Swagelok Welding System User Manual: Micro Series
Contents
1. Figure 36 SWS 4MRH B Rigid Weld Head 34 2001 Swagelok Company all rights reserved October 2001 Micro Series Table 9 _SWS 4MRH B Rigid Weld Head Parts List Reference Description Part No Minimum No Order Quantity 1 Housing Brush Side 21160 1 2 Work Pin 11412 1 3 Brush Spring 11405 1 4 Brush 11404 A 1 5 Rotor 11403 A 1 6 See Electrode Chart N A N A 7 Ceramic Insert 11446 1 8 SS Round Head Screw 13158 1 2 56 x 0 125 in modified 9 Gear Assembly 10009 1 1 10 Transmission 11447 1 11 SS Dowel Pin 0 093 x 0 375 in 13211 10 12 Locking Lever 11435 1 13 Plastic Flat Head Screw 13157 1 4 40 x 0 313 in 14 Housing Gear Side 21159 1 15 SS Socket Head Cap Screw 13112 10 4 40 x 0 250 in 16 SS Button Head Cap Screw 13167 10 4 40 x 0 250 in 17 Latch Keeper 13197 10 18 Interface Cover Gear Side 11422 1 19 Purge Gas Tubing 10010 2 1 20 Plastic Drive Shaft Sleeve 09999 10 21 Interface Assembly Rigid 21241 1 22 Pinion Gear Bearing 11411 1 23 Drive Coupling Gear 11424 1 24 Interface Cover Brush Side 10007 1 25 SS Round Head Screw 2 56 x 0 125 in 13159 10 26 Solid Drive Coupling 11414 1 27 Drive Shaft 11425 1 28 Drive Spring Clip 13202 1 29 SS 2 Internal Star Washer 13220 10 30 Coupling Collar 11448 1 For part ordering information contact your Swagelok representative O Use Part Number 1142. RAIDO MICRO SERIES The micro weld heads are used to weld work pieces from 1 16 to 1 2 in 3 to 12 mm OD The Series 4 Micro Weld Head can weld work pieces from 1 16 to 1 4 in 3 to 6 mm OD and is available in both rigid drive and flexible drive configurations The Series 8 Micro Weld Head can weld work pieces from 1 8 to 1 2 in 5 to 12 mm OD and is available in a rigid drive configuration All micro weld heads operate with a detachable motor module See Figure 1 Series 4 Flexible Drive Series 8 Rigid Drive Module Series 4 Rigid Drive Figure 1 Rigid Drive and Flexible Drive Micro Weld Heads 2001 Swagelok Company all rights reserved October 2001 This manual presents information that is specific to the micro weld heads Additional handling is necessary because the motor module and weld head are separate units The micro weld head fixtures do not use separate collets so fixture setup differs slightly from the Series 5 10 20 fixture block procedures The procedures unless noted are the same for all micro weld heads Most figures in this section show the Series 4 Rigid Drive Micro Weld Head Refer to the Power Supply manual for information on power supply setup and weld procedure guidelines This manual includes e using the micro fixture tool e installing the motor module e connecting the micro weld head to the motor module e installing replacing the electrode e electrode geometry
3. e calculating the arc gap gage settings e setting the arc gap e fixturing the work e connecting the micro weld head to the fixture e considerations during welding e using the optional bench mounting bracket e fixture block maintenance e micro weld head maintenance e parts drawings Micro Series 2001 Swagelok Company all rights reserved October 2001 Micro Series Using the Micro Fixture Tool Tabs to engage the Each micro weld head includes a micro fixture tool See Rotor Drive Gear EEA TE j i rench Opening for Figure 2 The primary purpose of the tool is to latch and Bench Mauri Bracket Adapter Screws unlatch the fixtures In addition the tool can be used for the following Y Key Chain e aligning the micro weld head rotor Hole e attaching the optional bench mount bracket Series 8 only j Slots Used to Open The micro fixture tool has a hole that allows the tool to be des Eures secured to a key chain Figure 2 Micro Fixture Tool 2001 Swagelok Company all rights reserved October 2001 Installing the Motor Module 1 To connect the motor module to the power supply connect the four connectors to the rear panel of the power supply by performing the following steps See Figure 3 Locate the motor module b 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 connecto
4. Fixed Side Plate Right 20709 1 10 1 4 in Fixed Side Plate Right 20710 1 10 2 mm Fixed Side Plate Right 20711 1 10 3 mm Fixed Side Plate Right 20712 1 10 4 mm Fixed Side Plate Right 20714 1 10 6 mm Fixed Side Plate Right 20715 1 11 1 16 in Fixed Side Plate Left 20698 1 11 1 8 in Fixed Side Plate Left 20699 1 11 3 16 in Fixed Side Plate Left 20700 1 11 1 4 in Fixed Side Plate Left 20701 1 11 2 mm Fixed Side Plate Left 20702 1 11 3 mm Fixed Side Plate Left 20703 1 11 4 mm Fixed Side Plate Left 20705 1 11 6 mm Fixed Side Plate Left 20706 1 12 1 16 in Moveable Side Plate Right 20725 1 12 1 8 in Moveable Side Plate Right 20726 1 12 3 16 in Moveable Side Plate Right 20727 1 12 1 4 in Moveable Side Plate Right 20728 1 12 2 mm Moveable Side Plate Right 20729 1 12 3 mm Moveable Side Plate Right 20730 1 12 4 mm Moveable Side Plate Right 20732 1 12 6 mm Moveable Side Plate Right 20733 1 For part ordering information contact your Swagelok representative 2001 Swagelok Company all rights reserved October 2001 39 Micro Series Figure 39 SWS 8MRH B Rigid Weld Head 2001 Swagelok Company all rights reserved October 2001 Micro Series Table 12 SWS 8MRH B Rigid Weld Head Parts List Reference Description Part No Minimum No Order Quantity 1 Housing Brush
5. 10 See Figure 30 A Hold the micro weld head as shown Gently lift the brush from the brush side A housing noted in the figure and rotate it outward a few degrees 11 Note the position of the spring in the groove in the weld head brush The spring ends bend toward the brush when the spring lays in the groove Remove the spring See Figure 30 B 12 Clean any oxide deposits from the weld head brush with the provided stainless steel wire brush 7 13 Inspect all other weld head components and clean any PA that are dirty Blow any loose dirt from the weld head insert Spring so with clean dry low pressure air Ends Bend Toward Brush Figure 30 Lifting the Weld Head Brush for Cleaning 2001 Swagelok Company all rights reserved 27 October 2001 Series 8 Micro Weld Head Disassembly and Cleaning To disassemble the Series 8 micro weld head for cleaning use the following instructions See Figure 31 and Figure 32 for part references 1 Remove the two screws that secure the latch bracket and remove the bracket from the weld head See Figure 31 2 Lay the micro weld head down on a clean dry surface with the model and serial numbers facing up 3 Remove the seven screws from the weld head housing See Figure 32 A 4 Rock the gear side housing gently to loosen it from the rest of the assembly Lift and remove the housing 5 Remove the rotor by lifting it clear of the brush side housing See Figure 32 B
6. 125 in 13159 10 28 Coupling Collar 11448 1 29 Flexible Drive Shaft 11419 1 For part ordering information contact your Swagelok representative Use Part Number 11401 A for the CWS 4MFH A Use Part Number 11402 A for the CWS 4MFH A Use Part Number 10455 for the CWS 4MFH A 2001 Swagelok Company all rights reserved 37 October 2001 38 Figure 38 SWS 4MFB XxX Fixture Micro Series 2001 Swagelok Company all rights reserved October 2001 Micro Series Table 11 SWS 4MFB XX Fixture Parts List Reference Description Part No Minimum No Order Quantity 1 Latch Cam Right 12045 B 1 2 SS Socket Head Cap Screw 4 40 x 0 313 in 13320 10 3 Latch Cam Left 12044 B 1 4 SS Shoulder Screw 4 40 13286 10 5 SS 4 Washer 0 312 in 13285 10 6 SS Binding Screw 4 40 x 0 188 in 13287 10 7 SS Disk Spring 0 230 x 0 322 in 13319 10 8 1 16 in Moveable Side Plate Left 20716 1 8 1 8 in Moveable Side Plate Left 20717 1 8 3 16 in Moveable Side Plate Left 20718 1 8 1 4 in Moveable Side Plate Left 20719 1 8 2 mm Moveable Side Plate Left 20720 1 8 3 mm Moveable Side Plate Left 20721 1 8 4 mm Moveable Side Plate Left 20723 1 8 6 mm Moveable Side Plate Left 20724 1 9 Non Conductive Tape 14098 10 10 1 16 in Fixed Side Plate Right 20707 1 10 1 8 in Fixed Side Plate Right 20708 1 10 3 16 in
7. 6 6 00 11 41 11 54 11 66 Table 5 SWS SMRH B Arc Gap Gage Dia 0 813 in Setting Setting Setting Setting Setting Setting Setting Setting for for for for for for for for Actual 0 020 in 0 025 in 0 030 in 0 035in 0 51mm 0 64mm 0 77mm 0 89 mm Nominal OD Arc Gap Arc Gap Arc Gap Arc Gap Arc Gap Arc Gap Arc Gap Arc Gap OD in in in in in in mm mm mm mm 1 8 0 125 0 490 0 495 0 500 N A 12 45 12 57 12 70 N A 1 4 0 250 0 552 0 557 0 562 0 567 14 02 14 15 14 28 14 40 3 8 0 375 0 614 0 619 0 624 0 629 15 60 15 73 15 86 15 98 1 2 0 500 0 677 0 682 0 687 0 692 17 20 17 33 17 46 17 58 Table 6 SWS SMRH B Arc Gap Gage Dia 20 65 mm Setting for Setting for Setting for Setting for Nominal OD Actual OD 0 51 mm Arc 0 64mm Arc 0 76mm Arc 0 89 mm Arc mm mm Gap mm Gap mm Gap mm Gap mm 6 6 00 13 84 13 97 14 09 14 22 8 8 00 14 84 14 97 15 09 15 22 10 10 00 15 84 15 97 16 09 16 22 12 12 00 16 84 16 97 17 09 17 22 3 Set the arc gap gage to the value from the table using the provided 3 32 in hex wrench Measure from the bottom of the arc gap gage to the top of the adjustment screw See Figure 11 B 4 Insert the arc gap gage into the micro weld head rotor opening 2001 Swagelok Company all rights reserved October 2001 13 3 7 8 Micro Series Hold the micro weld head so that the electrode tip is pointing down Loosen the electrode clamping screw to
8. Side Bottom 21158 1 2 SS Socket Head Cap Screw 2 56 x 0 250in 13176 10 3 Housing Brush Side Top 11523 1 4 Brush Spring 11510 1 5 Brush 11506 1 6 Transmission 11503 1 7 Gear Assembly 11515 1 8 Dowel Pin Included with 11515 N A N A 9 Rotor 11502 1 10 See Electrode Chart N A N A 11 SS Round Head Screw 2 56 x 0 125 in modified 13158 1 12 Ceramic Insert 11505 1 13 Latch 11520 1 14 Latch Bracket 11519 1 15 Plastic Flat Head Screw 4 40 x 0 313 in 13309 1 16 Housing Gear Side Top 11524 1 17 SS Socket Head Cap Screw 4 40 x 0 812 in 13161 10 18 Housing Gear Side Bottom 21157 1 19 SS Socket Head Cap Screw 4 40 x 0 375 in 13114 10 20 SS Socket Head Cap Screw 4 40 x 0 250 in 13112 10 21 SS Button Head Cap Screw 4 40 x 0 250 in 13167 10 22 Latch Keeper 13197 10 23 Interface Cover Gear Side 11422 1 24 Purge Gas Tubing 10010 3 1 25 SS Flat Head Screw 00 96 x 0 320 in 13206 10 26 Retaining Drive Clip 13205 1 27 Drive Shaft 11511 1 28 Interface Assembly Rigid 21242 1 29 Pinion Gear Bearing 11411 1 30 Drive Coupling Gear 11424 1 31 Interface Cover Brush Side 10007 1 32 SS Button Head Cap Screw 6 32 x 0 250 in 13155 10 33 Coupling Collar 11448 1 34 Brass Pan Head Screw 4 40 x 0 187 in 13296 10 35 SS 4 External Star Washer 13171 10 36 Solid Drive Coupling 11414 1 37 Brush Spacer 11513 10 38 Plastic Drive Shaft Sleeve 09999 10 For part ordering information contact your Swagelok representative Use Part Numbe
9. clean dry low pressure air Correct Position Incorrect Position Spring Covered by Brush Spring Exposed Under Brush Figure 34 Spring Position 2001 Swagelok Company all rights reserved 29 October 2001 Micro Series 30 2001 Swagelok Company all rights reserved October 2001 Micro Series Parts Drawings This section includes exploded assembly drawings and associated parts lists These drawings are provided as a guide to identifying part names For specific part ordering information contact your Swagelok representative The parts identified in this section include SWS M MTR B Motor Module SWS 4MRH B Rigid Weld Head SWS 4MFH B Flexible Weld Head SWS 4MFB XX Fixture SWS 8MRH B Rigid Weld Head SWS 8MFA XX Fixture 2001 Swagelok Company all rights reserved 31 October 2001 Micro Series Figure 35 SWS M MTR B Motor Module 32 2001 Swagelok Company all rights reserved October 2001 Micro Series Table 8 SWS M MTR B Motor Module Parts List Reference Description Part No Minimum No Order Quantity 1 Motor Module Cover Brush Side 10011 1 2 SS Button Head Cap Screw 4 40 x 0 250 in 13167 10 3 Latch 11434 1 4 Motor Module Cover Gear Side 11427 1 5 SS Socket Head Cap Screw 4 40 x 0 250 in 13112 10 For part ordering information contact your Swagelok representative 2001 Swagelok Company all rights reserved 33 October 2001
10. 0 64 mm 6 00mm 15 75 mm 0 64mm 11 515 mm 2 2001 Swagelok Company all rights reserved 11 October 2001 Micro Series Setting the Arc Gap The micro weld head also includes an arc gap gage which is reguired to set the arc gap The gage fits the rotor aperture and adjusts for the desired arc gap 1 Measure the OD of the work to be welded with a caliper or micrometer and record the value See Figure 11 A 2 Locate the OD value in the following table that matches the OD of the work Find the arc gap gage setting listed for that OD and record it Figure 11 Setting Arc Gap Gage 12 2001 Swagelok Company all rights reserved October 2001 Micro Series Table 3 SWS 4MRH B SWS 4MFH B Arc Gap Gage Dia 0 620 in Setting Setting Setting Setting Setting Setting for for for for for for Actual 0 020 in 0 025in 0 030in 0 54mm 0 64mm 0 76mm Nominal OD Arc Gap Arc Gap Arc Gap Arc Gap Arc Gap Arc Gap OD in in in in in mm mm mm 1 16 0 062 0 361 0 366 0 371 9 19 9 32 9 44 1 8 0 125 0 393 0 398 0 403 9 99 10 12 10 24 1 4 0 250 0 456 0 461 0 466 11 58 11 71 11 83 Table 4 SWS 4MRH B SWS 4MFH B Arc Gap Gage Dia 15 75 mm Setting for Setting for Setting for Nominal OD Actual OD 0 51 mm Arc 0 64mm Arc 0 76mm Arc mm mm Gap mm Gap mm Gap mm 3 3 00 9 91 10 04 10 16
11. 01 A for the CWS 4MRH A Use Part Number 11402 A for the CWS 4MRH A Use Part Number 10456 for the CWS 4MRH A 2001 Swagelok Company all rights reserved 35 October 2001 Micro Series Figure 37 SWS 4MFH B Flexible Weld Head 36 2001 Swagelok Company all rights reserved October 2001 Micro Series Table 10 SWS 4MFH B Flexible Weld Head Parts List Reference Description Part No Minimum No Order Quantity 1 Housing Brush Side 21160 1 2 Work Pin 11412 1 3 Brush Spring 11405 1 4 Brush 11404 A 1 5 Rotor 11403 A 1 6 See Electrode Chart N A N A 7 Ceramic Insert 11446 1 8 SS Round Head Screw 2 56 x 0 125 in modified 13158 1 9 Gear Assembly 10009 1 1 10 Transmission 11447 1 11 SS Dowel Pin 0 093 x 0 375 in 13211 10 12 Locking Lever 11435 1 13 Plastic Flat Head Screw 4 40 x 0 313 in 13157 1 14 Housing Gear Side 21159 1 15 SS Socket Head Cap Screw 4 40 x 0 250 in 13112 10 16 Drive Spring Clip 13202 1 17 Purge Gas Tubing 10010 1 1 18 Flexible Tube Assembly 11415 1 19 SS Button Head Cap Screw 4 40 x 0 250 in 13167 10 20 Latch Keeper 13197 10 21 Interface Cover Gear Side 11422 1 22 Interface Assembly Flex 21240 1 23 Pinion Gear Bearing 11411 1 24 Drive Coupling Gear 11424 1 25 Interface Cover Brush Side 10007 1 26 SS 2 Internal Star Washer 13220 10 27 SS Round Head Screw 2 56 x 0
12. 28 26 Micro Series A Caution Do not clamp the motor module in a vise while cleaning Power Lug Sockets Purge Port Figure 27 Cleaning the Power Lug Sockets and the Purge Port Figure 28 Cleaning the Weld Head Power Lugs 2001 Swagelok Company all rights reserved October 2001 Micro Series Series 4 Micro Weld Head Disassembly and Cleaning To disassemble the Series 4 micro weld head for cleaning use the following instructions See Figure 29 and Figure 30 for part references 1 Lay the micro weld head down on a clean dry surface with the model and serial numbers facing up 2 Remove the five screws from the weld head housing See Figure 29 A Idler fanai 3 Rock the gear side body gently to loosen it from the Gears es Electrode rest of the assembly Lift and remove the housing Electrode M Screw 9 4 Remove the rotor by lifting it clear of the brush side 9 Ceramic Insert housing See Figure 29 B 5 Loosen the electrode clamping screw then remove the electrode and ceramic insert See Figure 29 C 6 Clean the rotor with the provided stainless steel wire brush 7 Clean the ceramic insert with the provided nylon brush 8 Remove and inspect the two idler gears for damage Replace if necessary See Figure 29 D 9 Clean the two idler gears with isopropyl alcohol and Figure 29 Removing Series 4 Micro a soft cloth Weld Head Components for Cleaning
13. 6 Loosen the electrode clamping screw then remove the electrode and ceramic insert See Figure 32 C 7 Clean the rotor with the provided stainless steel wire brush 8 Clean the ceramic insert with the provided 9 Remove and inspect the four idler gears for damage Electrode T Replace if necessary See Figure 32 D 10 Clean the idler gears with isopropyl alcohol and a soft cloth 28 Gear Side nylon brush Ceramic Insert gt 4 Micro Series Ss Figure 31 Removing Series 8 Micro Weld Head Latch Bracket A Housing Screws Housing Mes Rotor Figure 32 Removing Series 8 Micro Weld Head Components for Cleaning 2001 Swagelok Company all rights reserved October 2001 Micro Series 11 Replace the idler gears in the micro weld head Correct Idler Gear Placement housing Verify the idler gear axles are pressed into Pressed Fully into Body Incorrect the body See Figure 33 12 Clean any oxide deposits from the exposed surface of lt ED the weld head brush with the provided stainless steel e wire brush 13 Verify that the spring under the weld head brush is not i e exposed See Figure 34 If necessary reposition the spring under the weld head brush m Figure 33 Correct Placement of Idler Gears in Micro Weld Head Housing 14 Inspect all other weld head components and clean any that are dirty Blow any loose dirt from the weld head with
14. Bracket 1 Determine the mounting orientation of the bracket on the workbench See Figure 21 Secure the bracket to the workbench Make sure the latch is accessible 2 Open the latch on the side of the bracket 3 Slide the micro weld head into the bracket from below until the raised detent on the bracket is aligned to the recess of the micro weld head body Fasten the latch to secure the micro weld head to the bracket Figure 21 Using the Series 4 Bench Mount Bracket 22 2001 Swagelok Company all rights reserved October 2001 Micro Series Series 8 Bench Mount Bracket 1 Remove one of the button head screws holding the latch bracket to the weld head See Figure 22 A Insert one of the supplied adapter screws 2 Secure the adapter screw with a 1 4 in wrench or the micro fixture tool See Figure 22 B 3 Repeat steps 1 and 2 for the remaining latch bracket screw Verify the latch bracket remains securely attached to the weld head 4 Secure the bracket to the workbench 5 Position the weld head so that the exposed ends of the adapter screws slide through the hole in the bracket See Figure 22 C Figure 22 Using the Series 8 Bench Mount Bracket 6 Secure the weld head using the two knurled thumb nuts supplied with the bench mounting bracket Keep the thumb nuts on the adapter screws when not using the bench mount bracket See Figure 23 Figure 23 Storing the Thumb Nuts on the Adapter S
15. Continuous minimum time in seconds Start Power U low Low Norm Maximum Recommended 30A Average Amps Series 8 Shield gas flow rate std ft3 hr 15 to 20 std L min 7 1 to 9 4 Prepurge and Postpurge Continuous minimum time in seconds Start Power U low Low Norm Maximum Recommended Average Amps 38A Use U low start power for 0 010 in 0 25 mm wall thickness 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 When welding 1 2 in or 12 mm OD with a Series 8 weld head use the single pass one revolution weld procedure only Table7 Wall Thickness and Arc Gap Material Thickness mm Arc Gap In mm In mm 0 010 to 0 020 0 25 to 0 51 0 020 0 51 0 021 to 0 030 0 52 to 0 76 0 025 0 64 0 031 to 0 045 0 77 to 1 14 0 030 0 76 0 046 to 0 055 1 15 to 1 40 0 035 0 89 20 Micro Series A Caution The Series 8 weld head can not be used with 1 2 in ATW fittings 2001 Swagelok Company all rights reserved October 2001 Micro Series Considerations During Welding The approach to welding using the micro weld head is Hold Here similar to that used for other Swagelok
16. allow the electrode to fall against the arc gap gage See Figure 12 Tighten the electrode clamping screw to hold the electrode in place Do not over tighten Remove the arc gap gage The rotor may move due to the torque of tightening the clamping screw Use your finger to hold the rotor in place Figure 12 Setting the Arc Gap Attach it to the motor module Complete the steps in Connecting the Micro Weld Head to the Motor Module beginning on page 5 When complete proceed with step 8 Press HOME to return the rotor to the home position 2001 Swagelok Company all rights reserved October 2001 Micro Series Fixturing the Work The work pieces must be properly prepared before fixturing 1 Locate the centering gage Turn the gage so the labeled side faces the part to be installed first Insert the gage into the fixture See Figure 13 2 Open the fixture side facing the labeled side of the centering gage by rotating the latch 90 See Figure 14 The fixture opens with a scissors type action Figure 14 shows how to use the micro fixture tool on the Series 4 fixture Figure 13 Inserting Centering Gage Centering Gage Label Towards Part Opening Note Use the micro fixture tool the Fixture for Series 4 and Series 8 Figure 14 Insert First Work Piece 2001 Swagelok Company all rights reserved 15 October 2001 Micro Series 3 Insertthe first work piece butting the weld end Caution agains
17. crews 2001 Swagelok Company all rights reserved October 2001 23 Fixture Block Maintenance The micro weld head fixtures reguire regular cleaning and maintenance Daily Maintenance 1 Clean the surfaces of the fixture that contact the work pieces Use the wire brush included in the micro weld head tool package See Figure 24 2 If applicable check the fixture insulating tape for damage Replace the tape if it is loose or torn exposing the metal under it See Figure 25 To replace the tape a Remove the damaged tape from both sides of the fixture Disassembly of the SWS 8MFA 08 and SWS 8MFA 12MM may be necessary to assist in replacing the tape Disassemble by removing the screws that hold the arc covers on each side of the fixture Refer to the Part Drawings section of this manual for more detail b Clean the surfaces with alcohol or acetone c Apply one end of the pre cut tape strip to the inside edge of the underside surface The tape should wrap in the direction shown in Figure 25 d Wrap the tape tightly approximately 1 1 2 turns The tape should end at the outside edge of the top surface 24 Clean these Micro Series Series 8 Fixture Clean these surfaces Figure 24 Cleaning the Micro Weld Head Fixtures Outside Edge Inside Edge Figure 25 Checking Replacing the Insulator Tape 2001 Swagelok Company all rights reserved October 2001 Micro Series Micro Weld Head Maint
18. e Plate Left 12503 12MM 1 9 SS Flat Head Screw 00 90 x 0 188 in 13302 10 10 1 8 in Fixed Side Plate Right 12502 02 1 10 1 4 in Fixed Side Plate Right 12502 04 1 10 3 8 in Fixed Side Plate Right 12502 06 1 10 1 2 in Fixed Side Plate Right 12502 08 1 10 6 mm Fixed Side Plate Right 12502 6MM 1 10 8 mm Fixed Side Plate Right 12502 8MM 1 10 10 mm Fixed Side Plate Right 12502 10MM 1 10 12 mm Fixed Side Plate Right 12502 12MM 1 11 Arc Cover Moveable 12506 B 1 12 Arc Cover Fixed 12505 B 1 13 SS Socket Head Cap Screw 4 40 x 0 250 in 13112 10 14 1 8 in Fixed Side Plate Left 12501 02 1 14 1 4 in Fixed Side Plate Left 12501 04 1 14 3 8 in Fixed Side Plate Left 12501 06 1 14 1 2 in Fixed Side Plate Left 12501 08 1 14 6 mm Fixed Side Plate Left 12501 6MM 1 14 8 mm Fixed Side Plate Left 12501 8MM 1 14 10 mm Fixed Side Plate Left 12501 10MM 1 14 12 mm Fixed Side Plate Left 12501 12MM 1 15 SS Shoulder Screw 4 40 13288 10 16 Wave Washer 13291 10 17 SS 6 Washer 13290 10 18 SS Screw 6 32 x 0 240 in 13289 10 For part ordering information contact your Swagelok representative 2001 Swagelok Company all rights reserved 43 October 2001 Micro Series 44 2001 Swagelok Company all rights reserved October 2001
19. e the fixture on the micro weld head Make sure the fixture latches e On the Series 4 Micro Weld Head make sure the are closed before attaching fixture is firmly seated Rotate the locking lever the fixture to the micro weld 90 to secure the fixture to the micro weld head head The electrode can be See Figure 19 A damaged if the latches are left open during welding e On the Series 8 Micro Weld Head engage the two latch springs over the button keepers on the sides of the fixture and close the latch levers See Figure 19 B The micro weld head assembly and the work are ready for welding 2 Press PURGE to begin the shielding gas flow The shielding gas should remain on at all times when using A Caution the micro weld head Make sure that the purge line 3 Program the power supply and perform the weld using or a heavy work piece does the parameters in Operating the Weld Head on not exert a side load force on page 20 the fixture This may cause an unacceptable weld damage to the micro weld head or both SE We gt Latch Spring Captures Ls Button Keepers Locking Latch Springs 2 Lever Figure 19 Placing the Fixture on the Micro Weld Head 2001 Swagelok Company all rights reserved 19 October 2001 Operating the Weld Head Operate the weld head using the following parameters Series 4 Shield gas flow rate std ft3 hr 8 to 10 std L min 3 8 to 4 7 Prepurge and Postpurge
20. eld head housing opening See Figure 4 A and Figure 4 B showing views of the rotor misaligned and in proper alignment The drive gear on the base of the micro weld head must be aligned so that it meshes with the drive pins on the motor module Figure 4 Rotor Manual Adjustment 2001 Swagelok Company all rights reserved 5 October 2001 2 Locatethe shielding gas port on the micro weld head and verify that the O ring is in place See Figure 5 The O ring seals the gas port A valve in the port opens the gas flow through the motor module The valve opens when the micro weld head is properly connected to the motor module 3 Align the connecting surfaces of the micro weld head and motor module See Figure 5 A gt Micro Series Caution The micro weld heads should not be started in any rotor position except fully homed See Figure 5 Arc start in any other location may cause weld head damage Caution Step Programs should not be used with Series 4 or Series 8 Micro Weld Heads Caution Tack programs or programs that include tacks should not be used with the micro weld heads Mating Connections Figure 5 O ring and Mating Connections 2001 Swagelok Company all rights reserved October 2001 Micro Series it is firmly seated then lock the assembly together with the two side latches See Figure 6 A and Figure 6 B 4 Push the micro weld head onto the motor module until A Cautio
21. enance Perform micro weld head maintenance daily and every 1200 1500 welds Depending on usage and wear maintenance may be performed before the 1200 1500 weld interval Daily Maintenance At the start of each work day 1 Inspect the micro weld head for cleanliness Pay close attention to the rotor area See Figure 26 2 Press HOME Check the rotor for smooth rotation If the rotation is erratic or noisy disassemble the micro weld head and clean the rotor idler gears and brush 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 alcohol See Figure 26 2 Store the micro weld head in a clean dry place 2001 Swagelok Company all rights reserved October 2001 WARNING DISCONNECT THE WELD HEAD FROM THE POWER SUPPLY BEFORE PERFORMING THE ADJUSTMENT AND MAINTENANCE PROCEDURES A Caution Do not use lubricants inside the weld head Figure 26 Inspect Exposed Surfaces of the Weld Head 25 Periodic Maintenance Clean the motor module and weld head after every 1200 1500 welds Motor Module 1 Disconnect the weld head from the motor module 2 Clean the motor module power lug sockets with the provided stainless steel brush See Figure 27 3 Carefully remove any obstructions from the purge port See Figure 27 4 Clean the two power lugs on the weld head with the provided stainless steel wire brush See Figure
22. ies Aligning the Work Pieces Series 4 Micro Weld Head Fixture To align tubing in the Series 4 Micro Weld Head Fixture follow these steps 1 Using the micro fixture tool place the latch in the open position then open the fixture See Figure 17 A 2 Loosen the two alignment screws See Figure 17 A 3 Insert the tubing See Figure 17 B 4 Close the fixture and latch and then align the tubing See Figure 17 C 5 Tighten the two alignment screws See Figure 17 C Screw Tighten Screw Tighten Close Screw Latch Figure 17 Aligning the Tubing in the Series 4 Micro Weld Head Fixture 2001 Swagelok Company all rights reserved 17 October 2001 Series 8 Micro Weld Head Fixture To align tubing in the Series 8 Micro Weld Head Fixture follow these steps 1 Using the micro fixture tool place the latch in the open position then open the fixture See Figure 18 A 2 Loosen the two alignment screws See Figure 18 A 3 Insert the tubing See Figure 18 B 4 Close the fixture and latch and then align the tubing See Figure 18 C 5 Tighten the two alignment screws See Figure 18 C Micro Series Loosen Screws 2 Close Fixture Tighten Screws 2 Close Latch Figure 18 Aligning the Tubing in the Series 8 Micro Weld Head Fixture 2001 Swagelok Company all rights reserved October 2001 Micro Series Connecting the Micro Weld Head to the Fixture Caution 1 Plac
23. n Do not force the micro weld head and motor module together The drive gears of the micro weld head and the motor module must be aligned for the pieces to mate correctly If you have problems mating the components rotate the micro weld head drive gear a small amount and try again See Step 1 on page 5 Figure 6 Connecting Weld Head and Motor Module 2001 Swagelok Company all rights reserved October 2001 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 HHH P Electrode Package PIME Designator Material Designator Electrode ip Diameter C Ceriated Length T Thoriated The ceriated electrode material type is a mixture of 98 tungsten 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 Installing Replacing the Electrode The micro weld head tool package includes a screwdriver tweezers and an electrode cleaning tool Use these tools for installing or replacing the electrode 1 Select the proper electrode for the job Table 1 Series 4 Electrode Selecti
24. on Electrode Electrode Diameter Electrode Part No Component OD Length L D CWS C 040 405 P 1 8 in 0 405 in 0 040 in 1 16 in 10 29 mm 1 02 mm 3mm CWS C 040 325 P 1 4 in 0 325 in 0 040 in 6mm 8 26 mm 1 02 mm Table2 Series 8 Electrode Selection Electrode Electrode Diameter Electrode Part No Component OD Length L D CWS C 040 405 P 1 4 in 0 405 in 0 040 in 6 to8mm 10 29 mm 1 02 mm CWS C 040 325 P 3 8 in 0 325 in 0 040 in 10 mm 8 26 mm 1 02 mm CWS C 040 281 P 1 2 in 0 281 in 0 040 in 12 mm 7 14 mm 1 02 mm Figure 7 Micro Series Q Tungsten Electrode 2001 Swagelok Company all rights reserved October 2001 Micro Series 2 Disconnect the micro weld head from the Caution motor module A Only ceriated tungsten 3 Manually turn the rotor drive gear shown in should be used in the micro Figure 4 until the electrode clamping screw is weld heads The use of other exposed See Figure 8 types of tungsten may cause weld head damage Note Replace the electrode when it shows signs of deterioration Electrode Clamping Screw Figure 8 Electrode Clamping Screw Location A Caution Do not rotate the rotor with the electrode clamping screw loose Damage to the micro weld head housing may result 4 While holding the micro weld head as shown in Figure 9 A loosen the electrode clamping screw This orien
25. r sleeve clockwise by hand until it is tight This connection provides the control signals to drive the motor module c 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 motor module d 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 motor module e Insert the motor module 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 2 Press HOME to return the drive coupling to the home position Micro Series Figure 3 Motor Module Connectors A Caution Ensure that the fixture connector is fully seated in the mating socket and the threaded sleeve is tight Note The motor module shielding gas connector must be a single end shut off SESO Swagelok Quick Connect stem SS QC4 S 400 2001 Swagelok Company all rights reserved October 2001 Micro Series Connecting the Micro Weld Head to the Motor Module 1 Using the micro fixture tool turn the weld head drive gear on the base of the micro weld head to align the rotor opening to the w
26. r 11521 for the SWS 8MRH A Use Part Number 11522 for the SWS 8MRH A Use Part Number 11516 for the SWS 8MRH A 2001 Swagelok Company all rights reserved 41 October 2001 Micro Series Figure 40 SWS 8MFA XX Fixture 42 2001 Swagelok Company all rights reserved October 2001 Micro Series Table 13 SWS 8MFA XX Fixture Parts List Reference Description Minimum No Order Quantity 1 1 8 in Moveable Side Plate Right 12504 02 1 1 1 4 in Moveable Side Plate Right 12504 04 1 1 3 8 in Moveable Side Plate Right 12504 06 1 1 1 2 in Moveable Side Plate Right 12504 08 1 1 6 mm Moveable Side Plate Right 12504 6MM 1 1 8 mm Moveable Side Plate Right 12504 8MM 1 1 10 mm Moveable Side Plate Right 12504 10MM 1 1 12 mm Moveable Side Plate Right 12504 12MM 1 2 Latch Right 12508 1 3 Split Base Adjustable 12516 1 4 Split Base Fixed 12515 1 5 Button Keeper 13300 10 6 SS Flat Head Screw 4 40 x 0 375 in 13108 10 7 Latch Left 12507 1 8 1 8 in Moveable Side Plate Left 12503 02 1 8 1 4 in Moveable Side Plate Left 12503 04 1 8 3 8 in Moveable Side Plate Left 12503 06 1 8 1 2 in Moveable Side Plate Left 12503 08 1 8 6 mm Moveable Side Plate Left 12503 6MM 1 8 8 mm Moveable Side Plate Left 12503 8MM 1 8 10 mm Moveable Side Plate Left 12503 10MM 1 8 12 mm Moveable Sid
27. t the centering gage surface Close and latch When closing the fixture be that side of the fixture Make sure that the latch is sure the moving side of the fully closed against the body of the fixture fixture engages into the small See Figure 15 groove on the stationary side 4 Remove the centering gage ofthe mire Open the other side of the fixture and insert the second work piece Butt the weld ends together Close and latch that side 6 Check the weld joint for proper fit and alignment See Figure 15 Verify that the latches are fully closed See Figure 15 Series 4 or Figure 16 Series 8 7 Connect the purge gas line to the work pieces Refer to the Purge Gas Delivery System section in the Power Supply manual Open the shut off valve in the purge gas line 9 Set the flow meters according to the weld procedure n guideline for both the shielding and internal purge gas 7 The length of time for internal purge before welding F a depends on the internal volume and length of the work piece to be welded Refer to the Gas Flow Rate Correct Wrong Tables in the Power Supply manual Figure 15 Checking the Weld Joint and Latch Position Series 4 Fixture Correct Wrong Figure 16 Proper Latch Position Series 8 Fixture 16 2001 Swagelok Company all rights reserved October 2001 Micro Ser
28. tation helps to prevent the electrode from falling out during installation 2001 Swagelok Company all rights reserved 9 October 2001 Micro Series 5 Install a new electrode using tweezers Insert the electrode through the ceramic insulator and into the rotor to its full insertion depth Make sure the sharp tip of the electrode is pointing out See Figure 9 B 6 Tighten the clamping screw sufficiently to prevent the electrode from falling out of the rotor Do not over tighten the clamping screw Note Clean the electrode before every weld for optimum performance Figure 9 Installing the Electrode 10 2001 Swagelok Company all rights reserved October 2001 Micro Series Calculating Arc Gap Gage Settings To determine the arc gap gage setting for a specific arc gap use the formula below j i J 7 p lt 3 4 B ARC GAP 2 2 C GAGE SETTINGS Where A largest OD onthe weld end ofthe tubing or fitting welding diameter B arc gap gage diameter C desired arc gap Figure 10 Arc Gap Gage Setting Formula Example No 1 Series 4 Weld Head 1 8 to 1 8 in tube butt weld A 0 125 in largest outside diameter Arc gap gage diameter B 0 620 in Desired arc gap C 0 03 in 0 125 in 0 620 in 0 03 in 0 4025 in 2 2 Example No 2 Series 4 Weld Head 6 to 6 mm tube butt weld A 6 00 mm largest outside diameter Arc gap gage diameter B 15 75 mm Desired arc gap C
29. weld heads N Develop a weld procedure guideline as you would for any job The power supply controls and indicators work the same However the unique qualities of the micro weld head and its fixtures cause some noticeable differences during welding Hold Here e The sound of the weld is slightly louder compared to other Swagelok weld heads This is due to the reduced size of the fixture e You may notice a clicking sound during the downslope cycle This is normal The fixture contracts slightly due to heat dissipation producing the sound e Because the fixture is small heat build up may make the device too hot to handle immediately after welding Hold the fixture in the base areas shown in Figure 20 Use the optional aluminum WARNING cooling plate to hold the fixture and allow it to THE FIXTURE MAY BE HOT Figure 20 Cooling Plate cool faster See Figure 20 AFTER WELDING IS COMPLETE USE CAUTION e Extended internal purging assists the WHEN HANDLING cooling process 2001 Swagelok Company all rights reserved 21 October 2001 Micro Series Using the Optional Bench Mounting Bracket Caution The bench mounting brackets attach Series 4 and Series 8 A i Do not put the micro weld head in a vise Severe damage may result which would void any warranty Micro Weld Heads to a workbench There are two mounting plates on the bracket giving you a choice of mounting orientations Series 4 Bench Mount
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