Swagelok Welding System User Manual: Troubleshooting
Contents
1. Reset the arc gap to the table setting in the appropriate weld head user manual Insufficient arc gap for the material or the heat input Increase the arc gap by 0 005 in 0 13 mm above the table settings Work pieces are out of round 1999 Swagelok Company all rights reserved August 2001 Increase the arc gap or replace the work piece OABITAL WELDING SYSTEM Incomplete inside diameter penetration Insufficient heat input Compare the power supply setting to the weld procedure guideline being used Adjust weld parameters as necessary 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 Incorrect weld procedure guideline Incorrect arc gap Tip of electrode is worn or ground improperly Inconsistent heats of materials or changes in material chemistry Verify consistency of material with material supplier Adjust weld parameters as necessary Inspect the entire weld joint n the fixture block prior to welding Weld joint is off center or misaligned After welding the tubing fitting assembly is not straight The end surfaces of the work pieces being welded are not perpendicular to their center axis The fixtur2. DS yqodoe 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 encountered 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 1999 Swagelok Company all rights reserved August 2001 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 Mainte
3. Weld puddle protrusion Check internal purge gas flow rate for excessive back pressure Weld head is not properly attached to the fixture block Reattach the weld head to fixture block Engage the weld head locking lever Oxidation film on the electrode Insufficient shielding gas Increase shielding gas flow rate Insufficient post purge time Increase post purge time Partially blocked or cut shielding gas line Check for leaks and or blockages Replace purge lines if needed O ring missing between the weld head and motor module Micro Weld Head Only Check and install O ring if necessary Shielding gas line disconnected inside weld head Disassemble weld head and reconnect the line Bent or broken Electrode was Replace the electrode Tighten electrode not secured in electrode clamping screws the rotor Weld head 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 1999 Swagelok Company all rights reserved August 2001 OABITAL WELDING SYSTEM Fixture Block When closing the fixture block side plate the latch does not lock The latch is n
4. properly or fuse spring is missing Insert fuse properly Replace fuse spring if necessary Incorrect arc gap setting Reset the arc gap with the arc gap gage Excessive purge gas flow Reduce flow to the value shown on the weld procedure guideline Insufficient shielding gas flow or contaminated shielding gas Check the shielding gas source for low pressure Check gas lines for leaks Change to a different gas source or change oxygen removal filter Electrode in poor condition Replace electrode Damaged electrical connections in the weld head Weld head needs repair Call for service Poor contact between locking ring tab and ground extension Inspect and clean all contact surfaces Poor contact between rotor and brush Inspect and clean all contact surfaces Poor contact between tubing collet and fixture block Inspect and clean all contact surfaces Start power set to low Set start power to normal OABITAL WELDING SYSTEM Note All fuses should be rated at 250 V ac 110 V ac power supplies use a 20 A fuse 1 4 x 1 1 4 in 220 V units use a 10 A fuse 5 x 20 mm Note The ceramic fuse is located on the rear panel of the power supply See Figure 1 Ceramic Fuse Location Figure 1 fluctuations during the weld cycle exceeding 2V Weld head not seated properly into the fixture block Reattach the wel
5. used Contamination on work pieces Nicks cuts in the internal purge gas line Change to correct type of purge gas Clean the work pieces before welding Replace gas line Troubleshooting Note The purge restrictor must be of adequate size to prevent excessive inside diameter back pressure 1999 Swagelok Company all rights reserved August 2001 Troubleshooting Symptom Hole in the weld bead Incorrect arc gap Remedy Reset the arc gap with the arc gap gage Excessive internal purge gas back pressure or surge Remove any obstruction of the internal purge gas flow or reduce the pressure Improper tube preparation Inspect and reface tubing Incorrect weld parameter setting impulse Check and adjust the weld parameter settings Loss of shield gas flow Check the shielding gas source for low pressure Check gas lines for leaks Change to a different gas source or change oxygen removal filter Concave weld puddle Excessive heat input 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 Insufficient inside diameter purge gas pressure Compare flow meter settings to the weld procedure guideline being used Adjust if necessary Electrode touches the work Incorrect arc gap
6. and power block assembly drawing in the Power Supply manual Use compressed air to blow off debris Rotor gear ring is misaligned with secondary gears Realign the rotor with the weld head opening Refer to the Maintenance section of the appropriate weld head user manual Fixture connector has broken or damaged pins wires Call for service Home sensor is damaged or misaligned Call for service Rotor squeaks when turning Dirty or worn weld head body halves Disassemble the weld head and clean or replace components Gear bearings worn or dirty Clean or replace bearing assemblies as needed Dirty ball bearings in rotor Disassemble rotor and clean or replace ball bearings as needed Rotor does not move or makes a clicking noise when turning Debris on gears Check for weld spatter or debris on gears Loose drive clip in the micro weld head Check and replace drive clip if needed See the appropriate micro weld head assembly drawing in the appropriate weld head user manual Brush spring is installed incorrectly in micro weld head Install the brush spring in the correct orientation Refer to the Maintenance section of the appropriate weld head user manual Bent motor shaft 1999 Swagelok Company all rights reserved August 2001 Call for service OABITAL WELDING SYSTEM Erratic rotor rotation speed control Wel
7. d head to the fixture block Engage the weld head locking lever Work pieces are out of round 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 Insufficient shielding gas flow or contaminated shielding gas Outside diameter discoloration Insufficient shielding gas flow Increase shielding gas flow rate and prepurge time Check gas lines for leaks Change to a different gas source 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 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 Inside diameter discoloration Insufficient internal purge gas 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 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
8. d spatter on gears Inspect the rotor primary secondary and drive gear s for damage Replace damaged gears Arcing damage on rotor gear teeth Inspect rotor and replace if damaged Dirty weld head debris on encoder sensor or encoder wheel Disassemble the weld head and clean thoroughly Encoder wheel slips on motor shaft Call for service Fixture Call for service connector has broken wire Arc damage on Arcing from Clean gear or replace if rotor gear rotor necessary Damage to weld Arcing Disassemble the weld head head body Clean or replace parts as halves needed Follow the recommended maintenance schedule outlined in the Maintenance section of the appropriate weld head user manual Excessive heat from welding Check weld procedure guideline Use a larger weld head allow a cooling period between welds or allow continuous shielding gas flow when welding Weld head was dropped Check for damage and replace parts as necessary Check rotor for smooth operation Call for service if damage is severe Troubleshooting 1999 Swagelok Company all rights reserved August 2001 Troubleshooting Electrode Symptom Material found on the electrode tip Electrode touched the weld puddle Remedy Replace electrode and check arc gap setting Check work pieces for out of roundness
9. e block side Prepare the work piece weld ends properly Refer to the appropriate weld head user manual Tighten screws as plate screws are not needed tight After welding the The fitting tubing was Center fitting tubing fitting tubing joint is still visible 10 not centered properly The electrode is bent or was not properly installed Inspect the electrode and replace if necessary Reset the arc gap with the arc gap gage Troubleshooting 1999 Swagelok Company all rights reserved August 2001
10. nance section of the appropriate manual If in doubt about a procedure call your Swagelok representative Power Supply Symptom Front panel screen blank The circuit breaker is off Remedy Turn on circuit breaker The power supply line cord is not plugged in Plug power cord into the wall outlet The replaced or new ceramic fuse fails immediately when power is turned on Internal component failure Call for service Power supply fan does not operate Internal component failure Call for service Cannot store procedures or weld data on the PC Memory Card PC Memory Card write protect switch is on Slide the write protect switch on the PC Memory Card to the OFF position Troubleshooting Note 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 1999 Swagelok Company all rights reserved August 2001 Troubleshooting Weld Head Symptom Rotor does not return to the home position Fixture connector is not fully engaged Remedy Check that the fixture connector is seated and its collar is tight Rotor is not at the home position when the power supply is turned on Use ROTOR JOG to move the rotor to the home position then cycle power off and on Dirty home sensor Disassemble the weld head and check the home sensor for dirt See the appropriate motor
11. ot inserted into the fixture block side plate completely Reinsert the latch into the side plate until it rests against the latch pin Bent latch Replace latch Oversized tubing Replace fitting tubing with the correct size Wrong size collets 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 not fit into the bottom part of the fixture block A burr is in the slot or on the latch Use a fine file to remove burrs 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 broken or damaged Replace the locking ring tab The weld head is incorrectly assembled Reassemble using the instructions found in Maintenance Arc damage on fixture Clean fixture Remove and replace any damaged parts Troubleshooting 1999 Swagelok Company all rights reserved August 2001 Troubleshooting Welding Process Symptom Arc fails to start 1999 Swagelok Company all rights reserved August 2001 Blown ceramic power supply fuse Remedy Replace the ceramic power supply fuse with one of the same type and rating Fuse not seated in fuse holder
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