Series 5 Weld Head User`s Manual (SWS-MANUAL-5HC
Contents
1. Use part number 10006 1 for the CWS 5H B 2001 2004 Swagelok Company all rights reserved 33 April 2004 HR LO v Sem D U Figure 44 SWS 5H C Rotor Assembly April 2004 2001 2004 Swagelok Company all rights reserved 34 Series 5 Weld Head Table 10 SWS 5H C Rotor Assembly Parts List Reference Description Part No Minimum No Order Quantity i NA 10 10 10 7 5 NA For part ordering information contact your Swagelok representative 2001 2004 Swagelok Company all rights reserved 35 April 2004 Series 5 Weld Head CO D Figure 45 SWS 5H C Motor and Power Block Assembly 36 2001 2004 Swagelok Company all rights reserved April 2004 Series 5 Weld Head Table 11 SWS 5H C Motor and Power Block Assembly Parts List No Order Quantity N A N A N A Home Sensor Mount 11125 SS Socket Head Cap Screw 2 56 X 0 375 in 13145 10 Power Block Motor Side 21126 1 SS Dowel Pin 0 125 X 0 375 in 10 135 Work Posi NA 11122 i i 10 10 i 10 i 10 10 10 10 i Power Block Work Side 21207 1 CO oo MIO A OIN gt aa lt a O CO NII G1 RJ OINI gt O NINININI DO SOIN gt 2 NA zr i 28 i 29 10 30 NA i NA 32 NA 33 10 34 10 For part ordering information contact your Swagelok representative Use Part Number 11103 B for the CWS 5H B Use Part2. DIRECT OR INDIRECT CONSEQUENTIAL OR INCIDENTAL DAMAGES Series 5 Weld Head SERIES 5 WELD HEAD Weld Head The Series 5 SWS weld head delivers consistent precise welds for outside diameters from 1 8 to 5 8 in 3 to 16 mm A DC motor in the weld head drives a rotor which carries the tungsten electrode around the weld joint Optical circuitry in the weld head sends precise feedback to the power supply to control the speed of the rotor All moving parts in the weld head are mounted in low friction devices to provide smooth consistent operation Figure 1 Series 5 Weld Head A spring loaded floating brush continuously contacts approximately one third of the circumference of the rotor This configuration ensures consistent uniform electrical conductance to the rotor and electrode Fixture Block The Series 5 SWS fixture block accurately aligns and holds tubing fittings and valve bodies The modular design allows you to select different side plates and create the configuration needed for the job The fixture block 1s separate from the weld head allowing work pieces to be easily aligned and fixtured before welding Using multiple fixture blocks can increase productivity Each fixture block is designed to accommodate a range of work piece sizes A unique and patented Universal Collet Insert UCI fits into the fixture block to match the diameter of the work piece The collet design firmly holds tubing
3. Swagelok Company all rights reserved 29 April 2004 Series 5 Weld Head 30 2001 2004 Swagelok Company all rights reserved April 2004 Series 5 Weld Head Parts Drawings This section includes exploded assembly drawings and associated parts lists These drawings are provided as a guide to 1dentifying part names For specific part ordering information contact your Swagelok representative The parts identified in this section include e SWS 5H C Weld Head e SWS 5H C Rotor Assembly e SWS 5H C Motor and Power Block Assembly e CWS S5TFB Tube Fixture Block e CWS 5FSP1 Special Purpose Fixture Block e CWS 5FSP2 Special Purpose Fixture Block e SWS 5FSP3L Side Plate e SWS 5FSP3R Side Plate e SWS 5FSP4L Side Plate e SWS 5FSPA4R Side Plate 2001 2004 Swagelok Company all rights reserved 31 April 2004 man 5 Weld Head Figure 43 SWS 5H C Weld Head 32 2001 2004 Swagelok Company all rights reserved April 2004 Series 5 Weld Head Table 9 SWS 5H C Weld Head Parts List Reference Description Part No Minimum No Order Quantity i i 2 i 3 i 10 10 10 7 i 3 o 10 10 i i 10 2 i 13 SS Socket Head Cap Screw 4 40 X 0 260 in 13182 10 modified 14 Housing Work Side 21133 1 15 Motor Assembly N A 16 Rotor Assembly 11051 1 17 Housing Motor Side 21211 1 For part ordering information contact your Swagelok representative 9 Use part number 11160 for the CWS 5H B
4. and 2 cerium and is commonly referred to as 2 ceriated This electrode type has demonstrated improved arc starting performance over the 2 thoriated type particularly when using purified shielding gas 2001 2004 Swagelok Company all rights reserved 5 April 2004 Series 5 Weld Head Calculating Arc Gap Gage Settings To determine the arc gap gage setting for a specific arc gap use the formula below rN hi TW w O A B ARC GAP 2 2 C GAGE SETTING Where largest OD on the weld end of the tubing or fitting welding diameter B Arc gap gage diameter C desired arc gap Figure 6 Arc Gap Gage Setting Formula Example No 1 Series 5 Weld Head 1 4 to 1 4 in tube butt weld A 0 253 in largest outside diameter Arc gap gage diameter B 1 244 in Desired arc gap C 0 028 in 02ain AR 4 0 028 in O777in Example No 2 Series 5 Weld Head 6 to 6 mm tube butt weld A 6 081 mm largest outside diameter Arc gap gage diameter B 31 60 mm Desired arc gap C 0 71 mm 6081mm 3160mm 071mm 19 551 mm 2 6 2001 2004 Swagelok Company all rights reserved April 2004 Series 5 Weld Head Setting the Arc Gap A L The proper arc gap setting facilitates control of the weld and LX improves consistency The following steps cover how to set 77 Qi the arc gap K The arc gap 1s set by using the arc gap gage provided with the j N weld head The gage 1s adjusted for the desired arc ga
5. and fittings that vary 0 005 in 0 13 mm from nominal outside diameter The collets exchange quickly making the fixture block very adaptable to changing work requirements Figure 2 Series 5 Fixture Block 2001 2004 Swagelok Company all rights reserved 1 April 2004 Series 5 Weld Head Unpacking the Weld Head Components The following weld head components are packaged in a foam lined shipping container e weld head e arc gap gage e electrode package e tool package Perform the following steps when your Swagelok Series 5 weld head arrives 1 Inspect the container for damage 2 Remove the components from the container 3 Check the items for any damage 4 Verify that the weld head serial number matches the serial number on the shipping container 5 Record the model and serial numbers and the delivery dates on page 7 of the Regulatory Module 2 2001 2004 Swagelok Company all rights reserved April 2004 Series 5 Weld Head Installing the Weld Head The weld head has four connectors that plug into the power supply See Figure 3 The four connectors on the cable are e fixture e electrode red e work green e weld head shielding gas Connect the four connectors to the rear panel of the power supply by performing the following steps see Figure 4 1 Locate the weld head 2 Align the notch on the multi pin connector with the small tab in the mating socket on the rear panel labe
6. point to the Plenum appropriate side plate See Figure 21 cap screws in the appropriate side plate just enough to CO loosen 1t from the plenum See Figure 21 to locate the appropriate side plate Cap Screws Side Plate y Figure 21 Loosening the Side Plate Turn the fixture block upright and remove the tops of the CWS 5FSP2 Side Plates See Figure 22 Using the centering gage place one Micro Fit fitting in one of the side plates Reinstall that side plate top Insert the second Micro Pit fitting into the other side plate and close its top Side Plate Centering Gage Figure 22 Removing the Top of the Side Plate 2001 2004 Swagelok Company all rights reserved April 2004 Series 5 Weld Head 7 Align the two Micro Fit fittings by adjusting the side Align Fitting with Fitting plate that is loose See Figure 23 8 While maintaining the fitting to fitting alignment tighten the four cap screws in the adjustable side plate Take care to tighten the screws evenly to prevent the side plate from slipping Figure 23 Aligning the Micro Fit Fittings 2001 2004 Swagelok Company all rights reserved 19 April 2004 Series 5 Weld Head Mating the Weld Head to the Fixture Block l 20 Rotate the locking lever on the weld head counter clockwise until it stops See Figure 24 Insert the weld head into the fixture block See Figure 25 A Rotate the locking lever clockwise to
7. properly install an electrode in the weld head Selecting the Proper Electrode Electrode length and diameter depend on your weld head model and the outside diameter of the work piece being welded To select the correct electrode use the Electrode Selection Table Table 1 Electrode Selection Table Electrode Component Electrode Diameter Electrode Part No OD Length L D CWS C 040 705 P 1 8 in 0 705 in 0 040 in 3 16 in 17 90 mm 1 02 mm 3 mm CWS C 040 605 P 1 4 in 0 605 in 0 040 in 5 16 in 15 37 mm 1 02 mm 6 mm 8 mm CWS C 040 555 P 0 555 in 0 040 in 14 10 mm 1 02 mm CWS C 040 450 P 5 8 in 0 450 in 0 040 in 15 mm 11 43 mm 1 02 mm CWS C 040 405 P 16 mm 0 405 in 0 040 in 10 29 mm 1 02 mm UN DC Y 2001 2004 Swagelok Company all rights reserved April 2004 Series 5 Weld Head Electrode Geometry This illustration shows the electrode shape Swagelok suggests Properly ground electrodes provide consistent repeatable welds Pre ground electrodes are available from your Swagelok representative See your parts list for ordering information The electrode part numbers are assigned as follows SWS X HWR HAH FHF P f Electrode Package peer Designator Material Designator Electrode lip Diameter C Ceriated Length T Thoriated U The ceriated electrode material type is a mixture of 98 Figure 5 Tungsten Electrode tungsten
8. 2004 Series 5 Weld Head Figure 51 SWS 5FSP4L XX Side Plate 48 2001 2004 Swagelok Company all rights reserved April 2004 Series 5 Weld Head Table 17 SWS 5FSP4L XX Side Plate Reference Description Part No Minimum No Order Quantity 1 SFSP4L XX Bottom 1 4 in 04 21213 1 3 8 in 06 21217 6 mm 06 mm 21221 3 5FSP4L XX Top 1 4 in 04 21212 1 3 8 in 06 21216 6 mm 06 mm 21220 4 SS Socket Head Cap Screw 4 40 X 0 500 in 13163 10 5 Screw Retainer 12114 10 6 SS Socket Head Cap Screw 4 40 X 0 187 in 13207 10 7 Locking Tab 12134 1 2001 2004 Swagelok Company all rights reserved 49 April 2004 Series 5 Weld Head Figure 52 SWS 5FSP4R XX Side Plate 50 2001 2004 Swagelok Company all rights reserved April 2004 Series 5 Weld Head Table 18 SWS 5FSP4R XX Side Plate Reference Description Part No Minimum No Order Quantity 1 5FSP4R XX Bottom 1 4 in 04 21215 1 3 8 in 06 21219 6 mm 06 mm 21223 2 SFSP4R XX Top 1 4 in 04 21214 1 3 8 in 06 21218 6 mm 06 mm 21222 3 Locking Tab 12134 1 4 SS Socket Head Cap Screw 4 40 X 0 187 in 10 5 Screw Retainer 10 2001 2004 Swagelok Company all rights reserved 51 April 2004 Series 5 Weld Head 52 2001 2004 Swagelok Company all rights reserved April 2004 Swagelok TM Swagelok Company 2001 2004 Swagelok Company Printed in U S A PPI April 2004 R1 SWS MANUAL 5HC E
9. CREATE 2 Select MANUAL ENTRY then press ENTER 3 Select LEVELS ONLY then press ENTER 4 Enter 2 levels then press ENTER 5 Enter the programmer name Typically it would be your name S Enter the Side 1 tube diameter 5 then press ENTER 7 Select 5H from the Weld Head pick list 2001 2004 Swagelok Company all rights reserved April 2004 WARNING DISCONNECT THE WELD HEAD FROM THE POWER SUPPLY BEFORE PERFORMING THE ADJUSTMENT OR MAINTENANCE Rotor Area Figure 28 Inspect Exposed Surfaces of the Weld Head A Caution Do not use lubricants inside the weld head 23 Series 5 Weld Head 8 Using Table 7 enter the following parameters Table 7 Parameters Parameter Entry Start Power Normal Start Current 20 Rotor Delay 0 Prepurge 5 Postpurge 5 Downslope 0 9 Using Table 8 enter the following parameters for level 1 and level 2 Table 8 Level I and Level 2 Parameters Parameter Level 1 Setting Level 2 Setting Impulse 2 2 0 2 1 5 Maintenance 2 0 Pulse Rate 1 Pulse Width 50 Speed Hi 8 00 0 00 Speed Lo 0 00 10 Press the WELD mode key 11 Select SAVE TO MEMORY then press ENTER 12 Enter the procedure name Timing Test then press ENTER Checking the Weld Head Timing 1 Select WELD TEST 2 Press START 3 After verifying the screen displays WELD HEAD IS CLEAR TO ROTATE press ENTER O O Weld Time 5 15 1 0 Ramp 0 Wrong Corre
10. Number 11102 B for the CWS 5H B 2001 2004 Swagelok Company all rights reserved 37 April 2004 Series 5 Weld Head Figure 46 CWS 5TFB Tube Fixture Block 38 2001 2004 Swagelok Company all rights reserved April 2004 Series 5 Weld Head Table 12 CWS STFB Tube Fixture Block Parts List No Order Quantity 10 2 3 4 5 N A N A 6 N A 7 10 8 1 9 1 10 N A N A T 12 10 13 14 Top Side Plate left 1 E 16 16 N A N A 17 10 E 16 19 70 20 2 For part ordering information contact your Swagelok representative 2001 2004 Swagelok Company all rights reserved 39 April 2004 Series 5 Weld Head Figure 47 CWS 5FSP1 Special Purpose Fixture Block 40 2001 2004 Swagelok Company all rights reserved April 2004 Series 5 Weld Head Table 13 CWS 5FSP1 Special Purpose Fixture Block Parts List Reference Description Part No Minimum No Order Quantity 1 Locking Tab 12134 1 3 SS Socket Head Cap Screw 4 40 X 0 250 in 13112 10 4 Plastic Spacer 10 5 Bellville Spring Washer 10 i l i 9 7 For part ordering information contact your Swagelok representative O 2001 2004 Swagelok Company all rights reserved 41 April 2004 mans 5 Weld Head Figure 48 CWS 5FSP2 Special Purpose Fixture Block 42 2001 2004 Swagelok Company all rights reserved April 2004 Series 5 Weld Head Table 14 CWS 5FSP2 Special Purpose Fixture Block Parts List Reference Descri
11. alcohol or cleaning solution Dry the balls thoroughly Remove Electrode Figure 38 Removing the Rotor and Electrode Clamping Plate Screws Opening Brush a Ring Gear Ring R a Rotor Pin Location Figure 39 Placing the Rotor on the Work Surface Separate Figure 40 Separating the Gear Ring from the Brush Ring 2001 2004 Swagelok Company all rights reserved April 2004 Series 5 Weld Head 7 Remove the ceramic insert See Figure 41 Ceramic Insert 8 Inspect the ceramic insert If it has carbon or other a deposits clean it with a fine grit abrasive pad or soft nylon brush 9 Remove the electrode clamping plate Clean it with a fine grit abrasive pad See Figure 42 10 Inspect the brush and gear rings for dirt or other deposits Clean the rings with a fine grit abrasive pad or soft stainless steel wire brush Figure 41 Removing the Ceramic Insert 11 Dry all parts with clean low pressure air before reassembly Electrode gt ae Clamping Plate Figure 42 Removing the Electrode Clamping Plate Weld Head Assembly Assembly of the weld head and rotor is the reverse of the disassembly procedures Caution To assemble the weld head follow these steps A Do not pinch any internal 1 Complete the steps in reverse order in Rotor on page 28 wiring during reassembly 2 Complete the steps in reverse order in Weld Head Disassembly on page 25 2001 2004
12. ase oil paint or other surface contaminants Method Result Burrs in Burrs Flow Path Hack Saw Cut f p LZ JL Gap End Rolled by Cutter Irregular Tube Blade and Roller Diameter Tube Cutter Burrs Reduced Flow Area Face Perpendicular Smooth Transition to Axis at Wall Faces Tube Facing Tool Square Corners No Gaps Figure 10 Tube Preparation 2001 2004 Swagelok Company all rights reserved 11 April 2004 Series 5 Weld Head Fixturing the Work Select or configure the appropriate fixture block Select the collets to match the work outside diameter Selecting the Fixture Block and Collets 1 Select the fixture block that accepts the outside diameter of the tube to be welded Table S Fixture Block Model Minimum Weld Extension Length CWS 5TFB 1 8 to 5 8 in 3 4 in 19 mm 3 to 16 mm CWS 5FSP1 1 4 in Used when welding VCR or VCO fittings with captured male or female nuts with extension lengths of less than 3 4 in 19 mm CWS 5FSP2 1 8 to 1 2 in Used to hold Micro Fit fittings with 6 to 12mm an extension length of 1 4 in 6 mm SWS 5FSP3L 1 8 to 1 2 in Used to hold certain valves with an 3 to 12mm extension length of 1 2 in 12 mm SWS 5FSP3R SWS 5FSP4L 1 4 to 3 8 in Used to hold Swagelok valves BN 6 to 9 mm DI DS HD DA and DP with an SWS 5FSP4R extensi
13. ct 4 Verify the rotor completes two revolutions then check Figure 29 Rotor Position that no part of the rotor is exposed after it stops See Figure 29 WARNING If the rotor does not complete the revolutions and stop THE ROTOR WILL ROTATE correctly contact your Swagelok representative ONE REVOLUTION TO HOME POSITION 15 SECONDS AFTER COMPLETING THE TWO REVOLUTIONS 24 2001 2004 Swagelok Company all rights reserved April 2004 Series 5 Weld Head Weld Head Disassembly and Cleaning This section describes how to disassemble the weld head and rotor Weld Head To disassemble the weld head follow these steps 1 Blow any loose material from the weld head assembly with clean low pressure air 2 Remove the four screws locking ring and locking ring plate See Figure 30 3 Remove the work extension screw with lock washer and the work extension Inspect the work extension for pitting wear or damage See Figure 31 4 Replace work extension if necessary Refer to the Parts Drawings at the end of this manual for part ordering information 2001 2004 Swagelok Company all rights reserved April 2004 Locking Ring i L Screws Locking Ring Plate Figure 30 Removing the Locking Ring and Locking Ring Plate Work ____ U Extension Screw Work Extension BT 0 Dowel we Pin a OS Figure 31 Removing the Work Extensi
14. e Figure 14 A 3 Lock down the top side plate See Figure 14 B 4 Remove the centering gage Figure 13 Place the Centering Gage Note When welding a Swagelok ATW fitting to tubing butt the tubing against the centering gage first Figure 14 Placing First Work Piece in the Fixture Block 14 2001 2004 Swagelok Company all rights reserved April 2004 Series 5 Weld Head 5 Butt the second work piece against the first work piece and lock down the top side plate See Figure 15 6 Inspect 360 around the weld joint for fit and alignment If alignment is not correct proceed to the next section Adjusting the Fixture Block The modular design of the Series 5 Fixture block allows you to assemble the block to meet a variety of welding requirements In order to maintain precise alignment of the work pieces in the fixture block the side plates must be periodically aligned This section covers e Tube to tube e Micro Fit fitting to tube e Micro Fit fitting to Micro Fit fitting Tube to tube Fixture block To align the fixture block follow these steps 1 Turn the fixture block over and locate the directional arrows on the plenum The arrows point to the appropriate side plate See Figure 16 2 Using the provided 3 32 in hex wrench unscrew the four cap screws in the appropriate side plate just enough to loosen it from the plenum See Figure 16 to locate the appropriate side plate 3 Tur
15. embly with clean low pressure air 11 Ensure that the two power strap screws are tight See Figure 36 12 Ensure that the work plate screw is tight and free from excessive oxidation See Figure 37 Clean the work plate with a fine grit abrasive pad if necessary 13 Inspect the gears for wear and replace if damaged by referring to the appropriate motor and power block assembly drawing in Parts Drawings at the end of this manual 2001 2004 Swagelok Company all rights reserved April 2004 Brush A QE P lt Groove Figure 35 Inspecting the Brush Figure 36 Inspecting the Power Strap Screws Figure 37 Inspecting the Work Plate and Screws 27 Series 5 Weld Head Rotor Eee U oe Screw e To disassemble the rotor follow these steps Clamping J Plate Screw l 28 Remove the rotor screws and the electrode clamping plate screws from the rotor Remove the electrode from the ceramic insert See Figure 38 Place the rotor on a clean dry surface with the rotor opening facing up Separate the gear ring from the brush ring enough to clear the two rotor pins See Figure 39 Completely separate the gear ring from the brush ring as shown in Figure 40 Lay the rings flat on the work surface Remove the ball bearings from the gear and brush rings Inspect the ball bearings for wear and damage Replace if necessary If the ball bearings are dirty clean them with isopropyl
16. er and n open the top of the tube side plate Side Plate G 4 Choose and install a collet that holds tubing that matches i the outside diameter of the Micro Fit fitting a 7 if not Figure 18 Loosening the Side Plate 16 2001 2004 Swagelok Company all rights reserved April 2004 Series 5 Weld Head 5 Unlatch and remove the top of the CWS 5FSP2 Side Plate See Figure 19 6 Using the centering gage place a straight length of tubing minimum length 0 75 in 19 1 mm in the tube side plate and lock down the top of the plate Side Plate A eS gt 2 Centering Gage SZ Figure 19 Removing the Top ofthe Side Plate 7 Place the Micro Fit fitting in the fitting side plate and close and latch the top 8 Align the Micro Fit fitting with the tubing Align Fitting with Tubing See Figure 20 Figure 20 Aligning the Micro Fit Fitting With the Tubing 9 While maintaining the fitting to tubing alignment tighten the four cap screws in the adjustable side plate Take care to tighten the screws evenly to prevent the side plate from slipping 2001 2004 Swagelok Company all rights reserved 17 April 2004 Series 5 Weld Head Micro Fit Fitting to Micro Fit Fitting Fixture Block To align the fixture block follow these steps l Using the provided 3 32 in hex wrench unscrew the four Directional Turn the fixture block over and locate the directional arrows on the plenum The arrows
17. ge Dia 31 60 mm Setting for Setting for Setting for Setting for Setting for Nominal OD Actual OD 0 50 mm Arc 0 64mm Arc 0 76mm Arc 1 02mm Arc 1 14 mm Arc mm mm Gap mm Gap mm Gap mm Gap mm Gap mm 3 17 80 17 94 18 06 18 19 18 32 6 60 19 30 19 44 19 56 19 69 19 82 8 8 00 20 30 20 44 20 56 20 69 20 82 10 10 00 21 30 21 44 21 56 21 69 21 82 22 82 12 12 00 22 30 22 44 22 56 22 69 Table4 SWS 5H C ATW Arc Gap Gage Dia 1 244 in 31 60 mm Setting for 0 035 in 0 89 mm ATW Size Cuff OD Arc Gap 1 4 in 0 801 in 3 8 in 0 863 in 1 2 in 0 931 in 6 mm 20 19 mm 8 mm 21 20 mm 10 mm 22 20 mm 12 mm 23 32 mm 2001 2004 Swagelok Company all rights reserved April 2004 Series 5 Weld Head Inserting the Electrode into a Rotor 1 Without the fixture block attached press WELD on the operator panel 2 Use JOG to position the rotor as shown in Figure 8 Loosen the two electrode clamping screws If you are replacing the electrode remove the electrode 4 Insert the new electrode with the sharp tip pointing out Tighten the electrode clamping screws slightly to hold it in place temporarily 5 Set the proper arc gap with the arc gap gage Electrode Clamping Screws Figure 8 Electrode Installation WARNING DO NOT PRESS START WHILE TOUCHING THE ELECTRODE A Caution Do not jog or move the rotor unless the electrode is clamped in place 2001 2004 Swagelok Company all rights reserved 9 Apr
18. il 2004 Series 5 Weld Head Setting the Arc Gap 1 Use JOG to position the rotor as shown in Figure 9 This allows access to the electrode clamping screws 2 Insert the arc gap gage into the rotor See Figure 9 A Tilt the weld head upward Loosen the electrode screw allowing the electrode to drop onto the gage surface See Figure 9 B 4 Tighten the electrode clamping screws just enough to secure the electrode Remove the arc gap gage 5 Press HOME to return the rotor to the home position Figure 9 Setting the Arc Gap A Caution Do not jog or move the rotor unless the electrode is clamped in place 10 2001 2004 Swagelok Company all rights reserved April 2004 Series 5 Weld Head Preparing the Work It is important to prepare the tube pieces properly before welding Refer to Figure 10 Tubing must be square and burr free to ensure repeatable high quality autogenous fusion welds Cut the tubing to length with a hacksaw or tube cutter Face the tube ends with a lathe or a portable facing tool Deburr the ends making sure that both the inside and outside diameters are square and burr free Clean the tube ends using an appropriate solvent Minimize the chance of a poor quality weld by following these guidelines e Tube ends must be square e Tube ends must not have a wall thickness variation exceeding 15 of nominal e Tube ends must be burr free e Tube ends must be free of any rust gre
19. ion See Figure 27 a Remove lever cam by removing the set screw from the latch and pulling the lever cam from the fixture block b Clean the lever cam and lightly lubricate if necessary c Replace the set screw and verify that it is locked tightly in position Non Anodized Surfaces Under the Collets Inside Plate Surfaces Figure 26 Cleaning the Collets and Collet Mounting Surfaces Lever Cam Figure 27 Lever Cam and Latch 2001 2004 Swagelok Company all rights reserved April 2004 Series 5 Weld Head Weld Head Daily Maintenance Perform weld head maintenance daily and every 1 000 to 1 200 welds Depending on usage and wear maintenance may be performed before the 1 000 weld mark At the start of each work day 1 Inspect the weld head for cleanliness Pay close attention to the rotor area See Figure 28 2 Press HOME Check the rotor for smooth rotation If the rotation is erratic or noisy disassemble the weld head and clean the rotor gears and brush See Weld Head Disassembly and Cleaning on page 25 At the end of each work day 1 Remove dirt carbon and vapor deposits from the weld head with a clean soft cloth and a solvent such as isopropyl alcohol 2 Store the weld head in a clean dry place Weld Head Periodic Maintenance Every 1 000 to 1 200 welds measure the rotor speed to verify its accuracy Creating the Weld Head Timing Check Program 1 Select PROG
20. led FIXTURE Insert the connector in the socket Turn the connector sleeve clockwise by hand until it 1s tight This connection provides the control signals to drive the weld head 3 Insert and fully seat the red connector into the socket on the rear panel labeled ELECTRODE Twist the connector 1 4 turn clockwise to lock it into place This connection is the negative terminal of the weld head 4 Insert the green connector into the socket on the rear panel labeled WORK Twist the connector 1 4 turn clockwise to lock it into place This connection is the positive terminal of the weld head 5 Insert the weld head shielding gas connector into the Swagelok Quick Connect stem labeled TO WELD HEAD Ensure that the connector is firmly attached This connection provides shielding gas to the weld head through a solenoid valve in the power supply 2001 2004 Swagelok Company all rights reserved April 2004 Fixture Electrode SY P Weld Head A Shielding Gas Figure 4 Weld Head Connectors A Caution Ensure that the fixture connector is fully seated in the mating socket and the threaded sleeve is tight Note The weld head shielding gas connector must be a single end shut off SESO Swagelok Quick Connect stem SS QC4 S 400 Series 5 Weld Head Installing the Electrode in the Weld Head This Swagelok weld head comes with a selection of electrodes The following instructions show how to
21. n the fixture block upright and release both levers and open both sides of the fixture block 2001 2004 Swagelok Company all rights reserved April 2004 Figure 15 Placing Second Work Piece Plenum Directional Arrows NSN SES N Q Cap Screws EN Side Plate 3 Figure 16 Loosening the Side Plate Series 5 Weld Head 4 Place a straight length of tubing minimum length 1 50 in 38 1 mm in the collets such that it rests across both side plates 5 Close and lock the side plate that 1s not adjustable See Figure 17 6 Lock down the top of the loosened side plate 7 Tighten the four cap screws in the loosened side plate Take care to tighten the screws evenly to prevent the side plate from slipping 8 Open the side plates and remove the tubing Figure 17 Placing the Tubing Micro Fit Fitting to Tube Fixture Block To align the fixture block follow these steps 1 Turn the fixture block over and locate the directional arrows on the plenum The arrows point to the i appropriate side plate See Figure 18 ban CWS 5FSP2 2 Using the provided 3 32 in hex wrench unscrew the four Directional gt 4 gt Ae AS KS cap screws in the appropriate side plate just enough to Arrows SS K R loosen it from the plenum See Figure 18 to locate the a E appropriate side plate Cap Screws r 3 Turn the fixture block upright and release the lev
22. nce daily and after every 1 000 to 1 200 welds Fixture Block Daily Maintenance At the start of each workday 1 Inspect the fixture block for cleanliness wear and damage See Figure 26 2 Remove dirt carbon and vapor deposits from the fixture block with a clean soft cloth A solvent such as alcohol or acetone can be used Remove heavier deposits with a fine grit abrasive pad At the end of each workday clean and store the fixture block in a dry place 2001 2004 Swagelok Company all rights reserved April 2004 Series 5 Weld Head Note If you experience problems while performing the procedures in this section refer to Troubleshooting or contact your Swagelok representative Note Replace any defective parts Service replacement parts are available through your Swagelok representative 21 Series 5 Weld Head Fixture Block Periodic Maintenance Every 1 000 to 1 200 welds l 2 3 22 Inspect and clean the collets See Figure 26 A Check for scratches and dents Remove dirt and oxides from all surfaces of the collet with a soft stainless steel wire brush Remove any oxides from the non anodized mating surfaces of the side plates with a fine grit abrasive pad See Figure 26 B Remove any dirt and oxides from the inside surfaces of the side plates with a clean soft cloth See Figure 26 C Remove heavier deposits with a fine grit abrasive pad Check the lever cam and latch for smooth operat
23. on 25 Series 5 Weld Head 5 26 Remove the weld head housing screws from the housing Housing Using a slight rocking motion carefully separate the i 47 Screws locking ring half of the weld head housing from the a motor half See Figure 32 Carefully separate the weld head housing halves so that internal components are not damaged See Figure 32 Remove the rotor from the motor half of the weld head housing See Figure 33 Carefully lift the power block subassembly out of the motor half of the weld head housing See Figure 34 Weld Head Housing Motor Half Se Figure 32 Removing the Locking Ring Figure 33 Removing the Rotor Power Block Subassembly Weld Head Housing Ground Side Figure 34 Removing the Power Block Subassembly 2001 2004 Swagelok Company all rights reserved April 2004 Series 5 Weld Head 9 Examine the brush See Figure 35 Inspect and clean the brush using the following steps a Check the brush for excessive wear b Ensure the brush has a groove Replace the brush if the groove 1s not present by referring to the appropriate motor and power block assembly drawing in Parts Drawings at the end of this manual c Remove any oxidation from the brush with a fine grit abrasive pad 10 Blow any loose material from the power block ass
24. on length of 1 4 in 6 mm 2 Select the proper collets for the diameter of the parts being welded Refer to Table 6 Table 6 Collets Model OD Capacity Comments CWS 5UCI X 1 8 in to 5 8 in Tubing 3 mm to 16 mm Add mm suffix for metric sizes CWS 5UFCI 95 n a Fixture collets to hold adapter inserts for CWS 5FSP1 side plate CWS 5UFCI X 1 8 in to 5 8 in Tube collet for 5FSP1 B 3 mm to 16 mm and 5FSP2 CWS 5MWCI 04 For Micro Fit fittings CWS 5MWCI 06 For Micro Fit fittings CWS 5MWCI 08 For Micro Fit fittings SWS 5F3UCI X For valves 7 6 mm 8 mm 10 mm Where X identifies the collet size in 1 16ths or metric mm suffix 12 2001 2004 Swagelok Company all rights reserved April 2004 Series 5 Weld Head Installing the Collets in a Tube Fixture Block 1 Release both levers and open the tube fixture block See Figure 11 2 Install the collet halves in both the top and bottom side plates and tighten the collet screws Make sure the collet shoulder is flush against the fixture side plate See Figure 12 B Figure 12 Installing Collets 2001 2004 Swagelok Company all rights reserved 13 April 2004 Series 5 Weld Head Aligning the Work Pieces in the Tube Fixture Block 1 Place the centering gage in one side of the tube fixture block The centering gage must span the width of the collet See Figure 13 2 Butt one work piece against the centering gage Se
25. p and 2 then installed in the rotor aperture With the gage in place the electrode can be positioned with reasonable accuracy Setting the Arc Gap Gage 1 Measure the outside diameters of the work pieces being welded using a caliper or micrometer See Figure 7 A The M100 will calculate the arc gap automatically for you during an Auto Entry weld development This is based on the standard OD 2 Refer to Table 2 to find the actual outside diameter nearest to your measurement Figure 7 Setting the Arc Gap Gage 3 Adjust the arc gap gage to match the setting from Table 3 See Figure 7 B 2001 2004 Swagelok Company all rights reserved 7 April 2004 Series 5 Weld Head Table 2 SWS 5H C Arc Gap Gage Dia 1 244 in Setting Setting Setting Setting Setting Setting Setting Setting Setting Setting for for for for for for for for 0 025in 0 030in 0 035in 0 040in 0 045in 0 050 in 0 51 mm 1 02mm Nominal Actual Arc Gap Arc Gap Arc Gap Arc Gap Arc Gap Arc Gap Arc Gap Arc Gap OD in OD in in in in in in in mm mm 1 8 0 125 0 710 0 715 0 720 0 725 0 730 0 735 17 91 18 04 18 29 18 42 1 4 0 250 0 772 0 777 0 782 0 787 0 792 0 797 19 48 19 61 19 86 19 99 3 8 0 375 0 835 0 840 0 845 0 850 0 855 0 860 21 08 21 21 21 46 21 59 1 2 0 500 0 897 0 902 0 907 0 912 0 917 0 922 22 66 22 19 23 04 23 17 5 8 0 625 0 960 0 965 0 970 0 975 0 980 0 985 24 25 24 38 24 63 24 76 Table 3 SWS 5H C Arc Gap Ga
26. ption Part No Minimum No Order Quantity 1 SS Socket Head Cap Screw 4 40 x 0 250 in 13112 10 2 Locking Tab 12134 1 3 Plastic Screw Retainer 12169 10 6 Locator Pin 1 i 9 Lever Cam Assembly 12130 2 1 SS Socket Head Cap Screw 4 40 X 0 250 in 13112 10 12 SS Socket Head Cap Screw 4 40 X 0 563 in 13115 10 For part ordering information contact your Swagelok representative O 2001 2004 Swagelok Company all rights reserved 43 April 2004 Series 5 Weld Head Figure 49 SWS 5FSP3L Side Plate 44 2001 2004 Swagelok Company all rights reserved April 2004 Series 5 Weld Head Table 15 SWS 5FSP3L Side Plate a Description Part No Minimum i Ouantity a Bottom Side Plate N A Lever 21030 1 Locking Tab 12134 1 SS Set Screw 4 40 X 0 495 in modified 13226 10 SS Socket Head Shoulder Screw 4 40 X 0 125 X 13248 10 0 375 in 10 Ball Plunger 5 40 X 0 250 in 13246 10 11 Bellville Spring Washer 13247 10 14 SS Socket Head Cap Screw 4 40 X 0 187 in 13207 10 COV N O O1 A O N 2001 2004 Swagelok Company all rights reserved 45 April 2004 Series 5 Weld Head Figure 50 SWS 5FSP3R Side Plate 46 2001 2004 Swagelok Company all rights reserved April 2004 Series 5 Weld Head Table 16 SWS 5FSP3R Side Plate Reference Description Part No Minimum No Order Quantity 0 375 in 9 7 2001 2004 Swagelok Company all rights reserved 47 April
27. secure the weld head See Figure 25 B Check status on the front panel to verify the power supply is in the READY state Figure 25 Mating the Weld Head to the Fixture Block 2001 2004 Swagelok Company all rights reserved April 2004 Operating the Weld Head Operate the weld head using the following parameters Shield Gas Flow Rate std ft hr f 10 to 20 std L min 4 7 to 9 5 Prepurge and Postpurge 200 minimum time in seconds Start Power U Low Low Normal Maximum Recommended 50 Amps at 50 Duty Cycle Average Amps Flow should be continuous for cooling when welding at high current rates Use U low start power for wall thickness less than 0 010 in 0 25 mm and an arc gap of 0 020 in 0 51 mm or less Use Low start power for wall thickness less than 0 030 in 0 76 mm and an arc gap of 0 025 in 0 64 mm or less Use Norm start power for wall thickness greater than 0 030 in 0 76 mm and an arc gap of 0 035 in 0 89 mm or less U low power setting only available on M100 Power Supply Maintenance To ensure your Swagelok Welding System SWS equipment is always in proper working order you must perform periodic maintenance on the system components This section describes the procedures necessary for maintaining the fixture blocks and weld head Detailed part drawings and information are included at the end of this manual for your reference Perform fixture block maintena
28. www swagelok com SERIES 5 WELD HEAD es x 4 ae a in b j PEt D cit TTL mT A AN WE WM i AA d T i A WW USER S MANUAL Weld AC To _ 1 FOG BIOCK ARE 1 Unpacking the Weld Head Components 2 Installing the Weld Head 3 Installing the Electrode in the Weld Head 4 Calculating Arc Gap Gage Settings 6 Setting the Arc Gap 20 0 cccceccecceeeceeeeeeseeeeeeeeeees 7 Fixturing the Work 12 Installing the Collets in a Tube Fixture Block 13 MAIN NANC nsc A Y uso 21 Pas Or IVO FF 31 ON The Swagelok Limited Lifetime Warranty Swagelok hereby warrants to the purchaser of this Product that the non electrical components of the Product shall be free from defects in material and workmanship for the life of the Product All electrical components installed in or on the Product are warranted to be free from defects in material and workmanship for twelve months from the date of purchase The purchaser s remedies shall be limited to replacement and installation of any parts that fail through a defect in material or workmanship MANUFACTURER SPECIFICALLY DISAVOWS ANY OTHER REPRESENTATION EXPRESS OR IMPLIED WARRANTY OR LIABILITY RELATING TO THE CONDITION OF USE OF THE PRODUCT AND IN NO EVENT SHALL SWAGELOK BE LIABLE TO PURCHASER OR ANY THIRD PARTY FOR ANY
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