head signals the power supply when the fixture block is connected. Fixture turns off and the power supply is ready to weld.

The safety interlock feature is not included on all weld heads. Table 3-8 lists the first serial number of each weld head model that includes the safety interlock feature.

Table 3-8 Weld Heads with Safety Interlock

Model No. Serial No.

CWS-M-MTR-A 10212 or higher

CWS-4MRH-A 20090 or higher CWS-4MFH-A 30045 or higher

CWS-8MRH all

CWS-5H-B 60100 or higher CWS-10H-A 70033 or higher CWS-20H-A 80015 or higher SWS-20H-B all

Note: Use only safety interlock weld heads with the D100 power supply.

3-33

Operation

CWS−D100−B Welding System

Mating the Weld Head to the Fixture Block

1. Rotate the locking lever on the weld head counter-clockwise until it stops. See Figure 3-26.

2. Insert the weld head into the fixture block. See Figure 3-27(A).

3. Rotate the locking lever clockwise to secure the weld head. See Figure 3-27(B).

4. Examine the Fixture light. Verify that it is off.

Figure 3-26 Releasing the

Locking Lever

Figure 3-27 Mating the Weld Head to

the Fixture Block

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September 2005

CWS−D100−B Welding System

Entering the Weld Parameters

The following describes the parameters that are set on the SWS front panel as well as briefly discussing how the parameters are determined.

Using a Weld Procedure Guideline

There are several reference weld procedure guidelines included in Appendix I, Weld Procedure Guidelines, of this manual. If assistance is needed in obtaining more Weld Procedure Guidelines, please provide your Swagelok representative with your specific requirements.

The weld procedure guideline listed in Table 3-9 is based on 1/2 in. tubing with a 0.049 in. wall thickness.

Operation

Table 3-9 Sample Weld Procedure Guideline

Weld Parameter Setting

Impulse 58.8 Maintenance 17.6 Impulse Rate 10 Impulse Width 35 Arc Start 32 Duration 0.5 Prepurge 10 Weld Time (2 revolutions) 36 Downslope 18 Postpurge 20 Rotor Speed 26

Using the weld procedure guideline in Table 3-9, enter the listed values on the front panel rotary switches. Once this is done, the digital display windows should read a zero with a flashing decimal point. The unit is ready for operation.

Note: If the displays do not read zero, please refer to “Operational Mode” on page 3-12.

3-35

Operation

CWS−D100−B Welding System

Effects of Weld Parameters

The following text briefly discusses how the weld parameters relate to the current waveform and the effects of any parameter changes.

Weld Parameters Affect the Output Waveform

WELD CURRENT PARAMETERS

58.8

MaintenanceImpulse Pulse Rate % Impulse

17.6 10 35

Weld Time

35 %

1 s

65 %

32 A (Avg)

Downslope

Time

Figure 3-28 Weld Current Waveform

The shape and duration of the output current waveform created during the weld cycle is determined by the weld parameter settings entered on the SWS front panel. The values from the weld procedure guideline in Table 3-9 create a current waveform as shown in Figure 3-28.

During a typical weld, the power supply pulses between high amp current and low amp current. In the example shown at the right, the current control settings are:

D IMPULSE 58.8 A D MAINTENANCE 17.6 A D IMPULSE RATE 10 pulses per second D IMPULSE WIDTH 35 %

In this case, the current pulses between the high and the low levels 10 times per second. The current is at the high level 35 % of the time and at the low level 65 % of the time.

3-36

Effects of Weld Parameter Changes

Impulse and Rotor Speed affect the depth of penetration of the weld.

Impulse Width also affects weld penetration. The control allows fine tuning of the weld penetration level.

Pulse rate is typically set so that each weld spot overlaps the previous one by at least 60 %.

September 2005

CWS−D100−B Welding System

Setting the Shield Gas Flow

1. Verify the shielding and purge gas connections to the work pieces.

Operation

2. Set the shielding gas flow meter to the proper setting. Refer to Table 3-10.

3. Press

PURGE to operate the shielding gas solenoid valve

and to start the shielding gas flow. Allow the system to purge for several minutes on initial setup to clear the shielding gas system of oxygen.

4. Press

PURGE again to close the shield gas

solenoid valve.

Table 3-10 Shield Gas Flow Rates (Argon)

Weld Head Series std ft3/h (L/min)

5 10 to 15 (4.7 to 7.1)

10 10 to 20 (4.7 to 9.4) * 20-A 10 to 20 (4.7 to 9.4) * 20-B 20 to 40 (9.4 to 18.8) *

*Set the flow to the higher rates when welding at high current levels.

Caution! Excessive or insufficient

flow rates may affect arc start and arc stability.

Starting and Completing the Weld

1. Check the following before starting the weld:

D All rear panel connections are complete. D Shielding and purge gas lines are

properly connected.

D The inert gas source is on. D Correct gas flow rates are set. D Weld pieces are properly aligned and clamped in

the fixture block.

D The proper arc gap is set. D The weld head is connected to the fixture block. D The proper weld procedure guideline settings have

been entered.

D All status indicator lights are off. D The internal purge gas is flowing.

Note: Although the power supply welds in any orientation, it is recommended that it be placed in the upright position before welding.

3-37

Operation

CWS−D100−B Welding System

WARNING! Do not touch the cable

connectors during arc start. If the cables have been damaged, a potential for electric shock exists.

Note: If the arc fails to start, the power supply enters the idle state. See Section 7, Troubleshooting, for possible causes and corrective actions.

2. Press START. Total time for the process is the sum of the

following times:

D prepurge D duration (negligible) D weld time D downslope D postpurge

In the example given in Table 3-9, the total process would be 84.5 seconds.

Display Indications During Welding

During welding, the status indicator lights on the front panel light in the following sequence:

D Prepurge D Start D Weld Time and Rotor* D Downslope D Postpurge

*Rotor remains on during Weld Time and Downslope, and until the rotor returns to the

home position after welding.

Average Current LED Display

Compare the value shown on the display with the average current value listed under Arc Start on the weld procedure guideline. The Arc Start value is calculated during the development of the guideline. The value displayed during welding is generally within 10 % of the calculated value.

3-38

September 2005

CWS−D100−B Welding System

Average Voltage LED Display

The value displayed during weld time is typically between 5 V and 15 V. The display may be used to monitor voltage fluctuations that can result from

D electrode wear D out-of-round tubing D contamination of shielding gas.

After the Weld is Complete

Operation

1. Wait for all status indicator lights to go off.

2. Check if the fixture block has cooled enough to be safely handled. Allow additional cooling time if necessary before handling. If necessary, increase postpurge time to aid cooling.

3. Release the locking lever on the weld head housing.

4. Remove the weld head from the fixture block. If it is difficult to remove the weld head, release one of

the side plate lever cams.

5. Remove the internal purge gas lines from the welded assembly.

6. Release the levers on the fixture block.

7. Open the side plates of the fixture block.

8. Remove the welded assembly.

WARNING! USE GLOVES OR OTHER

PROTECTIVE DEVICES IF YOU MUST HANDLE PARTS IMMEDIATELY AFTER WELDING. THE PARTS CAN BE EXTREMELY HOT AND MAY CAUSE BURNS.

Caution! Do not immerse the hot

fixture block in water after welding. If using only one fixture block, allow it to cool before performing the next weld. More than one fixture block can be used for repetitive welding.

Note: Inspect and clean the electrode after each weld. Look for oxidation, wear, or weld material on the tip.

3-39

Operation

CWS−D100−B Welding System

Operation Summary

1. Install the electrode.

2. Set the arc gap using the arc gap gage.

3. Prepare the work pieces.

4. Select the correct fixture block and collets.

5. Install the collets in the fixture block.

6. Align the work pieces in the fixture block.

7. Connect the internal purge gas line to the work piece to be welded, and set the flow meter.

8. Press

9. Press

PURGE, and set the shield gas flow. PURGE to stop the shielding gas flow prior to

starting the weld.

10. Connect the weld head to the fixture block.

11. Program the welder.

12. Press

ST ART and complete the weld.

13. Remove the weld head from the tube fixture block.

14. Remove the welded assembly from the tube fixture block.

3-40

September 2005

Section 4 Micro Weld Heads

CWS-4MRH-A, CWS-4MFH-A, CWS-8MRH

Introduction

The micro weld heads are used to weld work pieces from 1/16 in. to 1/2 in. (3 mm to 12 mm) OD. The Series 4 Micro Weld Head can weld work pieces from 1/16 in. to 1/4 in. (3 mm to 6 mm) OD and is available in both rigid-drive and flexible-drive configurations. The Series 8 Micro Weld Head can weld work pieces from 1/4 in. to 1/2 in. (6 mm to 12 mm) OD and is available in a rigid-drive configuration. All micro weld heads operate with a detachable motor module. See Figure 4-1.

Series 4

Flexible-Drive

Figure 4-1 Rigid-Drive and Flexible-Drive Micro Weld Heads

Series 8

Rigid-Drive

Motor

Module

Series 4

Rigid-Drive

4-1

Micro Weld Heads

CWS−D100−B Welding System

This section presents information that is specific to the micro weld head assembly. Additional handling is necessary because the motor module and weld head are separate units. The micro weld head fixtures do not use separate collets, so fixture setup differs slightly from the Series 5/10/20 fixture block procedures.

The procedures, unless noted, are the same for all micro weld heads. Most figures in this section show the Series 4 Rigid-Drive Micro Weld Head.

Topics common to all weld heads are not covered in this section. See Sections 2, 3, and 5 for information on power supply setup and weld procedure guidelines.

The section includes

D micro fixture tool D installing the motor module D installing the micro weld head D installing/replacing the electrode D setting the arc gap D fixturing the work D connecting the micro weld head to the fixture D considerations during welding D using the optional bench mounting bracket.

4-2

September 2005

CWS−D100−B Welding System

Using the Micro Fixture Tool

Each micro weld head includes a micro fixture tool. See Figure 4-2. The primary purpose of the tool is to latch and unlatch the fixtures. In addition, the tool can be used for the following:

D aligning the micro weld head rotor

Micro Weld Heads

Tabs to Engage the

Rotor Drive Gear

Wrench Opening for Bench Mount Bracket Adapter Screws

D attaching the optional bench mount bracket

(Series 8 only)

The micro fixture tool has a hole that allows the tool to be secured by a key chain.

Installing the Motor Module

Connect the motor module to the power supply the same way as a Series 5/10/20 Weld Head.

1. Turn off the power supply circuit breaker on the rear panel. See Figure 4-3.

2. Connect the motor module to the power supply. See page 2-7 in Section 2, Installation, for instructions.

Key Chain

Hole

Slots Used to Open

and Close Fixtures

Figure 4-2 Micro Fixture Tool

3. Turn on the power supply.

4. Press

STOP/RESET.

The motor moves the rotor drive gear to its home position.

Figure 4-3 Power Supply

Circuit Breaker

4-3

Micro Weld Heads

CWS−D100−B Welding System

Correct

Wrong

Micro

Fixture

Tool

Drive Gear

Figure 4-4 Rotor Manual Adjustment

Installing the Micro Weld Head

1. Using the micro fixture tool, turn the drive gear on the base of the micro weld head to align the rotor opening to the weld head housing opening. See Figure 4-4(A) and Figure 4-4(B), showing views of the rotor misaligned and in proper alignment.

The drive gear on the base of the micro weld head must be aligned so that it meshes with the drive pins on the motor module housing.

2. Locate the shielding gas port on the micro weld head and verify that the O-ring is in place. See Figure 4-5.

The O-ring seals the gas port. A valve in the port opens the gas flow through the motor module. The valve opens when the micro weld head is properly connected to the motor module.

3. Align the connecting surfaces of the micro weld head and motor module. See Figure 4-5.

Valve

Figure 4-5 O-ring and Mating Connections

4-4

Mating Connections

O-ring

September 2005

CWS−D100−B Welding System

Micro Weld Heads

4. Push the micro weld head onto the motor module until it is firmly seated, then lock the assembly together with the two side latches. See Figure 4-6(A) and (B).

5. Press

STOP/RESET.

The rotor turns one revolution and stops at the home position. The opening in the rotor aligns to the opening in the micro weld head housing. If not, disconnect the weld head and repeat the procedure.

Caution! Do not force the micro weld

head and motor module together. The drive gears of the micro weld head and motor module must be aligned for the pieces to mate correctly. If you have problems mating the components, rotate the micro weld head drive gear a small amount and try again. Refer to step 1. on page 4-4.

Figure 4-6 Connecting Weld Head and Motor Module

4-5

Micro Weld Heads

CWS−D100−B Welding System

Installing/Replacing the Electrode

WARNING! TURN OFF THE POWER

SUPPLY BEFORE INSTALLING AN ELECTRODE!

Note: Experience suggests replacement of the electrode when it shows signs of deterioration.

The micro weld head accessory package includes a screwdriver, tweezers, and an electrode cleaning tool. Use these tools for installing or replacing the electrode.

1. Select the proper electrode for the job to be performed. See Appendix C, Electrode Selection Tables and Geometry.

2. Turn off the power supply circuit breaker on the rear panel. See Figure 4-3.

3. Disconnect the micro weld head from the motor module.

4. Manually turn the rotor drive gear, shown in Figure 4-4, until the electrode clamping screw is exposed. See Figure 4-7.

Electrode

Clamping Screw

Figure 4-7 Electrode Clamping

Screw Location

Caution! Do not rotate the rotor with

the electrode clamping screw loose. Damage to the micro weld head housing may result.

4-6

September 2005

CWS−D100−B Welding System

5. Loosen the electrode clamping screw holding the micro weld head as shown in Figure 4-8(A).

This orientation helps to prevent the electrode from falling out during installation.

6. Install a new electrode with the tweezers to avoid contamination. Insert the electrode through the ceramic insulator and into the rotor to its full insertion depth. Make sure the sharp tip of the electrode is pointing out. See Figure 4-8(B).

7. Tighten the clamping screw sufficiently to prevent the electrode from falling out of the rotor. Do not overtighten the clamping screw.

Micro Weld Heads

8. Clean the electrode with the provided electrode cleaning tool.

Push the electrode into the electrode cleaning tool and rotate back and forth two to three times.

Note: Clean the electrode before every weld to ensure optimum performance.

Figure 4-8 Installing the Electrode

4-7

Micro Weld Heads

CWS−D100−B Welding System

Figure 4-9 Setting Arc Gap Gage

Setting the Arc Gap

The micro weld head accessory package also includes an arc gap gage. The gage is required to set the arc gap. The gage fits the rotor aperture and adjusts for the desired arc gap.

1. Measure the OD of the work to be welded with a caliper or micrometer and record the value. See Figure 4-9(A).

2. Refer to the CWS-4MRH-A/CWS-4MFH-A or CWS-8MRH tables in Appendix E, Arc Gap Gage Setting Tables. Find the “Actual OD” column.

3. Locate the OD value in the table that matches the OD of the work. Find the arc gap gage setting listed for that OD and record it.

4. Set the arc gap gage to the value from the table using the provided 3/32 in. hex wrench. Measure from the bottom of the arc gap gage to the top of the adjustment screw. See Figure 4-9(B).

Figure 4-10 Setting the Arc Gap

Caution! Make sure the electrode

is secure, but do not overtighten. The electrode could be damaged as a result.

5. Insert the arc gap gage into the micro weld head rotor opening.

6. Hold the micro weld head so that the electrode tip is pointing down. Loosen the electrode clamping screw to allow the electrode to fall against the arc gap gage. See Figure 4-10.

7. Tighten the electrode clamping screw to hold the electrode in place. Do not overtighten. Remove the arc gap gage.

The rotor may move due to the torque of tightening the clamping screw. Use your finger to hold the rotor in place.

8. If the micro weld head is disconnected from the motor module, attach it to the motor module. Complete the steps in Installing the Micro Weld Head, beginning on page 4-4. When complete, return here.

9. Turn on the power supply.

10. Press

STOP/RESET.

4-8

The rotor starts moving and stops at the home position.

September 2005

CWS−D100−B Welding System

Fixturing the Work

The work pieces must be properly prepared before fixturing. See page 3-28 in Section 3, Operation, for information.

1. Locate the centering gage. Turn the gage so the labeled side is face up. Insert the gage into the fixture. See Figure 4-11.

The orientation of the fixture does not matter.

2. Open the fixture side facing the labeled side of the centering gage by rotating the latch 90°. See Figure 4-12.

The fixture opens with a scissors type action. Figure 4-12 shows how to use the micro fixture tool on both the Series 4 and Series 8 fixtures.

Micro Weld Heads

Figure 4-11 Inserting Centering Gage

Opening the

Fixture

Note: Use the micro fixture tool for

Series 4 and Series 8 fixtures

Figure 4-12 Insert First Work Piece

4-9

Micro Weld Heads

CWS−D100−B Welding System

Caution! When closing the fixture,

be sure the moving side of the fixture engages into the small groove on the stationary side of the fixture.

3. Insert the first work piece, butting the weld end against the gage surface. Close and latch that side of the fixture. Make sure that the latch is fully closed against the body of the fixture. See Figure 4-13.

4. Remove the centering gage.

5. Open the other side of the fixture and insert the second work piece. Butt the weld ends together. Close and latch that side.

6. Check the weld joint for proper fit and alignment. See Figure 4-13. Verify that the latches are fully closed. See Figure 4-13 (Series 4) or Figure 4-14 (Series 8).

7. Connect the purge gas line to the work pieces. See Figure 2-6 in Section 2, Installation.

8. Open the shut-off valve in the purge gas line.

Correct Wrong

Figure 4-13 Checking the Weld Joint

(Series 4 Fixture)

Correct

9. Set the flow meters according to the weld procedure guideline for both the shielding and internal purge gas.

Table 4-1 Shield Gas Flow Rates (Argon)

Weld Head Series std ft3/h (L/min)

4MH 8 to 10 (4 to 4.7) 8MH 15 to 20 (7.1 to 9.4)

The length of time for internal purge before welding depends on the internal volume and length of the work piece to be welded. See Appendix G, Gas Flow Rate Tables.

Wrong

Figure 4-14 Proper Latch Position

(Series 8 Fixture)

4-10

September 2005

CWS−D100−B Welding System

Connecting the Micro Weld Head to the Fixture

1. Place the fixture on the micro weld head.

D On the Series 4 Micro Weld Head, make sure the

fixture is firmly seated. Rotate the locking lever 90° to secure the fixture to the micro weld head. See Figure 4-15(A).

D On the Series 8 Micro Weld Head, engage the two

latch springs over the button keepers on the sides of the fixture and close the latch levers. See Figure 4-15(B).

The micro weld head assembly and the work are ready for welding.

2. Press

PURGE to begin the shielding gas flow. The

shielding gas should remain on at all times when using the micro weld head.

Micro Weld Heads

Caution! Make sure the fixture latches

are closed before attaching the fixture to the micro weld head. The electrode can be damaged if the latches are left open during welding.

Caution! Make sure that the purge line

or a heavy work piece does not exert a side load force on the fixture. This may cause an unacceptable weld, damage to the micro weld head, or both.

3. Program the power supply and perform the weld using the procedures established in Section 3, Operation.

4-11

Micro Weld Heads

CWS−D100−B Welding System

Locking

Lever

Latch Spring Captures Button Keepers

Latch Springs (2)

Figure 4-15 Placing the Fixture on the Micro Weld Head

4-12

September 2005

Swagelok CWS-D100-1B, CWS-D100-2B User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual