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

www.swagelok.com

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. . . . . . . . . . . . . . . . . . .

TOC−1

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. . . .

TOC−2

September 2005

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. . . . . . . . . . . . . . . . . . . . . . . . .

TOC−3

Table of Contents

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. . . . . . . . . . . . . . . . . . . . . . . . . . . .

TOC−4

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

TOC−5

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

1-2

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

1-4

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

1-8

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

+ 247 hidden pages

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

Specifications and Main Features

Frequently Asked Questions

User Manual