High Volume Swaging Unit User`s Manual, HVSU, (MS
Contents
1. A WARNING Failure to deburr the OD of the tube could prevent the tube from bottoming properly against the tooling shoulder A CAUTION Failure to deburr the ID of the tube could result in burrs entering the system and damaging other components of your system 7 Wipe the ID and OD of the tooling free of debris Preswage in Process LED A WARNING Debris on the tooling ID could result in damage to the ferrules ar 8 Load the nut and ferrule assembly onto the die and raise handle the retainer up Fig 13 Retainer 9 Insert the tubing into the nut and ferrule assembly until the tube bottoming sensor is activated The green Preswage in Process light will illuminate momentarily to indicate proper tube bottoming Fig 14 10 Pull the retainer latch handle to lower the retainer then remove the preswaged assembly Fig 14 Preswaging the Tubing 10 High Volume Swaging Unit User s Manual Fitting Installation and Gauging These instructions are for the traditional Swagelok tube fittings For other fitting types refer to the applicable Swagelok tube fitting installation instructions Installation 1 Turn the nut onto the fitting body until fingertight Fig 15 2 While holding the fitting body stable tighten the nut 1 2 turn with a wrench Fig 16 Gauging On initial installation the standard Swagelok gap inspection gauge assures the installer or inspector that a fitting has been sufficiently tightened2. individually for replacement as needed raw Ordering Number Puck Assemblies Puck assemblies can be reordered individually for replacement as needed rar Ordering Number Spacers Spacers can be reordered individually for replacement as needed Die Assembly Ordering Number MS HVSU SPC 400 MS HVSU SPC 600 MS HVSU SPC 810 Warranty Information Swagelok products are backed by The Swagelok Limited Lifetime Warranty For a copy visit swagelok com or contact your authorized Swagelok representative Caution Do not mix or interchange parts with those of other manufacturers Swagelok TM Swagelok Company WD 40 TM WD 40 Manufacturing Company 2012 2013 Swagelok Company Printed in U S A October 2013 R2 MS 13 223
3. High Volume Swaging Unit HVSU User s Manual OWAN 2 High Volume Swaging Unit User s Manual Contents DANGLY RAP oe Oe Oe ee eee See 3 Safety Summary 0 0 00 cece eee ees 3 High Volume Swaging Unit HVSU Safety Information sav stoke ec ee ere we olga ny eed 3 Product Information anaana eee eee 4 General Information 000 eee eee ees 5 SS o maa tae ea nta noe Oh arias ence See a 6 PIV OW SEP sia steeds Marae eke nak eee eae ata 6 Tooling Assembly and Installation 7 ODEON ccc ee eee ae ae a ee eee 9 Fitting Installation and Gauging 10 Maintenance oag anga bags pb hab pani 11 Troubleshooting AA AA ah Jee eee 14 Tooling Ordering Information 15 High Volume Swaging Unit User s Manual 3 Safety Safety Summary This manual contains important information for the operation of the Swagelok High Volume Swaging Unit HVSU Users should read and understand the contents before operating the HVSU The HVSU has no internal serviceable parts Return the HVSU to your authorized Swagelok sales and service representative for service WARNING Statements that indicate a hazardous situation which if not avoided could result in death or serious injury CAUTION Statements that indicate a hazardous situation which if not avoided could result in minor or moderate injury NOTICE Statements that indicate a hazardous situation which if not avoided could res
4. Position the standard Swagelok gap inspection gauge next to the gap between the nut and the body Fig 17 E f the gauge will not enter the gap the fitting is sufficiently tightened Fig 17 Using the Gap Inspection Gauge High Volume Swaging Unit User s Manual 11 E f the gauge will enter the gap additional tightening is required Maintenance Na LIGA ye aa Fig 18 Cycle Counter Cycle Counter The cycle counter can be used to track the number of preswage cycles and or tooling usage Fig 18 Puck and Contact Plate Cleaning Every 25 000 cycles clean the puck and contact plate according to the following procedure 1 Squeeze the latch arms and remove the puck assembly from the contact plate 2 Use a clean towel and spray WD 40 lubricant or an equivalent water dispersal lubricant liquid only onto the towel 3 Wipe the puck assembly and the face of the contact plate with the towel to remove dirt and contaminants Latch arm Contact plate Puck assembly r Fig 19 Puck and Contact Plate NOTICE Do not spray lubricant directly onto the puck assembly or contact plate Unit performance could be affected 4 Reinstall the puck assembly Do not wipe off the lubricant 12 High Volume Swaging Unit User s Manual HVSU Lubrication Every 100 000 cycles lubricate the following locations with a NLGI grade 2 white lithium grease spray or brush on Retainer Shaft 1 Remove the clip from left end of the retai
5. a tube more than once Tubing is difficult to remove from Tube wall thickness may be below Gently rock the tubing back and forth to the HVSU after preswaging recommended minimum wall remove it thickness Use tubing with a wall thickness equal to or larger than the minimum recommended Do not rotate the tubing The HVSU fails to swage The working pressure is too low Verify the working pressure is set to the sufficiently as indicated by the recommended air pressure defined in Table 2 gap inspection gauge after fitting Check the air line connections to the HVSU installation Do not swage a tube more than once If the working pressure is sufficient return the unit to your authorized Swagelok sales and service representative There is audible air flow The regulator is set too high Adjust the regulator If the problem persists return the unit to your authorized Swagelok sales and service representative Oil is leaking from the HVSU Return the unit to your authorized Swagelok sales and service representative Contact your authorized Swagelok sales and service representative for additional assistance High Volume Swaging Unit User s Manual 15 Tooling Ordering Information Tooling Tool kits are ordered separately according to size Each kit contains a die assembly a puck assembly and a spacer to match the size of tubing to be used Replacement Die Assemblies Die assemblies are consumable and can be reordered
6. cer into the retainer with the recessed face facing away from the puck aligning the orientation pin and sliding the spacer down until it is flush with the retainer surface Fig 10 and 11 Retainer surface Orientation pin Fig 10 Installing the Spacer Fig 11 Spacer Flush with the Retainer High Volume Swaging Unit User s Manual 9 Operation 1 Use the on off switch to turn on the power to the HVSU NOTICE 2 Refer to Table 2 Recommended Air Pressure for the Fitting performance may be affected if recommended correct operating pressure pressure setting is not used Table2 Recommended Air Pressure Air Pressure psig bar AN CAUTION Do not place fingers or hands behind or in the retainer when operating the HVSU wee magang 3 Turn the handle on the pressure regulator on the front of the HVSU until the pressure gauge displays the correct operating pressure Fig 12 Pressure regulator 4 To ensure the proper pressure verify the retainer latch handle is up Insert a piece of tube without nut and ferrules into the die to actuate it Remove the tube and verify the pressure gauge has returned to the desired value 5 Pull the retainer latch handle forward to lower the retainer 6 Prepare the tube ends according to the following E Cut the tube squarely Use of a Swagelok tube saw guide is recommended Nut and ferrule assembly E Remove any burrs Use of a Swagelok deburring tool is recommended
7. l Product Information Latch arms Retainer handle Carrying handle On Off switch Retainer Preswage in Process LED Pressure Cycle counter gauge Pressure regulator 12V Electrical connection Pneumatic connection Rating Power Power label supply cord High Volume Swaging Unit User s Manual 5 General Information Description The Swagelok High Volume Swaging Unit HVSU is designed NOTICE to preswage ferrules on to a tube Refer to Tubing Data The HVSU should be used to preswage only Swagelok MS 01 107 for acceptable tube wall thicknesses tube fittings A tube bottoming sensor ensures proper tube bottoming to start the preswage process The nut bottoming sensor stops the preswage process after the designed preswage stroke has been reached Product Technical Data Dimensions in mm 8 3 W by 11 1 H by 26 L 211 W by 279 H by 660 L Weight Ibs kg 70 31 8 Electrical Requirements Voltage Service Current Requirements Requirement HVSU 12 V dc 3 33 A maximum Power supply 120 to 240 V ac Unpacking the HVSU Shipping Case Contents M HVSU MS HVSU X with X indicating power cord Power supply MS HVSU PS 12V 3 8 in Male quick connect stem SS QC6 D 600 0 050 in hex key MS HD 050 User manual MS 13 223 Fig 1 Shipping Case Report any missing or damaged parts to your authorized Tooling ordered separately Swagelok sales and service representative immediately Note The to
8. ner shaft Fig 20 Fig 20 Removing Clips from Retainer Shaft 2 Remove the retainer shaft Note The retainer will now be loose and should be placed on a stable surface 3 Clean the shaft with a towel Brass washer Fig 21 Applying Lubricant to Retainer Shaft 4 Spray or brush lithium grease on both ends of the shaft including the inside of the retainer Fig 21 High Volume Swaging Unit User s Manual 13 Connector Shaft 1 Liberally spray or brush lithium grease in the area behind the square block that holds the retainer shaft Fig 22 Fig 22 Applying Lubricant to Connector Shaft 2 Wipe off any excess grease Latch Pins 1 Push one pin forward toward the front of the retainer as far as possible 2 Clean the pin with a towel 3 Spray or brush lithium grease on the exposed portion of the pin Fig 23 Fig 23 Applying Lubricant to Latch Pins 4 Repeat steps 1 through 3 for the other pin 5 Squeeze the latch arms and set the retainer into place Note Verify brass washers are in counterbores Lubricate with lithium grease if needed to hold washers in place 6 Reinsert the retainer shaft and replace the clip 14 High Volume Swaging Unit User s Manual Troubleshooting Tubing is difficult to or will not Tubing is out of tolerance or has a Measure the tubing wall thickness install into the tooling die burr on end of tubing Verify the tube is properly cut and prepared for swaging Do not swage
9. oling kit comprised of a puck assembly a die assembly and a spacer is ordered and shipped separately 6 High Volume Swaging Unit User s Manual Setup HVSU Setup 1 Lift the HVSU from the shipping case using the handle on the top of the unit Place the HVSU on a stable surface A CAUTION The HVSU weighs 70 Ibs 31 8 kg 2 Inspect the HVSU and tooling for damage 3 Record the model number and serial number from the rating label on the back of the unit for your reference Fig 2 4 Connect the power supply to the electrical connection on the back of the HVSU Fig 3 Connect the power cord to a properly rated and grounded electrical receptacle 5 Connect a filtered dry compressed air supply line maximum 125 psig 8 6 bar to the supplied quick connect NOTICE Do not exceed a 125 psig 8 6 bar supply line Damage to the unit could result 6 Connect the supplied quick connect to the pneumatic connection on the back of the HVSU Fig 3 Electrical connection Pneumatic connection OWA s Model High Volume Swaging Unit Do Not Exceed 50 psig 3 4 bar Input 12VDC 3 33A Max O D Serial 011201 irre ryt Fig 2 Rating Label Fig 3 Back of the HVSU Tooling Assembly and Installation Assembly Select a tooling set consisting of a puck assembly a die assembly and a spacer to match the size of tubing to be used The puck and die must be assembled together 1 Place the die into
10. the puck with the flange facing upward 2 Ensure the flat of the die assembly is aligned with the nut bottoming sensor and the die assembly is seated flush with the puck assembly face Fig 4 3 Use a 0 050 in hex key to turn the set screw until the die assembly is held in place Ensure the die has slight movement in the puck Fig 5 NOTICE Do not overtighten the set screw Damage to the die assembly could result Detail Flush Die Assembly Nut bottoming High Volume Swaging Unit User s Manual 7 Die assembly Puck assembly Fig 4 Die and Puck Assemblies Fig 5 Securing the Puck Set Screw Z CAUTION Disconnect the air pressure and turn the power off prior to installing or changing tooling Installation 1 Pull the retainer latch handle forward to lower the retainer Fig 6 and 7 Contact plate Retainer latch handle Retainer Fig 6 Pulling the Retainer Latch Handle Fig 7 Lowered Retainer 2 Squeeze the left and right latch arms and place the die puck assembly into the contact plate with the marks on the die puck assembly aligning with the latch arm screws and release the arms Ensure that the nut contact sensor is pointing downward Fig 8 and 9 Latch arms IN Die puck assembly Nut contact sensor Latch arm 77 Screws k Fig 8 Squeezing the Latch Arms Fig 9 Installed Die Puck Assembly 8 High Volume Swaging Unit User s Manual 3 Install the spa
11. ult in damage to the equipment or other property A Safety alert symbol indicating a potential personal injury hazard A Safety alert symbol indicating a potential for personal injury from electrical shock High Volume Swaging Unit HVSU Safety Information A ELECTRIC SHOCK can kill A Touching live electrical parts and failure to operate equipment properly can cause fatal electric shock and severe burns Incorrectly installed or improperly grounded equipment is a hazard To avoid injury M Do not touch live electrical parts M Keep all panels and covers securely in place Em Follow local electrical codes and the guidelines in this manual when installing the HVSU 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 E Frequently inspect input power cord for damage or bare wiring replace immediately if damaged M Properly unplug the power cord Grasp the plug to remove it from the receptacle WARNING Danger of eyes being injured Eye protection must be worn while operating or working near the equipment WARNING Keep dry Equipment and components are not waterproof Do not use electric tools in a damp or wet environment CAUTION Fingers can be injured Do not place fingers or hands near the retainer assembly while operating the HVSU 4 High Volume Swaging Unit User s Manua
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