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Orbital Welding, Regulatory, M100 Power Supply

1. wT kN TH on f Supply Manifold Secondary Shielding Gas OH Inert Gas Solenoid Valve N Cylinder Internal Purge Gas Flow Meter bme EEr Secondary Solenoid Bypass Plug Weld Head i i Re IL f Internal Purge Gas SWS Fixture Block Shut Off Valve Secondary Solenoid Bypass Plug Figure 8 Optional Gas Delivery System 12 2005 Swagelok Company all rights reserved September 2005 M100 Power Supply Preliminary Check Before placing the SWS into operation you should make some preliminary checks to verify the power supply is operating correctly To check the system follow these steps 1 Connect the power supply power cord to an appropriate electrical outlet 2 Turn on the power supply circuit breaker 3 At this point an owner password which can be up to 11 characters in length is requested You must enter a password to continue e The programmer or the welding user does not need the owner password Discrete passwords are available for these users e The owner of the welding system should consider the owner password a master key and protect it as such 4 Position the weld head so that the rotor can be easily seen See Figure 10 Do not attach the fixture block to the weld head Figure 10 Postitioning the Weld Head to View the Rotor Rotati
2. www swagelok com REGULATORY USER S MANUAL ON Regulatory REGULATORY This module contains the following information e Warranty Information Form e Declaration of Conformity e Registration Information e Safety Summary e Power Supply Warning Label e Referenced Specifications The Warranty Information Form must be completed and returned to your Swagelok Representative to activate the warranty The Registration Information page provides a convenient place to record pertinent Power Supply and Weld Head information 2005 Swagelok Company all rights reserved 1 September 2005 Regulatory 2 2005 Swagelok Company all rights reserved September 2005 Swagelok Welding System Warranty Information Form IMPORTANT Please complete and return this form to your Swagelok Representative for warranty activation Date of Delivery Power Supply Model Number Serial Number Weld Head Model Number Serial Number Company Name Local Swagelok Distributorship Market Area check all that apply Q Semiconductor Q Analytical Instrumentation Q Oil amp Gas LI Process Instrumentation QU Power LI Steam Utilities LI Bioprocess Pharmaceutical Q Other Please describe User Type check all that apply Q OEM Q Maintenance Department Q Fabricator Q University or Research and Development Lab Q Contractor Q Operator Training Program Q Other Please describe Intended
3. Weld Parameter Development This section describes the procedures necessary for developing weld parameters to create welds that meet required specifications This section includes e developing a weld procedure guideline e evaluating the weld e adjusting software settings for weld quality I Note Developi nga Weld This procedure assumes you are Procedure Guideline fusion butt welding austenitic Stainless steel tubing In order to create a weld that meets the required specifications you may need to adjust the welding Note parameters You start with the Example Weld Procedure This procedure is only a guideline Guideline Worksheet on page 107 Each of the following The final weld quality depends on the steps on pages 92 through 106 correspond to the steps on operator s welding experience and on the example worksheet After completing each step verify the proper use of welding techniques the recorded value on the example worksheet The Worksheet entry values in the procedure correspond to the steps in the Example Weld Procedure Guideline Worksheet found The example is based on 1 2 in OD 0 049 in wall thickness 316L stainless steel tubing using the Series 5 Weld Head However the procedure applies for all weld heads A blank worksheet is included on page 109 for you to use when creating your own weld procedure guidelines The steps in the worksheet show you how to develop the speed current and timing for the SWS
4. 2005 Swagelok Company all rights reserved 91 September 2005 M100 Power Supply Determining the Work Specifications 1 Record the programmer s name 2 Record the joint type TB TB Tube Butt Weld to Tube Butt Weld TB ATW Tube Butt Weld to Auto Tube Weld Worksheet entry TB TB 3 Record the material being welded for each side 316L 316 SS Low Carbon 316LV 316 SS Low Carbon Controlled Sulfur 304L 304 SS Low Carbon Worksheet entry 316LV 316LV 4 Record the tube or pipe outside diameter Worksheet Entry 0 5 in 5 Record the wall thickness Worksheet Entry 0 049 in 6 Record the weld head model See weld head manuals for selection Worksheet Entry CWS 5H B 7 Record the proper electrode Refer to the Electrode Selection Table in the appropriate weld head manual Worksheet Entry C 040 605 8 Record the arc gap for the weld head being used Refer to the Arc Gap Gauge Setting Table in the appropriate weld head manual Worksheet Entry 0 035 in 9 Record the ID purge gas flow rate and the type of purge gas Refer to Table 4 Shield Gas Flow Rates Argon on Page 74 Worksheet Entry 15 SCFH Argon 10 Record the shield gas flow rate and the type of shielding purge gas Refer to Table 4 Shield Gas Flow Rates Argon on Page 74 Worksheet Entry 13 SCFH Argon 11 Record the purge gas pressure from the ID purge pressure Refer to Table 5 Purge Rate and Pressure Tables on Page 75 Worksheet Entry
5. 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 Inspect the electrode after each weld Look for oxidation wear or weld material on the tip 77 M100 Power Supply Data Recording Printer The SWS Data Recording Printer is a small size thermal printer housed inside the M100 power supply case See Figure 73 The data recording printer is covered under the same watranty as the M100 power supply Load the Paper I 78 Turn the latch counter clockwise to release the printer body from the case Remove the printer body from the case by pulling it forward See Figure 74 Figure 74 Opening the Data Recording Printer Drawer 2005 Swagelok Company all rights reserved September 2005 M100 Power Supply 2 Lift the printer head fully by raising the lift arm located Lift Arm with the manual paper feed wheel next to the printer cover panel Manual Feed Wheel Figure 75 Lift the Printer Head 3 Press the ends of the spindle and lift to remove the paper roll spindle pin and used paper spindle O T S Figure 76 Press the Ends of the Spindle and Lift 2005 Swagelok Company all rights reserved 79 September 2005 M100 Power Supply 4 Install the new roll of thermal paper and load the paper into the feed mecha
6. Regulatory Safe Practices and Safety Precautions Read ANSI 249 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 5 ae i WARNING Shielding gas cylinders contain gas under high pressure If damaged a cylinder can explode Since gas cylinders SHIELDING GAS CYLINDERS lly part of th ldi b to treat CAN EXPLODE IF DAMAGED oa ay of the welding process be sure to trea O A ROPER YT EA e Protect compressed gas cylinders from excessive heat mechanical shocks slag open flames sparks and arcs e Install cylinders in an upright position by securing to a stationary support or cylinder rack to prevent falling or tipping e Keep cylinders away from any welding or other electrical circuits e Never weld on a pressurized cylinder explosion will result e Use only correct shielding gas cylinders regulators hoses and fittings designed for the specific application maintain them and associated parts in good condition e Turn face away from valve outlet when opening cylinder valve e Keep protective cap in place over valve except when cylinder is in use or connected for use e Read and follow instructions on compressed gas cylinders associated equipment and CGA publication P 1 listed in Safety Standards 2005 Swagelok Company all rights reser
7. 4 Insert the weld head shielding gas connector into the Swagelok Quick Connect stem labeled TO WELD HEAD Figure 6 Weld Head Connectors A Caution Ensure that the threaded multi pin 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 A Caution Ensure that the weld head shielding gas connector is firmly attached This connection provides shielding gas to the weld head through a solenoid valve in the power supply 2005 Swagelok Company all rights reserved September 2005 M100 Power Supply Installing the Gas Delivery System The gas delivery system provides shielding gas to the weld head to reduce oxidation or contamination of the weld puddle tungsten electrode and Heat Affected Zone HAZ There are two types of gas delivery systems commonly used For a typical gas delivery system refer to the installation procedure below For a gas delivery system using a secondary shielding gas solenoid valve see Optional Gas Delivery System beginning on page 11 Typical Shielding Purge Gas Delivery System Figure 7 shows a typical system Be sure to adhere to the following precautions e Ensure that the gas storage container s are secured before using them e Ensure all connections are tight and do not leak e Use only a
8. CONFIG COUNT MISFIRES Allows you to specify whether misfires will be counted on the reset table weld counter PASSWORD CHANGE SECURITY PROGRAMMER OWNER Allows an authorized user to change or set passwords for a particular privilege level If the password field for that privilege level is left blank no password 1s required to access those functions There are three password privilege levels available with the M100 power supply In ascending order of privilege e Security Password The security password is used to secure the M100 power supply during periods that it is unattended If a Security password 1s entered it must be entered to access any function of the equipment Owner password and Programmer password can override e Programmer Password Programmer privilege allows you to change the programmer password and is required for full use of the equipment This privilege level has full WELD mode and FILE mode privileges If a Programmer password has been set users without it will only have WELD mode and limited FILE mode privileges Owner password can override e Owner Password A privileged password is one that only the person responsible for the welder should know This level accesses all privileges and can override the programmer and security level passwords if necessary Think of this password as a master key and protect it as such 2005 Swagelok Company all rights reserved September 2005 DATALOG conri
9. Compare the material wall thickness and outside diameter size of the work pieces being welded to the weld procedure guideline being used Adjust weld parameters as necessary Reset the arc gap with the arc gap gage Change the electrode Verify consistency of material with material supplier Adjust weld parameters as necessary Inspect the entire weld joint n the fixture block prior to welding Prepare the work piece weld ends properly Refer to the appropriate weld head user manual Tighten screws as needed Center fitting tubing Inspect the electrode and replace if necessary Reset the arc gap with the arc gap gage 2005 Swagelok Company all rights reserved September 2005 Swagelok VCR VCO Ultra Torr Micro Fit TM Swagelok Company 2005 Swagelok Company Printed in U S A PPI September 2005 R1 MS 13 202 www swagelok com GLOSSARY USER S MANUAL ON GLOSSARY Active Procedure The procedure sometimes referred to as Weld Program or Weld Schedule that is loaded for use in the M100 This is the program that will be used in WELD mode functions Arc The flow of electrical current between an anode and cathode In welding the flow of current between an electrode and the work Arc Gap The distance between the electrode and the work Arc Gap Gage The gage used to set the arc gap in the weld head rotor Arc Radiant Energy The ultra violet light emitted
10. Model Number Serial Number Delivery Date 2005 Swagelok Company all rights reserved 7 September 2005 Regulatory 8 2005 Swagelok Company all rights reserved September 2005 Regulatory Safety Summary The safety information presented here pertains to both the Swagelok Welding System SWS and the process of Gas Tungsten Arc Welding GTAW Read Operating Instructions Read all of the instructions in this manual prior to operating the SWS Statements 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 A 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 2005 Swagelok Company all rights reserved September 2005 Regulatory ELECTRIC SHOCK can kill Touching live electrical parts can cause fatal shocks and severe burns Incorrectly installed or improperly grounded equipment i
11. WELE Pinea If a Program password is not entered the security will allow the user to access all Programmer functions Figure 69 Password 70 2005 Swagelok Company all rights reserved September 2005 M100 Power Supply UTILITY RESET WELD COUNTER Note The M100 advances the Weld Count The Weld Counter that appears on the main or remote each time a new weld is started screen and in data log can be reset or changed Key in the DATALOG CONFIG PASSWORD GUPEA new counter number and press ENTER RESET WELD COUNTER SET DATE TIME INITIALIZE CARD CLEAR APPLICATION EXECUTOR VER 505 Fo PANEL VER 101 LOADER LO VER 800 LOADER HI VER 800 data conf pass UTIL load hi ver gt gt RESET WELD COUNTER set date time Figure 70 Reset Weld Counter UTILITY SET DATE TIME If the date or time displayed is incorrect you can enter a new date and time SAVE TIME NOW option must be pressed after changes are made Caution UTILITY INITIALIZE CARD AN All daia willbe cleared If the PC memory card data or formatting becomes corrupt from the PC memory card the card can be cleared and initialized when the PC memory card is initialized 2005 Swagelok Company all rights reserved 71 September 2005 M100 Power Supply UTILITY CLEAR APPLICATION n Extreme Caution This is an owner password protected function used when eth it soft updating the application software installed in the unit The Sn
12. Weld Overlap Time For example using 0 049 wall thickness and the average travel speed from step 3 b 0 049 x 2 3 8 60 0 098 0 063 1 555 1 6 seconds 4 Calculate the total weld time Weld Time per Revolution Weld Overlap Time Total Weld Time For example using the weld time per revolution from step 2 and the weld overlap time from 3 c 24 5 1 6 26 1 seconds 5 Calculate the weld time per level Total Weld Time Number of Levels Weld Time per Level For example using the weld time from step 4 and 4 levels 26 1 4 6 525 6 5 seconds per level 2005 Swagelok Company all rights reserved 101 September 2005 M100 Power Supply Socket Welds Because socket welds are not full penetration welds a modified concept is used to calculate the weld procedure guideline Refer to the Automatic Socket Weld Procedure Guideline Worksheet located on page 113 The modification is to the High Low current value and the Impulse value Adjusting the electrode offset will change the profile of the weld Adjusting the weld level heat will change the profile of individual levels All socket welds use a single pass technique The arc gap Not will be 0 010 in 0 25 mm for all sizes and offset 0 015 in Start all socket welds between 0 35 mm as shown in Figure 90 The welding diameter is 11 and 12 o clock positions to assist based on the socket OD the formation of a weld pool Socket Wall Th
13. 1 Ss nn 2005 Swagelok Company all rights reserved 109 September 2005 M100 Power Supply Calculating Weld Parameters Inches Continued Step Setting 8 Total weld time single pass in seconds Seconds per Revolution Weld Overlap Total Time Single Pass 60 rom Seconds per Revolution 60 ___ _ Wall Thickness x 2 Travel Speed 60 Weld Overlap _x2 __ 60 Seconds per Revolution Weld Overlap Total Time Single Pass 9 Rotor delay time use the weld overlap time from step 7 10 Prepurge time in seconds 11 Postpurge time in seconds Downslope Total Weld Time x 0 2 Downslope _ x0o2 Pulse rate x 2 364 Travel Speed 30 x Wall Thickness Impulse Rate 1 182x sd 110 2005 Swagelok Company all rights reserved September 2005 M100 Power Supply Weld Procedure Guideline Worksheet Metric Standard Determine the Work Specifications Step Parameter Setting 1 Programmer s Name 2 Joint Type 3 Material Type 4 Weld Diameter in Millimeters 5 Wall Thickness in Millimeters 6 Weld Head Model No T Electrode Part No 8 Arc Gap in Millimeters Arc Gap Gauge Setting 9 ID Purge Gas Flow in L min Gas Type 10 Shielding Gas Flow in L min Gas Type 11 ID Purge Gas Pressure in mm wc Calculating Weld Parameters Step Setting 1 Travel speed mm per sec Table 8 2 Rotor speed in rpm for all levels Travel Speed Circumference x 60 rpm Tube OD x x Circu
14. RONS Figure 64 Long Printout 2005 Swagelok Company all rights reserved 65 September 2005 M100 Power Supply DATALOG AUTO PRINT CONFIG PASSWORD UTILITY This function allows you to specify whether the print is PRINT COUPON i PRINT ALL COUPONS to be output only when requested or automatically every E AO l nth weld XFER MEM TO CARD PRINT FORMAT LONG DATALOG OF COUPONS AE FRIST EE This function allows you to specify how many weld data aa ee logs the unit will store in internal memory Selection of NONE will command the unit to store no weld data logs Selection of a number will command the unit to store that number of logs then roll off the oldest log as new logs are added Selection of ALL will command the unit to store all logs until the files are erased or the memory 1s full DATALOG ENABLE CARD When this function is turned ON the unit will transmit the weld data as welds are made to the data card port The Weld Mode Error function MEMORY CARD FULL or REQ MEMORY CARD will be active DATALOG ENABLE SERIAL When this function is turned ON the unit will transmit the datalog records as welds are made to the serial port in comma delimited format DATALOG ERASE DATALOG MEM Erases all datalog records from memory DATALOG ERASE DATALOG CARD Erases all datalog records from PC memory card Figure 65 Number of Coupons 66 2005 Swagelok Company all rights reserved Se
15. To exit press any Mode key gt gt MANUAL ENTRY load and edit 7 M100 power supply will recognize any invalid fields See Step 3 on page 54 8 Save to one of the following Figure 58 Manual Create Input e Save to memory e Save to PC memory card e Active no save 9 Press ENTER 10 Enter a procedure name and press ENTER The procedure is complete CREATE PROCEDURE LOAD AND EDIT This submode is used to copy a weld procedure that is similar to the one you want to create and it places you directly into EDIT ITEM so you can make changes The default name will be untitled to remind you a new name is needed You cannot overwrite an existing procedure from this function 60 2005 Swagelok Company all rights reserved September 2005 M100 Power Supply SETUP MODE The SETUP Mode handles a number of auxiliary functions of the M100 power supply User preferences can also be changed in this mode See page 24 Setup Mode Directory Submode Activity Onscreen Display Page DATALOG PRINT COUPON 62 Transfer memory XFER MEM TO 62 SERIAL XFER MEM TO CARD Modify print format PRINT FORMAT 62 Auto print option AUTO PRINT 66 Number of coupons OF COUPONS 66 Enable card or ENABLE CARD 66 serial port ENABLE SERIAL Erase datalog ERASE DATALOG 66 memory or card MEM ERASE DATALOG CONFIG PASSWORD UTILITY SETUP DATALOG CARD CONFIGURE J Figure 59 Setup Mode se 68 CONFIG PAS
16. 23 cm high without handle Extension Cords Model Supply Wire gauge Wire gauge Voltage 0 to 50 ft 50 to 100 ft 0 to 15 m 15 to 30 m SWS M100 1 115 V ac 12 AWG 10 AWG SWS M100 HP 1 2 5 mm 4 0 mm SWS M100 2 230 V ac 12 AWG 10 AWG SWS M100 HP 2 2 5 mm 4 0 mm Some power loss will occur depending on the length of the extension cord See table to determine the minimum wire size to use 128 2005 Swagelok Company all rights reserved September 2005 Swagelok VCR VCO Ultra Torr Micro Fit TM Swagelok Company 2005 Swagelok Company Printed in U S A PPI September 2005 R1 MS 13 202 www swagelok com TROUBLESHOOTING USER S MANUAL ON TROUBLESHOOTING This section contains troubleshooting charts to assist you with problems It contains troubleshooting guidelines for both hardware and weld process problems including e power supply e weld head e electrode e fixture block e welding process Swagelok Welding System SWS Repair Procedure In some cases the stated remedy to a problem listed in the charts may be Call for service If so contact your Swagelok representative for over the phone troubleshooting Be prepared to give the following information to the Swagelok representative e serial and model number of the equipment e complete description of the application e detailed description of the symptom Provide complete details of any problem enco
17. ANN AUTO ENTRY 1 level WELD TYPE gt gt MULTI LEVEL 1 level Figure 57 Number of Passes List 2005 Swagelok Company all rights reserved September 2005 M100 Power Supply 11 Select levels M100 power supply prompts for the number of levels desired At this point the M100 power supply calculates the remainder of the data for the weld procedure e The electrode is selected based on the weld head and tube diameter entered e The arc gap is selected based on the weld head wall thickness and OD e The start power is selected based on wall thickness e The tube purge pressure is selected based on the diameter e The shield purge rate is selected based on the weld head type e The prepurge and postpurge times are selected based on the weld head e The level data is calculated based on a set of factors A B C thickness speed and OD speed taken from the latest table developed for Weld Guideline Preparation e If tacks were selected the tack current is calculated from the first level data All tacks are evenly spaced starting at 10 degrees e The start current is calculated from first level data e The downslope time is calculated as a percentage of the total weld time e The arc gap gauge setting is calculated based on weld head diameter and arc gap value e After all work specifications are entered the M100 power supply will create the description If tac
18. L min 13 to 18 mmwc 7 to 12 std L min 6 mm 1 2 to 1 7 mb 0 7 to 1 3 torr 2 in l 170 std ft hr 0 4 to 0 7 iwc 15 to 50 std ft hr 3 8 in 50 mm 80 L min 13 to 18 mmwc 7 to 12 std L min 10 mm 1 0 to 1 7 mb 0 4 to 0 9 torr 3 in 400 std ft hr 0 2 to 0 5 iwc 30 to 50 std ft hr 1 2 in 75mm 190 L min 5 to 13 mmwc 12 mm 0 5 to 1 2 mb 0 4 to 0 7 torr 4 in 0 083 in 720 std ft hr 0 2 to 0 4 iwc 30 to 50 std ft hr 3 4 in 100 mm 2mm 340 L min 5 to 13 mmwc 20 mm 0 5 to 1 0 mb 0 4 to 0 9 torr 6 in 0 083 in 1670 std ft hr 0 2 to 0 5 iwc 1 in 150 mm 2mm 790 L min 5 to 13 mmwc 25mm 0 5 to 1 2 mb Note These weld tables are for use on butt welds only If Weld Head Purge Rates exceed Swagelok recommendations be cautious of arc wander For best results use constant weld head purge between welding cycles ATW welds and Weld Ring welds typically will require approximately 15 more purge pressure Pressures must be adjusted for ID encroachment of 0 to 10 of wall thickness at the bottom of the weld Indicated purge rates are for minimum color line ID purge rates shall be adjusted to the desired ID color line Restrictor sizes are approximate purge rate and pressure are critical parameters 2005 Swagelok Company all rights reserved 75 September 2005 M100 Power Supply Starting and Completing the Weld 1 Check the following before starting the weld All rear panel connections are complete Shielding and purge
19. LEVEL 0 DELETE LEVEL INSERT TACK 0 DELETE TACK CURRENT LIMIT 100 PURGE LIMIT 100 CURRENT TOLER 2 5 SPEED TOLER 25 REQUIRED FIELDS MODIFY current limit gt gt PURGE LIMIT current toler create 100 4 Figure 53 Adjust Limits 2005 Swagelok Company all rights reserved September 2005 M100 Power Supply MODIFY PROCEDURE REQUIRED FIELDS If you wish to require some or all the fields in WELD INFO to be filled in by the welder before welding this setting is available Three configurations are available e NO the field is not required e REQ the field must be entered before welding begins and will be cleared with power off e CHG the field must be entered before welding begins and must be re entered for every weld An asterisk will appear before each field requiring data in the WELD INFO mode CREATE PROCEDURE AUTO ENTRY The AUTO ENTRY is a quick and easy way to create a weld procedure You are prompted to select the weld parameters from a series of pick lists and the M100 power supply calculates the initial values for tacks levels and other data You must complete all the steps listed below or your work will not be saved 1 Select Programmer Enter your name or ID with the alphanumeric keypad 2 Select joint type Select the joint type The list presented gives the type of tube for each side of the joint Some of the options include e TB TB side 1 Tube B
20. Number of Tacks _ __ Submode Menu WELD AD UST VIEW INFO ST 0 TE Active Procedure J PROCEDURE TEST 1 9 WELD i Mode DESCRIPTION 500 0 049 SS316L 4 00 S Generated WELDER JSMITH PROGRAMMER JOHNS N Step Invalid Description or ATW JOINT PARAMETERS Procedure JOINT TYPE MATERIAL TUBE DIAMETER AOG WALL THICKNESS Parameter HEAD ELECTRODE OD GAS DEIN 5H B GAP 0 035 ARGON ARGON C 040 605 GAGE 0 907 12 1 3 Status Indicators READY lt Weld Warnings Errors W 000 Counter Active Key Indicators START PURGE JOG HOME PRINT Prompt Line REMOTE PENDANT Submode Menu Warnings Errors _ 000 __ Weld Counter READY Figure 27 WELD Mode Display 32 2005 Swagelok Company all rights reserved September 2005 M100 Power Supply WELD READY MIA ADJUST VIEN INFO TEST When the M100 power supply is in the WELD WELD mode it indicates that it is ready to weld by READY on the screen and READY on the remote This means that 1f START is pressed the weld cycle will begin as programmed in the active weld procedure In this submode PURGE JOG HOME PRINT and STOP are active START PURGE JOG HOME PRINT WLD adj view inf tst TESTI 500 049 SS 316 04 000 Figure 28 READY Display If the M100 power supply is not ready to weld the word LED ERR eT ee DISABLED will be displayed and an error indicator will call attention
21. SETUP DATALOG CARD ENABLED ON is active the PC memory card is inserted but the write protect is on When SETUP DATALOG CARD ENABLED ON is active the PC memory card is inserted and the write protect is on but the card is not initialized and data cannot be written to the card To initialize card go to SETUP UTILITY INITIALIZE CARD 2005 Swagelok Company all rights reserved September 2005 M100 Power Supply Warnings Wrong Weld Head Printer Paper Out Printer Head Up Printer Overtemp Short Prepurge Test Mode Weld Errors Rotor Jammed Misfire Arc Failed Tack Not Complete High Temperature Low Arc Voltage Stop Pressed Speed Tolerance Current Tolerance Information Box System Clean Up Description The active procedure calls for a different weld head than the weld head connected to the power supply The printer is out of paper The printer head is up for loading The printer temperature is over its rated temperature You will not be able to print until the warning is removed The prepurge time is set for less than 5 seconds If the parameters of the weld include continuous purge this warning will not be displayed The M100 power supply is in test mode and will not execute a weld Description The rotor has stopped turning during the weld program The arc was not established The arc failed during the weld The tack failed to be completed as programmed The powe
22. Use check all that apply Q Maintenance Q Distributor Use Rental Demonstration Service Q New Construction Q Cleanroom Class Q Research and Development Q Training Q Other Please describe 2005 Swagelok Company all rights reserved September 2005 2005 Swagelok Company all rights reserved September 2005 tu EL i Wy DECLARATION OF CONFORMITY CE DECLARATION DE CONFORMITE EG UBEREINSTIMMUNGSERKLARUNG DICHIARAZIONE DI CONFOMITA CE EC DECLARACION DE CONFORMIDAD Manufacturer Authorized Representative Swagelok Company Swagelok AG 29500 Solon Road St Gallerstrasse 84 Solon Ohio 44139 3492 CH 8853 Lachen USA Switzerland Product Orbital Gas Tungsten Arc Produit Produkt Prodotto Producto Welding GTAW System Model SWS M100 Mod le Modell Modello Modelo AZ A gt i RES This Product Complies With The Following European Community Directives Ce produit conforme aux directives suivantes de la Communaut Europ enne Dieses Produkt entspricht den nachstehend aufgef hrten Richtlinien der Europ ischen Union Questo prodotto conforme ai seguenti direttivi della Comunita Europea Este producto cumple con las directivas siguientes de la Comunidad Econ mica Europea EMC DIRECTIVE 89 336 EEC LOW VOLTAGE DIRECTIVE 73 23 EEC AS AMENDED BY THEIR COUNCIL DIRECTIVES The Following Standards Were Used To Verify Compliance With The Directives Les normes suivantes ont t appli
23. a value in the joint parameters highlighted pressing FWD once will move the cursor to highlight the weld head type which is the first value in the next group Pressing FWD again will move the cursor to the next screen of data 2005 Swagelok Company all rights reserved 25 September 2005 M100 Power Supply FWD and BACK can also be used to scroll through pop up menus and pick lists that are more than one screen long When entering a value using the alphanumeric keys BACK can be used as a backspace key and FWD will move the cursor forward one space FWD and BACK appear on the same keys as PRINT and HOME respectively The PRINT and HOME functions are only available when the M100 power supply is in the WELD WELD mode FWD and BACK are available in other modes 26 2005 Swagelok Company all rights reserved September 2005 Weld Function Keys The yellow green and red weld operation keys are used to control the welder The keys are only active in the WELD WELD mode START PURGE Pressing this key will start the weld with the active weld procedure Pressing this key will toggle the weld head purge gas on and off When the purge gas is on the word PURGE will flash on the screen and the remote to indicate the continuous purging When PURGE is not flashing the active weld procedure controls the flow of purge gas Pressing this key will jog the rotor at the speed set in the SETUP CONFIGURATI
24. analysis of the welding process Remember that data recording is just a method used to monitor the welding process and does not guarantee the quality of the weld 88 2005 Swagelok Company all rights reserved September 2005 M100 Power Supply PC Memory Card A Swagelok PC memory card is a flash memory device designed for use with the M100 power supply No other memory card may be used in its place The PC memory card has a Write Protect Switch When the switch is on the card will read only The M100 power supply will prompt you if the switch 1s on and you attempt to write or delete The PC memory card has three 3 basic functions 1 Weld procedures may be stored outside the internal memory of the unit on the PC memory card The procedures may be re installed into the internal memory of any M100 or used directly from the card e File SAVE STORE TO CARD page 49 e File COPY Copy Procedures Files page 51 2 Weld data logs may be stored on the PC memory card as they are made or downloaded from the internal memory to the card for transfer to a PC e Setup Mode DATALOG ENABLE CARD page 66 e Setup Mode DATALOG XFER MEM TO CARD page 62 3 Front Panel application software may be loaded into the M100 power supply using the PC memory card e Setup Mode UTILITY CLEAR APPLICATION Page 72 2005 Swagelok Company all rights reserved 89 September 2005 M100 Power Supply PC Interface C
25. are obtained by entering the programmer password 1f one has been set at initial start up POWER SUPPLY CREATE EDIT ITEM INSERT LEVEL 4 DELETE LEVEL INSERT TACK 0 DELETE TACK CURRENT LIMIT PURGE LIMIT CURRENT TOLER SPEED TOLER REQUIRED FIELDS REMOTE PENDANT MODIFY create required fields gt gt EDIT ITEM insert level 4 Figure 18 Programming Mode Display 2005 Swagelok Company all rights reserved 23 September 2005 M100 Power Supply Accesses the SETUP mode SETUP This is a multi purpose mode in which user Datalog preferences options for data logging and other Config parameters can be set Any modifications made Password in SETUP mode are saved on the system and Utility not in a specific procedure SETUP Mode Access Access to the setup mode is limited to users with programming privileges or higher Programming privileges are obtained by entering the programmer password at initial start up if one has been set POWER SUPPLY DATALOG CONFIG PASSWORD UTILITY D PRINT COUPON an PRINT ALL COUPONS XFER MEM TO SERIAL XFER MEM TO CARD PRINT FORMAT LONG AUTO PRINT 0 OF COUPONS NONE ENABLE CARD OFF ENABLE SERIAL OFF ERASE DATALOG MEM ERASE DATALOG CARD REMOTE PENDANT conf pass erase datalog card gt gt PRINT COUPON print all coupons Figure 19 Setup Mode Display 24 2005 Swagelok Company all rights reserved Septe
26. commonly used character such as a space or a period e Press the key twice quickly to select the first character on the top line of the key e Press the number three times quickly to select the second character on the top line of the key e Press the number four times quickly to select the third character on the top line of the key e Press a different key or wait approximately half of a second without pressing the same key to enter the selected symbol e Use the arrows to scroll to any errors that may have been made e After the desired string or value has been completed press ENTER to confirm the selection CANCEL Key Pressing CANCEL will cancel the last entry and LD revert to the previous submode selected If you press CANCEL while in a direct data entry field it will revert to the previous value Contrast Keys Use these keys to adjust the display contrast To change the screen color from white background with black letters to black background with white letters press the Contrast Keys several times Data Recording Printer Feed Key Press this key to advance the paper through the data recording printer 2005 Swagelok Company all rights reserved September 2005 M100 Power Supply ABC DEF GHI 1 2 3 JKL MNO PQR 4 5 6 stu vwx yz 7 8 9 LE SPACE Bs Figure 24 Alphanumeric Keys Figure 25 Contrast Keys and Data Recording Printer Feed Key 29 M100 Power
27. data recording printer is designed to require a minimum of maintenance and service Contact your Swagelok representative for any electrical or mechanical repairs that must be performed Clearing Paper Jams In the event of a paper jam do not force paper into the unit or try to pry the paper out of the unit This may damage the thermal print mechanism Instead 1 Turn off the power supply 2 Turn the latch counter clockwise to release the data recording printer body from the case Extend the data recording printer body from the power supply by pulling p gure 81 Opening the Data Recording it forward See Figure 81 Printer Drawer 3 Lift the printer head fully by raising the lift arm located with the manual paper feed wheel next to the printer cover panel See Figure 82 Figure 82 Lift the Printer Head 2005 Swagelok Company all rights reserved 83 September 2005 M100 Power Supply 4 Cut the paper off at the roll Carefully remove the paper A Caution in the data recording printer mechanism by advancing Do not pull the paper the Manual Feed Wheel or using tweezers or small backwards toward the paper needle nose pliers Remove the paper through the front roll This can damage the panel See Figure 83 print head mechanism 5 Ifthe paper cannot be cleared the front panel cover may be removed by removing two screws located on the underside of the front panel cover Clear the paper jam and replace the front
28. during the welding Increase tack size or the number of tacks 2005 Swagelok Company all rights reserved 103 September 2005 M100 Power Supply Weld Program with Ramp Time Note Ramp Time will affect the collection of data logs if the weld time is not at least one second longer than the Ramping is used in two applications The first and most commonly used 1s ramping between levels Its main purpose is to spread over a set period of time the change of amperage between levels The second is to Ramp up slowly Ramp Time when starting a weld Its main purpose is to apply heat to the material in a controlled manner which is necessary with some materials The ramp time is applied to the beginning of the level it is entered Ramping between levels If you desire to ramp the heat down from level one to level two you apply the desired ramp time to level two see Figure 91 Ramp Time nn rc Level 2 f f f i 7 Ramp cd AU f l f Level 3 Level 4 AUTANT onnn Af ARENSE LE d L 7 7 5 A A LE DE I AU na ap IAN AT AT LP MH HHH HA 7 ON NU AO HL HAN Z ST HAA LUN f LL A oan Level 1 ous Level 3 Beier Weld Time ela rime Weld Time Time Figure 91 Ramp Between Levels 104 2005 Swagelok Company all rights reserved September 2005 M100 Power Supply Ramping up in level one If you desire to ramp the heat up from a minimum value to welding temperature over a set period of time
29. from the welding arc Arc Start The period of the welding cycle following prepurge During this short period of time approximately 0 01 second high voltage is applied between the electrode and work piece initiating the arc The only control of this period is with start power Arc Welding A type of welding process that uses an electrical arc as a source of heat to melt and join metals Arcing A condition in welding where the arc follows a path other than from the electrode to the work This can cause damage to the weld head and fixturing components Argon An inert monatomic gas used as a shielding and purge gas for gas tungsten arc welding 2005 Swagelok Company all rights reserved 1 September 2005 ATW Automatic Tube Weld A type of weld that uses a cuff at the joint of the weld fitting to aid in alignment and supply extra material to the weld joint This weld will require more Arc Gap and more heat than a comparable Butt Weld Autogenous In orbital welding autogenous describes the process of welding two parts together using the fusion process without the use of filler material Automatic Welding A welding process in which all of the parameters are controlled by the welding machine during the weld cycle The process may or may not perform the loading and unloading of the work pieces Average Current In pulse welding high current is maintained for some fraction of each output cycle and low current i
30. gas lines are properly connected The inert gas source is on Correct gas flow rates are set Weld pieces are properly aligned and clamped in the fixture block The proper arc gap is set The weld head is connected to the fixture block The proper weld procedure program has been selected and entered WELD mode display shows READY The internal purge gas is flowing 2 Press START Total time for the process is the sum of the following times Prepurge Rotor delay Weld time all levels Downslope Postpurge Display Indications During Welding During welding the status messages are displayed on the screen in the following sequence 76 Loading Prepurge Arc Start Tacks Rotor DLY delay Ramp Levels time remaining Downslope time remaining Postpurge Note Although the power supply welds in any orientation it is recommended that it be placed in the upright position before welding WARNING DO NOT TOUCH THE CABLE CONNECTORS DURING ARC START IF THE CABLES HAVE BEEN DAMAGED THE POTENTIAL FOR AN ELECTRICAL SHOCK EXISTS Note If the arc fails to start the power Supply status becomes MISFIRE See the Troubleshooting section for possible causes and corrective actions 2005 Swagelok Company all rights reserved September 2005 After the Weld is Complete l Wait for the M100 power supply to return to Ready state If a weld error occurs refer to page 35 Check 1f t
31. impulse maintenance and impulse width values for the level You are allowed an adjustment range within the limits set in PROGRAM MODIFY CURRENT LIMIT see page 56 The limit is usually about 10 of the initial average for that level The M100 power supply adjusts the average current by following the appropriate weld procedure guideline 1 Select the level Use the UP DOWN keys to highlight the level you wish to adjust on the selection list then press ENTER For example to adjust the current for level 1 select and press ENTER on LEV 1 CURR line 2 Adjust the current setting The average current value for the selected level is then highlighted and can be adjusted using the UP DOWN keys The adjusted value will be automatically constrained by the current limits The M100 power supply can be returned to the Ready state by pressing WELD or highlighting the WELD submode with the menu arrows 38 WELD ADJUST VIEW INFO TEST LEV 1 CURR LEV 2 CURR LEV 3 CURR LEV 4 CURR PREPURGE POSTPURGE JOG HOME PRINT WLD adj view inf tst postpurge 20 gt gt CLEAR ADJUSTMENT lev 1 curr 35 0 Figure 31 Clear Adjustments WELD AURIS VIEW INFO TEST WELD CLEAR ADJUSTMENTS LEV 1 CURR 35 0 LEV 2 CURR 33 9 LEV 3 CURR 22 9 LEV 4 CURR 31 9 PREPURGE 20 POSTPURGE 20 wld ADJ view inf tst clear adjustments gt gt LEV 1 CURR 35 0 lev 2 curr 33 9 Figure 32 Current Level Adjustment 2005 Swagelok Company
32. in level one Ramp time e Change the Speed High RPM and the Speed Low RPM to Zero RPM f Increase the start penetration by increasing the weld time of level one or by increasing the weld input amperage g Decrease the start penetration by decreasing the weld input amperage h Level one is now a Ramp up time and Rotor Delay Level The first weld level will be level two Make heat changes to weld accordingly using either WELD ADJUST or PROG MODIFY EDIT ITEM AUAN Downslope HAHN UAHA AW IN nnan JAT RAT HTH NLL Alo UE A ASRA ap p p TUE a LUZ PNH ETH HF LU LLL SES SA bumunun NT Lie NS Z LLL Level 1 Level 2 Level 3 Level 4 Level 5 Rotor No Rotor Movement Weld Time Weld Time Weld Time Weld Time Delay 0 1 Sec Level for Initial Penetration Welding Levels Figure 93 Ramp Time Weld Penetrates Completely Before Rotor Moves 106 2005 Swagelok Company all rights reserved September 2005 M100 Power Supply Example Weld Procedure Guideline Worksheet Determine the Work Specifications Step Setting i John J Jones 2 TE T8 316LV STELV 0 5 Inches 5 0 049 0 049 CWS SH E 7 C 040 605 0 036 Inches 0 907 Inches 9 ID Purge Gas Flow in SCFH 15 SCFH 10 Shielding Gas Flow in SCFH 13 SCFH 11 ID Purge Gas Pressure in IWC 1 2 IWC For ATW fittings use the corrected wall thickness To determine the wall thickness for an ATW fitting add 40 of the ATW cuff thic
33. interface on the front panel of the power supply includes a keypad and the display The keypad provides a means of entering information needed to operate the M100 The display allows you to monitor the welding process and to perform programming and file operations A remote pendant can also be used to operate the unit It has a keypad and a display 2005 Swagelok Company all rights reserved September 2005 M100 Power Supply A Swagelok PC memory card is a flash memory device designed for use with the M100 power supply No other memory card may be used in its place The PC memory card has a Write Protect Switch When the switch is on the card will read only The M100 power supply will prompt you if the switch is on and you attempt to write or delete The PC memory card has three 3 basic functions 1 Weld procedures may be stored outside the internal memory of the unit on the PC memory card The procedures may be re installed into the internal memory of any M100 power supply or used directly from the card 2 Weld data logs may be stored on the PC memory card as they are made or downloaded from the internal memory to the card for transfer to a PC 3 Front panel application software may be loaded into the M100 power supply using the PC memory card 16 2005 Swagelok Company all rights reserved September 2005 M100 Power Supply Operator Display POWER SUPPLY Tube or Wall Number Number a Op Thickness Ma
34. panel cover 6 Reload the paper after the jam has been cleared Slide the data recording printer back into the power supply and tighten the latch Front Panel Slot Figure 83 Clearing a Paper Jam 84 2005 Swagelok Company all rights reserved September 2005 M100 Power Supply Optional Equipment The optional equipment available for your Swagelok Welding System SWS is listed below Contact your Swagelok representative for additional information on any listed option Optional equipment includes e SWS remote pendant e remote pendant extension cables e weld head extension cables e data logging monitoring e PC interface cable SWS Remote Pendant See Figure 84 The remote pendant allows you to access all the controls and functions of the M100 power supply The screen on the remote pendant is not as large as on the main screen Therefore only data highlighted on the main screen will be displayed on the remote screen The unit is attached to the power supply via a cable and the connector labeled Remote on the front panel See Figure 85 Remote Pendant Extension Cable The remote pendant extension cable is 35 feet long This allows the remote pendant to reach the weld head when the weld head extension cable is used ABC DEF GHI 1 2 3 JKL MNO PQR e 4 5 SPACE STU KE VWX 1 7 8 i Figure 84 Remote Pendant Note The SWS remote pendant for the D Series power supply will not work on the
35. repeated for every level The tacks section can display 4 tacks at a time The M100 power supply allows up to 10 tacks procedure If more then 4 tacks are present they can be displayed by using the FWD BACK keys that will scroll a tack at a time 2005 Swagelok Company all rights reserved September 2005 M100 Power Supply CREATE EDIT ITEM INSERT LEVEL DELETE LEVEL INSERT TACK 0 DELETE TACK CURRENT LIMIT PURGE LIMIT CURRENT TOLER EDIT PROCEDURE 100 CREATE WELDER ME LEVEL PAR 4 IMPULSE Ose 1 7 MAINTENANCE 20 6 0 6 0 6 20 6 WELD TIME 4 6 4 6 4 6 4 6 RAMP 0 0 0 0 0 0 0 0 PULSE RATE 4 4 4 4 PULSE WIDTH 30 30 30 30 SPEED HI 35 0 35 0 35 0 35 0 SPEED LO 35 0 35 0 5 5 ENTER VALUE BETWEEN 2 0 EDIT PROCEDURE PR TEST1 L 01 04 IMP gt gt 28 0 VALUES 2 0 100 AMPS Figure 51 Adjusting the Floating point Numbers PROCEDURE TEST1 PROG DESCRIPTION 0 500 0 049 SS 316L 04 00 PROGRAMMER ME 35 0 35 0 UNITS AMPS AND_100 53 M100 Power Supply Page Three This page contains the level sections The M100 power supply allows from 1 99 levels but only 4 levels may be displayed at one time If a procedure has more than 4 levels the remaining levels can be displayed by using the FWD BACK keys that will scroll a level at a time To use EDIT ITEM 1 Select MODIFY EDIT ITEM press ENTER 2 Using the alphanumeric keys make the d
36. speed of 3 in min to 6 5 2 11 2 55 15 in min is a general range for GTAW welding Worksheet Entry 5 5 2 Calculate the Rotor Speed in rpm a Calculate the circumference using the formula Tube OD x x Circumference For example 0 5 x 3 1416 1 5708 inches circumference b Use the travel speed from step 1 b and the circumference from step 2 a to calculate and record the rpm Travel Speed Circumference rom For example 5 5 1 5708 3 5014 3 5 rpm Worksheet Entry 3 5 3 Calculate the Impulse Level 1 a Determine the wall thickness 0 049 in ATW Fitting To determine the wall thickness used for an ATW fitting add 40 of the ATW cuff thickness to the fitting wall thickness ATW Cuff Thickness Fitting Wall Thickness Figure 89 ATW Fitting wall Thickness The new ATW wall is then used in Table 10 for the A factor 94 2005 Swagelok Company all rights reserved September 2005 M100 Power Supply b Locate the wall thickness 0 049 in and then read the corresponding A factor in Table 10 Table 10 Wall Thickness and A Factor Wall Thickness Range in mm TO 0 020 0 78 0 021 to 0 034 1 1 0 035 to 0 046 0 87 to 1 17 1 4 0 047 to 0 055 1 4 0 056 to 0 065 1 4 0 066 to 0 070 1 41 0 071 to 0 075 1 33 0 076 to 0 080 1 25 0 081 to 0 085 1 17 0 086 to 0 090 1 11 0 091 to 0 095 1 05 0 096 to 0 109 0 90 0 110 to 0 118 0 84 0 119 to 0 154 0 65 c Calculate and record
37. to an error in the active procedure Correct the error or select a different program file and the unit will be ee able to proceed with the weld See page 35 for more information on error indicators START PURGE JOG HOME PRINT WLD adj view inf tst D INVALID PROCEDURE DISABLED Figure 29 DISABLED Display WELD Executing a Weld When START is pressed the M100 power supply begins executing a weld according to the active weld procedure During the weld the status line on the display and the remote will indicate the current voltage level number being executed and time remaining in each step If tacks are part of the selected weld procedure they are executed before the level s As the tacks and levels are executed the data for each is highlighted 2005 Swagelok Company all rights reserved 33 September 2005 M100 Power Supply POWER SUPPLY REMOTE PENDANT WELD ADJUST PROCEDURE MESEM WLD adj view inf tst DESCRIPTION 500 0 049 SS316L WELDER JSMITH PROGRAMMER JOHNS TESTI 5007049 SS 316 04 JOINT PARAMETERS 000 JOINT TYPE MATERIAL TUBE DIAMETER WALL THICKNESS HEAD ELECTRODE ARC OD GAS ID GAS 5H B GAP 0 035 ARGON ARGON C 040 605 GAGE 0 907 12 1 3 READY START PURGE JOG HOME PRINT Figure 30 WELD Mode Display After the weld is completed properly the unit returns to the READY state If error conditions occurred during the weld the error will be displayed and ENTER will have
38. weld are the same material and duplicates side 1 information in side 2 If necessary changes can be made in MODIFY EDIT ITEM Select weld head Select the weld head to be used Since each weld head series is compatible with specific ranges of OD only the compatible weld heads are presented for selection Select number of passes If the tube diameter is 1 4 in or less the M100 power supply prompts you to select whether a single level multiple pass procedure or multiple level single pass procedure is to be calculated Select tacks levels or both After the weld head and number of passes are selected the M100 power supply presents a list for you to select tacks levels or both for the unit to calculate Select tacks M100 power supply prompts for the number of tacks desired MODIFY MANUAL ENTRY LOAD AND EDIT MODIFY PROCEDURE TEST1 DESCRIPTION 0 050 0 63 WELDER ME JOINT PARAMETERS JOINT TYPE MATERIAL S 3 TUBE DIAMETER WALL THICKNESS HEAD ELECTRD ARC GAP 0 000 gage 0 000 unit inches Enter side 1 Diameter AUTO ENTRY 2 000 0 062 0 125 TUBE OD gt gt Figure 56 OD Pick List TEST PROCD PROG MODIFY PROCD PROCEDURE TEST DESCRIPTION WELDER ME PROGRAMMER ME JOINT PARAMETERS JOINT TYPE MATERIAL TUBE DIAMETER WALL THICKNESS ELECTRD ARC AMR ere me MULTI LEVEL 1 PASS I I 1 level multi pass S 3161 0 000 PCAN A
39. 05 Swagelok Company all rights reserved September 2005 MODIFY PROCEDURE EDIT ITEM This function allows you to edit the active weld procedure Use the FWD BACK keys to move between fields of information and the UP DOWN keys to highlight information to be changed Page one This page is primarily composed of textual information which is important for identifying the procedure and is displayed in the WELD WELD mode All fields of a procedure are directly modifiable in the EDIT mode except for three Procedure Name Welder Name and Description Procedure name This can only be modified in the FILE mode Welder Name This can only be changed in WELD INFO mode Description Is automatically generated and updated by the M100 power supply It cannot be directly modified It is composed of 6 individual fields that help identify the procedure These fields are DDDDD WWW MMMMMM LL TTC 5 characters for Side 1 Tube Outside diameter 3 characters for Side 1 Tube Wall thickness First 6 characters of Side 1 Material Number of Levels in procedure Number of Tacks in procedure QAP 40 Is blank for most procedures An S indicates a step procedure an I indicates an invalid procedure and an A indicates an ATW procedure Page two This page contains the Start Parameters and Tacks sections The Start Parameters are values that are executed once in the procedure as opposed to level type information which is
40. 1 2 iwc 92 2005 Swagelok Company all rights reserved September 2005 M100 Power Supply Setting Single or Multi Level Program Parameters 1 Calculate the Travel Speed a Determine the travel speeds by locating the wall thickness 0 049 and the OD size 1 2 1n in the appropriate table Table 8 or Table 9 then reading the corresponding travel speeds Table 8 Travel Speed Setting Chart Fractional Wall Thickness Travel Speed in Tube Pipe in per min 0 010 to 0 020 116 10 0 021 to 0 034 18 8 0 035 to 0 046 14 7 0 047 to 0 055 3 8 1 8 6 0 056 to 0 065 5 0 066 to 0 070 4 5 0 071 to 0 075 3 4 4 0 076 to 0 080 3 6 0 081 to 0 085 3 3 0 086 to 0 090 3 0 091 to 0 095 2 6 0 096 to 0 109 2 3 0 110 to 0 154 2 4 2 Table 9 Travel Speed Setting Chart Metric Wall Thickness OD Size Travel Speed 0 20 to 0 50 4 2 0 51 to 0 86 3 4 0 87 to 1 17 oOo w 6 3 0 1 18 to 1 40 2 5 1 41 to 1 65 2 1 1 66 to 1 78 5 8 1 9 1 79 to 1 90 1 7 1 91 to 2 03 7 8 1 5 2 04 to 2 16 1 4 2 17 to 2 29 1 3 2 30 to 2 41 1 1 2 42 to 2 77 1 0 2 78 to 4 0 50 0 8 2005 Swagelok Company all rights reserved 93 September 2005 M100 Power Supply b Calculate and record the corrected travel speed using the following formula Average Travel Speeds OD Speed Wall Thickness Speed 2 Corrected Travel Speed Note For example for a 1 2 in x 0 049 in wall thickness A travel
41. 1 5 05 entire weld procedure as well as the results SERIAL 1050 DATE JUL 13 1999 TIME 03 42p WELD 12 DESCRIPTION PROCEDURE WPS TEST 1A DESCRIPTION 0 500 049 SS 316 04 03 PROGRAMMER XXXXXXXXX WELDER XXXXXXXXX JOINT TYPE TUBE TUBE MATERIAL SS 316L SS316L HEAT A123456789 A123456789 DIAMETER 0 500 IN 0 500 IN WALL THICK 0 049 IN 0 049 IN PROJECT MANUAL 123 DRAWING AIR 12 456 WELD HEAD 5H 60801 ELECTRODE C 040 555 ARC GAP SET 0 035 IN 0 907 IN OD GAS ARGON AA98765432 OD FLOW 12 CFH ID GAS ARGON BB98765432 ID PRESSURE 1 3 IWC OPEN 1 12345 OPEN 2 67890 LAST CAL JUN 15 1999 MIN VOLTS 4 0 CUR TOL 2 5 SPEED TOL 2 5 CUR LIMIT 100 PURGE LIMIT 100 INPUTS START POWER NORM START CUR 35 0 AMPS ROTOR DELAY 1 1 SECONDS DOWNSLOPE 3 6 SECONDS PREPURGE 20 SECONDS POSTPURGE 20 SECONDS TACKS DEGREES AMP SECONDS 1 0 35 0 1 0 2 120 35 0 1 0 3 240 35 0 0 9 IMPULSE AVG LEV IMPULSE MAINT RATE WIDTH CURR 1 68 6 20 6 4 30 35 0 2 65 2 20 6 4 30 33 9 3 61 7 20 6 4 30 32 9 4 58 3 20 6 4 30 31 9 RPM LEV TIME RAMP HI LOW AVG 1 4 6 0 0 3 50 3 50 35 0 2 4 6 0 0 3 50 3 50 35 0 3 4 6 0 0 3 50 3 50 35 0 4 4 6 0 0 3 50 3 50 35 0 OUTPUTS AVERAGE AMPS VOLT RPM TIME KJ 34 9 6 7 35 51 46 1 0 33 8 6 6 35 51 46 1 0 32 8 6 6 35 51 46 0 9 31 8 6 6 35 51 46 0 9 D S 15 5 6 6 35 51 3 6 0 3 PERFORMANCE CONFIRMATION a WELD COMPLETE PERFORMANCE ACCEPTABLE QA QC NOTES lt
42. 31 8 66 35 51 4 6 0 9 D S 155 66 35 51 3 6 0 3 7 PERFORMANCE CONFIRMATION WELD COMPLETE PERFORMANCE ACCEPTABLE QA QC NOTES Figure 62 Short Printout 2005 Swagelok Company all rights reserved 63 September 2005 M100 Power Supply The Medium printout shown in Figure 63 contains the SWAGELOK WELDING SYSTEM output information most commonly requested This printout DATA RECORD MEDIUN gives header information description inputs outputs and performance confirmation MODEL M100 1 VER 1 01 5 05 SERIAL 1050 DATE JUL 13 1999 TIME 03 42p WELD 12 DESCRIPTION PROCEDURE WPS TEST 1A DESCRIPTION 0 500 049 SS 316 04 03 XXXXXXXXX PROGRAMMER WELDER XXXXXXXXX LAST CAL JUN 15 1999 MIN VOLTS 4 0 CUR TOL 2 5 SPEED TOL 2 5 CUR LIMIT 100 PURGE LIMIT 100 INPUTS LVL AMPS RPM TIME 1 35 0 35 50 4 6 2 33 9 35 50 4 6 3 32 9 35 50 4 6 4 319 35 50 4 60 OUTPUTS AVERAGE LVL AMPS VOLT RPM TIME KJ 1 349 6 7 35 51 4 6 1 0 2 338 6 6 35 51 4 6 1 0 3 32 8 6 6 35 51 4 6 0 9 4 31 8 6 6 35 51 4 6 0 9 D S 15 5 6 6 35 51 3 6 0 3 7 PERFORMANCE CONFIRMATION WELD COMPLETE PERFORMANCE ACCEPTABLE QA QC NOTES Figure 63 Medium Printout 64 2005 Swagelok Company all rights reserved September 2005 M100 Power Supply The Long printout shown in Figure 64 contains all ee TER information on inputs and outputs This printout lists the DATA RECORD LONG MODEL M100 1 VER 1 0
43. 5 Turn off the power supply circuit breaker on the rear panel of the unit See Figure 4 Figure 4 Turn Off Circuit Breaker Installing the Weld Head Tig weld head assembly Hour connectors that plug AEE E E Electrode into the power supply See Figure 5 Connector hs Work The four connectors on the cable are mM e Threaded multi pin connector e Electrode red e Work green e Weld head shielding gas si Weld Head lt Shielding Gas Figure 5 Weld Head Assembly 2005 Swagelok Company all rights reserved September 2005 M100 Power Supply Connect the four connectors to the rear panel of the power supply by performing the following steps see Figure 6 1 Align the notch on the multi pin connector with the small tab in the mating socket on the rear panel labeled 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 2 Insert and fully seat the red connector into the socket on the rear panel labeled ELECTRODE Twist the connector one quarter turn clockwise to lock it into place This connection is the negative terminal of the weld head 3 Insert the green connector into the socket on the rear panel labeled WORK Twist the connector one quarter turn clockwise to lock it into place This connection 1s the positive terminal of the weld head
44. Average Current 39 34 12 Amperes Raising the Maintenance current raises the average current This increases the heat input per unit of electrode travel resulting in increased inside diameter convexity and weld bead width 118 Figure 99 Improper Weld Example No 3 Figure 100 Improper Weld Example No 4 Reference Illustration of Proper Weld 2005 Swagelok Company all rights reserved September 2005 M100 Power Supply Weld Example No 5 Table 18 lists the parameter change used to create the weld shown in Figure 101 Table 18 Weld Example No 5 Parameter Impulse Width 30 Average Current 32 30 Amperes Shortening the Impulse Width lowers the average current This decreases the heat input per unit of electrode travel resulting in no inside diameter penetration This Setting Figure 101 Improper Weld Example No 5 Weld Example No 6 Table 19 lists the parameter change used to create the weld shown in Figure 102 Table 19 Weld Example No 6 Parameter Reference Setting This Setting Impulse Width 40 Figure 102 Improper Weld Example Average Current 32 34 No 6 Amperes Lengthening the Impulse Width raises the average current This increases the heat input per unit of electrode travel resulting in increased inside diameter convexity and weld bead width Reference Illustration of Proper Weld 2005 Swagelok Company all rights reserved 119 September 2005 M100 Power
45. Clean fixture Remove and replace any damaged parts 6 2005 Swagelok Company all rights reserved September 2005 Troubleshooting Welding Process Symptom Remedy Arc fails to start Blown ceramic Replace the ceramic power Note power supply fuse a alas dee a SE All fuses should be rated at 250 V a ac 110 V ac power supplies use a Fuse not seated in Insert fuse properly Replace fuse holder properly fuse spring if necessary 20 A fuse 1 4 x 1 1 4 in 220 V or fuse spring is units use a 10 A fuse 5 x 20 mm missing Incorrect arc gap Reset the arc gap with the setting arc gap gage Excessive purge Reduce flow to the value Note gas flow shown on the weld procedure guideline The ceramic fuse is located on the Insufficient Check the shielding gas pean panel of the power supply See shielding gas flow source for low pressure Figure 1 or contaminated Check gas lines for leaks shielding gas Change to a different gas source or change oxygen removal filter Electrode in poor Replace electrode condition Damaged electrical Weld head needs repair Call connections in the for service weld head Poor contact Inspect and clean all between locking contact surfaces ring tab and ground extension Poor contact Inspect and clean all between rotor and contact surfaces brush Poor contact Inspect and clean all between tubing contact surfaces collet and fixture b
46. H B GAP 0 035 ARGON C 040 605 GAGE 0 907 12 USE ARROWS FWD BACK TO POSITION CURSOR REMOTE PENDANT use arrows fwd back Figure 34 Review Active Weld Settings 40 2005 Swagelok Company all rights reserved September 2005 M100 Power Supply INFO This submode allows the equipment operator to enter data to the DATALOG record output Data must be entered in a field displaying an asterisk required field prefix Information entered here will be displayed on the printout and in the Weld Datalog Record POWER SUPPLY ADJUST VIEW WELDER HEAD SN HEAT 1 HEAT 2 OD GAS ID GAS OPEN 1 OPEN 2 PROJECT DRAWING REMOTE PENDANT adj view INF tst drawing gt gt WELDER head sm Figure 35 INFO Submode Display INFO The selection is cleared when the unit is powered down 2005 Swagelok Company all rights reserved 41 September 2005 M100 Power Supply INFO WELDERS WELD ADJUST VIEW TEST The welder name or ID may be entered here by using the alphanumeric keypad This entry field is cleared on unit HEAD SN power down eae HEAT 2 OD GAS ID GAS OPEN 1 OPEN 2 PROJECT DRAWING wld adj view INF tst WELDER gt gt Figure 36 Welder Name Selection INFO HEAD SN WELD ADJUST VIEW TEST The serial number of the weld head being used may be entered here The model number of the weld head is entered CCE NN during creating of the procedure This entry fi
47. Logging Outputs Note The data recorder must have high impedance inputs greater than 1 MQ Note Variables such as material chemistry weld end preparation electrode condition and shielding gas may also affect the weld quality The user must decide how to use the information provided by this feature 87 M100 Power Supply Swagelok neither sells nor recommends a specific type or brand of recording equipment However when selecting data recording equipment remember that the frequency response sampling rate of the equipment will determine how accurately a data printout will reflect the actual welding process A data collecting device should have a sampling rate at least ten times faster than the maximum weld impulse rate 99 pulses per second Thus a sampling rate of 1000 samples per second will help ensure accurate recording of the data The equipment should also be capable of gathering data over the longest programmed weld time When an analog strip chart recorder is used the 0 V dc to 4 V dc signals drive the strip chart pens This type of recorder generally has limited memory and does not store data for future retrieval When the data must be captured and stored for future reference digital recording equipment is used This equipment converts the analog signals to data patterns that are stored to some device such as a memory unit or a hard disk The data can be recalled as needed and can be used for later
48. M Series power supply Figure 85 Remote Pendant Connector 2005 Swagelok Company all rights reserved September 2005 85 M100 Power Supply Weld Head Extension Cables The weld head extension cables allow the user to position the weld head up to 50 feet away from the power supply The extension cable is placed between the power supply and weld head Install the extension cable as follows 1 Turn off the power supply circuit breaker 2 Disconnect the weld head from the power supply Plug the appropriate weld head connectors into the end of the extension cable 3 Insert the connectors at the other end of the extension cable into the appropriate sockets on the power supply rear panel 4 Turn on the power supply 5 Locate the HOME and PURGE pushbuttons on the front panel See Figure 86 6 Press HOME and check for rotor rotation Press HOME again if the rotor 1s not at the home position 7 Press PURGE and check for gas flow through the weld head Allow the shielding gas to flow for at least 60 seconds to clear the gas lines of oxygen Press PURGE again to stop the gas flow 86 Note When using an extension cable increase the prepurge time by 1 second for each foot of extension cable Il A WM FWD HOME PURGE Figure 86 Pushbutton Locations 2005 Swagelok Company all rights reserved September 2005 M100 Power Supply Analog Data Logging Monitoring The pow
49. ON submode see page 67 Press JOG and hold for rotor motion The rotor will stop when JOG is released An indicator in the bottom right corner of the screen gives the location of the rotor in degrees in relation to the home position see Figure 22 Pressing STOP will stop the e Weld in progress immediately e Rotor homing in process 2005 Swagelok Company all rights reserved September 2005 M100 Power Supply AN MY WM START PURGE STOP Figure 21 Weld Operation Keys IA ADJUST VIEW INFO TEST WELD START PURGE Figure 22 Rotor Position 27 M100 Power Supply Pressing this key will print the information for PRINT J the most recent weld performed To obtain a printout of a weld prior to the most recent weld performed you must go to SETUP DATALOG see page 62 The type of printout to be produced can be selected in the SETUP DATALOG submode FWD Pressing this key will move the rotor to the HOME J home position The rotor will always move at full speed when HOME is pressed Figure 23 Rotor Home Position 28 2005 Swagelok Company all rights reserved September 2005 Alphanumeric Keys The white alphanumeric keys are used to enter information into a field where direct field entry is possible Each key has up to four characters To select the desired symbol do the following e Press the key once to select the large bottom symbol which is a number or a
50. PY FILE SAVE LOAD PROCEDURE PRINT PROCEDUR PRINT DIRECTORY LOAD PROC SAVE C TEST2 0620 014 SS 316L S TEST3 125 0 28 SS 316L S TESTA 250 0 28 SS 316L TEST5 500 0 014 SS 316L TEST6 750 014 SS 316L TEST 8258 0 28 SS 316L TESTS 250 0 28 SS 316L S TEST9 250 0 28 SS 316L 0004 DELETE COPY LOAD PROCEDURE C testl gt gt C TEST2 S test3 Figure 43 Load a Procedure Display 2005 Swagelok Company all rights reserved September 2005 M100 Power Supply LOAD PRINT PROCEDURE DELETE COPY This function allows you to print a weld procedure No datalog information is available here To print procedure 1 Select Print Procedure then press ENTER 2 Highlight the desired weld procedure using the UP DOWN keys The FWD BACK keys move the highlighted area 1 2 page at a time making scrolling easier Press ENTER PRINT PROCEDURE C TESTI 500 0 014 SS 316L C TEST2 0620 014 SS 316L 1 S TEST3 125 0 28 SS 316L 1 S TEST4 250 0 28 SS 316L PRINT PROCEDURE C test4 gt gt C TESTI S test2 Figure 44 Print a Procedure Display Note Card files will be listed first preceded by the letter C System memory files will be preceded by the letter S 2005 Swagelok Company all rights reserved 47 September 2005 M100 Power Supply LOAD PRINT DIRECTORY SAVE DELETE To print a directory of the weld procedures select PRINT nn DIRECTORY then press ENTER PRINT PROCED
51. SWORD UTILITY Remote keyclick REMOTE 68 D PRINT COUPON KEYCLICK Re ea oo e ca EE S de 68 EB Modify minimum MINIMUM VOLT 68 volts Count Misfires COUNT 69 MISFIRES PASSWORD Change owner CHANGE OWNER 69 password Change programmer CHANGE 69 password PROGRAMMER Change security CHANGE 69 SECURITY conf pass UTILITY Reset weld counter RESET WELD 71 de aie card COUNTER print all coupons Set date and time SET DATE TIME 71 Initialize card INITIALIZE CARD 71 Clear application CLEAR 72 Figure 60 Setup Mode Display APPLICATION EXECUTOR VER F Panel Version F PANEL VER 72 Loader Lo Version LOADER LO VER 72 Loader Hi Version LOADER HI VER 2005 Swagelok Company all rights reserved 61 September 2005 M100 Power Supply DATALOG PRINT COUPON When this function is selected the M100 power supply lists all Data records from memory or an installed PC memory card Select the desired file using the UP DOWN and FWD BACK keys The highlighted record will be printed when ENTER is pressed DATALOG PRINT ALL COUPONS When this submode is selected and the ENTER key is pressed the M100 power supply will print all the data records in memory DATALOG XFER MEM TO SERIAL This submode allows you to transfer all the system datalog records to the serial port This function does not transfer weld procedures The port is active in this function even if the DATALOG ENABLE SERIAL is in the OFF positi
52. Supply M100 Modes of Operation The M100 has four modes to perform different types of functions e WELD Page 30 e FILE Page 45 e PROG Page 52 e SETUP Page 61 WELD Mode us eos Jfer The WELD mode includ f th e V mode includes most of the _ functions needed to execute a weld Pressing Bola WELD in the top left corner of the keypad at any a time accesses this mode Quick adjustments to the current setting can be made in this mode in addition to performing welding operations Mam ADJUST VIEW INFO TEST START PURGE JOG HOME PRINT Figure 26 Menu Access to WELD Mode 30 2005 Swagelok Company all rights reserved September 2005 M100 Power Supply Weld Mode Directory Submode WELD ADJUST VIEW INFO TEST Page 33 Executing a weld Current voltage level number 33 currently executing and time remaining in each step is displayed 35 38 38 39 View settings in active Joint parameters start parameters 40 weld procedure tacks levels and other settings are displayed a 42 4 Set certification number or OD GAS ID GAS 43 Dewar serial number Open 1 and 2 available for OPEN 1 OPEN 2 43 additional information up to 10 characters Set project name or drawing 44 name 44 Check or demonstrate TEST weld program 2005 Swagelok Company all rights reserved September 2005 31 M100 Power Supply POWER SUPPLY tupeor Wal Number Pipe OD Thickness Material of Levels
53. Supply Weld Example No 7 Table 20 lists the parameter change used to create the weld shown in Figure 103 Table 20 Weld Example No 7 Parameter Reference Setting This Setting Figure 103 Improper Weld Example Speed rpm 4 15 No 7 Raising the Rotor Speed decreases the heat input per unit of electrode travel resulting in no inside diameter penetration Weld Example No 8 Table 21 lists the parameter change used to create the weld shown in Figure 104 Table 21 Weld Example No 8 Parameter Reference Setting This Setting Speed rpm 2 26 Figure 104 a a Example O Lowering the Rotor Speed increases the heat input per unit of electrode travel resulting in increased inside diameter convexity and weld bead width Reference Illustration of Proper Weld 120 2005 Swagelok Company all rights reserved September 2005 M100 Power Supply Pulse Rate Reference Weld Table 22 lists the parameter used to create the reference weld shown in Figure 105 Table 22 Pulse Rate Reference Weld Parameter Reference Setting This Setting 10 Pulse Rate 10 cycles s Pulse Rate Weld Example No 1 Table 23 lists the parameter change used to create the weld shown in Figure 106 Table 23 Weld Example No 1 Parameter Reference Setting This Setting Pulse Rate 10 5 cycles s Lowering the pulse rate reduces weld spot overlap Pulse Rate Weld Example No 2 Table 24 lists the parameter change used to crea
54. Swagelok single ended shut off Quick Connect stem on the shield purge line for the shielding gas connector e Adjust the low pressure regulator gauge to reduce the gas storage container source pressure to 25 to 50 psig 1 9 to 3 5 bar When complete continue to the Preliminary Check procedure beginning on page 13 2005 Swagelok Company all rights reserved September 2005 M100 Power Supply Flow Meter for Flow Meter for 2 Stage Regulator Internal Purge Gas tn Range 0 to 30 ft h e peg ule i High Pressure Gauge Low Pressure Gauge Range 0 to 1 02 m h Range 0 to 0 to 3000 psig 0 to150 psig Range 0 to 1 70 m h 0 to 206 8 Bar 0 to 10 3 Bar N Supply Manifold Internal Purge Gas Shut Off Valve C C Inert Gas Cylinder Tubing to be Welded gt Fi Shielding Gas A AZ Supply Inlet Purge Fitting F SK Swagelok Union or Reducing Union with Purge Fitting Nylon Ferrules or Ultra Swagelok Union or Reducing SWS M100 Union with Nylon Ferrules or Power Supply Ultra Torr for Purge Gas Restriction SWS Fixture Block Figure 7 Typical Gas Delivery System 10 2005 Swagelok Company all rights reserved September 2005 M100 Power Supply Optional Gas Delivery System The optional gas delivery system is generally used in Ultra High Purity UHP gas sytems w
55. URE PRINT DIRECTORY PRINTING DIRECTORY PRINT DIRECTORY print procedure gt gt PRINT DIRECTORY load procedure Figure 45 Print the Directory Display Note Card files will be listed first preceded by the letter C System memory files will be preceded by the letter S 2005 Swagelok Company all rights reserved 48 September 2005 M100 Power Supply SAVE STORE TO MEMORY PR ETE This function stores the active procedure in memory If a STORE TO MEMORY procedure has been edited or adjusted you may overwrite SJ the procedure or create a new procedure with a new name SAVE STORE TO CARD This function stores the active procedure on the PC memory Card SAVE TO MEMORY FILE ENTER PROCEDURE NAME TO SAVE AS TEST1 ENTER PROCEDURE NAME TO SAVE SAVE TO MEMORY enter procedure name gt gt TEST1 Figure 46 Store Procedure to Memory Display 2005 Swagelok Company all rights reserved 49 September 2005 M100 Power Supply DELETE DELETE PROCEDURE ue This function allows you to delete an unwanted weld dure file f d Select th d DELETE PROCEDURE procedure file from memory or card Select the procedure Se from the list presented and press ENTER ERASE CARD DELETE ERASE MEMORY The erase memory selection will erase all procedures from memory but will not delete the datalog records DELETE ERASE CARD The erase card selection will erase all procedures from the PC mem
56. a minimum Do not operate the data Using the Data Recording Printer recording printer without paper Refer to section on Activate the data recording printer from the power supply paper loading by one of the following methods e Press PRINT on the power supply front panel BACK F e Establish an automatic print cycle by setting the automatic print counter from the SETUP PRINT DATALOG function Figure 80 Print Key and Data e Press to advance the paper Recording Printer Feed Key The data recording printer will always print the last valid weld data record If no valid data exists no data record will be printed Data Recording Printer Options e Select FILE LOAD PRINT PROCEDURE This function 1s printed on the data recording printer See FILE LOAD PRINT PROCEDURE on page 47 e Select FILE LOAD PRINT DIRECTORY This function 1s printed on the data recording printer See FILE LOAD PRINT DIRECTORY on page 48 e Select the Print Format short medium or long from the SETUP DATALOG PRINT FORMAT See SETUP DATALOG PRINT FORMAT on page 62 e Select SETUP DATALOG PRINT COUPON This function is printed on the data recording printer See SETUP DATALOG PRINT COUPON on page 62 e Select SETUP DATALOG PRINT ALL COUPONS This function 1s printed on the data recording printer See SETUP DATALOG PRINT ALL COUPONS on page 62 82 2005 Swagelok Company all rights reserved September 2005 M100 Power Supply Maintenance The SWS
57. able The M100 power supply may be connected directly to your personal computer The data sent to the computer is in comma delimited format The computer needs communications software included with Windows 3 1 or above but not normally with DOS operating systems DOS systems must have communications software installed such as Telex or Procom Please check with your computer supplier The communication set up 1s e baud 9600 e parity none e 1 stop bit e 8 bit The storage requirements will be approximately 1 5 K per each data log file weld file Please check that you have adequate memory space available This is a very small usage of memory and should not be a problem Your application requirements for handling the information after your computer receives the data should be considered when purchasing a software program Therefore consult your software supplier before purchasing a program A PC Interface Cable SWS PC CABLE is shipped with each M100 power supply One end of the cable is connected to the printer port on the back of the M100 power supply See Figure 88 Table 7 M100 Printer Port Pin Outputs Pin No Signal Name from SWS M100 Power Supply 2 Transmit 3 Receive 5 Clear to Send CTS 7 9 Printer Port Signal Ground 15 V dc 20 Data Transmit Ready DTR 24 Ground Figure 88 PC Interface Cable 90 2005 Swagelok Company all rights reserved September 2005 M100 Power Supply
58. ad not Replace the electrode Reattach correctly the weld head to the fixture attached to the block Engage the weld head fixture block locking lever Incorrect arc gap Check the length of the setting electrode and replace it Reset arc gap Melted No shielding gas Check for shielding gas flow electrode and set the proper flow rate 2005 Swagelok Company all rights reserved 5 September 2005 Troubleshooting Fixture Block Symptom Remedy When closing The latch is not inserted Reinsert the latch into the fixture block into the fixture block side the side plate until it side plate the plate completely rests against the latch latch does not pin lock Replace ai Replace fitting tubing with the correct size Replace with the correct size collet Hinge worn out Replace the hinge and dowel pins Worn out latch cam Replace the latch cam The latch does A burr is in the slot or on Use a fine file to remove not fit into the the latch burrs bottom part of the fixture block side plate The latch is bent or Remove the hinge damaged and replace all damaged parts The fixture The arc gap is incorrect Reset arc gap block does not fit onto the weld head according to the Weld Procedure Guideline The locking ring tab is Replace the locking broken or damaged ring tab The weld head is Reassemble using the incorrectly assembled instructions found in Maintenance Arc damage on fixture
59. all rights reserved September 2005 M100 Power Supply ADJUST Prepurge and Postpurge WELD LONNIE VIEW INFO TEST The prepurge and postpurge times of the weld procedure WELD selected can be adjusted the same way as the average current oe Le Dan settings Select PREPURGE or POSTPURGE on the selection LEV 2 CURR 33 9 list and change the time The range of adjustment can be set in LEV 3 CURR 22 9 LEV 4 CURR 31 9 PROGRAM MODIFY PURGE LIMIT POSTPURGE 20 wld ADJ view inf tst lev 4 curr 31 9 gt gt PREPURGE 20 postpurge 20 Figure 33 Prepurge and Postpurge Adjustment 2005 Swagelok Company all rights reserved 39 September 2005 M100 Power Supply VIEW This submode allows you to review the settings in the active weld procedure Joint parameters start parameters tacks and levels as well as other settings are displayed You cannot change any information in the VIEW submode POWER SUPPLY WELD ADJUST VIEW INFO TEST PROCEDURE TEST1 WELD DESCRIPTION 500x0 049 SS316L 04 00 S WELDER JSMITH PROGRAMMER JOHNS WELD ADJUST VIEW INFO TEST IMPULSE PROCEDURE TEST DESCRIPTION 500x0 049 SS316L 04 00 WELD TIM WELDER JSMITH PROGRAMMER JOHNS RAMP WELD ADJUST VIEW INFO TEST PROCEDURE TEST1 WELD DESCRIPTION 500x0 049 SS316L 04 00 S WELDER JSMITH PROGRAMMER JOHNS JOINT PARAMETERS JOINT TYPE POSITION MATERIAL CURRENT TUBE DIAMETER TACK TIME WALL THICKNESS HEAD ELECTRODE 5
60. ameter 1s e less than 1 4 in multiple pass technique multiply the total weld time for a single pass by two and set WELD TIME according to that result e 1 4 in or greater single pass technique use the total weld time for a single pass For example since the tubing in this example has an outside diameter of 1 2 in the Weld Time is 18 2 sec 8 Determine and record the Rotor Delay by calculating the weld overlap time in 7 b on page 96 Worksheet entry 1 1 9 Record a Prepurge Time of 20 seconds Use a continuous purge when using the micro weld head by pressing the PURGE pushbutton Worksheet entry 20 2005 Swagelok Company all rights reserved September 2005 Note Experience suggests that tubing with an outside diameter of less than or equal to 1 2 in typically requires two revolutions two passes Tubing with a larger outside diameter requires one revolution one pass Caution When welding 1 2 in or 12 mm outside diameter with the 8 MRH Weld Head use a single pass one revolution weld procedure only Note The suggested minimum Prepurge time is 10 seconds for all weld heads Higher Prepurge times may be necessary for certain applications 97 M100 Power Supply 10 Record a Postpurge Time of 20 seconds Note The suggested minimum Postpurge MOREMEELENNE 20 Time is 20 seconds This time allows 11 Calculate and record the Downslope using the following for sufficient cooling of t
61. ameters relate to the current waveform and the effects of any parameter changes Weld Time Weld Parameters Affect the Output Waveform p RU 70 The shape and duration of the output current waveform 50 _ D Te created during the weld cycle is determined by the weld 46 parameter settings entered on the M100 front panel The S values from the weld procedure guideline in Section 5 30 DR D DE DD create a current waveform as shown in Figure 71 and 20 _ AAP Figure 72 10 D During a typical weld the power supply pulses between high amp current Impulse and low amp current Maintenance In Figure 72 the current control settings are SEC 5 Figure 71 Single Level Weld Current Waveform IMPULSE 56 4 A Level 1 WELD CURRENT PARAMETERS 53 6A Level 2 Impulse Maintenance Pulse Rate Impulse 20 9 resale 96 4 15 8 3 30 m lt Weld Time 48 4 A Level 4 Oije l a70 MAINTENANCE 15 8 A oui Downslope _ IMPULSE RATE 3 pulses per second 50 _ i IMPULSE WIDTH 30 40 30 A A m H 4 IL y In this case the current pulses between the high and the low HAP levels 3 times
62. ami FL 33126 OSHA Safety and Health Standards 29 CFR 1910 and 1926 from U S Government Printing Office P O Box 371954 Pittsburgh PA 15250 LE SOUDAGE A L ARC peut tre dangereux e Lisez et respectez cette tiquette ainsi que le manuel utilisateur UN CHOC ELECTRIQUE peut tre mortel Ne posez pas l appareil sur des surfaces combustibles e Seules des personnes qualifi es peuvent Ne touchez pas les parties lectriques sous tension installer et utiliser cet appareil L lectrode et le rotor sont sous tension pendant le soudage 14326 E 16 2005 Swagelok Company all rights reserved September 2005 Regulatory 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 Z 49 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 4 OSHA 29CFR 1910 Subpart Q Welding Cutting and Brazing Aquire 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 Aquire from U S Government Printing Of
63. ause injury or death e Do not breathe fumes or gases e If inside ventilate the area and or use exhaust at the arc to remove welding fumes and gases e If ventilation is poor use an approved air supplied respirator e Read the Material Safety Data Sheets MSDSs and the manufacturer s instructions for metals consumables coatings cleaners and degreasers e 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 e 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 e Do not weld on coated metals such as galvanized lead or cadmium plated steel unless the coating 1s 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 e The ultraviolet light emitted by the welding arc acts on the oxygen in the surrounding atmosphere to produce ozone Test results 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 pract
64. be triggered and a weld error message will be displayed See the Power Supply module Dedicated Line An electrical service line used for only one device The device is isolated from interference created by other equipment and can utilize the full current capacity of the line breaker GTAW An acronym for Gas Tungsten Arc Welding the process used in the Swagelok Welding System SWS Heat Input The heat conducted into the weld during the weld cycle It is generally expressed in joules or kilojoules see Datalog Printout Impulse High Amps The maximum current level generated during the weld cycle Also referred to as high amps Inches of Water Column IWC Unit of pressure measurement 1 PSI 2 31 ft of water column 27 72 in of water column Inclusion A defect or discontinuity in the work material or weld that could become a site for stress or corrosion 1999 2005 Swagelok Company all rights reserved 3 September 2005 Internal Purge Gas The backing gas used at the back of a weld joint or within a tube or vessel to prevent oxidation and encroachment Jog The term used when positioning the rotor with the rotor JOG key before or after the weld cycle Joule A unit of energy used to express heat input One joule is equal to one ampere times one volt for one second Also termed a watt second Level Factor A percentage of the level 1 impulse current used to calculate the impulse current drop in s
65. ber 2005 M100 Power Supply Using an Extension Cord If it is necessary to use an extension cord follow the guidelines below ion e Use only extension cords that meet the A Caution specifications indicated in Table 31 The voltage drop in an extension cord 100 ft long e Extension cords longer than 100 ft 30 m are may affect the output not recommended performance of the SWS M100 Unpacking the Power Supply Note _ Keep the shipping container for The SWS M100 power supply is packaged in a plastic storing and or shipping shipping container The power supply part number and serial number are located on a label on the outside of the container Table 2 Shipping Container Contents Part Description Qty Welder Power Supply SWS M100 1 SWS M100 HP Examples SWS M100 1 or SWS M100 HP 2 Power Cord CWS CORD 1 Examples CWS CORD 1 or CWS CORD 9 1 4 in Male Quick Connect 1 Secondary Solenoid 1 Bypass Plug Swagelok Welding System SWS MANUAL M100 1 Users Manual Examples SWS MANUAL M100 E or SWS MANUAL M100 J PC Memory Card SWS PCCARD 1MB 1 PC Interface Cable SWS PC CABLE 1 Denotes Model Denotes Language 4 2005 Swagelok Company all rights reserved September 2005 Remove the contents of the shipping container by performing the following steps l Remove the following items e Swagelok Welding System user s manual e Swagelok Quick Connect stem e Secondary solenoi
66. c BSS UTILITY CHANGE SECURITY a CHANGE PROGRAMMER E CHANGE OWNER MWS UTILITY SETUP CHANGE SECURITY CHANGE PROGRAMMER CHANGE OWNER DATAL CHANGE SECURITY PASSWORD ENTER NEW PASSWORD RETYPE NEW PASSWORD ENTER YOUR PASSWORD UP TO 11 CHARACTERS CHANGE SECURITY change owner gt gt CHANGE SECURITY change programmer Figure 68 Change Password Note lf the owner password does not work contact your Swagelok representative for instructions Note If no programmer password is used all users will have programmer priveleges with full File mode activities Note The M100 power supply must be turned off to activate security 69 M100 Power Supply To change a Password 1 Select the function Select the password level you want to change Security Programmer Owner a Security The programmer password or the owner password must be entered Enter the new security password and verify the new password by retyping it in the confirmation field b Programmer The old programmer password or the owner password must be entered Enter the new programmer password and verify the new password by retyping it in the confirmation field c Owner The existing owner password must be entered Enter the new password and verify the new password by retyping it in the confirmation field Clear Application WELD Unlimited PROGRAM SET UP FILE SECURITY
67. ce or change oxygen removal filter Change to correct type of purge gas Clean the work pieces before welding Increase prepurge time Check the gas source for low pressure Reconnect gas line Increase internal purge gas flow rate and prepurge time Increase prepurge time Check the gas source for low pressure Reduce exit port size with a purge restrictor See Note Change to correct type of purge gas Clean the work pieces before welding Note The purge restrictor must be of adequate size to prevent excessive inside diameter back pressure 2005 Swagelok Company all rights reserved September 2005 Troubleshooting Symptom Hole in the weld Incorrect arc gap bead Excessive internal purge gas back pressure or surge Improper tube preparation Incorrect weld parameter setting impulse Loss of shield gas flow Concave weld puddle Excessive heat input Insufficient inside diameter purge gas pressure Electrode touches the work Incorrect arc gap Insufficient arc gap for the material or the heat input Work pieces are out of round 2005 Swagelok Company all rights reserved September 2005 Remedy Reset the arc gap with the arc gap gage Remove any obstruction of the internal purge gas flow or reduce the pressure Inspect and reface tubing Check and adjust the weld parameter settings Check the shielding gas source for low pressure C
68. d September 2005 Weld Puddle The portion of the weld that is molten Weld Time The portion of the weld cycle in which the current 1s at the level needed to fully penetrate the weld joint The current will pulse between Impulse and Maintenance levels 1999 2005 Swagelok Company all rights reserved September 2005 10 2005 Swagelok Company all rights reserved September 2005 Warranty Information Swagelok products are backed by The Swagelok Limited Lifetime Warranty For a copy visit swagelok com or contact your authorized Swagelok representative Swagelok VCR VCO Ultra Torr Micro Fit TM Swagelok Company 2005 Swagelok Company Printed in U S A PPI September 2005 R1 MS 13 202
69. d bypass plug e Power cord e PC memory card e PC interface cable Remove the power supply by lifting it by the handle Place the power supply on a stable cart platform or table Check the power supply and accessories for damage Check that a roll of thermal printing paper is installed in the data recording printer Check that the serial number on the rear panel of the power supply matches the serial number on the shipping container label Record the model number serial number and the delivery date on the Registration Information page in the Regulatory Module 2005 Swagelok Company all rights reserved September 2005 M100 Power Supply M100 Power Supply Installing the Power Supply To get the maximum performance and reliability from your SWS it must be set up and installed properly To install the power supply follow these steps I Position the power supply so that the front and rear panel controls are easily accessible Insert the power cord into the polarized receptacle on the rear of the power supply See Figure 3 Tighten the connector lock at the base of the receptacle to secure the cord in the receptacle Ensure that the power cord reaches an electrical outlet Figure 3 Insert the Power Cord Here WARNING DO NOT CONNECT THE POWER CORD TO THE OUTLET AT THIS TIME 2005 Swagelok Company all rights reserved September 2005 M100 Power Supply
70. e If it is blown replace it with a fuse of the same type and rating 4 Turn on the power supply 2005 Swagelok Company all rights reserved September 2005 Note The fuse can be checked with an ohmmeter A Caution Use only insulated pliers to remove fuse Figure 109 Ceramic Fuse Location 123 M100 Power Supply Use the following instructions to change the HEPA filter as necessary HEPA Filter Replacement 1 Turn off the power to the power supply unit prior to replacing the HEPA filter 2 Place handle in position shown to open HEPA filter cover 86999900600606000000 DS000000000000000 3 Using a small pointed tool push the two latches to fully disengage them and release the HEPA filter cover See Figure 110 e0o0 Ooo 00o o o o 0 0 ao o o o 0 0 0 o eee 0 000D00D0DO0DO O0 000D O0DDOODO O0 000D O0DOODOE O0 000D O0DDOODO 0d O00DDOCDDOODO C 60006 00000 4 Push latches to disengage the filter HEPA Filter Cover 5 Swing the HEPA filter cover open to reveal the HEPA filter See Figure 111 HEPA Filter Cover Figure 111 HEPA Filter Location 124 2005 Swagelok Company all rights reserved September 2005 M100 Power Supply 6 Remove the HEPA filter Ensure the fan 1s not spinning Clean the fan guard with an absorbent non a Fan Guard abrasive low lint wipe and is
71. e entered in these locations These entry fields will clear on aegis HEAD SN unit power down HEAT 1 nn HEAT 2 OD GAS ID GAS OPEN 1 OPEN 2 PROJECT DRAWING wld adj view INF tst open 2 gt gt PROJECT drawing Figure 40 Project Name Drawing Name Entry Fields TEST The TEST submode of the WELD mode is used to check or demonstrate a weld procedure WELD TEST is similar to WELD WELD except that no current is applied to the electrode and the weld head does not have to be installed into the fixture block The weld count will not advance in the TEST submode To use the TEST submode Select and install a weld procedure press START The M100 power supply will ask you to check that the rotor is clear to rotate press ENTER to begin the TEST 44 2005 Swagelok Company all rights reserved September 2005 M100 Power Supply FILE MODE FILE mode 1s used to access and edit weld procedure files in memory and on the PC memory card File Mode Directory Submode Activity Onscreen Display Page LOAD Load procedure LOAD PROC 46 followed by a list of procedures SAVE DELETE COPY Print procedure PRINT PROCEDURE 47 FILE followed by a list of procedures Print directory PRINT DIRECTORY 48 SAVE Store to memory STORE TO 49 A MEMORY Store to card STORE TO CARD 49 DELETE Delete procedure DELETE 50 PROCEDURE ERASE MEMORY 30 ERASE CARD 50 COPY One procedure from 1 CARD TO MEM 51 Figure 41 File Mode ca
72. eld 1s cleared HEAT 1 on unit power down HEAT 2 OD GAS ID GAS OPEN 1 OPEN 2 PROJECT DRAWING wld adj view INF tst welder gt gt HEAD SN heat 1 Figure 37 Weld Head Serial Number 42 2005 Swagelok Company all rights reserved September 2005 M100 Power Supply INFO HEAT 1 HEAT 2 2 ang WELD ADJUST VIEW TEST The heat number or lot number of the materials being WELDER welded may be entered in these locations The entry field HEAD SN will clear on unit power down HEAT 1 HEAT 2 OD GAS ID GAS OPEN 1 OPEN 2 PROJECT DRAWING wld adj view INF tst head sn gt gt HEATI heat 2 Figure 38 Heat or Lot Number INFO Shield Gas and Purge Gas Sn nn ee Certification Numbers WELDER The certification number or Dewar serial number may be HEAD SN entered in these locations These entry fields will clear on HEAT 1 unit power down ID GAS OPEN 1 OPEN 2 PROJECT DRAWING wld adj view INF tst heat 1 gt gt OD GAS id gas Figure 39 Shield Gas and Purge Gas Certification Numbers INFO Open 1 and Open 2 These two lines are available for any additional information up to 10 characters These entry fields will clear on unit power down 2005 Swagelok Company all rights reserved 43 September 2005 M100 Power Supply INFO PROJECT WELD ADJUST VIEW TEST The project name and the drawing name or number may b
73. eo acts cleared without the new new application software on a PC memory card should be software update the unit on hand before the current software is cleared will be DISABLED SEE EXTREME CAUTION Procedure to clear and load update software Select CLEAR APPLICATION and press ENTER Key in Owner Password and select ENTER Verify Confirmation to Continue YES NO SEE EXTREME CAUTION Press ENTER Turn Power OFF upon prompt oe ot a oe 0 Insert the PC memory card with the new software into the card port 8 Turn power ON 9 Remove the PC memory card upon prompt 10 Turn power OFF upon prompt 11 Turn power ON and the installation is complete UTILITY EXECUTOR VER XXX Note a The only software version that The Executor Software interfaces the Application or is updateable in the field is the Front Panel Software with the welding section of the Front Panel Version power supply UTILITY F PANEL VER XXX F Panel software often called the application software controls the user s communication with the M100 power supply UTILITY LOADER LO VER XXX UTILITY LOADER HI VER XXX Loader software controls the loading of Front Panel software 72 2005 Swagelok Company all rights reserved September 2005 M100 Power Supply Effect of Weld Parameters WELD CURRENT PARAMETERS Impulse Maintenance Pulse Rate Impulse 56 4 15 8 10 30 The following text briefly discusses how the weld par
74. er supply has four Bayonetted N Style connectors BNC on the lower portion of the rear panel to provide analog data outputs The data outputs have a signal range from 0 V dc to 4 V dc See Table 6 Connect a chart recorder or other recording device to these outputs to monitor the SWS during welding The data outputs include e current e voltage e rotor travel speed e enable The current voltage and rotor speed outputs are used to monitor the performance of the SWS Table 6 Data Output References Output Function 0 V Reference 4 V Reference Current 100 Voltage 20V Travel Speed 0 of max RPM 100 of max RPM Enable is a control signal for the external recorder Equipment with the capability to start and stop data recording can use this signal as the trigger to control the recording function The polarity of the enable signal is selectable Refer to SETUP CONF MON POLARITY on page 68 The data from these outputs does not indicate whether the weld is acceptable but instead provides a record of the equipment performance during the welding process The data can be compared to the weld procedure guideline as a method of quality control Visual mechanical and other testing must also be done to verify the weld integrity As with any connection proper leak testing should be performed once the weld is completed 2005 Swagelok Company all rights reserved September 2005 Figure 87 Data
75. esired changes on all three pages of the weld procedure If the value entered 1s outside the limits allowed for that parameter a warning will appear If you elect to leave an invalid entry the program will not run 3 Press any mode key to exit If any of the procedure fields are invalid you will be prompted with the number of errors and ask to save or correct errors Correct Errors If Correct Errors is chosen the cursor will be located on the first error Save If Save with Errors is chosen the procedure will be invalid 4 You will be asked if you wish to rename the procedure If you don t rename the M100 power supply will default to the original file name If you then enter ENTER with the original file name it will be overwritten without a warning message If you enter a new name both files will be saved To delete one of the files go to FILE DELETE 54 2005 Swagelok Company all rights reserved September 2005 M100 Power Supply MODIFY PROCEDURE INSERT LEVEL The number of levels in a procedure is displayed next to the INSERT LEVEL function on the menu list The programmer can create up to 99 levels in a weld procedure When INSERT LEVEL is selected the levels are displayed and you can use FWD BACK to select the point of insertion in the procedure The new level will be added immediately before the selected level The new level will make a copy of the selected level You must then go to EDIT ITEM to modif
76. fice Superintendent of Documents P O Box 371954 Pittsburgh PA 15250 www osha gov 2005 Swagelok Company all rights reserved 17 September 2005 Regulatory 18 2005 Swagelok Company all rights reserved September 2005 Swagelok VCR VCO Ultra Torr Micro Fit TM Swagelok Company 2005 Swagelok Company Printed in U S A PPI September 2005 R1 MS 13 202 www swagelok com M100 POWER SUPPLY USER S MANUAL SOA TO a AE 2 Installing the Power Supply 6 Installing the Weld Head T Installing the Gas Delivery System ccccceceeeeeeeees 9 IPFO e EE 14 Front Panel CONMOIS sesccscsisncnsnguassacsinaaciendianesmcnsanesanacmanencas 15 Effect of Weld Parameters ccccccccceeceeeseeceeeeeeneeeeeens 73 Setting the Shield Gas Flow 74 Starting and Completing the Weld 76 Operation SUuMmMary 17 Data Recording Printer 18 Optional EQUIDMENE ire serres 85 Weld Parameter Development 91 Developing a Weld Procedure Guideline 91 Step Programs Multi Level 100 EVAAA V O erare nee EEEN UTT 115 MAMENANG RP 122 PECCO eea aa E A E 126 OV M100 Power Supply M100 POWER SUPPLY The M100 power supply features microcontroller electronics and closed loop circuitry to precisely control output current The software is accessible using the M100 operator display and keypad or the remote keypad The da
77. h Maintenance rpm x 1 Impulse Width Average rpm Example We want to stop the rotor 0 rpm during the impulse period 0 x 0 30 3 5 x 1 0 30 0 3 5 x 0 70 2 45 average rpm 2 Calculate the seconds per revolution using this rpm 60 Average rpm Seconds per Revolution For example 60 2 45 24 49 24 5 seconds 3 Calculate the average travel speed to find the weld overlap time a Calculate the circumference Tube OD x x Circumference For example 0 5 x 3 1416 1 5708 b Calculate the average travel speed using the average rpm and the circumference Average rpm x Circumference Average Travel Speed For example using the average rpm from step 2 and the circumference from step 3 3 2 45 x 1 5708 3 84846 3 8 IPM 100 Note The Impulse Rate must be less than or equal to 10 cycles per second for Step programs Note Do not use the Impulse Width for heat penetration adjustments in a step program Program timing problems may result Make heat adjustments with the Impulse Amps or the Maintenance Amps A Caution Step Programs are not used with Series 4 or Series 8 Micro Weld Heads Note Step Programs do not produce speed data for the data log record 2005 Swagelok Company all rights reserved September 2005 M100 Power Supply c Calculate the weld overlap using the wall thickness and the average travel speed Wall Thickness x 2 Average IPM 60
78. he electrode formula and weld zone Weld Time x 0 2 Downslope setting Note For example using the Weld Time of 18 2 seconds from Additional Postpurge time may be step 7 d necessary for a weld made with a high average current setting 18 2 x 0 2 3 64 Worksheet entry 3 6 12 Calculate and record the Pulse Rate for 80 overlap using the following formula Travel speed 30 x wall thickness Pulse Rate For example for a wall thickness of 0 049 in 5 5 30 x 049 5 5 1 47 3 74 4 Worksheet entry 4 13 Determine and record the Impulse Width by locating the wall thickness and then reading the corresponding C factor in Table 12 Table 12 Wall Thickness and C Factor Wall Thickness Range in Ooo m 0 010 to 0 020 15 0 021 to 0 034 15 0 035 to 0 046 25 0 047 to 0 055 30 0 056 to 0 065 33 0 066 to 0 070 35 0 071 to 0 075 36 0 076 to 0 080 37 0 081 to 0 085 38 0 086 to 0 090 40 0 091 to 0 095 45 0 096 to 0 109 50 0 110 to 0 154 50 For example a wall thickness of 0 049 in has a C factor of 30 Worksheet entry 30 98 2005 Swagelok Company all rights reserved September 2005 M100 Power Supply 14 When developing a multi level program the level times are calculated using the following formulas Note a Calculate and record the Weld Time for Each Level Always round the weld time for each by choosing the number of levels desired and using level up to the next ten
79. he fixture block has cooled enough to be safely handled Allow additional cooling time 1f necessary before handling If necessary increase postpurge time to aid cooling 3 Release the locking lever on the weld head housing Remove the weld head from the fixture block If it is difficult to remove the weld head release one of the side plate levers Remove the internal purge gas lines from the welded assembly 6 Release the levers on the fixture block Open the side plates of the fixture block 8 Remove the welded assembly Operation Summary se nS SY eS 10 11 12 13 Install the electrode Set the arc gap using the arc gap gauge Prepare the work pieces Select the correct fixture block and collets Install the collets in the fixture block Align the work pieces in the fixture block Connect the internal purge gas line to the work piece to be welded and set the flow meter Press PURGE and set the shield gas flow Press PURGE to stop the shielding gas flow prior to starting the weld Connect the weld head to the fixture block Program the welder Press START and complete the weld Remove the weld head from the tube fixture block 2005 Swagelok Company all rights reserved September 2005 A Note M100 Power Supply 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
80. he parameters of the procedure using Test the VIEW submode In the WELD mode the weld function keys are active Pressing START for example would start a weld ing the active weld procedure noie a iNet ree a Though minor modifications to the INFO Submode Additional information active procedure are possible most may be added to data output by operator parameters must be set in the PROG TEST Submode Test of the active programming mode procedure 1s accomplished here POWER SUPPLY REMOTE PENDANT WELD ADJUST INFO PROCEDURE RENE DESCRIPTION 500 0 049 SS316L 04 WELDER JSMITH PROGRAMMER JOHNS JOINT PARAMETERS JOINT TYPE 500 049 SS MATERIAL READY TUBE DIAMETER WALL THICKNESS HEAD ELECTRODE 5H B GAP 0 035 C 040 605 GAGE 0 907 READY D START PURGE JOG HOME PRINT Figure 16 Weld Mode Display 20 2005 Swagelok Company all rights reserved September 2005 M100 Power Supply Accesses the FILE mode FILE In FILE mode a saved weld procedure can be Load selected from memory the active procedure Save can be saved or stored procedures can be Delete deleted or copied Procedure files can be saved in either the internal memory or the PC memory card Weld data log records are not accessed in the FILE mode The records are located in SETUP DATALOG Copy POWER SUPPLY DELETE LOAD PROCEDURE PRINT PROCEDURE PRINT DIRECTORY REMOTE PENDANT LOAD Save del copy print d
81. heck gas lines for leaks Change toa different gas source or change oxygen removal filter Compare the material wall thickness and outside diameter size of the components you are welding to the weld procedure guideline being used Verify settings match the guideline and adjust if necessary Compare flow meter settings to the weld procedure guideline being used Adjust if necessary Reset the arc gap to the table setting in the appropriate weld head user manual Increase the arc gap by 0 005 in 0 13 mm above the table settings Increase the arc gap or replace the work piece Troubleshooting Symptom Incomplete inside diameter penetration After welding the tubing fitting assembly is not straight After welding the fitting tubing joint is still visible 10 Cause Insufficient heat input Incorrect weld procedure guideline Incorrect arc gap Tip of electrode is worn or ground improperly Inconsistent heats of materials or changes in material chemistry Weld joint is off center or misaligned The end surfaces of the work pieces being welded are not perpendicular to their center axis The fixture block side plate screws are not tight The fitting tubing was not centered properly The electrode is bent or was not properly installed Remedy Compare the power supply setting to the weld procedure guideline being used Adjust weld parameters as necessary
82. here 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 A secondary solenoid bypass plug is inserted in the EXT GAS CONTROL connector on the rear panel to disable the Caution solenoid inside the power supply and provide 12 V to A Do not insert the secondary control the secondary solenoid solenoid bypass plug into the For the gas delivery system using a secondary shielding gas connector unless you are solenoid valve locate the using a secondary solenoid Inserting the plug disables e Secondary solenoid bypass plug the power supply solenoid e Secondary shielding gas solenoid valve e 1 4 turn internal purge gas shut off valve Referring to Figure 8 install the optional gas delivery system Be sure to adhere to the following precautions e Ensure that the gas storage container s are secured before using them e Ensure all connections are tight and do not leak e Observe correct polarity on the secondary solenoid bypass plug e Adjust the low pressure regulator gauge to reduce the gas storage container source pressure to 25 to 50 psig 1 9 to 3 5 bar 2005 Swagelok Company all rights reserved 11 September 2005 M100 Power Supply Shielding Gas T Stage Regulator SWS M100 Flow Meter g g Power Supply T
83. hield gas solenoid valve 74 2005 Swagelok Company all rights reserved September 2005 M100 Power Supply Table 5 Purge Rate and Pressure Tables Wall Minimum ID Swagelok Weld Head OO L Tube Size Thickness Purge Rate Pressure Purge Rates Restrictor Size 13 to 16 8 torr 1 16 in 0 015 in 0 2 std ft hr 7 to 9 iwc 10 to 20 std ft hr n a n a n a 0 1 L min 175 to 230 mmwc 5 to 10 std L min 17 4 to 22 4 mb 9 3 to 16 8 torr 1 std ft hr 5 to 9 iwc 10 to 20 std ft hr 1 16 in 0 5 L min 130 to 230 mmwc 5 to 10 std L min 12 4 to 22 4 mb 5 2 to 6 3 torr 1 4 in 0 035 in 6 std ft hr 2 8 to 3 4 iwc 10 to 20 std ft hr 1 8 in 6mm 1mm 3 std L min 71 to 86 mmwc 5 to 10 std L min 3mm 7 0 to 8 5 mb 2 8 to 4 7 torr 3 8 in 0 035 in 10 std ft hr 1 5 to 2 5 iwc 10 to 20 std ft hr 1 8 in 10 mm 1mm 5 L min 38 to 64 mmwc 5 to 10 std L min 3mm 3 7 to 6 2 mb 1 9 to 2 8 torr 1 2 in 0 049 in 15 std ft hr 1 0 to 1 5 iwc 10 to 40 std ft hr 1 4 in 12 mm 1mm 7 std L min 25 to 38 mmwc 5 to 12 std L min 6mm 2 5 to 3 7 mb 1 8 in 3mm 1 to 2 torr 3 4 in 20 std ft hr 0 5 to 1 1 iwc 15 to 40 std ft hr 1 4 in 20 mm 10 std L min 13 to 28 mmwc 7 to 14 std L min 6mm 1 2 to 2 7 mb 1 to 1 3 torr 1 in AO std ft hr 0 5 to 0 7 iwc 15 to 40 std ft hr 1 4 in 25 mm 20 std L min 13 to 18 mmwc 7 to 14 std L min 6mm 1 2 to 2 5 mb 1 to 1 3 torr 1 1 2 in 90 std ft hr 0 5 to 0 7 iwc 15 to 50 std ft hr 1 4 in 38 mm 43
84. ice WELDING HANDBOOK VOLUME 2 8TH EDITION AMERICAN WELDING SOCIETY e Shut off shielding gas supply when not in use 2005 Swagelok Company all rights reserved 11 September 2005 Regulatory ARC RAYS can burn eyes NOISE can damage hearing Arc rays from the welding process produce fr 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 e Do not look at welding arc e Use protective screens or barriers to protect others from flash and glare warn others not to watch the arc e 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 e Protect yourself and others from the hot work piece e Watch for fire and keep a fire extinguisher nearby e Do not weld on closed containers such as tanks drums or pipes unless they are properly prepared according to AWS F4 1 e Do not use welder to thaw frozen pipes e 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 2005 Swagelok Company all rights reserved September 2005
85. ickness i Socket OD A Arc Gap 0 010 in 0 25 mm Electrode Offset 0 010 to 0 020 in 1 16 in 1 5 mm 0 2 to 0 5 mm Minimum Pull Back gt SS Figure 90 Socket Weld Arc Gap 102 2005 Swagelok Company all rights reserved September 2005 M100 Power Supply Tacks Tacks are used for various reasons They are used by A Caution themselves and the weld is made at a later time or tacks are Tack programs or programs used with the weld following immediately The M100 that include tack should not power supply will automatically generate up to 10 tacks be used with the micro during Programming Auto Generate or you may add tacks weld heads to any program in PROG MODIFY INSERT TACK Choose the location of the tack in degrees use the Start Current of the program and start with 80 of the Rotor Delay time for each tack to be added If the tacks break during welding increase the time by 1 2 0 5 seconds for each tack If the tacks are not fully consumed by the weld decrease the time by 1 2 0 5 seconds for each tack Several cautions are important when using tacks e Ifthe tacks are to be welded at a later time they must be brushed before they are welded The oxidation will cause weld meander if it 1s not removed This is not necessary if the weld follows immediately e All tacks should be consumed completely by the weld Decrease tack size or the number of tacks e Tacks should not break
86. idation Ramp Ramp is a time entered into a weld level that allows a gradual amperage change from the previous level or Arc Start current Refer to Weld Program with Ramp Time in the Power Supply module Re enforcement The excess metal on the outside of the weld extending above the surface of the work Sometimes referred to as the crown Remote Pendant A hand held control device that allows remote operation of the SWS power supply Rotor The device that holds the tungsten electrode and moves around the weld joint during orbital welding Rotor Delay A time delay that is programmed into the weld procedure after arc start to allow the weld to penetrate the material by delaying the rotor movement This should be carefully controlled in single pass welds SCFH The acronym for standard cubic feet per hour The unit used to measure the flow rate of shielding and purge gases Shielding Gas The gas used to shield the tungsten electrode and work pieces during the welding cycle and cool the weld head 6 2005 Swagelok Company all rights reserved September 2005 Single Level A welding technique in which a single average value of current 1s used during the weld cycle Single Pass A welding technique in which the rotor moves one revolution during the weld time Socket A basic lap type of weld joint Refer to Socket Welds in the Power Supply module Solenoid Bypass An option that bypasses the i
87. ime from step 7 1 1 Seconds 10 Prepurge time in seconds 20 Seconds 11 Postpurge time in seconds 20 Seconds Downslope 3 6 Seconds Total Weld Time x 0 2 Downslope 18 2 x 0 2 3 64 3 6 Pulse rate 4 cycles per Travel Speed 30 x Wall Thickness Impulse Rate 5 5 30 x 0 049 5 5 1 47 3 74 4 108 2005 Swagelok Company all rights reserved September 2005 M100 Power Supply Weld Procedure Guideline Worksheet US Customary Standard inches Determine the Work Specifications Step Parameter Setting 1 Programmer s Name 2 Joint Type 3 Material Type 4 Weld Diameter in Inches 5 Wall Thickness in Inches 6 Weld Head Model No T Electrode Part No 8 Arc Gap in Inches Arc Gap Gauge Setting 9 ID Purge Gas Flow in SCFH Gas Type 10 Shielding Gas Flow in SCFH Gas Type 11 ID Purge Gas Pressure in IWC Calculating Weld Parameters Step Setting 1 Travel speed in per min Table 8 2 Rotor speed in rpm for all levels Travel Speed Circumference x 60 rom Tube OD x x Circumference x 3 1416 3 Impulse amps for level 1 Table 10 A x Wall Thickness in thousands of an inch x 1000 Impulse Amps XX 1000 4 Maintenance amps for all levels Table 11 B x Impulse Level 1 Maintenance Amps X X Start power u low low norm Impulse width C Table 12 T Start current Imp Level 1x Imp Width Maint x 1 Imp Width Arc Start O O1 x tL x
88. ion of the appropriate weld head user manual Check weld procedure guideline Use a larger weld head allow a cooling period between welds or allow continuous shielding gas flow when welding Check for damage and replace parts as necessary Check rotor for smooth operation Call for service if damage is severe 2005 Swagelok Company all rights reserved September 2005 Troubleshooting Electrode Symptom Remedy Material found Electrode Replace electrode and check on the electrode touched the weld arc gap setting Check work tip puddle pieces for out of roundness Weld puddle Check internal purge gas protrusion flow rate for excessive back pressure Weld head is not Reattach the weld head to properly fixture block Engage the weld attached to the head locking lever fixture block Oxidation film on Insufficient Increase shielding gas flow rate the electrode shielding gas Insufficient post Increase post purge time purge time Partially blocked Check for leaks and or or cut shielding blockages Replace purge lines gas line if needed O ring missing Check and install O ring if between the necessary weld head and motor module Micro Weld Head Only Shielding gas Disassemble weld head and line reconnect the line disconnected inside weld head Bent or broken Electrode was Replace the electrode Tighten electrode not secured in electrode clamping screws the rotor Weld he
89. irector Chevrons and Capital Letters y 2 mgs gt gt LOAD PROCEDURE u Indicate Cursor Position print procedure Figure 17 File Mode Display 2005 Swagelok Company all rights reserved 21 September 2005 M100 Power Supply File access can be limited by installing a programmer password FILE Mode Limited Access When a programmer password has been set the user has limited access to the LOAD PROCEDURE functions The procedure is read only which means no changes can be made The user may also access PRINT COUPON and PRINT DIRECTORY If any other function is requested the unit will ask for the programmer password The user cannot save weld changes delete weld procedures or transfer data to the PC memory card for weld procedures FILE Mode Unlimited Access When a programmer password has not been set or it was entered at initial start up the user has access to all the functions described later in this section under File Mode 22 2005 Swagelok Company all rights reserved September 2005 M100 Power Supply Accesses the PROG programming mode PROG In the PROG mode active procedures can be Modify modified and new procedures can be developed Create This mode can be password protected Any information entered in PROG CREATE or MODIFY is saved with the procedure PROG Mode Access Access to the programming mode is limited to users with programming privileges or higher Programming privileges
90. kness to the fitting wall thickness Refer to Figure 89 on page 94 Calculating Weld Parameters Example Step Setting 1 Travel speed in per min Table 8 5 5 in per min 2 Rotor speed in rpm for all levels Travel Speed Circumference rpm Tube OD x x Circumference 3 5 rpm 5 x 3 1416 1 5708 5 5 1 5708 3 5014 3 5 3 Impulse amps for level 1 Table 10 A x Wall Thickness in thousands of an inch x 1000 Impulse Amps 1 4 x 049 x 1000 68 6 4 Maintenance amps for all levels Table 11 B x Impulse Level 1 Maintenance Amps 20 6 Amps 0 30 x 68 6 20 58 20 6 5 Start power u low low norm Norm 6 Impulse width C Table 12 30 7 Start current Imp Level 1 x Imp Width Maint X 1 Imp Width Arc Start 68 6 x 30 20 6 x 1 0 30 35 Amps 68 6 Amps 20 58 20 6 x 0 70 20 58 14 42 35 00 2005 Swagelok Company all rights reserved 107 September 2005 M100 Power Supply Calculating Weld Parameters Example Continued Step Setting 8 Total weld time single pass in seconds 18 2 Seconds Seconds per Revolution Weld Overlap Total Time Single Pass 60 rom Seconds per Revolution 60 3 5 17 1429 17 1 Wall Thickness x 2 Travel Speed 60 Weld Overlap 049 x 2 5 5 60 0 098 0 0917 1 1 Seconds per Revolution Weld Overlap Total Time Single Pass 17 1 1 1 18 2 9 Rotor delay time use the weld overlap t
91. ks or levels are added or deleted the description will be updated 12 Store Save You have the option of saving the newly created procedure to memory or to the PC memory card The other option is Active No Save which allows the weld procedure to be the active procedure but it is not saved 13 Name Procedure If you chose to save you will be prompted to enter the procedure name 14 Screen Revert to PROGRAM CREATE The M100 power supply defaults back to the auto entry screen ready to program another weld procedure 2005 Swagelok Company all rights reserved 59 September 2005 M100 Power Supply CREATE PROCEDURE MANUAL ENTRY P This submode is used when the programmer wishes to enter AUTO ENTRY all values The M100 power supply will only check if the Fain aan tae values are valid not if they are appropriate for the weld procedure desired To use manual entry 1 Select MANUAL ENTRY then press ENTER 2 Enter the number of tacks desired 0 10 and press ENTER MODIFY 3 Enter the number of levels desired 0 99 and Levels Only Levels and Tacks press ENTER i Tacks Only 4 A zero or a minimum value is placed by the M100 power supply in all fields and places you in PROGRAM EDIT ITEM UP DN ARROW gt gt HIGHLIGHT FIELD gt THEN ENTER 5 Enter appropriate values in all available fields The M100 will generate the description from the entered information MANUAL ENTRY auto entry 6
92. lock Start power set to Set start power to normal low Figure 1 Ceramic Fuse Location 2005 Swagelok Company all rights reserved 7 September 2005 Troubleshooting Symptom Voltage fluctuations during the weld cycle exceeding 2V Outside diameter discoloration Inside diameter discoloration Cause Weld head not seated properly into the fixture block Work pieces are out of round Insufficient shielding gas flow or contaminated shielding gas Insufficient shielding gas flow Impurities in the gas supply Wrong type of purge gas used Contamination on work pieces Contaminants in the weld head and purge lines Shielding gas line disconnected from the power supply Insufficient internal purge gas Contaminants in the purge line Migration of oxygen from the internal purge gas exit port of the work pieces to the weld joint Wrong type of purge gas used Contamination on work pieces Nicks cuts in the internal Replace gas line purge gas line Remedy Reattach the weld head to the fixture block Engage the weld head locking lever Replace work pieces if out of standard specifications Check the shielding gas source for low pressure Check gas lines for leaks Change to a different gas source or change oxygen removal filter Increase shielding gas flow rate and prepurge time Check gas lines for leaks Change to a different gas sour
93. lows in std ft hr or std L min CONFIG DATE FMT This submode allows you to set the date format to e Month Day Year e Day Month Y ear e Year Month Day CONFIG REMOTE LIGHT Allows you to turn ON OFF the remote pendant backlight Backlighting makes the remote pendant display readable in low ambient lighting CONFIG REMOTE KEYCLICK Allows you to turn ON OFF the remote pendant key panel audible tone CONFIG PANEL LIGHT Allows you to turn ON OFF the main screen backlight This is desirable when the ambient temperature is at or above 40 C 104 F normal operating range of the screen The main screen backlight should be on except when operating above 40 C CONFIG PANEL KEYCLICK Allows you to turn ON OFF the main key panel audible tone when pressing keys CONFIG MON POLARITY Allows you to change the output polarity of the recorded output enable port located on the rear panel on to on CONFIG ALARM If this function 1s on and a weld error occurs the audio alarm is activated The status line displays the error Reset by pressing ENTER CONFIG MINIMUM VOLT Allows you to change the voltage that the M100 power supply senses for low arc voltage error The voltage will default to 4 volts The value may have to be adjusted up when using a weld head extension cable Refer to Weld Errors on page 35 68 2005 Swagelok Company all rights reserved September 2005 M100 Power Supply
94. mber 2005 M100 Power Supply Navigation and Selection Keys Two navigation keys are used to move through the menu of submodes in each mode These keys are also Hot and will take you immediately to the next menu selection of the current mode unless a weld is being executed Moves you forward in the submodes W AIIN WM WM e Moves you backward in the submodes The vertical arrow keys move you up and down through the pop up lists or are used in the WELD ADJUST submode to change the values The UP DOWN keys can be used to select a function from the pop up lists that appear below the menu of submodes Move up or down to highlight the function you wish to use and press ENTER to select the B ACK highlighted option PRINT Sometimes when you are modifying or selecting a value there will be a list of options FWD The vertical arrow keys can also be used to select from these pick lists Highlight the HOME option you want and press ENTER to select it Highlighted values can also be Figure 20 Navigation and changed by entering a number on the Selection Keys alphanumeric keypad BACK The FWD and BACK keys can be used to scroll PRINT through screens of information Joue In WELD VIEW mode or in PROGRAM MODIFY EDIT ITEM mode use FWD and BACK to scroll through the screens of procedure values Pressing these keys moves the cursor through one group of values For example if you have
95. me of the active procedure is a brief description of the procedure On the next line the welders and programmers names are listed The first page of parameters for the active procedure is also displayed In all modes the M100 power supply will display brief directions on how to make selections or continue a function in the bottom line of the display Prompt Line 2005 Swagelok Company all rights reserved September 2005 M100 Power Supply Operator Keypad The operator keypad has four types of keys e Mode keys e Navigation and selection keys e Weld function keys e Alphanumeric keys POWER SUPPLY REMOTE PENDANT ABC DEF GHI 1 2 3 JKL MNO PQR 4 5 6 STU VWX YZ T 8 9 Ho SPACE Figure 14 Operator Keypad MODE KEYS The four mode keys are located in the top row of the keypad These keys are hot meaning you can press them at any time except when a weld is being executed to change the operation mode Whenever a mode key is pressed the available series of submodes is displayed with the left most submode and the first active parameter of the submode highlighted selected WELD FILE PROG SETUP Figure 15 Mode Keys 2005 Swagelok Company all rights reserved 19 September 2005 M100 Power Supply Accesses the WELD mode WELD In the WELD mode you can execute a weld Adjust using the active procedure make minor View adjustments ADJUST to the procedure or Info review t
96. mference x 3 1416 x 60 3 Impulse amps for level 1 Table 10 A x Wall Thickness in mm x 39 4 Impulse Amps xX x 39 4 4 Maintenance amps for all levels Table 11 B x Impulse Level 1 Maintenance Amps X X Start power u low low norm Impulse width C Table 12 7 Start current Imp Level 1 x Imp Width Maint x 1 Imp Width Arc Start Oj O1 ____ x L___x 1 ___ ee ee ee 2005 Swagelok Company all rights reserved 111 September 2005 M100 Power Supply Calculating Weld Parameters Metric Continued Step Setting 8 Total weld time single pass in seconds Seconds per Revolution Weld Overlap Total Time Single Pass 60 rom Seconds per Revolution 60 ____ Wall Thickness x 2 Travel Speed Weld Overlap X 2 gt a Seconds per Revolution Weld Overlap Total Time Single Pass 9 Rotor delay time use the weld overlap time from step 7 10 Prepurge time in seconds 11 Postpurge time in seconds 12 Downslope Total Weld Time x 0 2 Downslope x02 __ Pulse rate Travel Speed x 2 364 1 182 x Wall Thickness Impulse Rate x 2 364 1 182X ss 112 2005 Swagelok Company all rights reserved September 2005 M100 Power Supply Automatic Socket Weld Procedure Guideline Worksheet US Customary Standard Inches Determine the Work Specifications Step Parameter Setting 1 Prog
97. mity e cracks e undercuts e excessive oxide 2 Inspect the weld on the inside of the tube Check for uniformity cracks undercuts and excessive oxidation full penetration excessive weld bead width variations excessive weld spot overlap Reference Weld Note Figure 96 shows a cross section of a proper weld The weld The welds are made with a 316L shows full penetration from the outside diameter to the inside stainless steel tube with the following diameter a crown on the outside diameter and minimal weld dimensions 1 2 in OD 0 049 in bead convexity on the inside diameter wall thickness Table 13 lists the parameters used to create the weld Compare welds with Figure 96 OD Weld Table 13 Reference Weld Parameters Bead Width Parameter Setting Impulse Amperes 58 8 OD Maintenance Amperes 17 6 Weld Pulse Rate cycles s 10 Zone Impulse Width 35 ID Speed rpm 3 mi in C it Arc Gap in 0 035 ID Weld Bead Width onvexity Avg Current Display Amperes 32 Figure 96 Reference Weld l Illustration The following examples show how changes in various parameters can affect the weld shape 116 2005 Swagelok Company all rights reserved September 2005 M100 Power Supply Weld Example No 1 Table 14 lists the parameter change used to create the weld shown in Figure 97 Table 14 Weld Example No 1 Parameter Reference Setting This Setting Impulse Amperes 49 8 Average Cu
98. nds Downslope Total Weld Time x 0 2 Downslope x 0 2 Pulse rate Travel Speed 30 x Wall Thickness Impulse Rate 30 X 114 2005 Swagelok Company all rights reserved September 2005 M100 Power Supply Evaluating the Weld A completed weld must meet structural and metallurgical requirements The weld must be uniform and free of cracks porosity and undercuts It must not have excessive oxidation And if it is a butt weld it must have E full penetration from the outside diameter to the inside diameter See Figure 94 DO k o Figure 94 Acceptable Identifying Typical Weld Discontinuities Weld Figure 95 shows typical weld discontinuities TYPICAL WELD DISCONTINUITIES SoS Incomplete Penetration Partial Penetration Concavity l Convexity Meander Axial Misalignment Angular Misalignment Figure 95 Typical Weld Discontinuities 2005 Swagelok Company all rights reserved 115 September 2005 M100 Power Supply Identifying Proper Welds The cross sectional welds in Figure 96 through Figure 107 on pages 116 through 121 show how changing various parameters affects the shape of the weld To check the weld follow these steps 1 Inspect the weld on the outside of the tube Check for e unifor
99. nism See Figure 77 a Lift the printer head fully by raising the lift arm located with the manual paper feed wheel next to the printer cover panel The lift arm has three positions Full down for printing and full up to load the paper The center position is not used b Before you place the paper into the support bracket feed the paper through the printer The paper enters the printer between the support brackets above the white plastic bar Feed the paper completely through the printer until it comes out the front panel slot The paper feeds from the top of the roll c Insert the spindle through the paper roll Press both ends of the spindle and insert into the slots Release ends and check spindle seating Figure 78 Advancing the Paper 80 2005 Swagelok Company all rights reserved September 2005 M100 Power Supply d Lower the printer head fully by lowering the lift arm Figure 79 Lower the Printer Head 5 Slide the data recording printer back into the unit case A Caution 6 Turn the latch clockwise to secure the data recording Once the paper enters the printer to the case feed mechanism do not pull it back in the direction of the paper roll Feed the paper with the Advance Paper Button 2005 Swagelok Company all rights reserved 81 September 2005 M100 Power Supply Operating the Data Recording Printer The controls used to operate the data recording printer have A Caution been kept to
100. nternal gas solenoid in favor of a secondary valve and is controlled by the power supply Speed Lo This is the rotor speed in RPM during the Maintenance portion of the weld cycle Refer to Step Programs Multi Level in the Power Supply module Speed Hi This is the rotor speed in RPM during the Impulse portion of the weld cycle Refer to Step Programs Multi Level in the Power Supply module Start Current The DC current used during the rotor delay Normally the average current of level one of the weld procedure Start Power The high voltage that starts the weld arc The M100 has three settings U LOW for use with wall thickness of 0 010 in 0 25 mm or less LOW for use with thin materials and the series 5 and 8 weld heads and NORMAL for all other applications Step Program A type of weld program in which the rotor speed is different between the impulse high pulse time and the maintenance low pulse time The rotor speed may vary from zero to the weld heads maximum rpm Refer to Step Programs Multi Level in the Power Supply module Straight Polarity The electrical configuration that makes the electrode the negative lead and the work the positive lead 1999 2005 Swagelok Company all rights reserved 7 September 2005 Tacks Small points of weld that do not penetrate the wall completely Usually spaced at three or four places around the tube diameter Used to hold the joint alignment and joint gap d
101. on 2005 Swagelok Company all rights reserved 13 September 2005 M100 Power Supply 5 Press WELD then JOG on the operator keypad to return the rotor to its home position 6 Turn off the power supply 7 Ifproblems occur refer to the Troubleshooting manual for a list of possible causes and corrective actions Operation This section describes the basic operation of the Swagelok Welding System SWS This section covers e Front panel controls e M100 modes of operation and functions e Entering the weld parameters e Setting the shield gas flow e Starting and completing the weld e Using the data recording printer e Using the PC memory card The welding process described in this section uses a weld procedure guideline for tubing with a 1 2 in OD and 0 049 in wall thickness A weld procedure guideline is a list of weld parameter settings for a particular job Keep in mind that the weld parameters listed in this section are for demonstration purposes and may not produce an optimum weld Weld Parameter Development describes how to optimize welding parameters Figure 11 Checking the Rotor Rotation 2005 Swagelok Company all rights reserved September 2005 M100 Power Supply Front Panel Controls SS Remote Display SI Remote Keypad 2 AD AM WY WW Remote Plug PC Memory Card Slot Data Recording Printer POWER SUPPLY Figure 12 Front Panel Controls The operator
102. on DATALOG XFER MEM TO CARD This submode allows you to transfer the system datalog records to the PC memory card This function does not transfer weld procedures The port is active in this function even if the DATALOG ENABLE CARD 1s in the OFF position DATALOG PRINT FORMAT CONFIG PASSWORD UTILITY This function allows you to specify a preferred format for PRINT COUPON qe PRINT ALL COUPONS XFER MEM TO SERIAL XFER MEM TO CARD PRINT FORMAT LONG AUTO PRINT 0 printed output from three choices The choices are long short and medium and each provides more or less information See Figure 62 through Figure 64 OF COUPONS NONE ENABLE CARD OFF ENABLE SERIAL OFF ERASE DATALOG MEM ERASE DATALOG CARD DATA conf pass util xfer mem to card gt gt PRINT FORMAT LONG auto print Figure 61 Print Format 62 2005 Swagelok Company all rights reserved September 2005 M100 Power Supply Weld Data Record Examples SWAGELOK WELDING SYSTEM The Short printout shown in Figure 62 contains PATA MEET oer only the header information description outputs MODEL M100 1 VER 1 01 5 05 SERIAL 1050 and performance confirmation DATE JUL 13 1999 TIME 03 42p WELD 12 DESCRIPTION PROCEDURE WPS TEST 1A DESCRIPTION 0 500 049 SS 316 04 03 PROGRAMMER XXXXXXXXX WELDER XXXXXXXXX OUTPUTS AVERAGE LVL AMPS VOLT RPM TIME KJ 1 349 67 35 51 4 6 1 0 2 338 6 6 35 51 46 1 0 3 328 66 35 51 4 6 0 9 4
103. opropyl alcohol prior to installing new filter See Figure 112 7 Install the new HEPA filter with gasket side towards fan guard 8 Swing the HEPA filter cover closed Use the tool from step 2 to press and engage the latches The latches will lock into place when the HEPA filter cover is completely closed See Figure 112 HEPA Filter GIB OI Cover Figure 112 Fan Guard 9 The cabinet of the M100 HP power supply can be cleaned with a low lint non abrasive wipe and isopropyl alcohol 2005 Swagelok Company all rights reserved 125 September 2005 M100 Power Supply Specifications Table 25 Power Supply Model Supply Service Output Voltage Amps Current dc SWS M100 1 115 V ac 20 2 to 100 A SWS M100 HP 1 SWS M100 1 115 V ac 15 2to70A SWS M100 HP 1 SWS M100 2 230 V ac 15 2 to 100 A SWS M100 HP 2 10 input voltage tolerance frequency range 50 to 60 Hz Table 26 M100 Duty Cycle Model 100 SWS M100 1 100 32 3 A 25 14 V 11 3 V 11 V SWS M100 2 100 32 3 A 25 14 V 11 3 V 11 V Table 27 M100 HP Duty Cycle Model 100 SWS M100 HP 1 15 9 V SWS M100 HP 2 15 9 V 126 2005 Swagelok Company all rights reserved September 2005 M100 Power Supply Welding systems may be operated at different power output settings prescribed by the appropriate Duty Cycle Rating Table 26 The Duty Cycle Rating expressed as refers to the maximum weld time allowed during a given
104. or no using the UP DOWN keys The default answer is no When storing is done press a mode key to continue 2005 Swagelok Company all rights reserved 51 September 2005 M100 Power Supply PROG MODE The PROG mode allows a programmer to modify and create weld procedures To ensure that only authorized programmers create procedures a password can be required to enter this mode Program Mode Directory Submode Activity Page Display MODIFY Edit item EDIT ITEM 53 Procedure 55 55 55 58 Change current limits CURRENT 56 LIMIT 100 Purge time limits PURGE 56 LIMIT 100 Current performance CURRENT 56 tolerance TOLER 2 5 Rotor speed SPEED 56 performance tolerance TOLER 2 5 Designate required REQUIRED 57 fields FIELDS CREATE Auto entry AUTO ENTRY 57 Procedure Manual entry MANUAL ENTRY 60 Load and edit LOAD AND EDIT 60 POWER SUPPLY CREATE EDIT ITEM Number of Levels INSERT LEVEL 4 DELETE LEVEL INSERT TACK 0 Number of Tacks DELETE TACK CURRENT LIMIT 100 PURGE LIMIT 100 CURRENT TOLER 2 5 SPEED TOLER 25 REQUIRED FIELDS MODIFY EDIT ITEM INSERT LEVEL 0 DELETE LEVEL INSERT TACK 0 DELETE TACK CREATE CURRENT LIMIT 100 PURGE LIMIT 100 CURRENT TOLER 2 5 SPEED TOLER 2 5 REQUIRED FIELDS Figure 49 Program Mode REMOTE PENDANT MODIFY create required fields gt gt EDIT ITEM insert level Figure 50 Program Mode Display 52 20
105. ord the Start Power U Low Low Norm for the weld head and wall Note thickness being used Refer to the appropriate weld Impulse Width is determined and head manual recorded in step 13 on page 98 and Worksheet entry norm entered as percentage in the formula 6 Calculate and record the Start Current using the following formula Impulse x Impulse Width Maint x 1 Impulse Width Arc Start For example 68 6 x 0 30 20 6 x 1 0 30 35 00 35 A Worksheet Entry 35 7 Calculate the Total Weld Time Single Pass in seconds using the following formulas a First calculate the Seconds per Revolution 60 rom Seconds per Revolution For example 60 3 5 17 1429 seconds 17 1 seconds b Next calculate the weld overlap time using the following formula Wall Thickness x 2 Travel Speed In seconds Weld Overlap Time For example 0 049 x 2 5 5 60 0 098 0 0917 1 1 seconds 96 2005 Swagelok Company all rights reserved September 2005 M100 Power Supply c Next calculate and record the Total Weld Time Single Pass using the following formula Seconds per Revolution Weld Overlap Total Weld Time Single Pass For example 17 1 1 1 Total Weld Time Single Pass 18 2 Total Weld Time Single Pass Worksheet entry 18 2 d Determine the total WELD TIME setting The total Weld Time setting depends on the number of passes needed to complete the weld diameter If the outside di
106. ory card but will not delete the datalog records The M100 will ask for confirmation that you want to erase the kas Save WEL go card Using the UP DOWN keys to highlight your selection erase card cc 29 ce 99 gt gt DELETE PROCEDURE ENTER yes to proceed or no to cancel eee ce neon Figure 47 Delete Procedure from Memory Display 50 2005 Swagelok Company all rights reserved September 2005 M100 Power Supply COPY Copy Procedure Files ee 1 MEM TO CARD ALL CARD TO MEM 1 MEM TO CARD ALL CARD TO MEM These functions allow you to download one file or all files ALL MEM TO CARD in memory to a PC memory card for storage or subsequent upload to another M100 power supply The unit will ask if you want to overwrite PC memory card files with memory files of the same name Select yes or no using the UP DOWN keys The default answer is no When storing is COPY CARD TO MEMORY done press a mode key to continue C TESTI 0 500 0 014 SS 316L 00 01 C TEST2 0 0620 014 SS 316L 00 02 S TEST3 0 125 0 28 SS 316L 00 03 S TEST4 0 250 0 28 SS 316L 00 04 COPY CARD TO MEMORY c test4 gt gt C TESTI s test2 Figure 48 Copy Procedure Display 1 CARD TO MEM ALL CARD TO MEM These functions allow you to download one file or all files from a PC memory card to memory The M100 power supply will ask you 1f you wish to overwrite files with the same name in memory Select yes
107. ote The circuit breaker is of the type that must be reset if it trips Reset the breaker by setting it to the OFF position before turning it on 2005 Swagelok Company all rights reserved September 2005 Troubleshooting Weld Head Symptom Rotor does not return to the home position Cause Fixture connector is not fully engaged Rotor is not at the home position when the power supply is turned on Dirty home sensor Rotor gear ring is misaligned with secondary gears Fixture connector has broken or damaged pins wires Home sensor is damaged or misaligned Dirty or worn weld head body halves Gear bearings worn or dirty Dirty ball bearings in rotor Rotor squeaks when turning Rotor does not move or makes a clicking noise when turning Debris on gears Loose drive clip in the micro weld head Brush spring is installed incorrectly in micro weld head Bent motor shaft 2005 Swagelok Company all rights reserved September 2005 Remedy Check that the fixture connector is seated and its collar is tight Use ROTOR JOG to move the rotor to the home position then cycle power off and on Disassemble the weld head and check the home sensor for dirt See the appropriate motor and power block assembly drawing in the Power Supply manual Use compressed air to blow off debris Realign the rotor with the weld head opening Refer to the Maintenance section of
108. per second The current is at the high level 20 A 30 of the time and at the low level 70 of the time 10 _ y 1 sec 1 sec bad Time Effects of Weld Parameter Changes Impulse current and rotor speed affect the depth of penetration of the weld Figure 72 Multiple Level Weld Current Waveform 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 70 2005 Swagelok Company all rights reserved 73 September 2005 M100 Power Supply Setting the Shield Gas Flow 1 Verify the shielding and purge gas connections to the A Caution work pieces E 7 xcessive or insufficient flow 2 Set the shielding gas flow meter to the proper setting rates may affect arc start and Refer to Table 4 arc stability Table 4 Shield Gas Flow Rates Argon Weld Head Series std ft h L min 5H 10 to 15 4 7 to 7 1 10H 10 to 200 4 7 to 9 4 20H A 10 to 200 4 7 to 9 4 20H B C 20 to 400 9 4 to 18 8 40H 25 to 500 12 to 24 4MH 8 to 10 4 to 4 7 8MH 15 to 20 7 1 to 9 4 Set the flow to the higher rates when welding at high current levels 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 Refer to Table 5 4 Press PURGE again to close the s
109. period of time with the balance of the cycle being required for cooling The industry uses a 10 minute Duty Cycle as a standard Using the 10 minute Duty Cycle the weld times and idle times for several Duty Cycle Ratings are presented in the following tables Table 28 M100 10 Minute Cycle Times Duty Cycle Rating Required Idle Time minutes minutes 50 7 on 100 Table 29 M100 HP 10 Minute Cycle Times Duty Cycle Rating Required Idle Time minutes minutes 20 on fe 0 0 Continually exceeding the duty cycle may activate an internal thermal protector that will disable the power supply and display a critical error message code on the operator interface screen 2005 Swagelok Company all rights reserved 127 September 2005 M100 Power Supply Table 30 M100 Power Supply Dimensions and Weight Model Dimensions overall Weight SWS M100 1 15 5 in 39 cm wide 42 5 Ib 19 4 in 49 cm deep 16 8 kg 9 in 23 cm high without handle SWS M100 2 15 5 in 39 cm wide 45 5 Ib WARNING 19 4 in 49 cm deep 20 6 kg 9 in 23 cm high without handle DO NOT USE EXTENSION CORDS THAT ARE IN POOR PHYSICAL CONDITION OR Table 31 M100 HP Power Suppl Dimensions and Weight HAVE INSUFFIGIENT Model Weight SWS M100 HP 1 16 375 in 41 6 cm wide 44 2 Ib 19 4 in 49 cm deep 20 1 kg 9 in 23 cm high without handle SWS M100 HP 2 16 375 in 41 6 cm wide 47 6 lb 19 4 in 49 cm deep 21 6 kg 9 in
110. ptember 2005 M100 Power Supply CONFIG JOG SPEED DATALOG PASSWORD UTILITY 50 SETUP This function allows you to specify manual jog speed as a RIM UNITS INCHES percentage of the maximum rotor RPM PURGE UNITS CFH DATE FMT MM DD YY REMOTE LIGHT REMOTE KEY CEICK PANEL LIGHT PANEL KEYCLICK MON POLARITY ALARM MINIMUM VOLT COUNT MISFIRES data CONF pass uti data fmt mm dd yy gt gt JOG SPEED 6 0 dim units inches Figure 66 Jog Speed CONFIG DIM UNITS This function allows you to change the linear measurement DATALOG CONFIG PASSWORD UTILITY SETUP JOG SPEED DIM UNITS INCHES PURGE UNITS CFH units between Metric and English measurement systems WCE ET MM DD YY REMOTE LIGHT ON Select inches millimeters or inches for OD and inches or millimeters for wall thickness REMOTE KEYCLICK ON ADJ LIMITS TEST OTHER DIM UNITS DATALOG The dimensional units displayed are defaulted from the last auto generated program MILLIMETERS IN OD MM TH IN OD MM TH UNITS gt INCHES MILLIMETERS UP DN ARROW gt gt HIGHLIGHT FIELD gt THEN ENTER data CONF pass util inches mm DIM UNIT gt INCHES millimeters Figure 67 Dimensional Units 2005 Swagelok Company all rights reserved 67 September 2005 M100 Power Supply CONFIG PURGE UNITS This preference allows you to either measure purge gas f
111. ptember 2005 M100 Power Supply Table 3 Status Conditions Disable High Temperature No Weld Head No Proc Selected Invalid Procedure Update Weld Info Req Memory Card Memory Card Full System Memory Full High Rotor Speed Card Write Protect Card Uninitialized 36 Description The power supply is over its rated temperature This condition will automatically reset when the power supply has cooled to within its limits There is no weld head attached to the power supply There is no procedure selected You must select a program from FILE or create one from PROGRAM CREATE The procedure selected is not executable The program weld field must be reset within tolerance using PROGRAM MODIFY EDIT ITEM A field that has been designated as requiring data and the information has not been entered in the WELD INFO mode When SETUP DATALOG CARD ENABLE ON is active a PC memory card must be installed to receive data The card write protect must be off The PC memory card installed does not have memory space available The number of saved procedures has exceeded the amount of available memory You must delete unused programs or delete data log records You may want to SAVE the procedure to a PC memory card The weld head connected to the power supply cannot provide the rotor speed programmed in the active procedure You must adjust the program rotor speed or change to the correct weld head When
112. qu es pour v rifier que ce produit conforme aux directives Die folgenden Normen wurden angewendet zur Uberpriifung der Ubereinstimmung mit den oben genannten Richtlinien Sono state usate le seguenti norme per verificare la conformita ai direttivi Las normas siguientes han sido utilizadas para verificar que el producto cumple con las directivas correspondientes EMC STANDARDS EN 50199 EN 55011 IEC 1000 4 2 IEC 1000 4 3 IEC 1000 4 4 LOW VOLTAGE STANDARDS EN 60974 1 EN 60974 12 Approved By Approuv e Par Genehmigt Durch Approvato da Aprobado por Position Poste Position Posto Puesto 4 gt Y Date Date Datum Data Fecha NS 708 LOL 2005 Swagelok Company all rights reserved 5 September 2005 2005 Swagelok Company all rights reserved September 2005 Regulatory Registration Information Your Swagelok representative provides support and service for your Swagelok Welding System SWS and maintains a local stock of precision fittings and valves Please take a moment to fill out 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 Serial Number Delivery Date Figure 1 Rating Label
113. r supply has exceeded its rated temperature The electrode has touched the weld puddle The operator has pressed the Stop Key to abort the weld in progress The weld did not perform within the specified speed tolerance The tolerance is set in PROGRAM MODIFY SPEED TOLERANCE The weld did not perform within the specified tolerance The tolerance is set in PROGRAM MODIFY CURRENT TOLERANCE Description System Clean up is an automatic Clean up function that the M100 power supply will perform when internal memory is nearing capacity The M100 power supply rearranges files to open up additional internal memory If the System Clean up Information box occurs often or takes excessive time to perform weld data logs may need to be deleted in SETUP DATALOG ERASE DATALOG MEMORY OR CARD 2005 Swagelok Company all rights reserved 37 September 2005 M100 Power Supply ADJUST CLEAR ADJUSTMENTS When a procedure has been adjusted by one of the displayed selections it is noted by adding ADJUSTED to the procedure name displayed on the screen Selecting CLEAR ADJUSTMENTS returns to the initial procedure values and the appended notation is removed Saving the Adjusted Active Procedure will also clear the appended notation ADJUST AVERAGE CURRENT PER LEVEL This selection allows you to make a quick adjustment to the current for a level The value that can be adjusted 1s the average current which 1s the average of the
114. rammer s Name 2 Joint Type 3 Material Type 4 Weld Diameter in Inches 5 Wall Thickness in Inches 6 Weld Head Model No T Electrode Part No 8 Arc Gap in Inches Arc Gap Gauge Setting 9 ID Purge Gas Flow in SCFH 10 Shielding Gas Flow in SCFH Calculating Weld Parameters Step Setting 1 Travel speed in per min Use 5 in per min 2 Rotor speed in rpm for all levels Travel Speed Circumference rom Socket OD x x Circumference x 3 1416 Travel Speed Circumference rom 3 Impulse amps for level 1 Table 10 1 2 x Socket Wall Thickness in thousands of an inch x 100 Amps 1 2x x 1000 4 Maintenance amps for all levels Table 11 33 x Impulse Amps Maintenance Amps 33 X 5 Start power u low low norm Norm 6 Impulse width 50 7 Start current Imp Level 1 x Imp Width Maint x 1 Imp Width Arc Start C x tL x 1 __ A aes 2005 Swagelok Company all rights reserved 113 September 2005 M100 Power Supply Calculating Socket Weld Parameters Inches Continued Step Setting 8 Total weld time single pass in seconds Seconds per Revolution Weld Overlap Total Time Single Pass 60 rom Seconds per Revolution 60 Wall Thickness x 2 Travel Speed 60 Weld Overlap _x2 __ 60 Seconds per Revolution Weld Overlap Total Time Single Pass 9 Rotor delay time use the weld overlap time from step 7 10 Prepurge time in seconds 11 Postpurge time in seco
115. rd to memory One procedure from 1 MEM TO CARD 51 memory to card All procedures from ALL CARD TO MEM 51 card to memory All procedures from ALL MEM TO CARD 51 memory to card POWER SUPPLY REMOTE PENDANT DELETE LOAD PROCEDURE PRINT PROCEDURE PRINT DIRECTORY print directory gt gt LOAD PROCEDURE print procedure save del Figure 42 File Mode Display 2005 Swagelok Company all rights reserved 45 September 2005 M100 Power Supply LOAD LOAD PROCEDURE This function allows you to select a procedure stored in memory or the PC memory card Select LOAD PROCEDURE and press ENTER to bring up the list of stored procedures Scroll through the list to highlight the procedure you would like to load then press ENTER The selected procedure 1s copied from memory to the work area as the active procedure and the M100 changes to the Weld mode If no weld procedure files are stored in memory a NO PROCEDURES FOUND message is displayed Load Procedure also allows you to load procedures from the PC memory card Install a PC memory card with weld procedures The weld procedures from the memory card will be displayed first with the letter C preceding the file name Weld procedures from internal memory will have the letter S preceding the name Arrows The arrows indicate more procedures above or below in the display The procedures may be reached by scrolling with the UP DOWN or FWD BACK keys 46 DELETE CO
116. rrent 39 28 87 Amperes Lowering the Impulse current lowers the average current This decreases the heat input per unit of electrode travel resulting in no inside diameter penetration Weld Example No 2 Table 15 lists the parameter change used to create the weld shown in Figure 98 Table 15 Weld Example No 2 Parameter Reference Setting This Setting Impulse Amperes 67 9 Average Current 35 2 Amperes Raising the Impulse current raises the average current This increases the heat input per unit of electrode travel resulting in increased inside diameter convexity and weld bead width 2005 Swagelok Company all rights reserved September 2005 Figure 97 Improper Weld Example No 1 Figure 98 Improper Weld Example No 2 Reference Illustration of Proper Weld 117 M100 Power Supply Weld Example No 3 Table 16 lists the parameter change used to create the weld shown in Figure 99 Table 16 Weld Example No 3 Parameter Reference Setting This Setting Maintenance 17 8 148 Amperes Average Current 30 2 Amperes Lowering the Maintenance current lowers the average current This decreases the heat input per unit of electrode travel resulting in no inside diameter penetration Weld Example No 4 Table 17 lists the parameter change used to create the weld shown in Figure 100 Table 17 Weld Example No 4 Parameter Reference Setting This Setting Maintenance 17 8 20 8 Amperes
117. s maintained for the remainder of the cycle The average current is the sum of these fractional components that occur during each cycle Backing Gas The gas used at the back of a weld joint or within a tube or vessel to prevent oxidation and undercut Butt Weld A weld joint where two work pieces are welded together with their long axes concentric and in line The joint can have various configurations such as square groove v groove J groove double v groove etc Centering Gage Gage used to center the work pieces in the fixture block Ceramic Insert A ceramic insulator used in the rotor to isolate the electrode from the weld head The insert helps prevent arcing Collet A device used to hold the work pieces in the fixture Collets are made in different sizes and shapes to accommodate different size and shapes of work pieces 2 2005 Swagelok Company all rights reserved September 2005 Concavity In welding the condition where the weld profile extends below the outside surface of the work Data Log Record This is the record of weld data such as the weld procedure used the real time data output collected information entered in WELD INFO and the acceptability performance of the weld Data Logging Collecting welding parameter data regardless of faults or alarms Data Monitoring Collecting data and comparing it to preset conditions If the data is found to be outside normal limits audio alarms may
118. s Weld Head Centering Gauge Yes Fixture Block lt D Quick Connect Stem S Power Supply Secondary Solenoid Bypass Plug Yes Power Supply Dial Digital Calipers or Micrometer Purge Connector s Z O O O 1 O O Shielding Purge Gas Lines Shielding Purge gas Source Pressure Regulator Internal Purge Gas Flow Meter Shielding Gas Flow Meter Internal Pressure Gauge O 1 OJO 1 1 The Series 40 weld head does not include an arc gap gauge centering gauge or electrode package All lines used for shielding purge gas should be the low moisture absorption type A compressed gas bottle or liquid Dewar source can be used Argon is the gas most frequently used 2005 Swagelok Company all rights reserved September 2005 M100 Power Supply Electrical Requirements Table 1 Power Supply Electrical Requirements Power Supply Voltage Service Current Model Requirement SWS M100 1 SWS M100 HP 1 115 V ac 20 A SWS M100 2 SWS M100 HP 2 230 V ac 15 A If the input voltage is 100 V or less the output power capabilities may be reduced Follow the electrical system guidelines below for power ere ES BE GROUNDED IF IT IS NOT e All wiring and related components must be GROUNDED ELECTRICAL installed according to local code and National SHOCK CAN OCCUR Electrical Code e A dedicated electrical circuit may be desired due to current need 2005 Swagelok Company all rights reserved 3 Septem
119. s a hazard e Do not touch live electrical parts e No user serviceable parts in the power supply other than a fuse Refer all other power supply servicing to your Authorized Swagelok representative 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 Verify that the power supply is properly grounded before use Make sure the power cord is plugged into a properly wired and grounded receptacle 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 Frequently inspect input power cord for damage or bare wiring replace immediately if damaged Properly unplug the power cord Grasp the plug to remove it from the receptacle 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 10 2005 Swagelok Company all rights reserved September 2005 Regulatory FUMES AND GASES can be hazardous Welding produces fumes and gases Breathing SAN these fumes and gases can be hazardous to your health Build up of gases can displace oxygen and c
120. ta recording printer prints program information as well as welded outputs The PC card may be used to store weld data and transfer data to a PC for QA QC records The M100 HP model also features a HEPA 0 3 micron filter on the exhaust fan non shedding clean room paper in the internal thermal printer non marking acetal feet and a smooth white powder coated finish for clean rooms Figure 1 Power Supply The M100 power supply uses screen prompted software for weld parameter control See Figure 2 The appropriate 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 to procedure guideline The guideline is used to maintain A Ans repeatability and quality control for subsequent jobs of the JO same type Figure 2 Power Supply Operator Display and Keypad 2005 Swagelok Company all rights reserved 1 September 2005 M100 Power Supply Installation 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 D Arc Gap Gauge Yes Weld Head lt Flat Blade Screw Driver e
121. te the weld shown in Figure 107 Table 24 Weld Example No 2 Parameter Reference Setting This Setting Pulse Rate 10 25 cycles s Raising the pulse rate increases weld spot overlap At times the welding parameters as described on page 107 must be adjusted to create an acceptable weld 2005 Swagelok Company all rights reserved September 2005 Figure 105 Pulse Rate Reference Weld Figure 106 Pulse Rate Weld Example No 1 SS L ZB HIN Figure 107 Pulse Rate Weld Example No 2 121 M100 Power Supply Maintenance ARNG The power supply has no internal serviceable parts and THE USER SHOULD NOT should not be disassembled SERVICE THE POWER SUPPLY Fuse Inspection and Replacement A 20 A 110 V ac system or a 10 A 220 V ac system ceramic fuse is on the rear panel of the power supply If the power is on but the arc fails to start you may have a blown fuse To inspect the fuse 1 Turn off the power supply See Figure 108 2 Unplug the power cord Figure 108 Power Supply Circuit Breaker in the OFF Position 122 2005 Swagelok Company all rights reserved September 2005 M100 Power Supply 3 Inspect the fuse and fuse cap a Unscrew the fuse cap using a flat blade screwdriver See Figure 109 b Inspect the fuse cap for damage overheating burning etc Replace the cap if necessary c Using an ohmmeter check the continuity of the fus
122. terial of Levels of Tacks Submode Menu es AD UST VIEW CNET INFO 1 TEST Active Procedure gt PROCEDURE a Eu Mode 0 DESCRIPTION ein 049 SS316L 0 S Sos WELDER JSMITH PROGRAMMER JOHNS Step Invalid escription or ATW JOINT TYPE MATERIAL TUBE DIAMETER Active __ WALL THICKNESS Parameters HEAD ELECTRODE OD GAS ID GAS 5H B GAP 0 035 ARGON ARGON C 040 605 GAGE 0 907 12 1 3 Status Indicators READY Warnings Errors W 000 lt Weld Counter Active Key START PURGE JOG HOME PRINT Indicators Promot Line REMOTE PENDANT Submode Menu capital letters indicate active submode ir WLD adj view inf tst _ Active Procedure TESTL Warning Errors i RO e READY Status Indicators ooa a Weld Counter Figure 13 Operator Display 2005 Swagelok Company all rights reserved 17 September 2005 M100 Power Supply The operator display shows information about the current mode of operation It also displays indicators warnings pop up menus and prompts when appropriate The remote pendant displays a limited range of information In each mode a series of submodes are displayed across the top of the screen When a submode that has several functions is selected those functions are listed in a pop up menu below the heading In the WELD and PROG modes the second line on the display shows the name of the active procedure and the current mode of operation Below the na
123. th of a second the following formula Note The Level Factor is used to calculate For example the Impulse Amps for all three levels 18 2 4 4 55 4 6 Seconds per Level after level one Worksheet entry 4 6 Total Weld Time Number of Levels Weld Time for Each Level b Calculate and record the Level Factor using the following formula Impulse Amps Level 1 x 15 Number of Levels 1 Level Factor For example 68 6 x 15 4 1 10 29 3 3 43 3 4 Amps Worksheet entry 3 4 c Calculate and record the Impulse Amps for all levels after level one using the following formula Impulse Amps for the Previous Level Level Factor Impulse Amps for this Level For example For level 2 68 6 3 4 65 2 Amps Worksheet entry 65 2 For level 3 65 2 3 4 61 8 Amps Worksheet entry 61 8 For level 4 61 8 3 4 58 4 Amps Worksheet entry 58 4 2005 Swagelok Company all rights reserved 99 September 2005 M100 Power Supply Step Programs Multi Level A Step Program should be used when the rotor speed differs between the Impulse high pulse period and the Maintenance low pulse period The rotor speed may vary from zero to maximum rotor rpm of the weld head being used Decreasing rotor rpm will increase heat input and increasing rotor rpm will decrease heat input 1 Calculate the average seconds per revolution before the weld overlap and total weld time Impulse rom x Impulse Widt
124. the Impulse Level 1 using the pote Because the IMPULSE setting following formula accepts values to only one decimal A x Wall Thickness x 1000 Impulse Value Level 1 pee eee Onan the number For example for a wall thickness of 0 049 in 1 4 x 0 049 in x 1000 68 6 A Worksheet entry 68 6 4 Calculate the Maintenance Amps a Locate the wall thickness 0 049 in and then read the corresponding B factor in Table 11 Table 11 Wall Thickness and B Factor a Thickness Range B Factor 0 010 to 0 020 0 2 to 0 5 0 15 0 021 to 0 034 0 51 to 0 86 0 20 0 035 to 0 046 0 87 to 1 17 0 30 0 047 to 0 055 1 18 to 1 40 0 30 0 056 to 0 065 1 41 to 1 65 0 30 0 066 to 0 070 1 66 to 1 78 0 31 0 071 to 0 075 1 79 to 1 90 0 32 0 076 to 0 080 1 91 to 2 03 0 33 0 081 to 0 085 2 04 to 2 16 0 36 0 086 to 0 090 2 17 to 2 29 0 39 0 091 to 0 095 2 30 to 2 41 0 40 0 096 to 0 109 2 42 to 2 77 0 43 0 110 to 0 154 2 78 to 4 0 0 45 2005 Swagelok Company all rights reserved 95 September 2005 M100 Power Supply b Calculate and record the Maintenance Amps using one the MAINTENANCE setting the following formula accepts values to only one decimal place you may need to round off the ee eg number For example 16 92 is Impulse Current level 1 x B Maintenance Value all levels rounded off to 16 9 For example for a wall thickness of 0 049 in 68 6 A x 0 30 20 58 20 6 A Worksheet entry 20 6 5 Determine and rec
125. the appropriate weld head user manual Call for service Call for service Disassemble the weld head and clean or replace components Clean or replace bearing assemblies as needed Disassemble rotor and clean or replace ball bearings as needed Check for weld spatter or debris on gears Check and replace drive clip if needed See the appropriate micro weld head assembly drawing in the appropriate weld head user manual Install the brush spring in the correct orientation Refer to the Maintenance section of the appropriate weld head user manual Call for service Troubleshooting Symptom Erratic rotor rotation speed control Arc damage on rotor gear Damage to weld head body halves Cause Weld spatter on gears Arcing damage on rotor gear teeth Dirty weld head debris on encoder sensor or encoder wheel Encoder wheel slips on motor shaft Fixture connector has broken wire Arcing from rotor Arcing Excessive heat from welding Weld head was dropped Remedy Inspect the rotor primary secondary and drive gear s for damage Replace damaged gears Inspect rotor and replace if damaged Disassemble the weld head and clean thoroughly Call for service Call for service Clean gear or replace if necessary Disassemble the weld head Clean or replace parts as needed Follow the recommended maintenance schedule outlined in the Maintenance sect
126. this manual e Power Supply Service WARNING There are no user serviceable parts in the A USERS SHOULD NOT power supply other than a fuse Refer all other SERVICE THE servicing to your Authorized Swagelok sales POWER SUPPLY and service representative 2005 Swagelok Company all rights reserved 15 September 2005 Regulatory Power Supply Warning Label This warning label is affixed to the power supply ARC WELDING can be hazardous Read and follow this label and the User s Manual Only qualified persons are to install and operate this unit z Pacemaker wearers keep away Do Not Remove Destroy or Cover This Label Return to authorized sales and service center for service ELECTRIC SHOCK can kill WELDING can cause fire or explosion Do not touch live electrical parts Do not locate unit over combustible surfaces Electrode and rotor are live during Do not weld on closed containers weld cycle Keep all panels and covers securely in place FUMES AND GASES can be hazardous ARC RAYS can burn eyes NOISE can damage hearing e Do not look at welding arc Do not breathe fumes or gases Ventilate area or use breathing device Read Material Safety Data Sheets MSDS s and manufacturer s instructions for the Wear proper eye and ear protection material used Read American National Standard 249 1 Safety in Welding and Cutting from American Welding Society 550 N W LeJeune Rd Mi
127. to be pressed for confirmation For more information on error indicators see page 35 34 2005 Swagelok Company all rights reserved September 2005 M100 Power Supply WELD Disable Warnings and Weld Errors Disable When the word DISABLED is on the status line a condition exists that must be corrected before a weld can be executed The line below DISABLED describes the condition Disabling conditions are preceded by D Warning conditions are preceded by W These both may be displayed but only the disabling D conditions must be cleared before welding Warning A warning W condition should be noted by the operator but welding may proceed with discretion WELD ERRORS The M100 has been programmed to monitor conditions during the weld cycle If the M100 detects an error the status line will indicate Weld Completed or Weld Not Completed the line below will describe the error and the audio alarm will sound if SETUP CONFIGURATION ALARM is on The condition must be acknowledged by pressing ENTER before the next weld may be accomplished All weld errors are recorded in the weld data Information Message Box A Caution Information message boxes may contain actions that should not be taken by the operator The Information Message Box may appear in any mode or submode The box may require a corrective action by the operator or may contain information only 2005 Swagelok Company all rights reserved 35 Se
128. to describe the depth of the weld The common usage to describe the correct level of penetration for tube and pipe welds is full penetration weld This means the weld has penetrated completely from the outside diameter to the inside diameter of the weld joint There are no portions of the weld joint that are visibly unfused Plenum A fixture block component that separates the side plates providing space for the weld head and forming a chamber for the shielding gas Postpurge The amount of time that the O D shielding gas is on after the welding is complete to cool the work pieces Power Supply The device that produces the electrical power for the welding process The SWS power supply is a constant current power supply Prepurge The amount of time that the O D shielding gas is applied before the arc start Pulse Rate The rate at which the output current level 1s changed between the high Impulse and low Maintenance settings The rate is expressed as pulses per second 1999 2005 Swagelok Company all rights reserved 5 September 2005 Pulse Weld A weld current that varies between a high level and a low level at a specific rate The technique reduces the heat input to the weld Pulse Width Impulse The percentage of time during one cycle that the weld current is at the Impulse High Amps level Purge Gas The gas backing or shielding used at the weld joint or within a tube or vessel to prevent ox
129. two procedures may be used 1 The weld does not penetrate immediately see Figure 92 The following is accomplished in PROG MODIFY EDIT ITEM a Set the Start Current to an acceptable level minimum 5 Amps or greater b Set the Start time to 0 1 seconds Enter the ramp up time in level one Ramp time Q Add the ramp up time to level one Weld time Adjust the procedure weld time to overlap the start of the weld for an even ID bead width Ramp Time Level 1 AT DR NE ER EE NN NNN NE SNS ENN ENN NN NNN ANR NN NNN NN NSS NN NSS SS SF NN NNN NNN I j Nanan IUT nn nl PNEU AA ANTON ZU he LMM Se NS Level 2 Weld Time Jo Level 1 Level 3 Level 4 Rotor Weld Time Weld Time Weld Time Delay Figure 92 Ramp Time Weld Does Not Penetrate Immediately Yo 2005 Swagelok Company all rights reserved 105 September 2005 M100 Power Supply 2 The weld must penetrate completely before the rotor begins to move see Figure 93 After the basic weld program is developed duplicate level one by using PROG MODIFY INSERT LEVEL The following is accomplished in PROG MODIFY EDIT ITEM a Set the Start Current to an acceptable level minimum 5 Amps or greater b Set the Start time to 0 1 seconds c Change the Weld time of level one to the desired ramp up time plus any rotor delay time needed for penetration d Enter the ramp up time
130. ubsequent levels Refer to Setting Single or Multi Level Program Parameters in the Power Supply module Maintenance Low Amps The minimum current level generated during the weld cycle Also referred to as background current or low amps Meander A welding condition in which the weld puddle is displaced to one side of the weld joint from the center line Misfire An action that occurs when the arc fails to start or sustain itself mm of Water Column Unit of pressure measurement Multiple Level A welding technique in which more than one average current level is used during the weld time Multiple Pass A welding technique in which the rotor moves more than one revolution during the weld time The technique is most helpful when fusion welding small diameter parts 2005 Swagelok Company all rights reserved September 2005 Orbital Welding A welding technique used for tubing pipes etc in which the arc rotates around the weld joint circumference Oxidation Heat discoloration or heat tint that occurs in the weld area caused by the presence of oxygen It can vary in color and intensity based on the weld temperature and the amount of oxygen present Oxidation can be detrimental to high purity systems and increase the chances of weld joint corrosion Ozone A gas produced when the ultraviolet light emitted by the welding arc reacts with the oxygen in the surrounding atmosphere Penetration The term used
131. untered to your Swagelok representative Good information helps identify the exact problem and expedite the solution This applies to problems that can be handled over the phone or those that require the unit to be returned for repair The result is faster repair times and more assurance that the repair meets with your approval Make the Swagelok representative aware if backup equipment is needed to temporarily replace the equipment being returned for repair 2005 Swagelok Company all rights reserved September 2005 Troubleshooting Troubleshooting Repair Replacement Instructions Certain remedies require a component such as a weld head to be disassembled cleaned or replaced For user maintenance procedures refer to the Maintenance section of the appropriate manual If in doubt about a procedure call your Swagelok representative Power Supply Symptom Remedy Front panel screen The circuit breaker is Turn on circuit blank off breaker The power supply line Plug power cord into cord is not plugged in the wall outlet The replaced or new Internal component Call for service ceramic fuse fails failure immediately when power is turned on Power supply fan Internal component Call for service does not operate failure Cannot store PC Memory Card write Slide the write protect procedures or weld protect switch is on switch on the PC data on the PC Memory Card to the Memory Card OFF position 2 N
132. ure Highlight the tack to be deleted and then press ENTER The M100 power supply will ask for confirmation before deleting the tack MODIFY PROCEDURE CURRENT LIMIT If you wish to limit the amount of average current adjustment allowed in the Adjust Average Current Per Level function on page 38 this setting allows such modification The value is expressed as a percentage and can be set to any value between 0 and 100 The default value is 100 You must have programmer privilege to access this function MODIFY PROCEDURE PURGE LIMIT If you wish to limit the amount of purge time adjustment allowed in the ADJUST PREPURGE POSTPURGE function on page 39 this setting allows such modification The value is expressed as a percentage and can be set to any value between 0 and 100 The default value is 100 You must have programmer privilege to access this function MODIFY PROCEDURE CURRENT TOLER If you wish to adjust the tolerance for the acceptable performance or check calculations for average current this setting allows selection of a new tolerance It can be set to any value between 0 0 and 9 9 The default value is 2 5 MODIFY PROCEDURE SPEED TOLER If you wish to adjust the tolerance for the acceptable rotor speed performance this setting allows selection of a new tolerance It can be set to any value between 0 0 and 9 9 The default value is 2 5 56 CREATE EDIT ITEM INSERT
133. uring welding Travel Speed The speed of the electrode as it passes over the weld joint usually expressed in inches per minute or millimeters per second Travel speed is normally entered into the machine as RPM Tungsten The material used to make the electrode Tungsten is typically alloyed with rare earth metals to enhance its current carrying capacity UCI An acronym used for universal collet insert the exchangeable component used in the fixture block to hold work pieces The patented inserts come in various sizes to match the outside diameter of the work pieces Warning W A status line displayed on the M100 under the READY status line during the WELD WELD mode They do not disable the machine but are warnings to the M100 operator to an equipment condition that may affect the weld Refer to Weld Disable Warnings and Weld Errors in the Power Supply module Watt A unit of electrical power measurement One ampere times one volt equals one watt Weld Coupon A sample weld made for evaluation purposes The weld is used for both visual and physical testing Weld Pool Shift See meander Weld Procedure The term used to describe a custom set of weld parameter values used to program the SWS for a particular welding job The parameter settings are based on the characteristics of the work and the SWS configuration It is sometimes called the weld schedule 8 2005 Swagelok Company all rights reserve
134. utt Weld to side 2 Tube Butt Weld e TB ATW side 1 Tube Butt Weld to side 2 Auto Tube Weld The side 2 ATW defaults to a normal cuff thickness However if desired you may adjust thickness setting 2005 Swagelok Company all rights reserved September 2005 MODIFY CREATE WELDER NAME HEAD SERIAL HEAT 1 HEAT 2 OD GAS ID GAS OPEN FIELD 1 OPEN FIELD 2 PROJECT NAME DRAWING NAME Figure 54 Designating the Required Fields MODIFY CREATE __ HAE COUR MANUAL ENTRY LOAD AND EDIT ed MODIFY create load and edit gt gt AUTO ENTRY manual entry Figure 55 Creating an Auto Entry Procedure 57 10 58 M100 Power Supply Select side 1 material Select the material for side 1 from the pick list The M100 power supply assumes that both sides of the weld are the same material and duplicates side information in side 2 If necessary changes can be made in MODIFY EDIT ITEM Select units Select the dimensional units desired for the weld procedure Options include inches millimeters and OD in inches wall thickness in mm Select side 1 diameter Select the OD for the tube for side 1 The M100 power supply assumes that both sides of the weld are the same material and duplicates side 1 information in side 2 If necessary changes can be made in MODIFY EDIT ITEM Select wall thickness Select the wall thickness for side 1 The M100 power supply assumes that both sides of the
135. ved 13 September 2005 Regulatory HOT PARTS can cause severe burns PASS HOT PARTS ARE PRESENT After welding the work piece weld head AFTER WELDING AND MAY and electrode can be extremely hot and may cause burns CAUSE BURNS MAGNETIC FIELDS can affect pacemakers WARNING e Pacemaker wearers keep away PACEMAKER WEARERS e Wearers should consult their doctor before going KEEP AWAY near arc welding operations 14 2005 Swagelok Company all rights reserved September 2005 Regulatory User Precautions WARNING VERIFY THE SYSTEM IS PROPERLY GROUNDED The power supply is grounded through the ground BEFORE USE 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 on the unit e Power Supply Grounding e Water and Moisture Do not expose the SWS equipment to water or visible moisture e Proper Use and Storage Do not store or use near hazardous materials Store indoors and cover the system when not in use e Weld Heads Disconnect the weld head completely from the power supply prior to servicing User service including cleaning or component replacement is limited to those operations identified in this manual e 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
136. y the values MODIFY PROCEDURE DELETE LEVEL The DELETE LEVEL function is used to remove a level from the procedure Highlight the level to be deleted and then press ENTER The M100 power supply will ask for confirmation before deleting a level MODIFY PROCEDURE INSERT TACK The number of tacks in a procedure is displayed next to the INSERT TACK function on the menu list The maximum number of tacks that can be used in a procedure is 10 When INSERT TACK is selected the tacks are displayed and you can use FWD BACK to select the point of insertion in the procedure The new tack will be added immediately before the selected tack The new tack will be a copy of the selected tack You must go to EDIT ITEM to modify the values 2005 Swagelok Company all rights reserved September 2005 EDIT ITEM INSERT LEVEL 4 DELETE LEVEL INSERT TACK 0 DELETE TACK CURRENT LIMIT 100 PURGE LIMIT 100 CURRENT TOLER 100 SPEED TOLER 100 REQUIRED FIELDS EDIT PROCEDURE PROCEDURE TEST1 PROG DESCRIPTION 0 500 0 049 SS 316L 04 00 WELDER ME PROGRAMMER ME LEVEL PAR IMPULSE MAINTENANCE WELD TIME RAMP PULSE RATE PULSE WIDTH SPEED HI SPEED LO CREATE CREAT INSERT LEVEL L 04 04 IMP 58 gt gt L 01 04 IMP 28 L 02 04 IMP 65 Figure 52 Inserting a Level 55 M100 Power Supply MODIFY PROCEDURE DELETE TACK The DELETE TACK function is used to remove a tack from the proced

Orbital Welding, Regulatory, M100 Power Supply

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