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Swagelok M200 Power Supply User's Manual, (MS-13

1. A SNAGELOK COR nnn Dr Solon OH 44138 US A tec eus7e7 51857042005 Fig 5 M200 Power Supply Rating Label Owad Tools and Accessories Required Table 2 Tools and Accessories Provided Tool Accessory Included With Hex wrenches 1 2 to 5 32 in Yes Weld head Electrode package Yes Weld head Arc gap gauge Yes Weld head Flat blade screw driver Yes Weld head Centering gauge Yes Fixture block Calipers or micrometer No Purge kit No Ordering number SWS PURGE KIT Low moisture gas lines No Gas source No Pressure regulator No ID purge gas flow meter No Pressure gauge No The Series 40 weld head does not include an electrode arc gap gauge or centering gauge package Electrical Requirements M200 Power Supply Installation All user supplied wiring and related components must be installed in accordance with local electrical codes A dedicated electrical circuit may be required to maintain optimum current levels If input voltage is 100 V or less output power capabilities may be reduced Table 3 Voltage and Current Requirements Power Supply Model Voltage Requirement Service Current 100 V ac 20A M200 230 V ac 16 A See Specifications page 100 for detailed power input and output information Using Exten
2. 1 2 in x 0 049 in Entry Step Parameter Tube Tube 316LV Screen 1 Programmer Joe Welder Weld Information Programmer box 2 Joint Type Example Tube to tube Tube Tube Weld Side 1 Tube to auto tube weld Tube ATW Side 1 Tube Weld Setup Side 2 Tube to auto socket weld Tube Socket Side2 Tube Joint field 3 Material Side 1 316LV Weld Side 1 Side 2 Side 2 316LV Weld Setup Joint field 4 Work piece diameter Weld Diameter Side 1 Side1 0 5 in Weld Setup Diameter Side 2 Side2 0 5 in Joint field For future calculations OD use larger of Side 1 and Side 2 0 5 in 5 Wall thickness Weld Wall Side 1 use socket wall thickness for Side 1 0 049 in Weld Setup socket weld Joint field Wall Side 2 Side 2 0 049 in For future calculations Wall use larger of side 1 and side 2 0 049 in 6 Head weld head model Weld 5H Weld Setup Setup field 7 Electrode part number Weld see weld head user s manual CWS C 040 555 P Weld Setup Setup field 8 Arc Gap for socket welds 0 070 in is suggested Weld see weld head user s manual for other weld 0 035 in Weld Setup styles Setup field 9 Arc Gauge Weld see weld head user s manual 0 907 in Weld Setup Setup field 10 Shield Gas Weld Argon Purge Setup ID Gas Gas Type field Argon 11 PrePurge Time Continuous purge suggested for micro weld Weld heads minimum 20 second purge for all Purge Setup other heads 20 s
3. 0004 eee 28 Performing a Weld _ 34 File SCr6ens J ur eo peak W ea Boe Q Aa 35 Program Screens 220000 38 Weld Log Screens a a 39 Setup Screens ew a 42 Remote Pendant 47 Maintenance eee eee 48 Printer ar 2a ane na Oe abr i sy s Bae em Ee 8 49 Changing Paper _ a 49 Clearing a Paper Jam a 50 Installing and Replacing the Optional Fan Filter 51 Weld Parameter Development 52 Weld Parameter Changes 4 53 Creating a Weld Procedure Guideline 53 Weld Procedure Guideline Worksheets 54 Owad WaCkS u chee heise eR SUKU OQ Oka 8 Dk SD S ee 4 65 RampTime ee eee 66 Ramping UpinLevel1 67 Added Rotor Delay Time Before Welding 69 Step Programs for Multilevel Weld Procedures 71 Weld Parameter Guideline Worksheet Reference Data 80 Single Level Mode Operation _ 84 Single Level Current Control Group 84 Single Level Timing ControlGroup 85 Single Level Weld Process Buttons 86 Single Level Status Indicator Lights 87 Single Level Weld Status Conditions 87 Single Level Weld Procedure Guidelines 88 Evaluating Weld Quality 25e058 96 Identifying Proper Wel
4. Fig 31 Summary Tab Owad Table 8 Weld Screen Buttons Test m Jog Jog Back x Shield Gas Start Me Check or demonstrate a weld procedure with this mode Press to put the power supply in an alternate operating mode that will not supply current to the electrode Press again to stop The current and voltage displays will not operate and the weld counter will not advance The light in the corner of the button will blink while the power supply is in Test mode Press to move rotor clockwise Press again to stop The light in the corner of the button will blink while the rotor is moving Press to move rotor counterclockwise Press again to stop The light in the corner of the button will blink while the rotor is moving Activates the mass flow controller and starts the flow of OD shield gas to the weld head Shield gas will flow to the weld head until you press the button again Pressing the Shield Gas button does not override Purge Setup settings in the weld procedure but gas will continue to flow after the weld procedure is complete Starts the weld process See Performing a Weld page 34 Press to return the rotor to its true home position The rotor will move at maximum speed when traveling to the home position regardless of the programmed rotor speed Prints last completed Weld Log record Aborts the weld and halts the rotor if pressed during the weld process Stop also tu
5. Fig 8 Connecting the Weld Head Assembly to the Power Supply WARNING Do not remove the weld head from the M200 power supply while a weld is in process Electrical shock can result Setting Up the Gas Supply System The M200 power supply has an integral mass flow controller MFO to control and monitor the flow of the gas supply system that provides OD shield gas to the weld head OD shield gas fills the weld chamber to protect the electrode and weld puddle from contaminating elements in the surrounding air ID purge gas flows within a tube or at the back of a weld joint to A CAUTION remove oxygen and prevent oxidation yg k Do not mix or interchange Typical OD Shield ID Purge Gas Supply System parts with those of other manufacturers Personal injury Figure 9 shows a typical gas supply system Before setting up or equipment damage can result the gas supply system read and understand the Safety section of this manual See page 5 s NOTICE 1 Make sure the gas storage containers are upright and Do not exceed an inlet pressure of secured before use F 100 psig 6 8 bar or MFC can be 2 Check all connections for leaks damaged 3 Use only Swagelok quick connect stems ordering number SS QC4 S 400 as gas connectors on the M200 power supply NOTICE j f The MFC is not a shutoff device There 4 Regulate the OD shield gas pressure to obtain the desired may be gas flow of up to 1 2 std ft3 h flow rate
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7. 23 High Amps Width 50 width suggested Fractional tubing Weld 50 Levels 1 Metric tubing 50 Owad AcWwanceec Wele Procedure Techhicues The M200 power supply incorporates features that allow adjustments to weld procedures created with using Auto Create Manual Create and Single Level Mode programming These features allow the programmer or owner to adjust the heat input by varying different weld procedure parameters They also enable optimization with advanced features such as tacking and ramping wade Tacks Tacks are small welding points that do not penetrate the wall completely They are used to hold the joint alignment and joint gap during welding The M200 power supply will allow up to 20 tacks in Auto Create or Manual Create Fig 59 See the Tack Parameter Guideline Worksheet below for use in conjunction with the Weld Procedure Guideline Worksheets Where the two worksheets have common parameters use the Tack Parameter Guideline Worksheet values E lf tacks break during welding E Increase the time by 0 5 seconds for each tack This will increase the tack size E Increase the number of tacks m lf tacks are not fully consumed by the weld decrease the time by 0 5 seconds for each tack m If the weld is to be completed at a later time tacks must be brushed to remove oxidation before welding Oxidation can cause weld bead meander if it is not removed Brushing is not required if th
8. 5 or 0 26 Pulse Rate for all levels Total travel speed step 19 Weld 30 x Wall step 5 Levels 1 30 x 2 15 30 X 0 109 1 Note Round up to nearest whole number If Weld Time ends in 5 and Pulse Rate is an odd number Note If Weld Time ends in Pulse Rate for all levels Pulse Rate 1 forces Pulse Rate 5 Pulse Rate must be x Weld Time to be even to prevent a skip a whole number between levels 1 Weld Time ends in 0 27 High Amps Width 320 x Wall step 5 12 Weld 320 x 12 320 x 0 109 12 47 Levels 1 Note Round up to nearest whole number 28 Add additional level columns now step 18 Weld Multiple level current factor Levels 4 FLevei High AMPS eye 1 Step 16 x 0 2 Nieves Step 18 x 0 2 99 4 x 0 2 4 5 0 High Amps for Level 2 High Amps eye 1 Step 16 FLevel _ 99 4 50 944 A 29 High Amps for Level 3 High Amps eye 2 Step 28 FL eve Step 28 Weld Levels 4 a 94 4 50 894 A 30 High Amps for Level 4 High Amps eye 3 Step 29 FL evel Step 29 Weld Levels 4 _ 89 4 50 844 A 31 Delay Current High Amps oye 1 step 16 x Width step 15 Weld Low Amps step 17 x 1 Width _ 94 4 x 0 47 43 2 General 696 A Start field x x 1 x 1 0 47 Owad Table 23 Fractional Step Program Parameter Guideline Worksheet Example Based on 2 0 in x 0 109 in E
9. The printer is out of paper Load a new roll of paper Information Peretre Unset awa i tsamgt tots t 0500 OF MV OO 9 Creation Gate 08 12 200 hogea sew mm nrws OD wan vaasn OD Short Prepurge Fig 88 Operational Condition Message Table 45 Operational Conditions Operational Message Description Remedy W Short The prepurge time is set Set prepurge time for prepurge for less than 5 seconds If longer than 5 seconds the Shield Gas button on or press the Shield Gas the Weld screen is active a button on the Weld this operational condition screen will not be be displayed W The OD shield or ID Change the gas to one Unsupported purge gas in the loaded supported by the Auto gas weld procedure is not Create menu supported by the M200 power supply W Weld head The weld head is not in Press Home on the touch not home the true home position screen W Wrong weld The active weld procedure Attach the correct weld head specifies a different weld head head Owad 106 M200 Power Supply User s Manual Weld Errors Weld errors indicate problems that occurred during the weld process Weld completed or Weld not completed will be displayed on the status line and on the summary screen Fig 84 A description of the error will be displayed in a dialog box and the alarm will sound if the alarm function has been turned on see Table 15 page
10. Level 1 Ramp Added Rotor Delay Time Guideline Worksheet Table 16 Fractional Example Based on or 1 2 in x 0 049 in Fractional Table 17 or 12 mm X 1 0 mm Metric Metric Tube Tube 316LV Entry Step Parameter Hold Rotor Through Level 1 Screen Ramp Time for Level 1 3 0 s Weld Levels 1 For future calculations Added Rotor Delay Time for full penetration Delay 0 1 second or greater 1 5s 21 Weld Time for Level 1 Weld Weld Time eye 1 Weld Time Weld Procedure Guideline Fractional tubing Levels 1 Worksheet step 21 Delay 504 15 30 95 s Ramp Time 3 Metric tubing Note Round up to nearest 0 5 second or whole number 4 0 1 5 3 0 85 s whichever is smaller 22 If Pulse Rate is an odd number and Weld Time is rounded to Weld nearest 0 5 second Levels 1 Pulse Rate for Level 1 only Pulse Rate Pulse Rate Weld Procedure Guideline Pulse Rate from previous Worksheet step 22 1 _ calculation is even forces Pulse Rate x Weld Time to be a whole number 1 25 High Amps Speed in rpm for Level 1 0 0 Weld Levels 1 26 Low Amps Speed in rpm for Level 1 0 0 Weld Levels 1 30 Delay Current 5 A or greater 5 A Weld General Start Field 31 Rotor Delay Time 0 1 second or greater 01 s Weld General Start field Owad Step Programs for Multilevel Weld Procedures A Step Program can be used to refine the control of the weld heat input A step program
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12. Stop bits 1 Flow control None Owad M200 Power Supply User s Manual 41 Export Copy Delete Tab Export Copy Delete The Export Copy Delete tab Fig 38 opens showing two USB Flash Drive ONLY panes Saree ele Gn w E Internal Memory USB Flash Drive left pane displays the T neprege folders in the Internal Memory Weld Log and USB Flash paste Drive Weld Log if drive is connected Shuwa wan ami ene m USB_Flash_Drive_ONLY right pane displays the folders for _ heehee USB Flash Drive Weld Log Kenta aah The selected folder and files will appear in the Name field below the pane Table 13 Export Copy Delete Tab Buttons Name field Weld Log Name field The Export button allows the Weld Log record to be exported from the Internal Memory Weld Log Fig 38 Export Copy Delete Tab Fig 39 into a text file f f f Each Weld Log record is a separate line Fields are separated by commas within the Weld Log mm The exported file can be imported into Microsoft Export Copy Delate Excel or Access USE Fash Drive OLY Select the folder to be exported and press Export The Weld Log Export dialog box will open The From and To locations will be shown Enter a file name in the Weld Log Name field Check Append to File if the file name already exists and you want to add the data to the file If the file name exists and Append to File is not selected the file will be overwritten Select a
13. www swagelok com Power Supply User s Manual This manual contains important information for the safe and effective operation of the Swagelok Welding System M200 power supply Users should read and understand its contents before operating the M200 power supply OWAN 2 M200 Power Supply User s Manual Owad Contents Safely aa ere eh s 9 e p Ov eee See wd Ome te a 5 Safety Summary 5 Signal Words and Safety Alert Symbols Used in this Manual 5 M200 Power Supply Warning Label 10 Referenced Documents 11 Installation and Setup _ aaa 13 Description r r r 14 Unpacking the M200 Power Supply 16 Registration Information 17 Tools and Accessories Required 18 Electrical Requirements 18 Setting up the M200 Power Supply 19 Installing the Weld Head 20 Setting Up the Gas Supply System 21 Typical OD Shield ID Purge Gas Supply System 21 Powering On the M200 Power Supply for the First Time 22 Powering Off the M200 Power Supply 22 Restarting the M200 Power Supply 22 Using the Touch Screen 23 User Interface 23 Operation s ss s s s scu a a ww saw a s we Q a u s 25 Malin Menu s oroi ay pupu BORE ae ge eg 25 Weld Screens
14. E Shut off gas supply when not in use Welding Handbook Vol 2 8th ed American Welding Society Owad gt gt gt ARC RAYS can burn eyes Arc rays from the welding process produce intense visible and invisible ultraviolet and infrared rays that can burn eyes The M200 power supply is meant for use only with enclosed Swagelok weld heads which minimize exposure to these harmful rays To avoid injury E Do not look at welding arc E Use protective screens or barriers to protect others from flash and glare warn others not to watch the arc E Wear personal protective equipment including eye protection WELDING can cause fire or explosion Welding on closed containers such as tanks drums or pipes can cause them to explode The hot work piece and hot equipment can cause fires and burns Ensure the area is free of combustibles before welding To avoid injury E Do not place the M200 power supply over a combustible surface See the label on the bottom of the M200 power supply Fig 1 E Do not weld in a combustible environment m Watch for fire and keep a fire extinguisher nearby H Do not weld on closed containers such as tanks drums or pipes unless they are properly prepared in accordance with AWS F4 1 E Do not use the M200 power supply to thaw frozen pipes E Do not use extension cords that are in poor physical condition or have insufficient current capacity Failure to do so can pose fir
15. Fig 8 and insert the connector Turn it clockwise to lock it in place An audible click indicates that the connection is locked This connection provides the control signals to drive the weld head Note Use the weld head adapter cable included in the shipping case if the weld head does not have a quarter turn connection Attach the weld head adapter cable to the end of the threaded multipin connector Tighten the weld head adapter cable until only two or three threads are visible 2 Insert the red connector arrow side up into the M200 power supply red socket labeled ELECTRODE Turn the connector one quarter turn clockwise to lock it in place This connection is the negative terminal of the weld head 3 Insert the green connector arrow side up into the M200 power supply green socket labeled WORK Turn the connector one quarter turn clockwise to lock it in place This connection is the positive terminal of the weld head 4 Insert the weld head OD shield gas Swagelok quick connect stem into the M200 power supply fitting labeled TO WELD HEAD This connection provides shielding gas to the weld head through the mass flow controller in the power supply Owad Weld head quarter turn connector Electrode red Work green OD shield gas Fig 7 Weld Head Assembly Connections NOTICE All connections must be fully seated and locked in place to prevent damage to connections or weld head OR CF
16. Table 14 Setup Upper Section Tabs Weld Log Specifies the frequency of the Weld Log printout Fig 41 When set to zero the printer prints out a Weld Log only when the Print button is pressed Setting Auto Print Count to any other number defines the interval at which Weld Logs are printed set to 1 the printer prints after every weld set to 10 the printer prints after every 10th weld etc Operation Allows the user to set some of the M200 power Fig 42 supply functions Jog Speed Enables the user to set the speed of the weld head when jogging as a percentage of the weld head full speed See the weld head user s manual for the full speed ratings of individual weld heads i j Fig 41 Weld Log Tab Electrode Touch Volts This is the voltage setting used to detect if the electrode touches the weld puddle The factory setting of 4 V should not be adjusted without testing but may have to be raised when using longer weld head extension cables Raising the voltage makes the M200 power supply more sensitive and can cause it to record an electrode touch when there was none and generate an error code Lowering the voltage can allow an electrode touch without generating an error code Fan Power On State The default setting for the fan power on state is ON The first time the M200 power supply is powered on the fan button on the Main screen will blink and the fan will be in the continuous run state Changing the Fan Power On
17. The typical pressure range is 45 to 50 psig 3 1 to 0 24 std L min when the shield gas is 3 4 bar Flow rates greater than 70 std ft3 h 33 std L min off may require higher pressures Two stage High pressure regulator Low pressure gauge gauge 0 to 3000 psig 0 to 100 psig 206 bar 6 8 bar Flow meter for ID purge gas Supply manifold ID purge gas shutoff valve Inert gas cylinder iii T Tubing to be welded OD shield gas M200 supply inlet power supply Fixture block Purge fittings Swagelok union or reducing union with nylon ferrules or ultra torr fitting See Table 2 for purge kit ordering number Fig 9 Typical Gas Supply System Owad 22 M200 Power Supply User s Manual Powering On the M200 Power Supply A for the First Time CAUTION The rotor will move when the 1 Connect the power cord to a properly rated and grounded M200 power supply is powered electrical receptacle on The rotor is a potential 2 Power on the M200 power supply by toggling the ON OFF pinch point switch on the left side of the unit to the ON I position The Swagelok screen will appear 3 The Setup Wizard Fig 10 will prompt the user to select a user language 4 The Swagelok Embedded System End User License Agreement page
18. These guidelines are for reference only modifications may be necessary to achieve the desired results Table Note E The Average Amps column lists a calculated value based on certain weld parameters This value should approximate the value shown on the Average Current display during the weld process Because it is a calculated value some variation may be seen based on the welding conditions Owad Note The M200 power supply Auto Create feature can be used to generate a one level multipass weld procedure Any procedure generated manually using the Single Level Weld Procedure Guidelines or generated automatically by the M200 power supply is only a guideline The final weld quality depends on the operator s welding experience and on the proper use of welding techniques Parameter adjustments will need to be made and weld quality verified in accordance with the user s quality standards OQ cO M200 Power Supply User s Manual NOILVdadO JGOW 14A371 STONIS WU 10 JOJEM JO SBYOU 8 0 9 WW 9 pue Ul p L 1OJ 18 EM JO SOYDUI p o Z 0 JAS sem ainssaid seb abing pasn sem abneb ainssaid uA 1 94 S 1 e Burqn ww 9 pue ww ul p L UO pe y PJEM ow BY JO 34I BY pu8 x 0 p sn aq moj seb PjaiyS GO snonunuo2 e ey p s BBns si 1 S8 ON v e ol Liy gel ooz 8z og r cl Ol O ge oe OL OL SEV FZI OL 920 O L 9
19. gt gt Folder Move field to the selected destination in the right Folder Move field c Copies the selected folder or file from the right lt lt MOPY Folder Move field to the selected destination in the left Folder Move field Owad 38 M200 Power Supply User s Manual Program Screens The Program screens Fig 34 are used to create new weld procedures using Auto Create or Manual Create Table 11 Program Screen Buttons Auto Create Fig 35 Manual Create Fig 36 Owad When you select Auto Create a dialog box will ask you to confirm overwriting the active weld procedure Press Yes to overwrite the active weld procedure The active fields on the Auto Create screen are shown in black As these fields are completed the inactive fields in gray will activate in response to the entries The eight most recent entries for the Programmer field will display in a drop down box To change the Levels and Tacks entries from the default press the field to display the keypad Enter your changes and press Done The Save Procedure drop down box has two options gm Active No Save will take you directly to the Main gt Weld screen for immediate use You can run the weld procedure and make changes before saving mM Save Procedure will take you to the Main gt File screen On this screen you can enter a name for the weld procedure and save it to internal memory or the external USB flash drive
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21. levels Note from Fig 56 page 52 each level begins with the Low Amps period of the pulse cycle The Weld Time multiplied by the Pulse Rate Weld Time x Pulse Rate that is the number of seconds per level X cycles per second must equal a whole number of cycles per level to ensure each level ends with a complete Low to High Amps cycle before beginning the next level Owad Table 16 Fractional Butt Weld Procedure Guideline Worksheet Example Based on 1 2 in x 0 049 in Entry Step Parameter Tube Tube 316LV Screen 31 For Wall lt 0 083 in Weld Rotor Delay Time Wall step 5 x 40 General ___ x 40 0 049 x 40 20 s Start field For Wall gt 0 083 in Wall lt 0 083 in Rotor Delay Time Overlap step 20 32 Downslope Timer ai step 20 constant Weld Constant OD lt 0 5 in 1 25 General Finish field 0 5 lt OD lt 1 0 in 2 5 1 0 in lt OD 15 If Downslope lt 10 Pulse Rate step 22 then Downslope 10 Pulse Rate forces a minimum of 10 pulses for Downslope 18 2 2 5 ASN s 0 50 in lt OD lt 1 0 in 10 4 2 5 7 3 gt 2 5 NOTICE When welding 1 2 in outside diameter with the 8 MRH weld head use a single pass one revolution weld procedure only Owad Table 17 Metric Butt Weld Procedure Guideline Worksheet Example Based on 12 0 x 1 0 mm Entry Step Parameter Tube Tube 316LV Screen 1 Programmer
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23. 0 035 0 907 7 0 0 500 0 049 0 035 0 907 7 0 sessed jo soquINN jenayeyy adA_ JUIOr wade ie Te ba S o oO Q o A 9 To N a o 2 2 co TB TB Table 35 Series 10H Weld Head Single Level Weld Procedure Guidelines Fractional Dimensions Y4 PS n feel S PS PS e es MOIS GI o oO oO o oO GO Oo jejejejejeje LO LO LO LO I LO LO LO LO LO N y cH pis m w w a w mola pays 2 S g CN CN N CN CN LO LO w et s Gk E Ta Ta Ta v olo solos sduy ebeiay alolalalHjn CN 92 OO tO O G p ds 10104 m S s o o NIOJ e s 6Bind1sod SO O O O O O O CF Oy Cy OO OD OO OO s adojsumoqg O fr tT Ol O O ps s a K S Ou PIOM MO OIN N O o TmINININIT GN C O s 6ind id SO O O O O O O NINININI NINN s SWIL c 2 2 LO LO LO LO fea 40104 G G v 3u uino Aejag 00y S S cu lt st 19a 10H NIN NN OO s LO PIM lo O iO iO iO O gt puov s Jed sasind ay esind 2 12 212 c ole lt Q C OO OO I OOOI Ol 0O v sduy MOT S SiSialalala w w Oe GN oO tO O O o O cO v sduvuBiH G Sl al al o o I lt O UlLu Uul O O O O O O O peads pael C
24. 122 will appear You must accept the terms of this agreement to continue the Setup Wizard and use the M200 power supply Welcome to Initial M200 Setup Vizard 5 Set the owner password If desired set security or programmer passwords See Passwords page 46 for more information 6 The Main Menu will appear Note The fan will turn on automatically Press the Fan button to turn the fan off Fig 10 Language Setup Wizard Powering Off the M200 Power Supply To power off the M200 power supply toggle the ON OFF switch Note The owner password is the master on the left side of the power supply to the OFF O position key to the M200 power supply If it is lost or forgotten contact your authorized Swagelok representative After ownership of the unit is verified you will receive a temporary Restarting the M200 Power Supply password to allow access to the unit 1 Power on the M200 power supply by toggling the on off switch on the left side of the unit to the ON I position Note Do not power off the M200 power supply when updating software 2 The Swagelok screen Fig 11 will appear 3 Enter the security or programmer password if one has been set 4 The Main Menu will appear ONLA Fig 11 Swagelok Screen Note The MFC requires 5 minutes to warm up to ensure accurate gas flow control if the M200 power supply is not at operating temperature Owad Using the Touch Screen The touch scree
25. 2 2 0 in 5 Wall thickness Weld Wall Side 1 use socket wall thickness for 0 109 in Weld Setup socket weld Joint field Wall Side 2 0 109 in For future calculations Wall use larger of side 1 and side 2 0 109 in 6 Head weld head model Weld 40H Weld Setup Setup field 7 Electrode part number Weld see weld head user s manual SWS C 094 2 365 Weld Setup Setup field 8 Arc Gap for socket welds 0 070 in is suggested Weld see weld head user s manual for other weld 0 060 in Weld Setup styles Setup field 9 Arc Gauge Weld see weld head user s manual 0 00 in Weld Setup Setup field 10 Shield Gas Weld Argon Purge Setup ID Gas Gas Type field Argon 11 PrePurge Time Continuous purge suggested for micro weld Weld heads minimum 20 second purge for all Purge Setup other heads 45 s Normal Purge PostPurge Time 20 seconds suggested purge time more than field 20 seconds for high average amp welds 45 s 12 Shield Flow Weld see Table 25 page 80 50 std ft3 h Purge Setup Normal Purge field 13 ID Flow Weld see Table 26 page 81 170 std ft3 h Purge Setup ID Pressure Normal Purge see Table 26 page 81 0 7 in water field Owad Table 23 Fractional Step Program Parameter Guideline Worksheet Example Based on 2 0 in x 0 109 in Entry Step Parameter Tube Tube 316LV Screen 14 For future calculations High Amp curre
26. 2 e e S 2 B da ooo on 3 3 ol S 3 2 oo amp 5 52 a 3 o o S2 da 3 3 ol amp 3 gt 3 2 PISIS IZI a 8 gt s 905 2 B 9 3 5 s s amp o v 8 gt gt 2 3 3 3 0 X 9 3 Qa SUO SUBWIC IM N s ull pin 21NDEI0 q JAM 18497 e UlS pe ri PIPM HdH9 pue HIVE s u S EgE 3 921 lt co Ww Q o Wu O W gt W l W l o O 92 Table 34 Series 5H Weld Head Single Level Weld Procedure Guidelines Fractional Dimensions M200 Power Supply User s Manual y e4 pis Mo Cl 1 to 4 4to 7 5to 10 5to 10 5to 10 U el PIS MO 4 PIA US 12 12 12 12 12 V sdwy Bei Av 8 6 17 0 19 0 19 1 32 0 p d ioloti 99 77 50 37 37 s Bind1sod 30 30 30 30 30 s adojsumog 10 14 14 s OWL PI NA 10 13 20 27 27 s aBundaig 10 10 10 10 10 s SWIL Aejag 10 0y4 0 3 0 3 0 3 0 3 0 5 y guany Aejag 10404 20 20 40 20 32 UPIM sdwy uBiH 17 22 31 28 35 puoo s Jad s s nd 97ey sInd 25 10 10 10 10 v sdwy mo 10 0 10 0 10 0 18 0 v sdwy uBIH 21 5 5 6 38 5 38 5 42 5 58 8 UILU Ul p ds jaaesL ul eBney ay ul dey oly Ul NEM ul za 0 250 0 035 0 030 0 777 7 0 0 375 0 035 0 035 0 845 7 0 0 500 0 035
27. 5 0 889 A 30 High Amps for Level 4 High Amps eye 3 Step 29 FL evel Step 28 Weld Levels 4 _ 88 9 5 0 83 9 A 31 Delay Current High Amps eye 1 Step 16 x Width step 15 Weld Low Amps step 17 x 1 Width 98 9 x 0 45 43 0 General 68 2 A Start field x x 1 x 1 0 45 Owad Table 24 Metric Step Program Parameter Guideline Worksheet Example Based on 54 0 mm x 2 6 mm Entry Step Parameter Tube Tube 316LV Screen 32 For Wall lt 2 1 mm Weld Rotor Delay Time Wall step 5 x 1 6 General x 40 Finish field For Wall gt 2 1 mm Rotor Delay Time Overlap step 24 x Average speed rom step 24 High Amps Speed step 27 6 5 x 0 284 0 32 58 s x Wall gt 2 1 mm 33 Downslope Timeratai step 24 constant Weld Constant OD lt 12 7 mm 1 25 General Finish field 12 7 lt OD lt 25 4 mm 2 5 25 4 mm lt OD 15 If Downslope lt 10 Pulse Rate step 26 then Downslope 10 Pulse Rate forces a minimum of 10 pulses for Downslope 217 7 15 OD gt 25 4 mm 125 s 10 2 5 14 5 gt 5 This step in conjunction with rounding the Weld Time to the nearest 0 5 second prevents consecutive periods of low amperage output during the transition from one level to the next This would be observed as skipping between weld levels Note from Fig 56 page 52 each level begins with the Low Amps p
28. 7 Weld Time s 5 0 5 0 Ramp Time s 0 0 0 0 Pulse Rate Hz 4 0 4 0 High Amps Width 28 0 28 0 High Amps Speed rpm 3 5 3 5 Low Amps Speed rom 3 5 3 5 Average Amps A 35 7 34 7 33 7 32 7 During a typical weld the M200 power supply pulses between High Amps and Low Amps In this case the current pulses between the high and the low levels four times per second The current is at the high level 28 of the time and at the low level 72 of the time lt Weld Time gt lt Downslope lt High Current A High Amp Amps gt lt Low Current i Width Amps 70 Width High Amp 60 Current _ i 50 Low Amp Current 40 20 10 Start Blast Pre Tacks Rotor Purge Purge Delay 5s a 5s 5s 5s gt Optional Optional Time s Fig 56 Multilevel Weld Current Waveform Owad Post Purge Blast Purge Optional Weld Parameter Changes High Amps High Amps Width and Rotor Speed affect the depth of penetration of the weld The control of these parameters allows fine tuning of the weld penetration level Creating a Weld Procedure Guideline A Weld Procedure Guideline is the initial set of weld parameters used to program the M200 power supply for a specific weld job The M200 power supply Auto Create feature is recommended to gen
29. Date Range Dimensional Units Flow Units Pressure Units and Date Format and press Export c Select a folder or file from the Internal Memory Fig 39 Weld Log Export Dialog Box opy USB Flash Drive pane and press Copy The folder or file will be copied to the USB flash drive folder on the right Create Allows you to create an empty folder in the USB Folder Flash Drive Weld Log folders Folders you create must go into a previously existing folder To create an empty folder highlight the USB Flash Drive folder you want to put the new folder in Press the Weld Log Name field below the USB Flash Drive pane Type in the name of the new folder and press Create Folder The new folder will appear in the USB Flash Drive Weld Log folders in both panes Folder contents can be deleted from internal memory and the USB flash drive To delete a folder and its contents highlight the folder and press Delete A dialog box will ask you to confirm the delete Press Yes to delete the folder Delete Owad 42 M200 Power Supply User s Manual Setup Screens The Setup screen Fig 40 is divided into upper and lower sections The Upper Section Tabs apply primarily to system parameters passwords language software etc The Lower Section Tabs apply primarily to hardware parameters touch screen printer flow control etc Calibrate Touchscreen Fig 40 Setup Screen Owad M200 Power Supply User s Manual 43
30. Joe Welder Weld Information Programmer box 2 Joint Type Example Tube to tube Tube Tube Weld Side 1 Tube to auto tube weld Tube ATW Side1 Tube Weld Setup Side 2 Tube to auto socket weld Tube Socket Side2 Tube Joint field 3 Material Side 1 316LV Weld Side 1 Side 2 Side 2 316LV Weld Setup Joint field 4 Work piece diameter Weld Diameter Side 1 Side 1 12 0 mm Weld Setup Diameter Side 2 Side2 12 0 mm Joint field For future calculations OD use larger of Side 1 and Side 2 12 0 mm 5 Wall thickness Weld Wall Side 1 use socket wall thickness for 1 0 mm Weld Setup socket weld Joint field Wall Side 2 1 0 mm For future calculations Wall use larger of side 1 and side 2 1 0 mm 6 Head weld head model Weld 5H Weld Setup Setup field 7 Electrode part number Weld see weld head user s manual CWS C 040 555 P Weld Setup Setup field 8 Arc Gap for socket welds 0 25 mm is suggested Weld see weld head user s manual for other weld 0 76 mm Weld Setup styles Setup field 9 Arc Gauge Weld see weld head user s manual 22 56 mm Weld Setup Setup field 10 Shield Gas Weld Argon Purge Setup ID Gas Gas Type field Argon 11 PrePurge Time Continuous purge suggested for micro weld Weld heads minimum 20 second purge Purge Setup for all other heads 20 s Normal Purge PostPurge Time 20 seconds suggested purge time more than field 20 seconds for high average amp welds 20 s 12 S
31. Normal Purge PostPurge Time 20 seconds suggested purge time more than field 20 seconds for high Average Amp welds 20 s 12 Shield Flow Weld see Table 25 page 80 20 std ft3 h Purge Setup Normal Purge field 13 ID Flow Weld see Table 26 page 81 15 std ft3 h Purge Setup ID Pressure Normal Purge see Table 26 page 81 1 3 in water field Owad Table 16 Fractional Butt Weld Procedure Guideline Worksheet Example Based on 1 2 in x 0 049 in Entry Step Parameter Tube Tube 316LV Screen 14 For future calculations High Amp current factors F4 F and F see Table 28 page 82 F 2400 F4 Fo F3 Fo 0 Fz 2 3 15 For future calculations Width 820 x Wall step 5 12 100 _ 820 x 0 049 12 100 320 X_ 12 100 _ _ 0 28 16 High Amps for Level 1 F4 step 14 x Wall step 5 F3 Weld Fz x Width step 15 1 _ Levels 1 x 2400 x 0 049 0 Xk 1 2 3 x 0 28 1 71 7 A 17 Low Amps for all levels High Amps Levei 1 Step 16 Weld F3 step 14 1 Levels 1 1 71 7 2 3 1 21 7 A 18 For future calculations do not add columns on screen at this time Number of levels for multiple level schedule Nievas typically 4 allowed range is 1 to 99 4 19 For future calculations Travel speed calculation Travel speed based on wall thickness Speedwai See Table 28 page 82 Speedway 6 in min Trav
32. S Government Printing Office P O Box 371954 Pittsburgh PA 15250 LE SOUDAGE A L ARC peut tre dangereux e Lisez et respectez cette tiquette ainsi que le manuel utilisateur e Ne pas utiliser dans un environment combustible ou au dessus d une surface combustible e Ne touchez pas les parties lectriques sous tension e L lectrode et le rotor sont sous tension pendant le soudage Fig 2 M200 Power Supply Warning Label Owad Referenced Documents 1 AWS F4 1 Recommended Safe Practices for the Preparation for Welding and Cutting of Containers and Piping American Welding Society 550 N W LeJeune Rd Miami FL 33126 www aws org ANSI Z49 1 Safety in Welding Cutting and Allied Processes American Welding Society 550 N W LeJeune Rd Miami FL 33126 www aws org CGA Publication P 1 Safe Handling of Compressed Gases in Cylinders Compressed Gas Association 4221 Walney Road 5th Floor Chantilly VA 20151 2923 www cganet com OSHA 29CFR 1910 Subpart Q Welding Cutting and Brazing Acquire from U S Government Printing Office Superintendent of Documents P O Box 371954 Pittsburgh PA 15250 www osha gov OSHA 29CFR 1926 Subpart J Welding and Cutting Acquire from U S Government Printing Office Superintendent of Documents P O Box 371954 Pittsburgh PA 15250 www osha gov Owad 12 M200 Power Supply User s Manual Owad Installation an
33. TAEKE TAN to the Process tab a Start Tacks button will appear under the Weld Note Tacks should be offset at least 10 Head Installed graphic Press this from the location of the arc start button to complete the tacks The Start button will change to of the levels to prevent arc wander Start Levels Press this button to at arc start The weld head returns begin the remainder of the weld to the true home position after the procedure tacking section of a weld procedure To add tacks press the top of a column to highlight it then press the Add button on the right side of the window A new column containing a copy of the selected column s data will be added after the selected column Repeat for additional tacks To delete tacks press the top of the column or columns to select them then press the Delete button on the right side of the window Use the onscreen keypad to enter or change a parameter See page 65 for more information about weld procedures using tacks Summary Fig 31 This tab provides information on the M200 power supply s Disable Operational and Error conditions when a weld procedure is loaded The View button allows a look at the last completed weld in the Weld Log The Clear Errors button remove all nonactive errors from the Summary View but not the Weld Log Choose the Active Only check box to limit the Summary View to the active weld Weld Log notes will print with the Weld Log
34. after the ramp see Fig 60 m Ramping from higher current to lower will input more heat into the level by gradually decreasing the current until the Low Amps for the level has been attained E Ramping from lower current to higher will slow the heat input into the level by gradually increasing the current until the High Amps for the level has been attained Ramp time may be from 0 1 seconds up to taking the entire Weld Time for the level Level 1 Ramp _ High Amp le Current eve gt Ramp Time JU H Level 3 N N h Level 1 KN Low Amp j a m E Current F i Ramp lt Time Level 4 Average Current A A A AL TL 7 Rotor Level 1 Level 2 Level 3 Level 4 Start Delay Weld lt Weld gt lt Weld Weld Time Time Time Time Time Fig 60 Ramp Between Levels Owad Ramping Up in Level 1 Ramping in the first level may be used to slow the startup of the weld to allow controlled heat application which is required for some materials Two methods for gradually adding heat to the material in Level 1 are postponed penetration while welding and added rotor delay time before welding Postponed Penetration While Welding This method adds heat while the rotor advances This weld most likely will
35. and options user fields limits tolerances etc The Lower Section Tabs are fields that make up the basic parameters of a weld purge settings levels tacks and general settings Upper section tabs Weld procedure name Lower section tabs OD shield gas visual gauge Status indicator Time remaining counter Owad Procedure User Manual Example w tacks Description Creation Date 08 12 2009 0 500 049 316LV 04 03 SH Note Changing the weld procedure parameters will add modified to the weld procedure name on the screen and cause the name to turn red in color The weld procedure must be saved to make the changes a permanent part of the procedure See Table 9 page 36 Weld procedure parameters Fig 21 Weld Screens Weld count Electrode position Used to change electrode Test the active procedure no current applied Jogs electrode clockwise Jogs electrode counterclockwise Turns on OD shield gas Weld head installed Table 6 Weld Upper Section Tabs Information Fig 21 Displays a summary of weld setup parameters as well as ID purge and OD shield gas types for the active weld procedure The eight most recent entries for the Programmer field will display in a drop down box The Information tab also displays the Electrode Change button which positions the rotor for electrode replacement and prevents the M200 power supply from welding See the
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37. calculations Weld Time total for single pass Seconds per revolution spr 60 High Low Amps speed 60 60 4 38 13 7 spr Additional Weld Time to overlap Level 1 Overlap Wall step 5J x 2 Total travel speed step 19 60 x 2 60 1 0 x 2 165 60 0 73 s Timeyotal Spr Overlap 13 7 0 73 14 4 s 21 Weld Time for all levels Timer ai step 20 NLeveis step 18 Weld Levels 1 Note Round up to the nearest 0 5 second or whole number whichever is smaller 14 4 4 4 0 Note Weld Time number must always end in 5 or 0 Owad Table 17 Metric Butt Weld Procedure Guideline Worksheet Example Based on 12 0 x 1 0 mm Entry Step Parameter Tube Tube 316LV Screen 22 Pulse Rate for all levels Total travel speed step 19 Weld 80 x Wall step 5 Levels 1 30 x 165 30 x 1 0 6 Note Round up to nearest whole number Note If Weld Time ends in If Weld Time ends in 5 and Pulse Rate is odd number 5 Pulse Rate must be Pulse Rate for all levels Pulse Rate 1 forces Pulse Rate even to prevent a skip x Weld Time to be between levels a whole number 41 Weld Time ends in 0 23 High Amps Width 12 8 X Wall step 5 12 Weld 12 8 x 12 12 8 x 1 0 12 25 Levels 1 Note Round up to nearest whole number 24 For future calculations Work piece circumference OD step 4 X m x 3 1416 1
38. clamp tube thickness used for current calculations must be increased to in block first then push ATW firmly compensate for the additional heat needed In these cases it is against tube and then clamp common to add 40 of the ATW cuff thickness to the fitting wall thickness Fig 57 The M200 power supply Auto Create feature calculates this automatically The worksheets include this step Arc gap 0 020 in 0 51 mm ATW cuff Fitting wall W thickness thickness I Fig 57 Automatic Tube Weld Joint Table 18 Automatic Tube Weld ATW Guideline Worksheet Table 16 Fractional or Example Based on Table 17 1 2 in x 0 049 in Fractional Metric or 12 0 x 1 0 mm Metric Entry Step Parameter TB TB 316LV Screen For future calculations Fractional tubing ATW cuff thickness ATWeurt 0 025 in ATWe ust see part drawin Metric tubing cd 9 ATW ur 0 6 mm 4 For future calculations Fractional tubing ATW adjusted OD ATWcur X 2 OD 0 025 x 2 0 5 0 55 in x 2 Metric tubing 0 6 x 2 12 0 13 2 mm 5 For future calculations Fractional tubing ATW cuff thickness ATWourt 0 025 in ATWeurtt see Fig 57 0 025 x 0 40 0 049 0 059 in ATW adjusted wall thickness ATWoy X 0 40 Wall Metric tubing x 0 40 ATWcuff 0 6 mm 0 6 x 0 40 1 0 1 24 mm Owad Socket Welds All socket welds use a single pass technique The arc gap and Note To fixture push socke
39. for error voltage or current from 115 V and 180 V minimum the wall outlet for 230 V Reduce the extension cord or weld head cable length Or increase the gage of the extension cord D Power The M200 power supply is The M200 power supply source high exceeding the temperature will reset automatically temp rating when it has cooled to within limits D Rotor jam The rotor stopped turning Remove obstruction from during the weld procedure weld head and press Next Home on the Main screen D Update user fields A required field has not been completed Complete all required fields on User Fields 1 and User Fields 2 tabs on the Weld screen D USB flash drive required When Setup gt Weld Log Save to USB flash drive is active a USB flash drive must be attached Attach a USB flash drive D Weld engine DLL not found The M200 power supply cannot find the operating system or the software is not loading or has not been updated properly Call for service D Weld head not found A weld head is not attached to the power supply Attach the correct weld head Owad 104 M200 Power Supply User s Manual Operational Operational conditions should be noted but the weld may proceed with discretion A W on the status line indicates an operational condition Fig 83 Operational conditions are recorded in the Weld Log if the condition is not corrected before starting
40. head and shielding the weld zone Failure to provide an alternative external means of shielding can result in weld head and fixture damage Owad 46 M200 Power Supply User s Manual Passwords The M200 power supply may be programmed with up to three different password levels to restrict access to different features One password is available for each level of security Privileges will be granted based on the password entered at login Setting programmer and security passwords is optional If neither programmer nor security password is set all users will have programmer rights All passwords can be set reset or removed from their own level or higher When all three levels of passwords are set the following levels of security are enabled Security password The security password gives access to all features and functions of the M200 power supply except E Weld parameters cannot be changed outside of the predetermined limits of the weld procedure E Software cannot be updated m Access to weld procedures is limited to internal memory E The programmer and owner passwords cannot be reset If a security password is set but not a programmer password the security password will allow programmer privileges Programmer password The programmer password gives access to all features and functions of the M200 power supply except E Software cannot be updated E The owner password cannot be reset If a programmer password
41. is most commonly used when welding thick walled or larger diameter tubing to obtain more control over the current or decrease rotor speed In a Step Program the rotor speed is different between the High and Low Amps periods Decreasing rotor speed increases heat input increasing rotor speed decreases heat input The rotor speed may vary from zero to the maximum rotor speed of the weld head being used Calculations for Weld Time change significantly for a Step Program Use the following Step Program Parameter Guideline Worksheets to generate the necessary M200 power supply plug in values m The example fractional tube size is 2 0 in OD and 0 109 in wall thickness E The example metric tube size is 54 0 mm OD and 2 6 mm wall thickness Owad Table 23 Fractional Step Program Parameter Guideline Worksheet Example Based on 2 0 in x 0 109 in Entry Step Parameter Tube Tube 316LV Screen 1 Programmer Joe Welder Weld Information Programmer box 2 Joint Type Example Tube to tube Tube Tube Weld Side 1 Tube to auto tube weld Tube ATW Side1 Tube Weld Setup Side 2 Tube to auto socket weld Tube Socket Side2 Tube Joint field 3 Material Side 1 316LV Weld Side 1 Side 2 Side 2 316LV Weld Setup Joint field 4 Work piece diameter Weld Diameter Side 1 Side1 2 0 in Weld Setup Diameter Side 2 Side2 20 in Joint field For future calculations OD use larger of Side 1 and Side
42. is set but not a security password either the owner password or the programmer password may be entered to log in to the unit or to use the Lock Out feature Owner password The owner password gives access to all features and functions of the M200 power supply including software updates If any passwords in addition to the owner password are set the M200 power supply will display a user prompt for a password when it is powered on Enter and confirm the password and press Privilege Level to view the access granted Press Enter to use the password and log in to the M200 power supply Fig 48 If you do not set security and programmer passwords m The M200 power supply will not prompt for a password when it is powered on E Weld procedures can be updated without a password m All users will have programmer level rights m The Lock Out feature will not function Owad Fig 48 Login Screen Remote Pendant The pendant provides remote operation of the primary power supply controls Start Stop Home and Shield Gas It also displays power supply status indicators On Ready Weld and Error The pendant is attached to the power supply via a cable and he connector labeled Remote on the right side of the power supply Fig 49 Fig 49 Remote Pendant Owad Maintenance The M200 power supply has no internal serviceable parts and should not be disassembled The only field replaceable AN WARNING parts are the printer p
43. move when Electrode Change is pressed The rotor is a potential pinch point Note Electrode Change disables most other M200 power supply buttons teed fern AxGe m Ae Gam in Fig 22 Weld Setup Tab Fig 28 USser Fields 1 Tab Fig 24 User Fields 2 Tab Owad 30 M200 Power Supply User s Manual Table 6 Weld Upper Section Tabs Limits Tolerances Fig 25 Owad Limits Limits are used to restrict the amount of adjustment a user with a security password can make without entering a programmer or owner password Limits from O to 100 are set at the programmer and owner levels Current and Purge Limits are represented as a percentage of the weld procedure values Example if the Average Amps for Level 1 is 100 A and the current limit is 50 the M200 power supply will not allow an adjustment of Average Amps above 150 A or below 50 A The factory default for limits is 100 Average Amps can be adjusted within the limits on the lower section Levels tab using the up and down buttons See Adjusting Average Amps page 31 for more information Purge parameters can be adjusted within the limits on the Purge Setup tab Tolerances The Weld Log records out of range values for Average Amps Average Speed and OD Shield Flow in the Weld Log based on tolerances set Tolerances are adjustable at the programmer and owner levels as a percentage of the base value E Current and speed tolerances are ad
44. slide the end of the paper between the paper guides and behind the metal lip Fig 52 as far as it will go After a few seconds the printer will detect the paper and automatically feed it through the printer 7 After the paper is loaded slide the spindle through the paper roll Press the ends of the spindle together and snap it into the support bracket Fig 53 To remove slack in the paper re roll the paper or press Paper Feed on the Main Menu Press Paper Feed to advance and straighten the paper 8 Slip the end of the paper through the paper slot in the printer cover Press Paper Cut Setup gt Printer tab to remove the excess paper Close the printer cover Clearing a Paper Jam To clear a paper jam open the printer cover and press the cutting head release lever to set the cutting head in the partially open position If the paper jam cannot be cleared the cutting head can be rotated up to 90 for additional clearance Fig 54 Clear the jam and press the cutting head down to close Reload the paper if necessary Owad Fig 52 Loading the Paper Roll Support bracket Spindle Paper roll TO Fig 53 Properly Loaded Paper Roll Cutting head I a mm Ph Ba Cutting head relea
45. typically require approximately 15 more purge pressure Pressures must be adjusted for ID encroachment of 0 to 10 of wall thickness at the bottom of the weld Restricter sizes are approximate purge rate and pressure are critical parameters Table 27 ID Purge Gas Flow Rate and Pressure Metric Dimensions Tube Wall ieee Pressures Restricter Size Thickness Flow Rate millimeters Size mm mm std L min of water mbar mm 3 0 8 0 5 130 to 230 12 4 to 22 4 1 5 6 1 0 3 0 71 to 86 7 0 to 8 5 3 10 1 0 5 0 38 to 64 3 7 to 6 2 3 12 1 0 7 0 25 to 38 2 5 to 3 7 6 20 1 5 10 13 to 28 1 2 to 2 7 6 25 1 5 20 13 to 18 1 2 to 2 5 6 38 1 5 43 13 to 18 1 2 to 1 7 6 50 1 5 80 13 to 18 1 0 to 1 7 10 75 1 5 190 5 to 13 0 5 to 1 2 12 100 2 0 340 5 to 13 0 5 to 1 0 20 Indicated purge rates are for minimum color line ATW welds and weld ring welds typically require approximately 15 more purge pressure Pressures must be adjusted for ID encroachment of 0 to 10 of wall thickness at the bottom of the weld Restricter sizes are approximate purge rate and pressure are critical parameters Note These tables are for use on butt welds only If weld head purge rates exceed Swagelok recommendations the weld bead may meander For best results use constant weld head purge between welding cycles Owad Table 28 Fractional High Amps Current Factors and Travel Speeds Outside Diameter i
46. with a lower voltage lower welding current and duty cycle must be used An output guide is provided below The values are approximate and must be adjusted downward if the fuse or circuit breaker trips off Other loads on the circuit and fuse circuit breaker characteristics will affect the available output Do not exceed these welding conditions 15 A Plug on 15 A Branch 20 A Plug on 20 A Branch 10 duty cycle 10 duty cycle 95 A 120 A 15 A Plug on 20 A Branch 30 A Plug on 30 A Branch 10 duty cycle 10 duty cycle 105A 140 A estimate Owad M200 Power Supply Cycle Times The duty cycle rating expressed as a percentage refers to the maximum weld time allowed during a given period of time The balance of the cycle is required for cooling The industry standard is a 10 minute duty cycle The weld and idle times for several 10 minute duty cycle ratings are shown in Table 41 Table 41 M200 Power Supply 10 Minute Cycle Times Duty Maximum Required Idle Cycle Weld Time Time 30 3 min 7 min 60 6 min 4 min 100 10 min 0 min Continually exceeding the duty cycle may activate the internal thermal protector that will disable the power supply and display a disable condition on the screen M200 Power Supply Dimensions Table 42 M200 Power Supply Dimensions and Weight Dimensions Height 13 5 in 84 3 cm Width 22 8 in 57 9 cm Depth 15 5 in 89 4 cm Use of Extension Cords w
47. 0 minute period that the M200 power supply can operate at a given average current and voltage output setting Gas tungsten arc welding Heat input High amps High amp speed High amps width Inches of water ID ID purge gas Jog Jog back Level factor Low amps Low amp speed Millimeters of water Misfire Multilevel Multipass Normal purge OD OD shield gas Orbital welding The heat conducted into the weld during the weld cycle Typically expressed in joules or kilojoules The maximum current level generated during the weld process Also called impulse current This is the rotor speed in revolutions per minute during the high impulse portion of the weld process The percentage of time during one cycle that the weld current is at the high amps level Fractional unit of pressure measurement 1 psi 27 72 inches of water Inside diameter The gas used within a tube or at the back of a weld joint to remove oxygen and prevent oxidation Also called backing gas The action to move the rotor clockwise to position the electrode The action to move the rotor counterclockwise to position the electrode A percentage of the Level 1 high amps used to calculate the high amps drop in subsequent levels The minimum current level generated during the weld process Also called maintenance current This is the rotor speed in revolutions per minute during the low amps portion of the weld
48. 2 0 x 3 1416 37 7 mm 25 High Amps Speed rpm for all levels Total travel speed step 19 Weld Circumference step 24 Levels 1 e 165 37 7 4 38 rpm 26 Low Amps Speed rpm for all levels Total travel speed step 19 Weld Circumference step 24 Levels 1 165 37 7 4 38 rpm 27 Add additional level columns now step 18 Weld Multiple level current factor Levels 4 Flevel High AMPS evel 1 step 16 x 0 2 NLevels step 18 X 0 2 _ 55 2 x 0 2 4 2 8 High Amps for Level 2 High Amps eye 1 Step 16 FLevel _ 55 2 2 8 524 A 28 High Amps for Level 3 High Ampsi val 2 step 27 Weld FL evei Step 27 Levels 4 _ 52 4 2 8 496 A 29 High Amps for Level 4 High Amps va Step 28 FL eve Step 27 Weld _ Levels 4 ee 49 6 28 468 A 30 Delay Current High Amps eye 1 Step 16 x Width step 15 Weld Low Amps step 17 x 1 Width General Start field x x H 52 9 x 0 25 16 0 x 1 0 25 26 3 A This step in conjunction with rounding the Weld Time to the nearest 0 5 second prevents consecutive periods of low amperage output during the transition from one level to the next This would be observed as skipping between weld levels Note from Fig 56 page 52 each level begins with the Low Amps period of the pulse cycle The Weld Time multiplied by the Pulse Rate Weld Time x Pulse Rate that is the number of seconds
49. 20 X Wall step 5 12 Weld 320 x 12 Levels 1 Note Round up to nearest whole number 320 x 0 049 12 28 24 For future calculations Work piece circumference OD step 4 X m x 3 1416 0 50 X 3 1416 1 571 in 25 High Amps Speed rpm for all levels Total travel speed step 19 Weld Circumference step 24 Levels 1 5 5 1 571 3 5 rpm 26 Low Amps Speed rpm for all levels Total travel speed step 19 Weld Circumference step 24 Levels 1 gt 5 5 1 571 3 5 rpm 27 Add additional level columns now step 18 Weld Multiple level current factor Levels 4 Frevel High Amps evei 1 Step 16 x 0 2 Nieveis Step 18 _ x02 _ 71 7 x 0 2 4 3 6 High Amps for Level 2 High Amps eye 1 Step 16 FLevel _ 71 7 3 6 68 1 A 28 High Amps for Level 3 High Ampsi eye 2 Step 27 Weld Freve Step 27 __ Levels 4 ee 68 1 36 645 A 29 High Amps for Level 4 High Amps vas Step 28 FL eve Step 27 Weld Levels 4 645 36 60 9 A 30 Delay Current High Amps eye Step 16 x Width step 15 Weld Low Amps step 17 x 1 Width General x x 1 71 7 X 0 28 21 7 Start field x 1 0 28 356 A This step in conjunction with rounding the Weld Time to the nearest 0 5 second prevents consecutive periods of low amperage output during the transition from one level to the next This would be observed as skipping between weld
50. 45 The condition must be acknowledged by pressing OK in the dialog box before the next weld can be made Weld errors are recorded in the Weld Log and will display in red Table 46 Weld Error Conditions Weld Error Message Description Remedy AC power There was an interruption See M200 Power Supply failure in the alternating current Specifications page 100 to the M200 power supply Arc failed The arc failed during the Check the arc gap setting weld Current The weld did not perform Review current limits tolerance within the specified current tolerance Tolerance is set on the Weld screen Limits Tolerances tab DC power There was an interruption Call for service failure to the internal power source of the M200 power supply Electrode The electrode touched See Table 51 for remedies touch the weld puddle or work before performing the piece during the weld next weld MD busy bit The motor driver inside The M200 power the M200 power supply controlling weld head movement did not accept a command from the weld procedure supply will reset itself automatically MD command error The motor driver inside the M200 power supply controlling weld head movement did not accept a command from the weld procedure Powering off the M200 power supply then powering on again should correct this condition MFC no flow _ No OD shield gas flow Check gas connection is present The weld is and p
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52. HONE Fan housing Nonslip feet Fig 3 M200 Power Supply Left Side Owad Remote pendant connection Y 1 A Dy o Electrode connection red Work connection Printer housing green ID shield gas connections OD shield gas connections d A INPUT OUTPUT Z Auxiliary output connections Weld head connection Fig 4 M200 Power Supply Right Side Owad Unpacking the M200 Power Supply Table 1 Shipping Case Contents Description M200 power supply Ordering Number SWS M200 XX Y XX denotes power cord Qty plug type Y denotes user s manual language Power cord SWS M200 CORD XX 1 XX denotes power cord plug type 1 4 in male SS QC4 S 400 1 Quick Connect stem M200 Power Supply MS 13 212 Y 1 User s Manual Y denotes user s manual language other than English Warranty Information Form Remove the contents of the shipping case Table 1 1 Use the handle on the to
53. ICULAR PURPOSE LIMIT OF LIABILITY In the event that USER should be enjoined in any suit or proceeding arising from a claim for infringement of intellectual property rights from using the Product except any suit or proceeding based upon a design or modification incorporated in such Product at request of USER Swagelok at its option shall promptly either a secure termination of the injunction and procure for USER the right to use such Product without any obligation or liability or b replace such Product with non infringing materials or modify same to become non infringing or c remove said Product at Swagelok expense and refund the purchase price of the infringing Product to USER THIS SHALL BE USER S EXCLUSIVE REMEDY AGAINST SWAGELOK WITH RESPECT TO PATENT COPYRIGHT OR MASK WORK REGISTRATION INFRINGEMENT The sale of Product does not convey or transfer copyright under any proprietary or patent rights of any manufacturer IN NO EVENT REGARDLESS OF CAUSE SHALL SWAGELOK OR ITS AUTHORIZED DISTRIBUTORS ASSUME RESPONSIBILITY OR BE LIABLE FOR a PENALTIES OR PENALTY CLAUSES OF ANY DESCRIPTION b TO THE EXTENT PERMITTED BY LAW INDEMNIFICATION OF USER OR OTHERS FOR COSTS DAMAGES OR EXPENSES EACH ARISING OUT OF OR RELATED TO THE PRODUCT OR SERVICES OF THIS ORDER c CERTIFICATION UNLESS OTHERWISE SPECIFICALLY PROVIDED HERE WITH OR d INDIRECT OR CONSEQUENTIAL DAMAGES UNDER ANY CIRCUMSTANCE INCLUDING ANY LOST PROFITS BUSINESS I
54. Manual Create allows programmers to write their own weld procedures using the Weld screens When you select Manual Create a dialog box will open asking you to confirm overwriting the active weld procedure Press Yes to overwrite the active weld procedure The Weld screen will open with all data cleared so that you can enter parameters for a new weld procedure See Weld Parameter Development page 52 for more information and worksheets for use in developing a weld procedure The Manual Create screen may also be used to clear the active weld procedure Fig 34 Program Screen J Well riesd Typa C Fig 36 Manual Create Screen M200 Pc Weld Log Screens A Weld Log record is saved to internal memory for every completed weld This feature cannot be disabled but Weld Log records can be deleted after they are saved to internal memory The Weld Log records the following data Description Weld procedure with specific settings Inputs Weld level information Outputs Weld results Performance Operational conditions errors notes Confirmation The Weld Log screen has two tabs m View Print Serial E Export Copy Delete The Weld Log screen manages Weld Log records which are saved to the Internal Memory Weld Log folder Subfolders cannot be created in the internal memory Weld Log folder Weld Log files can be copied to an external USB flash drive Subfolders can be created on the USB flas
55. NTERRUPTION OR OTHER DAMAGES IN NO EVENT SHALL SWAGELOK LIABILITY EXCEED THE PURCHASE PRICE FOR THE PRODUCT REGARDLESS OF THE FORM OF ACTION WHETHER IN CONTRACT OR TORT INCLUDING NEGLIGENCE OR OTHER LEGAL BASIS EXPORT COMPLIANCE USER shall comply with all applicable export laws at the point that the Product its Embedded System or components thereof are transferred to USER s possession USER agrees to indemnify and hold harmless Swagelok for any losses sustained as a result of USER s failure to comply with U S or foreign import and export laws rules or regulations in connection with the Product Embedded System or components thereof MISCELLANEOUS The original English language version of this Agreement shall govern Any translation is provided as a courtesy only The United Nations Convention for the International Sale of Goods is specifically excluded Rev 10 07 M200 Power Supply User s Manual 123 OwA Warranty Information Swagelok products are backed by The Swagelok Limited Lifetime Warranty For a copy visit swagelok com or contact your authorized Swagelok representative Swagelok TM Swagelok Company Microsoft Excel Access TM Microsoft Corporation 2007 2010 Swagelok Company Printed in U S A OM May 2010 R2 MS 13 212
56. Ramp Time Metric tubing a re 40 30 7 0 s For future calculations Percent of Level 1 to overlap for proper ID bead width range is 0 to 100 RamMPoverlap 40 RamPoverlap decimal RamPoverlap 100 __ 100 40 100 0 40 21b Weld Time for remaining levels Ramp overlap Weld Weld Time eye 2 4 Seconds per revolution spr Levels 4 Weld Procedure Guideline Worksheet Fractional tubing step 20 17 1 8 0 x 1 0 40 Weld time eve 1 step 21 4 i _ i D x n RamPoverlap decimail gt Nievels Weld Procedure Guideline Worksheet step 18 1 Metric tubing x 1 1 13 7 7 0 x 1 0 40 Note Round up to nearest 0 5 second or whole number 4 1 32 s whichever is smaller 22 If Pulse Rate is an odd number and Weld Time is rounded to Weld nearest 0 5 second Levels 4 Pulse Rate for Level 1 Pulse Rate eye 1 Pulse Rate Weld Procedure Guideline Weld Time for Level 1 is Worksheet step 22 1 ___ rounded to a whole number forces Pulse Rate x Weld Time to be a whole number 1 If Pulse Rate is an odd number and Weld Time eye 2 4 iS rounded to nearest 0 5 second Pulse Rate for remaining levels Pulse Rate eyels 2 to 4 Pulse Rate Weld Procedure Guideline Worksheet step 22 1 Pulse rate from previous forces Pulse Rate x Weld Time to be a whole number cnoo Ravan 1 30 Delay Current 5 A or greater 5 A Weld General Start field 31 Rot
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58. Speedwai Speedop 2 er 58 51 2 54 5 mm min 20 For future calculations Work piece circumference OD step 4 X m x 3 1416 54 0 x 3 1416 169 6 mm 21 High Amps Speed rpm for all levels Total travel speed step 19 Weld Circumference step 20 Levels 1 gt 54 5 169 6 0 32 rpm 22 Low Amps Speed rpm for all levels Total travel speed step 19 Weld Circumference step 20 Levels 1 k 54 5 169 6 0 32 rpm 23 Percentage of standard High and Low Amps Speed used for Weld Step program Range is 0 to 100 Both cannot be 0 Levels 1 High Amps Low Amps High Amps Speed High Amps x High Amps Speed step 21 100 __ _ _ x 100 Low Amps Speed Low Amps x Low Amps Speed step 22 100 x _ 100 Note Round speed to 2 decimal places 75 100 75 x 0 32 100 0 24 rpm 100 x 0 32 100 0 32 rpm Owad Table 24 Metric Step Program Parameter Guideline Worksheet Example Based on 54 0 mm x 2 6 mm Entry Step Parameter Tube Tube 316LV Screen 24 For future calculations Weld Time total for single pass Average speed High Amp Speed step 23 x Width step 15 0 24 x 0 45 Low Amps Speed step 23 x 1 Width 0 32 x 1 0 45 rpm 0 284 Seconds per revolution spr 60 Average speed 60 60 0 284 211 3 spr Average Speed Average speed rpm x Circumferen
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60. and b access and use desktop functions other than through or in support of the Embedded System USER may not modify reverse engineer decompile create derivative works or attempt to derive the composition or underlying information structure or ideas of the Embedded System technology The software is not fault tolerant and is not designed manufactured or intended for any use requiring fail safe performance in which the failure of the licensed software could lead to death serious injury severe physical or environmental damage SOFTWARE MODIFICATION RECOVERY AND UPDATES Only Swagelok provided recovery or update software may be used on the Embedded System USER agrees that any license terms provided with update or recovery software along with this License Agreement shall govern USER s use of the software USER may use one copy of the update or recovery image for all USER purchased Product USER must keep the update or recovery software and shall not provide market or otherwise distribute the updated recovery software which is a separate item from the Embedded System USER shall either destroy or return to Swagelok any superseded update or recovery software provided to USER on external media WARRANTY SWAGELOK HARDWARE The standard Swagelok Limited Lifetime Warranty incorporated herein by reference applies to the Product hardware SOFTWARE AND FIRMWARE Unless otherwise provided in a separate Swagelok or third party license agre
61. aper and optional fan filter Contact your authorized Swagelok representative for any other service needs Do not attempt to service the M200 power supply Electrical shock can result Owad Printer Changing Paper The printer uses thermal paper rolls available from your authorized Swagelok representative Standard thermal paper rolls available at most office supply stores may also be used To change the paper roll 1 Press the latches and pull open the printer cover Fig 50 2 If there is still paper in the printer press the cutting head release lever to open the cutting head Remove the remaining paper Press the cutting head down to close 3 Press the ends of the spindle and lift it out of the support bracket Fig 51 Discard the used paper roll 4 Open a new paper roll and trim the edge so it is straight A torn or uneven edge will make loading the paper more difficult Printer cover Support Cutting head release lever Fig 51 Removing the Used Paper Roll A CAUTION The cutting edge is sharp Do not touch it or injury may result Owad 5 Place the paper roll on top of the power supply with the paper coming off the top of the roll Allow some slack in the paper Note The paper must be fed through the printer before the spindle is placed in the support bracket 6 Gently
62. arc intensity and consequently heat input resulting in no ID penetration High Amps Width Too Short Fig 72 High Amps Width setting changed from 28 to 24 This lowers the Average Amps from 35 7 to 33 7 A High Amps Current Too Low Fig 73 High Amps setting changed from 71 7 to 55 4 A This lowers the Average Amps from 35 7 to 34 1 A Low Amps Current Too Low Fig 74 Low Amps setting changed from 21 7 to 14 8 A This lowers the Average Amps from 35 7 to 30 7 A Rotor Speed Too High Fig 75 Rotor speed changed from 3 5 to 4 rpm This lowers the average heat input per unit of time Although the Average Amps for the weld is unchanged Weld Time is decreased by 12 5 and the heat input is decreased by 12 5 Fig 7O Reference Weld Cross Section 80 of A covered by B Fig 71 Reference Weld Puddle Overlap u Fig 72 High Amps Width Too Short Fig 73 High Amps Current Too Low Z Fig 74 Low Amps Current Too Low F l Fig 75 Rotor Speed Too High Owad Increased ID Convexity and Weld Bead Width Increased ID convexity and weld bead width can be caused by several improper weld procedure settings All of the examples shown below result from increased arc intensity and consequently heat input resulting in increased ID convexity and weld bead width High Amps Width Too Long Fig 76 High Amps Width setting changed from 28 to 33 Th
63. area and or use exhaust at the arc to remove welding fumes and gases mg When welding materials that produce toxic fumes such as galvanized steel lead cadmium plated steel or other coated metals unless the coating is removed from the weld area or any other welding material keep exposure below threshold limit values TLV permissible exposure limits PEL or other applicable health and safety limitation If necessary wear a respirator Read and understand the Material Safety Data Sheets MSDS and follow the manufacturer s instructions for metals consumables coatings cleaners degreasers or any other substance that may be present during the weld process E Do not work in a confined space unless it is well ventilated or you are wearing an air supplied respirator Always have a trained watch person nearby Welding fumes and gases can displace air and lower the oxygen level causing injury or death Be sure the breathing air is safe E Do not weld in locations near degreasing cleaning or spraying operations The heat and rays of the arc can react with vapors to form highly toxic and irritating gases E The ultraviolet light emitted by the welding arc acts on the oxygen in the surrounding atmosphere to produce ozone Test results based upon present sampling methods indicate the average concentration of ozone generated in GTAW process does not constitute a hazard under conditions of good ventilation and welding practice
64. as to flow continuously through the weld head To set the shield gas use the Single Level Weld Procedure Guidelines Worksheets starting on page 89 and select the OD shield gas visual gauge on the touch screen Use the keypad in the popup box to set Shield Flow and Purge Tolerance Starts the weld process Press to return the rotor to its true home position The rotor will move at maximum speed when traveling to the home position regardless of the programmed rotor speed Prints the last completed Weld Log record Aborts the weld and halts the rotor if pressed during the weld process Stop also turns off the OD shield gas flow Fig 65 Single Level Weld Process Buttons Note Electrode Change disables most other M200 power supply buttons OD shield gas visual gauge Fig 66 Single Level Shield Gas Flow Adjustment Popup Box Single Level Status Indicator Lights The status indicator lights Fig 67 monitor certain elements of M200 power supply operation The conditions monitored by some of the indicators are independent of the welding process Most of the indicators light during the welding process to show the control sequence executed by the M200 power supply The control sequence is affected by the values entered into the timing control group Weld Head indicates the weld head is connected PrePurge indicates the prepurge cycle is in progress Start indicates the power supply is in the arc start portion o
65. ce step 20 mm min 0 284 X 169 6 48 2 mm min Additional Weld Time to overlap Level 1 Overlap Wall step 5 x 2 Average speed mm min 60 x 2 60 2 6 x 2 48 2 60 6 5 s Timeyotail Spr Overlap 211 3 6 5 217 8 s 25 Weld Time for all levels Timer ai step 24 NLeveis step 18 Weld Levels 1 217 8 4 545 Note Round up to the nearest 0 5 second or whole number Note Weld Time number must whichever is smaller always end in 5 or 0 26 Pulse Rate for all levels Total travel speed step 19 Weld 30 x Wall step 5 Levels 1 30 x 54 5 30 x 2 6 1 Note Round up to nearest whole number Note If Weld Time ends in If Weld Time ends in 5 and Pulse Rate is an odd number 5 Pulse Rate must be Pulse Rate for all levels Pulse Rate 1 forces Pulse Rate even to prevent a skip x Weld Time to be between levels a whole number 15 1 1 2 27 High Amps Width 12 8 x Wall step 5 12 Weld 12 8 x 12 Levels 1 Note Round up to nearest whole number 12 8 x 2 6 12 45 28 Add additional level columns now step 18 Weld Multiple level current factor Levels 4 FLevei High Ampsi vel 1 Step 16 x 0 2 Nieves step 18 98 9 x 0 2 4 5 0 x 0 2 High Amps for Level 2 High Amps eye 1 step 16 Frevel _ z 98 9 5 0 93 9 A 29 High Amps for Level 3 High Ampsi eye 2 Step 28 Fi eve Step 28 Weld Levels 4 _ 93 9
66. condary gears Disassemble the weld head and check the home sensor for dirt See the motor and power block assembly drawing in the weld head user s manual Use compressed air to blow off debris Realign the rotor with the weld head opening Weld head 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 Brush spring is installed incorrectly in micro weld head Install the brush spring in the correct orientation Bent motor shaft Call for service Note See the Maintenance section of the weld head user s manual for more information about correcting problems with weld heads Owad Table 48 Weld Head Symptom Erratic rotor rotation speed control Cause Weld spatter on gears Remedy Inspect the rotor primary secondary and drive gears for damage Replace damag
67. ctrode The device that produces the electrical power for the welding process The M200 power supply is a constant current power supply The amount of time the OD shield gas is applied before the arc start The rate at which the output current level is changed between the high amps and low amps settings The rate is expressed as pulses per second A weld current that varies between a high level and a low level at a specific rate This technique helps to reduce the heat input to the weld The gas OD shield and ID purge used at the weld joint or within a tube to prevent oxidation A time entered into a weld level that allows a gradual amperage change from the previous level or Rotor Delay current The device that holds the electrode and rotates around the weld joint during orbital welding The current used to establish a weld puddle at the start of a weld before the rotor moves normally the average current the the first level of a weld procedure A time delay that is programmed into the weld procedure after arc start to allow the weld to penetrate the material The rate of rotor travel around the work piece measured in revolutions per minute Rotor speed is different for different weld heads See the weld head user s manual for technical data A welding technique in which a single average value of current is used during the weld process A welding technique in which the rotor moves one revolution during the wel
68. d Setup Owad Description The Swagelok Welding System M200 power supply provides precise control of weld current electrode travel speed and OD shield gas flow to produce consistent and repeatable weld results The unit features a touch screen display for easy navigation and data input To access menus and input weld data the operator presses the touch screen over the selection In the Single Level Mode users can enter data using simulated thumb wheels On off switch Power cord connection Four USB A version 1 1 ports on the side of the M200 power supply accept compatible USB hardware such as a USB mouse or keyboard with no additional software required A USB flash drive not supplied provides portable memory and can be used to transfer data to other M200 power supply units and or a PC A 1 GB USB flash drive is recommended There are additional ports for video SVGA output and a serial cable for direct PC connection 4 USB A 1 1 ports Touch screen NO USER SERVICEABLE COMPONENTS INSIDE REFER SERVICE TO QUALIFIED PERSONNEL We We K Speaker Video SVGA out connection Serial output connection MICROP
69. d assembly Weld Status Conditions See Troubleshooting page 102 for a list of disable operational and weld error conditions Owad A WARNING Do not touch the cable connectors during the weld If the cables have been damaged the potential for an electrical shock exists A CAUTION Use gloves or other protective devices if you must handle parts immediately after welding The parts can be extremely hot and may cause burns NOTICE Do not immerse the hot fixture block in water after welding Allow the fixture block to cool before performing the next weld Note Inspect the electrode after each weld Look for oxidation wear or weld material on the tip File Screens The File screens are used to load save print copy delete and view weld procedures The Main gt File screen has two tabs E Load Save Print Delete m File Copy When the File screen opens the M200 power supply searches the internal memory and a connected USB flash drive A large number of folders can slow the search process To reduce the time required delete unnecessary files or folders in the internal memory and on the USB flash drive Load Save Print Delete Tab The File screen opens in the Load Save Print Delete tab showing Folder and File Views in separate panes Fig 32 m The Folder View displays folders for the internal memory and a connected USB flash drive m The File View displays the weld procedures con
70. d by pressing Enter on the prompt screen before entering a new password The owner password can be reset but not removed See Passwords page 46 for more information Language Regional Time Fig 46 Dimensional units time and language are set from this tab These settings will affect most screens Software Displays the current software version and enables software updates To update software E Insert the USB flash drive containing the software update into a USB A port on the M200 power supply and press Update Software Enter the owner password and carefully follow the onscreen prompts E Do not power off the M200 power supply during the software update The update will take approximately 5 minutes m Restart the M200 power supply after the software update is complete for the updates to take effect Counters Statistics The read only section keeps track of arc starts welds and misfires The User Counters section allows setting the weld counter and gives the option of counting the weld misfires in with the weld counter Service Owad Displays the serial number and the last calibration date of the M200 power supply Fig 43 Current Privilege Level Button Fig 44 Privilege Level Dropdown Menu Fig 45 Setting or Resetting Passwords Fig 46 Language Regional Time Tab Table 15 Setup Lower Section Tabs Touchscreen Press Calibrate Touchscreen t
71. d process A basic lap type weld joint Step program Tack Travel speed Tungsten Weld coupon Weld log Weld pool Weld procedure Weld time A type of weld procedure in which the rotor speed is different between the high amps pulse time and the low amps pulse time The rotor speed may vary from zero to the weld head s maximum revolutions per minute A nonpenetrating weld used to hold the joint alignment and joint gap during welding Usually spaced at three or four places around the tube diameter The linear speed of the electrode as it passes over the weld joint usually expressed in inches per minute or millimeters per second Also can be expressed in revolutions per minute The material used to make the electrode A sample weld made for evaluation purposes The weld is used for both visual and physical testing Records and saves a description of each weld procedure including inputs and outputs and performance confirmation The molten metal that actually forms the weld Also called weld puddle A custom set of weld parameters used for a particular welding job The portion of the weld process in which the current is at the level needed to fully penetrate the weld joint Owad SWAGELOK EMBEDDED SYSTEM END USER LICENSE AGREEMENT GENERAL The Swagelok Welding System M200 Power Supply Product is being provided to Buyer Customer User USER with embedded firmware and software E
72. deline being used Adjust if necessary Electrode Incorrect arc gap Reset the arc gap with the touches the work arc gap gauge Insufficient arc gap for the material or the heat input Work pieces are out of round Increase the arc gap by 0 005 in 0 13 mm above weld head user manual settings Increase the arc gap or replace the work piece Owad Note The purge restricter must be of adequate size to prevent excessive inside diameter back pressure Table 51 Welding Process Symptom Incomplete inside diameter penetration Cause Insufficient heat input Remedy Compare the power supply setting to the weld procedure guideline being used Adjust weld parameters as necessary Incorrect weld procedure guideline 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 Incorrect arc gap Tip of electrode is worn or ground improperly Reset the arc gap with the arc gap gauge Change the electrode Inconsistent heats of materials or changes in material chemistry Verify consistency of material with material supplier Adjust weld parameters as necessary Weld joint is off center or misaligned Inspect the entire weld joint in the fixture block prior to welding After welding the tubing fitting assembly is not straight Th
73. dentifying Typical Weld Discontinuities Figure 69 shows typical weld discontinuities Incomplete Penetration Partial Penetration OD Concavity OD Concavity with ID Convexity Weld Bead Meander Axial Misalignment Angular Misalignment Fig 69 Typical Weld Discontinuities Owad Improper Welds The following weld examples show how changes in weld parameters affect weld shape The reference weld Fig 70 and 71 was made using a 316L stainless steel tube with a 1 2 in OD and 0 049 in wall thickness in accordance with the weld parameter settings shown below Parameter 1 4 High Amps A 71 7 60 9 Low Amps A 21 7 21 7 Weld Time s 5 0 5 0 Ramp Time s 0 0 0 0 Pulse Rate Hz 4 0 4 0 High Amps Width 28 0 28 0 High Amps Speed rpm 3 5 3 5 Low Amps Speed rpm 3 5 3 5 Average Amps A 35 7 32 7 Below are guidelines on what to look for when troubleshooting a weld that did not penetrate the ID displayed too much ID convexity and weld bead width or showed too much or too little weld puddle overlap To make adjustments to the parameters check them against the Auto Create values and see Advanced Weld Procedure Techniques page 64 for more tips on correcting an improper weld No ID Penetration Lack of ID penetration can be caused by several improper weld procedure settings All of the examples shown below result from decreased
74. ds 0 96 Identifying Typical Weld Discontinuities 96 Improper Welds 97 No ID Penetration l 97 Increased ID Convexity and Weld Bead Width 98 Weld Puddle Overlap 98 Specifications acs vee ee a a ee 100 M200 Power Supply Output and Duty Cycle 100 M200 Power Supply with 115 V Input 100 M200 Power Supply Cycle Times 101 M200 Power Supply Dimensions 101 Use of Extension Cords with the M200 Power Supply 101 Troubleshooting 0 1 0888 ea ae 102 Weld Status Conditions 102 Disable X 0200002 ee eee 102 Operational a oao 104 WeldErrors _ eee 106 Weld System Hardware and Weld Process Problems 108 Power Supply Repair 116 Glossary eee s arus osa ee o a Be N ela W Ns a 118 Swagelok Embedded System End User License Agreement 122 The Swagelok Limited Lifetime Warranty 124 Owad SAIS Safety Summary Arc welding can be hazardous A Read the entire safety information section and M200 Power Supply User s Manual before using this product Failure to do so can result in serious injury or death Signal Words and Safety Alert Symbols Used in this Manual WARNING Statements that indicate a hazardous situation which if not avoided could resu
75. e and shock hazards E Sparks and spatter are thrown from the weld arc The M200 power supply is meant for use with enclosed weld heads which minimizes exposure to spatter Wear proper protective equipment including eye protection Owad Fig 1 M200 Power Supply Mounting Caution Label A CYLINDERS may explode if damaged Gas cylinders used as part of the orbital GTAW process contain gas under high pressure If damaged a cylinder can explode To avoid injury Protect compressed gas cylinders from excessive heat mechanical shocks slag open flames sparks and arcs Follow all site safety precautions and protocol Install cylinders in an upright position by securing to a stationary support or cylinder rack to prevent falling or tipping Keep cylinders away from any welding or other electrical circuits Never weld on a pressurized cylinder explosion will result Use only correct shielding gas cylinders regulators hoses and fittings designed for the specific application maintain them and associated parts in good condition Keep head and face away from valve outlet when opening cylinder valve Keep valve protective cap in place over valve except when cylinder is in use or connected for use Read and follow instructions on compressed gas cylinders associated equipment and CGA publication P 1 listed in Referenced Documents page 11 Owad M200 Power Supply Warning Label This warning label must remai
76. e end surfaces of the work pieces being welded are not perpendicular to their center axis Prepare the work piece weld ends properly Refer to the weld head user manual The fixture block side plate screws are not tight Tighten screws as needed After welding the fitting tubing joint is still visible The fitting tubing was not centered properly The electrode is bent or was not properly installed Center fitting tubing Inspect the electrode and replace if necessary Reset the arc gap with the arc gap gauge Owad Power Supply Repair If the M200 power supply needs to be repaired contact your authorized Swagelok representative You will need to provide E serial and model number of the unit m complete description of the application E detailed description of the symptom Detailed information will help identify the exact problem and expedite the solution wade M200 Power Supply User s Manual 117 Owad Glossary Active procedure Automatic tube weld ATW Arc Arc failure Arc gap Arc gap gauge Arc start Argon Average current Blast purge Butt weld Centering gauge Concavity Dedicated line Duty cycle GTAW Owad The procedure loaded for welding Also called the weld program A weld using a fitting that has extra material machined integral with the fitting at the weld joint The flow of current between an electrode cathode and the wo
77. e weld head Poor contact between Inspect and clean all locking ring tab and contact surfaces ground extension Poor contact between Inspect and clean all rotor and brush contact surfaces Poor contact between Inspect and clean all tubing collet and fixture contact surfaces block Start power set too low Set start power to normal Voltage Weld head not seated Reattach the weld head to fluctuations properly into the fixture the fixture block Engage during the block the weld head locking weld cycle lever exceeding 2 V Outside diameter discoloration Work pieces are out of round Replace work pieces if out of standard specifications Insufficient OD shield gas flow or contaminated gas Insufficient OD shield gas flow Check the gas source for low pressure and leaks Change to a different gas source or change oxygen removal filter Increase flow rate and prepurge time Impurities in the gas supply Check gas lines for leaks Change to a different gas source or change oxygen removal filter Wrong type of gas used Change to correct type of gas Contamination on work pieces Clean the work pieces before welding Contaminants in the weld head and gas lines Increase prepurge time Check the gas source for low pressure OD shield gas line disconnected from the M200 power supply Reconnect gas line Owad Table 51 Welding Process Sy
78. e weld is made immediately after tacking Table 20 Tack Parameter Guideline Worksheet M200 Power Supply User s Manual 65 Coen tition 050 De uA V D4 0 Owen oym Fig 59 Tacks Tab Note Do not start a weld at a tack position NOTICE Tack programs or programs that include tacks should not be used with Swagelok micro weld heads Example Based on 1 2 in x 0 049 in Fractional or 12 0 x 1 0 mm Metric Entry Step Parameter TB TB 316LV Screen 1 Number of tacks up to 20 Nracks 3 2 Amps Delay current Weld Procedure Guideline Worksheet 35 6 A Weld step 30 Tacks 3 3 Time Weld Fractional tubing Fractional tubing Tacks 3 Time Wall Weld Procedure Guideline Worksheet step 5 x 30 x 30 Metric tubing Time Wall Weld Procedure Guideline Worksheet step 5 x 1 1 x 1 1 If Tack time lt Overlap Weld Procedure Guideline Worksheet step 20 Time Overlap 4 Number of degrees between tacks Degrees 360 Nr cks 360 0 049 x 30 15 s Metric tubing 1 0 x 1 1 11 s 1 5 gt 1 1 Weld Tacks 3 360 3 120 Owad Ramp Time Ramp time is time taken at the beginning of a level to allow a gradual amperage change from the arc start current for the first level or the previous level s Low and High Amps settings for all other levels The heat input effect of ramping depends on the levels current settings directly before and
79. ed gears Arcing damage on rotor gear teeth Inspect rotor and replace if damaged Dirty weld head debris on encoder sensor or encoder wheel Encoder wheel slips on motor shaft Disassemble the weld head and clean thoroughly Call for service Weld head connector has broken wire Call for service Arc damage on Arcing from rotor Clean gear replace if rotor gear necessary Damage to Arcing Disassemble the weld weld head head Clean or replace body halves parts as needed Owad Excessive heat from welding Check weld procedure guideline Use a larger weld head allow a cooling period between welds or allow continuous OD shield 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 Note See the Maintenance section of the weld head user s manual for more information about correcting problems with weld heads Table 49 Electrode Symptom Material found on the electrode tip Cause Electrode touched the weld puddle Remedy Replace electrode and check arc gap setting Check work pieces for out of roundness Weld puddle protrusion Check ID 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 lockin
80. el speed based on OD Speedop _ See Table 28 page 82 Speedgp 5 in min Total travel speed Speedway Speedop 2 _ 2 6 5 2 5 5 in min 20 For future calculations Weld Time total for single pass Seconds per revolution spr 60 High Low Amps speed 60 60 3 5 17 1 spr Additional Weld Time to overlap Level 1 Overlap Wall step 5 x 2 Total travel speed step 19 60 _ X 2 ___ 60 0 049 x 2 5 5 60 1 1 s Timeyotal Spr Overlap _ 17 14 1 1 182s 21 Weld Time for all levels Timer ai step 20 NLeveis step 18 Weld Levels 1 Note Round up to the nearest 0 5 second or whole number whichever is smaller 182 4 50 Note Weld Time number must always end in 5 or 0 Owad Table 16 Fractional Butt Weld Procedure Guideline Worksheet Example Based on 1 2 in x 0 049 in Entry Step Parameter Tube Tube 316LV Screen 22 Pulse Rate for all levels Total travel speed step 79 Weld 30 x Wall step 5 Levels 1 30 x 5 5 30 x 0 049 4 Note Round up to nearest whole number If Weld Time ends in 5 and Pulse Rate is odd number Note If Weld Time ends in Pulse Rate for all levels Pulse Rate 1 forces Pulse Rate 0 Pulse Rate must be x Weld Time to be even to prevent a skip a whole number between levels 41 Weld Time ends in 0 23 High Amps Width 3
81. ement Swagelok warrants for a period of 1 year from the date of shipment that the media on which the Swagelok developed software or firmware is furnished shall be free from defects in material and workmanship and shall conform to the published or other written specifications issued by Swagelok when used with the Product Swagelok makes no representation or warranty expressed or implied that the operation of the software or firmware will be uninterrupted or error free or that the functions contained in the Owad software or firmware will meet or satisfy the USER s intended use or requirements Satisfaction of this warranty consistent with other provisions herein will be limited to the replacement or repair or modification of or issuance of a credit for the Product involved at Swagelok s option This warranty shall not apply for a any alleged defect caused by misuse neglect improper installation operation maintenance repair alteration or modification accident or unusual deterioration or degradation of the software firmware or parts thereof due to physical environment or due to electrical or electromagnetic noise environment or b any use of the software on a program platform or application assembly other than that originally supplied or specified with the Product THIS WARRANTY IS IN LIEU OF ALL OTHER WARRANTIES WHETHER EXPRESS IMPLIED OR STATUTORY INCLUDING THE IMPLIED WARRANTIES OF MERCHANTABILITY OR FITNESS FOR A PART
82. ent Too High Fig 78 Low Amps Current Too High Fig 79 Rotor Speed Too Low Dy Fig 80 Not Enough Weld Pudale Overlap Cy Fig 81 Too Much Weld Puddle Overlap M200 Power Supply User s Manual 99 Owad Spectiications M200 Power Supply Output and Duty Cycle Table 38 M200 Power Supply Output Average Output Maximum Peak Maximum Open Current Range Output Current Circuit Voltage 2 to 160A 200A 90 V Table 39 M200 Power Supply Duty Cycle at 10 to 28 C 14 to 82 F Average Output Current Without Industrial With Industrial Duty Cycle Input Circuit Output Voltage Fan Filter Fan Filter 100 V 20 A 13 2 V 80 A 80 A 100 100 V 30 A 13 8 V 95A 80 A 115V 20A 13 6 V 90 A 80 A 100 115V 30A 14 4V 110A 80A 200 V 20 A 35 16 4 V 160 A 230 V 16 A 200 V 20 A 80 A 100 I 15 2 V 130 A 230 V 16 A 80 A Table 40 M200 Power Supply Duty Cycle at 40 C 104 F Average Output Duty Cycle Input Circuit Output Voltage Current 100 V 20 A 13 2 V 80 A 100 100 V 30A 13 8 V 95 A 115V 20A 13 6 V 90 A 100 115V 30A 14 0 V 100A 200 V 20 A 35 14 8 V 120A 230 V 16 A 200 V 20 A 100 14 0 V 100A 230 V 16 A M200 Power Supply with 115 V Input The rated output of the M200 power supply is available when connected to a 230 V 20 A branch circuit When connected to a branch circuit
83. erate the weld procedure but for instances where the work piece dimensions are not available in the M200 power supply dropdown boxes or manual program creation is desired the Weld Procedure Guideline Worksheets starting on page 54 can be used to determine work specifications and calculate weld parameters Butt Welds The Butt Weld Procedure Guideline Worksheets can be used to generate procedure guidelines for butt to butt tube and pipe welds as well as other cylindrical butt to butt welds The worksheets fractional page 54 metric page 58 go through the steps required to create a Weld Procedure Guideline Alongside each step is an example to show how an actual parameter value would be created Both examples are based on 316L tube to tube fusion butt welds The example fractional tube size is 1 2 in OD and 0 049 in wall thickness The example metric tube size is 12 0 mm OD and 1 0 mm wall thickness Note Any procedure generated manually using the Weld Procedure Guideline Worksheets or generated automatically by the M200 power supply is only a guideline The final weld quality depends on the operator s welding experience and on the proper use of welding techniques Parameter adjustments will need to be made and weld quality verified in accordance with the user s quality standards Owad Weld Procedure Guideline Worksheets Table 16 Fractional Butt Weld Procedure Guideline Worksheet Example Based on
84. eriod of the pulse cycle The Weld Time multiplied by the Pulse Rate Weld Time x Pulse Rate that is the number of seconds per level X cycles per second must equal a whole number of cycles per level to ensure each level ends with a complete Low to High Amps cycle before beginning the next level Owad Weld Parameter Guideline Worksheet Reference Data Table 25 OD Shield Gas Flow Rates Argon Swagelok Weld Flow Rate Head Series std ft h std L min 4MH 8to 15 4 0 to 7 1 8HPH 10 to 15 4 7 to 7 1 8MH 15 to 20 7 1 to 9 4 5H 15 to 25 7 1 to 11 8 10H 15 to 250 7 1 to 11 80 20H 20 to 409 9 4 to 18 80 40H 25 to 500 12 to 240 Set the flow to the higher rate when welding at high current levels wade Table 26 ID Purge Gas Flow Rate and Pressure Fractional Dimensions Tube Wall ID Pure ese Restricter Size Thickness Flow Rate inches Size in in std ft8 h of water torr in 1 16 0 015 0 2 7to9 13 to 16 8 1 8 0 028 1 0 5to 9 9 3 to 16 8 1 16 1 4 0 035 6 0 2 8 to 3 4 5 2 to 6 3 1 8 3 8 0 035 10 1 5 to 2 5 2 8 to 4 7 1 8 1 2 0 049 15 1 0 to 1 5 1 9 to 2 8 1 4 3 4 0 065 20 0 5 to 1 1 1to2 1 4 1 0 065 40 0 5 to 0 7 1 to 1 3 1 4 11 2 0 065 90 0 5 to 0 7 1 to 1 3 1 4 2 0 065 170 0 4 to 0 7 0 7 to 1 3 3 8 3 0 065 400 0 2 to 0 5 0 4 to 0 9 1 2 4 0 083 720 0 2 to 0 4 0 4 to 0 7 3 4 Indicated purge rates are for minimum color line ATW welds and weld ring welds
85. f the weld cycle Weld Time indicates the weld process is in progress Downslope indicates the downslope cycle is in progress e e PostPurge indicates the postpurge cycle is in progress OD shield gas continues to flow to the weld head and the rotor moves to the home position Rotor indicates the rotor is in motion The display Fig 67 monitors system operation during welding and provides message information The display functions are E Average Current indicates the average arc current measured during the weld process m Average Voltage indicates the average arc voltage measured during the weld process m Shield Gas indicates the gas flow to the weld head Single Level Weld Status Conditions See Troubleshooting page 102 for a list of disable operational and weld error conditions Seeder OOF 0o00 000 Q 0 94 a 00 Status line M200 Power Supply User s Manual 87 Fig 67 Single Level Status Indicator Lights and Display Owad Z lt mx W a o Wu O W gt W l W l o O Z O lt x W a o Wu O W gt W l W l o O 88 M200 Power Supply User s Manual Single Level Weld Procedure Guidelines These Single Level Weld Procedure Guidelines show suggested weld parameter settings based on E Swagelok weld head used E weld joint type m material type E outside diameter and wall thickness of the weld joint
86. g lever Oxidation film on the electrode Insufficient OD shield gas Increase OD shield gas flow Insufficient post purge time Increase post purge time Partially blocked or cut OD shield gas line Check for leaks and or blockages Replace gas lines if needed O ring missing between the weld head and motor module micro weld head only Check and install O ring if necessary OD shield gas line disconnected inside weld head Disassemble weld head and reconnect the line Bent or broken Electrode was not Replace the electrode electrode secured in the rotor Tighten electrode clamping screws Weld head not correctly Replace the electrode attached to the fixture Reattach the weld head to block the fixture block Engage the weld head locking lever Incorrect arc gap setting Check the length of the electrode and replace it Reset arc gap Melted No OD shield gas Check for OD shield gas electrode flow and set the proper flow rate Enable Shield Flow Control on Main gt Setup Flow Control tab Owad Table 50 Fixture Block Symptom When closing the fixture block side plate the latch does not lock Cause The latch is not inserted into the fixture block side plate completely Remedy Reinsert the latch into the side plate until it rests against the latch pin Bent latch Replace latch Oversized tubing Replace fitt
87. h drive After every completed weld a Weld Log file name is created automatically in accordance with the following convention 2007 09 27 10 56 00012 001251 123456 xml 2007 09 27 date 10 56 time 24 h clock 00012 weld counter resettable 001251 arc start counter nonresettable 123456 M200 power supply serial number xml file format View Print Serial Tab The Weld Log screen opens in the View Print Serial tab displaying two panes Fig 37 m Folder View left pane displays folders in the Internal Memory Weld Log and the USB flash drive Weld Log if drive is connected m File View right pane displays the files contained in the selected folder in the Folder View pane MVEA cee eee eee ee DB k h 1 es Fes m B Fig 37 View Print Serial Tab Owad Table 12 View Print Serial Tab Buttons Select the Weld Log from the File View pane and press View The File Preview window will appear showing the weld procedure name the weld count performance confirmation including any errors and time created Joint Level and Tack parameters will also be displayed Press OK to return to the Weld Log screen Prints the selected Weld Log record Transfers files and folders directly to a PC using a serial cable M200 power supply serial port settings Baud rate 38 400 Data bits 8 Parity None
88. h screen show the welding process sequence The status indicator lights on the touch screen show the welding process sequence or flash if the power supply detects that a weld parameter is set incorrectly Single Level Current Control Group The current control group determines the characteristics of the current output of the power supply during the weld process The controls Fig 63 function as follows m High Amps sets the maximum current output used during the weld process This setting affects the depth of penetration of the weld E Low Amps sets the minimum current output used during the weld process This is the current level required to maintain the arc and provide enough background heat to maintain the weld puddle m Pulse Rate sets the number of pulses per second between the High Amps and Low Amps current levels during the weld process m Amps Width sets the percentage of time the current is at the High Amps level for each High Amps Low Amps cycle m Delay Current sets the current during the Delay Time This current level helps stabilize the initiated arc and develops the weld puddle Owad Fig 63 Single Level Current Control Group M200 Power Supply User s Manual 85 Single Level Timing Control Group The timing control group determines the weld process timing The controls Fig 64 function as follows m Delay Time is the time in seconds between the arc start period and rotor movement The cu
89. hield Flow Weld see Table 25 page 80 10 0 std L min Purge Setup Normal Purge field 13 ID Flow Weld see Table 27 page 81 7 0 std L min Purge Setup ID Pressure a see Table 27 page 81 3 2 mbar Owad Table 17 Metric Butt Weld Procedure Guideline Worksheet Example Based on 12 0 x 1 0 mm Entry Step Parameter Tube Tube 316LV Screen 14 For future calculations High Amp current factors F4 F2 and F see Table 29 page 82 F 87 F4 Fo F3 F 0 Fz 2 3 15 For future calculations Width 12 8 x Wall step 5 12 100 12 8 x 12 100 12 8 x 1 0 12 100 0 25 16 High Amps for Level 1 F step 14 x Wall step 5 F3 Weld Fz x Width step 15 1 Levels 1 x x 1 87 x 1 0 0 2 3 x 0 25 1 652 A 17 Low Amps for all levels High Amps Levei 1 Step 16 Weld F3 step 14 1 Levels 1 1 55 2 2 3 1 16 7 A 18 For future calculations do not add columns on screen at this time Number of levels for multiple level schedule Nievas typically 4 allowed range is 1 to 99 4 19 For future calculations Travel speed calculation Travel speed based on wall thickness Speedwell See Table 29 page 82 Speedway 178 mm min Travel speed based on OD Speedop See Table 29 page 82 Speedgp 152 mm min Total travel speed Speedway Speedgp 2 2 178 152 2 165 mm min 20 For future
90. home If it is not press Next Home to move the rotor to the next of several home positions The weld head model determines the number of home positions Continue pressing Next Home until the rotor reaches true home Fig 18 If the weld head cannot find true home see Troubleshooting page 109 Owad Note In any M200 power supply screen or menu press Back to return to the previous screen Press Refresh to reload and update the current screen A CAUTION The rotor will move when Next Home is pressed The rotor is a potential pinch point True home Not true home fully open Fig 18 Rotor Home Position Table 5 Main Menu Selections and Functions Lock Out Fig 19 Paper Feed Single Level Mode Language Fig 20 Pressing Lock Out will lock the M200 power supply Once the M200 power supply is locked out pressing any button on the screen will cause a password prompt to appear The owner programmer or security password must be entered Note This feature is not available unless a programmer or security password has been set in Setup See Passwords page 46 for more information The printer is located on the right side of the M200 power supply above the weld head connection Paper Feed advances the paper through the printer See page 45 for information on changing the paper feed length The fan is normally in the Fan Power On State and will turn on as needed to cool the M200
91. ing 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 A burr is in the slot or on the latch Use a fine file to remove burrs bottom part of the Aras The latch is bent or Remove the hinge and block side damaged replace all damaged plate parts The fixture The arc gap is incorrect Reset the arc gap with the block does arc gap gauge not fit onto the eon head The locking ring tab is Replace the locking wade broken or damaged ring tab The weld head is incorrectly assembled Reassemble using the instructions found in the Maintenance section of the weld head user s manual Arc damage on fixture Clean fixture Remove and replace any damaged parts Table 51 Welding Process Symptom Cause Remedy Arc fails to Incorrect arc gap setting Reset the arc gap with the start arc gap gauge Excessive purge gas flow Reduce flow to the value shown on the weld procedure guideline Insufficient OD shield gas Check the gas source for flow or contaminated OD low pressure and leaks shield gas Change to a different gas source or change oxygen removal filter Electrode in poor Replace electrode condition Damaged electrical Call for service connections in th
92. ing side of the M200 power supply any flow supply are attached in reverse OD shield gas Insufficient input pressure Increase input pressure visual gauge is not reading desired flow rate damaged Power supply fan does not operate during weld process Internal component failure Call for service Touch screen is blank The M200 power supply ON OFF switch is off Toggle on the M200 power supply ON OFF switch The M200 power supply power cord is not plugged in Plug the M200 power supply power cord into the wall outlet Touch screen is not working properly cursor does not follow the fingertip Water or other contaminant is on the screen Let the screen dry or clean it with the M200 power supply powered off Touch screen is no longer calibrated Recalibrate the touch screen from Setup gt Touchscreen gt Calibrate Touchscreen wade Table 48 Weld Head Symptom Rotor does not return to the true home position Cause Weld head connector is not fully engaged Remedy Check that the weld head connector is seated on the M200 power supply and the collar is tight Bad weld head connector cable Replace weld head connector cable Rotor is not at the true home position when the power supply is toggled on Press Next Home to move the rotor to the home position Dirty home sensor Rotor gear ring is misaligned with se
93. is raises the Average Amps from 35 7 to 38 1 A High Amps Current Too High Fig 77 High Amps setting changed from 71 7 to 80 6 A This raises the Average Amps from 35 7 to 38 2 A Low Amps Current Too High Fig 78 Low Amps setting changed from 21 7 to 25 2 A This raises the Average Amps from 35 7 to 38 2 A Rotor Speed Too Low Fig 79 Rotor speed changed from 3 5 to 2 rpm This increases the average heat input per unit of time Although the Average Amps for the weld is unchanged Weld Time is increased by 75 and the heat input is increased by 75 Weld Puddle Overlap The pulse rate should be set so that each weld puddle overlaps the previous one by about 80 as shown in Fig 71 Changing the pulse rate can affect weld puddle overlap and cause inadequate weld penetration or weld distortion Not Enough Weld Puddle Overlap Fig 80 If the weld puddles do not overlap enough the weld can lose full penetration in some areas Increasing the pulse rate from 10 to 25 per second will increase weld puddle overlap and ensure full penetration of the weld joint Too Much Weld Puddle Overlap Fig 81 If the weld puddles overlap too much the weld puddle may become distorted around the perimeter Decreasing the pulse rate from 10 to 5 per second will decrease weld puddle overlap and provide a more uniform appearance around the edges of the weld Owad Fig 76 High Amps Width Too Long Fig 77 High Amps Curr
94. ith the M200 Power Supply N waARNINO Some power loss will occur depending on the length of the Do not use extension cords that extension cord See Table 43 to determine the minimum wire are in poor physical condition size to use or have insufficient current capacity Electrical shock can Table 43 Extension Cords result Wire Gauge Wire Gauge Supply 0 to 50 ft 50 to 100 ft Voltage 0 to 15 m 15 to 30 m NOTICE ys The voltage drop in an extension 115 V ac 12 AWG 2 5 mm 10 AWG 4 0 mm cord over 100 ft 30 m may affect the 230 V ac 12 AWG 2 5 mm 10 AWG 4 0 mm output performance of the M200 power supply Owad 4N9 M200 Power Siinnly leerse Mani jal Uz M200 Power Supply User s Manua c Troubleshooting This section contains troubleshooting guidelines for the M200 power supply and software including E weld status conditions E weld system hardware and weld process problems E power supply repair Weld Status Conditions Disable Disable conditions must be corrected before a weld can be executed A D on the status line indicates a disable condition Fig 82 Table 44 Disable Conditions Disable Message Description Remedy D Electrode Electrode Change is still Press Electrode Change change mode active again D Fault LCD The M200 power supply Call for service backlight touch screen backlight is not working properly D Fixture not found A fixture is no
95. justable up to 9 9 The factory default for new weld procedures is 2 5 gm Purge tolerance is adjustable up to 100 The factory default is 15 Example if the Average Amps for Level 1 is 100 A and the current tolerance is 5 the M200 power supply will return a current tolerance error at the end of the weld if the Average Amps is below 95 A or exceeds 105 A Current tolerance If the Average Amps tolerance is exceeded during the weld a current tolerance error will be recorded Speed tolerance If the average speed is outside of the average speed tolerance at the end of the weld a speed tolerance error will be recorded Purge tolerance Purge tolerance is represented by the yellow band in the shield gas flow meter displayed on the process tab If the OD shield flow is outside of the tolerance the shield gas bar flow meter display will turn red If there is no OD shield gas present during prepurge the M200 power supply will not proceed If the OD shield gas flow drops below 8 std ft3 h 3 8 std L min during a weld the M200 power supply will stop welding to prevent possible damage to the weld head See page 106 Weld Errors Gnetum w r Oret Torron a Farge Tan aat WJ x x eee 10 are C Aser os La W 3 ug terre WJ Fig 25 Limits Tolerances Tab Table 7 Weld Lower Section Tabs Process Displays the status and progress of the weld Fig 26 including tacks error messages and electrode po
96. ld Step program Range is 0 to 100 Both cannot be 0 Levels 1 High Amps Low Amps High Amps Speed High Amps X High Amps Speed step 21 100 __ x _ id 100 Low Amps Speed Low Amps X Low Amps Speed step 22 100 x _ 100 Note Round speed to 2 decimal places 75 100 75 x 0 34 100 0 26 rpm 100 x 0 34 100 0 34 rpm Owad Table 23 Fractional Step Program Parameter Guideline Worksheet Example Based on 2 0 in x 0 109 in Entry Step Parameter Tube Tube 316LV Screen 24 For future calculations Weld Time total for single pass Average speed High Amp Speed step 23 x Width step 15 0 26 x 0 47 Low Amps Speed step 23 x 1 Width 0 34 x 1 0 47 0 30 rpm Seconds per revolution spr 60 Average speed 60 ___ 60 0 30 200 0 spr Average Speed Average speed rpm x Circumference step 20 ___ in min 0 30 x 6 283 1 88 in min Additional Weld Time to overlap Level 1 Overlap Wall step 5 x 2 Average speed in min 60 _ _ x2 _ _ 6 0 109 x 2 1 88 60 7 0 s Timeyotai Spr Overlap _ 200 0 7 0 207 0 s 25 Weld Time for all levels Timer tai step 24 NLeveis step 18 Weld Levels 1 207 0 4 52 0 Note Round up to the nearest 0 5 second or whole number Note Weld Time number must whichever is smaller always end in
97. lt 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 o 3 P P x lt N i which if not avoided could result in damage to the equipment or other property Safety alert symbol indicating a potential personal injury hazard Safety alert symbol indicating a potential for personal injury from electrical shock Safety alert symbol indicating a potential for personal injury from exposure to fumes and gases Safety alert symbol indicating a potential for personal injury from exposure to the weld arc Safety alert symbol indicating a potential for personal injury resulting from a welding related fire or explosion Safety alert symbol indicating a potential for personal injury resulting from a welding related cylinder explosion Owad P gt WARNING Orbital gas tungsten arc welding GTAW can be hazardous Only qualified persons should use this equipment After welding the work piece weld head electrode fixture block and collets can be extremely hot and may cause burns Keep children away Pacemaker wearers should consult with their physician before operating this equipment Read and understand ANSI Standard Z49 1 Safety in Welding and Cutting from the American Welding Society and OSHA Safety and Health Standards 29 CFR 1910 and 1926 from
98. mbedded System USER agrees that the terms and conditions identified in this document Agreement govern the USER s purchase or use of the Embedded System No modification to any of the terms and conditions of this document shall be binding upon Swagelok Company and its subsidiaries Swagelok or its independent authorized distributors unless agreed to in writing and signed by Swagelok TRADEMARK AND TRADE NAMES Nothing in this Agreement or with the sale of the Product to USER shall be deemed to give any rights in connection with any trademarks service marks or trade names of Swagelok or any third party product subject to these terms and conditions Swagelok is a registered trademark of the Swagelok Company SOFTWARE OWNERSHIP AND USE The Embedded System shall be and remain the property of Swagelok or third parties which have granted Swagelok the right to license certain software or its use with the Embedded System and USER shall have no rights or interests therein except as set forth in this Agreement USER is granted a non exclusive non transferable worldwide perpetual right to use the Embedded System received with the Product solely in support of and for use with the Product USER shall not a install or use on the Embedded System either support software or additional software that provides functions in addition to the embedded application unless that support software or additional software was provided by Swagelok
99. mptom Inside diameter discoloration Cause Insufficient ID purge gas Remedy Increase ID purge gas flow rate and prepurge time Contaminants in the ID purge line Increase prepurge time Check the gas source for low pressure Migration of oxygen from the ID purge gas exit port of the work pieces to the weld joint Reduce exit port size with a purge restricter See Note Wrong type of gas used Change to correct type of gas Contamination on work pieces Clean the work pieces before welding Nicks cuts in the ID purge gas line Replace gas line Hole in the Incorrect arc gap Reset the arc gap with the weld bead arc gap gauge Excessive ID purge gas Remove any obstruction back pressure or surge of the ID purge gas flow or reduce the pressure Improper tube Inspect and reface tubing preparation Incorrect weld parameter Check and adjust the setting High Amps weld parameter settings Loss of OD shield gas Check the gas source for flow low pressure and leaks Change to a different gas source or change oxygen removal filter OD concave Excessive heat input Compare the material weld puddle wall thickness and outside diameter size of the components being welded to the weld procedure guideline being used Verify settings match the guideline and adjust if necessary Insufficient ID purge gas Compare flow meter pressure settings to the weld procedure gui
100. n High Amps Current Factors Table 29 Metric High Amps Current Factors and Travel Speeds Wall High Amps Gurrent Factors Biete Nominal Actual Nominal in F1 F2 F3 in min Tube Size in Pipe Size 0 010 to 0 020 1400 0 5 7 10 1 16 0 063 to 0 124 0 021 to 0 034 5450 91 3 3 8 1 8 0 125 to 0 249 0 035 to 0 046 2200 0 2 3 7 1 4 2 50 to 0 374 0 047 to 0 055 2400 0 2 3 6 3 8 0 375 to 0 499 1 8 0 056 to 0 065 2500 0 2 3 5 1 2 0 500 to 0 624 1 4 0 066 to 0 070 2500 0 2 2 4 5 5 8 0 625 to 0 749 3 8 0 071 to 0 075 900 110 2 2 4 3 4 0 750 to 0 874 0 076 to 0 080 900 100 2 0 3 6 7 8 0 875 to 0 999 1 2 0 081 to 0 085 2000 0 1 8 3 3 1 1 0 to 1 249 3 4 0 086 to 0 090 1800 0 1 6 3 1 1 4 1 250 to 1 499 1 0 091 to 0 095 1800 0 1 6 2 6 1 1 2 1 500 to 1 749 1 1 4 0 096 to 0 109 460 110 1 3 2 3 1 3 4 1 750 to 1 999 1 1 2 0 110 to 0 120 460 110 1 3 2 2 2 000 to 2 999 Outside Diameter mm Nominal Travel Pipe Size Wall Speed Nominal Actual ISO mm F1 F2 F3 mm min Tube Size mm Metric 0 40 to 0 51 55 0 5 7 254 2 0 to 3 0 1 60 to 3 15 _ 0 52 to 0 88 215 91 3 3 203 3 5 to 6 0 3 18 to 6 34 0 89 to 1 17 84 0 2 3 178 6 5 to 9 5 6 35 to 9 51 1 18 to 1 40 94 0 2 3 152 10 0 to 12 5 9 52 to 12 6 1 41 to 1 65 98 0 2 3 127 13 0 to 15 5 12 7 to 15 7 1 66 to 1 78 98 0 2 2 114 16 0 to 18 5 15 8 to 18 9 16 1 79
101. n affixed to the top of the power supply Fig 2 7 Do Not Remove Destroy or Cover This Label For user information contact Swagelok Co www Swagelok com ELECTRIC SHOCK can kill e Do not touch live electrical parts e Electrode and rotor are live during weld cycle e Keep all panels and covers securely in place FUMES AND GASES can be hazardous Do not breathe fumes or gases Use ventilation or exhaust to remove fumes from breathing zone Read Material Safety Data Sheets MSDS s and follow manufacturer s instructions for the material used UN CHOC ELECTRIQUE peut tre mortel e Seules des personnes qualifi es peuvent installer et utiliser cet appareil ARC WELDING can be hazardous e Read and follow this label and the User s Manual Only qualified persons are to install and operate this unit e Keep children away e Pacemaker wearers keep away e Return to authorized sales and service center for service WELDING can cause fire or explosion Do not weld on closed containers e Do not use in a combustible environment or over a combustible surface ARC RAYS can burn eyes e Do not look at welding arc e Wear personal protective equipment including eye and ear protection Read American National Standard 249 1 Safety in Welding and Cutting from American Welding Society 550 N W LeJeune Rd Miami FL 33126 OSHA Safety and Health Standards 29 CFR 1910 and 1926 from U
102. n of the M200 power supply is the built in method for navigating functions and entering data The touch screen responds to fingertip operation and was designed to accommodate gloves The touch screen may be difficult to use if it is dirty or has water droplets on its face Keep the touch screen clean and dry If the touch screen does not respond as expected it may need to be calibrated From the Main Menu select Setup gt Touchscreen gt Calibrate Touchscreen Fig 12 A series of cross hair targets will appear onscreen While in the position seated or standing you normally use the M200 power supply touch each target Fig 13 as it appears When no more targets appear the M200 power supply is calibrated User Interface The user interface of the M200 power supply was designed for easy navigation The path at the top of each screen except the Weld screens indicates your location M200 Power Supply Users Manual 23 Note Do not expose the M200 power supply to water or visible moisture The touch screen can be cleaned with glass cleaner and a clean cloth To prevent accidental operation power off the M200 power supply before cleaning Fig 12 Calibrate Touchscreen Button Path Location Main gt Setup Setup mode Main gt Program gt Auto Create Auto Create function in the Program mode To select a function or mode press the onscreen button or tab with your finger To enter information pre
103. not penetrate until some point during this first level The overlap time must be increased to ensure an even ID bead width through the whole first level See Fig 61 and the Level 1 Ramp Postponed Penetration Guideline Worksheet below for use in conjunction with the Weld Procedure Guideline Worksheets Where the two worksheets have common parameters use the Level 1 Ramp Postponed Penetration Guideline Worksheet values Ramp Time Level 1 Downslope WHH UU i 4 Delay Current 5A V N N Rotor Delay Level 1 Level 2 Level 3 Level 4 01s gt Weld lt Weld lt Weld gt lt Weld Time Time Time Time Fig 61 Postponed Penetration While Welding Owad Table 21 Level 1 Ramp Postponed Penetration Guideline Worksheet Table 16 Example Based on Fractional 1 2 in x 0 049 in Fractional or or 12 mm X 1 0 mm Metric Table 17 Tube Tube 316LV Metric Increase Level 1 Time Entry Step Parameter with Ramp Screen Ramp Time for Level 1 3 0 s Weld Note Choose a value that is either a whole number or 0 5 Levels 1 second 21 Weld Time for Level 1 Fractional tubing Weld Weld Time eye 1 Weld Time Weld Procedure Guideline 5 0 3 0 8 0 s Levels 1 Worksheet step 21
104. nt factors F4 F2 and F3 see Table 28 page 82 F 460 F4 Fo F3 Fo 110 Fs 1 3 15 For future calculations Width 320 x Wall step 5 12 100 820 x 12 100 820 x 0 109 12 100 0 47 16 High Amps for Level 1 F4 step 14 x Wall step 5 Fo F3 Weld x Width step 15 1 460 x 0 109 110 Levels 1 x x 1 1 3 xX 0 47 1 994 A 17 Low Amps for all levels High Amps Levei 1 Steo76 Weld F3 step 14 1 _ Levels 1 1 99 4 1 34 1 432 A 18 For future calculations do not add columns on screen at this time Number of levels for multiple level schedule NLevels typically 4 allowed range is 1 to 99 4 19 For future calculations Travel speed calculation Travel speed based on wall thickness Speedw l See Table 28 page 82 Speedway 2 3 in min Travel speed based on OD Speedop See Table 28 page 82 Speedop 2 in min Total travel speed Speedwai Speedop 2 2 2 3 2 2 2 15 in min 20 For future calculations Work piece circumference OD step 4 xX T X 3 1416 2 0 X 3 1416 6 283 in 21 High Amps Speed rpm for all levels Total travel speed step 19 Weld Circumference step 20 Levels 1 2 15 6 283 0 34 rpm 22 Low Amps Speed rpm for all levels Total travel speed step 79 Weld Circumference step 20 Levels 1 gt 2 15 6 283 0 34 rom 23 Percentage of standard High and Low Amps speed used for We
105. ntry Step Parameter Tube Tube 316LV Screen 32 For Wall lt 0 083 in Weld Rotor Delay Time Wall step 5 x 40 General a Start field x 40 7 0 x 0 30 0 34 62 s For Wall gt 0 083 in Rotor Delay Time Overlap step 24 x Average speed rom step 24 High Amps Speed step 21 x Wall gt 0 083 in 33 Downslope Time pia step 24 constant Weld Constant OD lt 0 5 in 1 25 General Finish field 0 5 lt OD lt 1 0 in 2 5 1 0 in lt OD 15 If Downslope lt 10 Pulse Rate step 26 then Downslope 10 Pulse Rate 207 0 15 OD gt 1 0 in 13 8 s 10 1 10 forces a minimum of 10 pulses for Downslope 13 3 gt 10 This step in conjunction with rounding the Weld Time to the nearest 0 5 second prevents consecutive periods of low amperage output during the transition from one level to the next This would be observed as skipping between weld levels Note from Fig 56 page 52 each level begins with the Low Amps period of the pulse cycle The Weld Time multiplied by the Pulse Rate Weld Time x Pulse Rate that is the number of seconds per level x cycles per second must equal a whole number of cycles per level to ensure each level ends with a complete Low to High Amps cycle before beginning the next level Owad Table 24 Metric Step Program Parameter Guideline Worksheet Example Based on 54 0 mm
106. o recalibrate the cursor position relative to your fingertip See page 23 for more information about calibrating the touch screen Press Front Panel Key Click on or off to turn on or off the audible click heard when a button is pressed Printer Fig 47 Displays Printer status paper out head up and settings Use this screen to set the Paper Feed Length short medium long and Paper Cut manual partial full Remote Displays Remote status connected type and settings Use this screen to turn the Remote Key Click on or off Weld Head Displays weld head status head connected head type Flow Control Sound Allows disabling of the MFC that controls the OD shield gas and turns off disable operational and error codes associated with OD shield gas flow Turns the Alarm on or off When this function is on and a weld error occurs the audible alarm will sound The error displays on the Status line and is recorded in the Weld Log Internal Memory Displays the status of the system memory capacity used space free space USB Flash Memory Displays the status of the USB flash drive memory capacity used space free space M200 Power Supply User s Manual 45 Fig 47 Printer Tab NOTICE Disabling the shield gas flow control allows a weld to be performed without using the M200 power supply internal shield gas flow control Shield gas is essential to cooling the weld
107. older View pane File View pane Load Save Print Delate Ret Fe tane fw onc r j Status line File Name box Fig 32 Load Save Print Delete Tab Note File names are limited to alphanumeric characters The M200 power supply software does not support symbols such as Sy hy Hy Yo a a a OF similar characters Owad Table 9 Load Save Print Delete Tab Buttons View Delete Load Rename Create Folder Select the weld procedure in the File View pane and press Print Select the weld procedure from the File View pane and press View The file preview window will appear showing the weld procedure name a description the programmer s name and the date the weld procedure was saved Joint Level and Tack parameters will also be displayed Press OK to return to the File screen Select the weld procedure or folder and press Delete A dialog box will open asking you to confirm the delete Press Yes to delete the weld procedure or folder Select the weld procedure from the File View pane and press Load A message in the Status line will confirm that the weld procedure was successfully loaded Select the folder in which to save the weld procedure Press the File Name box The keyboard will appear Enter the name of the new weld procedure and press Save The weld procedure will be saved and displayed in the File View pane To rename a weld procedure select the weld procedure The weld
108. or Delay Time 0 1 second or greater 01 s Weld General Start field Owad Added Rotor Delay Time Before Welding This method adds heat before the rotor begins advancing In this case full penetration is required before the rotor can advance but the heat input must be incremental See Fig 62 and the Level 1 Ramp Added Rotor Delay Time Guideline Worksheet below for use in conjunction with the Weld Procedure Guideline Worksheets Where the two worksheets have common parameters use the Level 1 Ramp Added Rotor Delay Time Guideline Worksheet values Level 1 becomes a Ramp up time and Rotor Delay Level The first weld level will be Level 2 To adjust the penetration E Increase the start penetration by increasing the Weld Time of Level 1 or by increasing the weld input current using Adjust from the Weld screen E Decrease the start penetration by decreasing the weld input amperage using Adjust from the Weld screen Downslope wT EN NI Z JM 41 f Start Current N W 5A 2 N O x Rotor Delay Level 1 Level 2 Level 3 Level 4 Level 5 0 1 s No Rotor gt lt Weld Weld gt Weld gt lt Weld Movement Time Time Time Time Level for Initial gt lt Welding Levels Penetration Fig 62 Added Rotor Delay Time Before Welding Owad Table 22
109. p of the M200 power supply to lift it out of the case Place the M200 power supply upright on a stable surface 2 Check the M200 power supply and accessories for damage 3 Record the model number and serial number from the rating label on the back of the M200 power supply Fig 5 along with the delivery date on the M200 Power Supply Warranty Information form and the Registration Information form page 17 Return the Warranty Information form to your authorized Swagelok representative to activate the warranty wade Note Contact your authorized Swagelok representative if the unit is damaged Note Do not store the M200 power supply near corrosive materials Store indoors and cover when not in use Registration Information Your authorized Swagelok representative provides support and service for your M200 power supply and Swagelok weld heads Please take a moment to fill out the information listed below See the rating label on the back of the M200 power supply Fig 5 for the model and serial numbers Keep this information available in case you need to contact your authorized Swagelok representative Date of Delivery Power Supply Model Number Serial Number Weld Head Model Number Serial Number Weld Head Model Number Serial Number Weld Head Model Number Serial Number Weld Head Model Number Serial Number Company Name Swagelok Distributorship
110. per level X cycles per second must equal a whole number of cycles per level to ensure each level ends with a complete Low to High Amps cycle before beginning the next level Owad Table 17 Metric Butt Weld Procedure Guideline Worksheet Example Based on 12 0 x 1 0 mm Entry Step Parameter Tube Tube 316LV Screen 31 For Wall lt 2 1 mm Weld Rotor Delay Time Wall step 5 x 1 6 General _ _Xx16 10x1 6 16 s Start field For Wall gt 2 1 mm Wall lt 2 1 mm Rotor Delay Time Overlap step 20 32 Downslope Time ota Step 20 constant Weld Constant OD lt 12 7 mm 1 25 General Finish field 12 7 lt OD lt 25 4 mm 2 5 25 4 mm lt OD 15 If Downslope lt 10 Pulse Rate step 22 then Downslope 10 Pulse Rate forces a minimum of 10 pulses for Downslope 144 125 115 s OD lt 12 7 mm 10 6 1 7 11 5 gt 1 7 NOTICE When welding 12 0 mm outside diameter with the 8 MRH weld head use a single pass one revolution weld procedure only Owad Automatic Tube ATW and Socket Welds In addition to tube butt welds the Weld Procedure Guideline Worksheets can be used to generate procedure guidelines for automatic tube welds ATW and socket welds These weld joints have features that require some weld parameter values to be different from tube to tube butt welds ATW Welds Because the ATW cuff adds material to the weld joint the wall Note To fixture center and
111. power supply To turn the fan on manually press Fan The fan will run continuously until Fan is pressed again Single Level Mode is for users who prefer the Swagelok D75 and D100 power supply programming format See Single Level Mode Operation page 84 for more information The Language screen allows you to change the language shown on the M200 power supply s screens Press the Language button to select the new language As soon as the language is selected the Back button at the bottom of the screen will display that language Press the Back button to return to the Main Menu and the screen will be in the selected language Displays the user s manual The user manual will display in the language selected if available The English version will display if it is not available Displays copyright and patent information M200 Power Supply User s Manual 27 M2C Welding Sy Q D Fig 19 Password Prompt Screen Note Changing the Fan Power On State to off on the Setup gt Operation tab will prevent the fan from turning on automatically when the M200 power supply is powered on Fig 20 Language Screen Owad 28 M200 Power Supply User s Manual Weld Screens The Weld screens Fig 21 are used to view and adjust see Note the parameters of the active weld procedure The screen is divided into upper and lower sections The Upper Section Tabs contain information related to the weld procedure
112. procedure name will be shown in the File Name box Press Rename and an input box and a keyboard will be displayed Enter a new file name and press Rename in the input box Create Folder allows you to create an empty subfolder in internal memory or on the USB flash drive To create a new subfolder highlight the folder you want to put the new subfolder in and select the File Name box Enter the name of the new folder using the keyboard and press Create Folder The new subfolder will appear in the Folder View pane Note Folders cannot be renamed using Rename M200 Power Supply User s Manual 37 File Copy Tab The File Copy tab Fig 33 allows the user to copy folders and files between folders in internal memory or to and from a USB flash drive Folder panes When the File Copy tab opens the internal memory and USB Flash Drive if attached folders will be shown in both folder panes Press a folder twice to display its contents Press twice again to close it To copy a file select the destination folder and the file to copy Press Copy gt gt or lt lt Copy If you select a folder the entire folder will be copied The Folder Move fields show the name of the folder or file selected The Status line at the bottom of the screen displays status and error messages Folder Move fields Table 10 File Copy Tab Buttons Status line c Copies the selected folder or file from the left Fig 33 File Copy Tab 9py
113. process Metric unit of pressure measurement 1 bar 1 02 x 10 4 millimeters of water An action that occurs when the arc fails to start A welding technique in which more than one level of current is used during the weld process A welding technique in which the electrode welds for more than one revolution during the combined levels in the weld procedure Often used in fusion welding of small diameter parts The purge setting used during the weld process Purge setting includes flow rate and time Outside diameter The gas used to shield the electrode and work pieces during the welding process and to cool the weld head A welding technique in which the arc rotates around the weld joint circumference Owad Oxidation Penetration Postpurge Power supply Prepurge Pulse rate Pulse weld Purge gas Ramp Rotor Rotor delay current Rotor delay time Rotor speed Single level Single pass Socket weld Owad A discoloration or tint that occurs in the weld area that is caused by the presence of oxygen It can vary in color and intensity based on the weld temperature and the amount of oxygen present Oxidation increases the chances of weld joint corrosion The depth of the weld at the weld joint A full penetration weld completely penetrates the weld joint from the outside diameter to the inside diameter The amount of time the OD shield gas is applied after welding to cool the work piece and ele
114. re than field 20 seconds for high average amp welds 45 s 12 Shield Flow Weld see Table 25 page 80 24 std L min Purge Setup Normal Purge field 13 ID Flow Weld see Table 27 page 81 80 std L min Purge Setup ID Pressure a see Table 27 page 81 2 5 mbar Owad Table 24 Metric Step Program Parameter Guideline Worksheet Example Based on 54 0 mm x 2 6 mm Entry Step Parameter Tube Tube 316LV Screen 14 For future calculations High Amp current factors F4 F2 and F see Table 29 page 82 F 18 F4 Fo F3 F gt 110 Fs 1 3 15 For future calculations Width 12 8 x Wall step 5 12 100 12 8 x 2 6 12 100 128x 12 100 _ _ _ 0 45 16 High Amps for Level 1 F step 14 x Wall step 5 F3 Weld Fz x Width step 15 1 18 x 2 6 110 Levels 1 x x 1 1 3 x 0 45 1 989 A 17 Low Amps for all levels High Amps Levei 1 step 16 Weld F3 step 14 1 _ Levels 1 1 98 9 1 3 1 43 0 A 18 For future calculations do not add columns on screen at this time Number of levels for multiple level schedule NLevels typically 4 allowed range is 1 to 99 4 19 For future calculations Travel speed calculation Travel speed based on wall thickness Speedwal See Table 29 page 82 Speedwa 58 mm min Travel speed based on OD Speedop See Table 29 page 82 Speedop 51 mm min Total travel speed
115. rk piece anode An action that occurs when the arc fails to sustain itself during the weld The distance between the electrode and the work piece The gauge used to set the arc gap in the weld head rotor The period of the welding cycle following prepurge During arc start approximately 0 01 second high voltage is applied between the electrode and work piece initiating the arc An inert gas used as an OD shield and ID purge gas for gas tungsten arc welding In pulsed current welding current levels are set to pulse between high amps and low amps during the weld process Average current is based on high amps current low amps current and high amps width Average current is calculated using the formula High Amps x High Amps Width Low Amps x 1 High Amps Width Average Current The purge setting used before prepurge and or after postpurge This can be used to reduce the overall purge time by increasing the purge gas flow rate prior to prepurge and or after postpurge A weld joint in which two work piece faces are aligned axially Gauge used to center the work pieces in the fixture block The condition in which the weld profile is below the surface of the work piece An electrical service line used for only one device A dedicated line isolates the device from interference created by other equipment and allows it to utilize the full current capacity of the line The percentage of time during a 1
116. rns off OD shield gas flow Owad Performing a Weld Read and understand all safety information contained in this manual before starting the weld 1 Complete all side panel connections as described in Setting Up the M200 Power Supply page 19 Installing the Weld Head page 20 and Setting Up the Gas Supply System page 21 Install the electrode and set the arc gap using the arc gap gauge in accordance with the weld head user s manual Install the collets in the fixture block Align and clamp the work pieces in the fixture block Load an existing weld procedure as described in Load Save Print Delete Tab page 35 or create a new weld procedure as described in Program page 38 Connect the ID purge gas line to the work pieces to be welded and set the flow meter Connect the weld head to the fixture block Press the Start button Display Indications During Welding During welding the status messages are displayed on the Process tab along with a time remaining counter After the Weld is Complete 1 2 The M200 power supply will return to the Ready state Check the fixture block to confirm that it has cooled before handling Increasing the postpurge or blast purge postweld time will aid cooling Remove the weld head from the fixture block If it is difficult to remove release one of the side plate levers 4 Remove the ID purge gas lines from the welded assembly Remove the welde
117. rocess The information displayed on the Weld screens is saved with the weld procedure See page 28 for more information about the Weld screens The File screens are used to print preview delete load and save weld procedures The File mode applies only to weld procedures and does not affect the M200 power supply Setup or Weld Log files See page 35 for more information about the File screens The Program screens are used to create new weld procedures using Auto Create or Manual Create See page 38 for more information about the Program screens Program The Weld Log screens are similar to the File screens but are exclusively for Weld Log records Weld Log records may be viewed printed copied or deleted using these screens Weld Log records may be saved to a USB flash drive for transfer to a PC Weld Log records may also be exported to a PC using a serial cable See page 39 for more information about the Weld Log screens Weld Log The Setup screens are used to change options set dimensional units and passwords and review settings Changes are saved in the M200 power supply s internal memory and are not part of a weld procedure The Setup mode also contains utilities for updating software resetting weld counts and monitoring free memory See page 42 for more information about the Setup screens When a Swagelok weld head is first connected to the M200 power supply the power supply assumes the rotor is at true
118. rrent specified for the Delay Current is maintained during this time The rotor does not move during this time E Prepurge is the time in seconds when OD shield gas flows through the weld head and around the weld joint before the arc is initiated Fig 64 Single Level Timing Control Group Note A minimum of 10 seconds prepurge is recommended for all Swagelok weld heads If weld head extension cables are used add one second for each foot of extension cable m Weld Time is the actual welding time in seconds at the average current During the Weld Time the output current cycles between High Amps and Low Amps at the Pulse Rate and High Amps Width entered During this time the rotor moves at the speed specified as the Rotor Speed Weld Time process forms the main body of the weld m Downslope is the time in seconds during which the average weld current decreases uniformly until the arc is extinguished During this time the rotor continues to move at the speed specified as the Rotor Speed Downslope reduces the likelihood of weld cracking E Postpurge is the time in seconds the OD shield gas continues to flow through the weld head and around the weld joint after the arc is extinguished This gas flow prevents oxidation and contamination of the weld bead and electrode while the work piece is cooling Z q aa m a o ui m e a m gt ui z D E Rotor Speed is expressed as a percen
119. se lever Fig 54 Clearing a Paper Jam Installing and Replacing the Optional Fan Filter The filter is not required for normal power supply operation It can be purchased for use in dusty environments To install or replace the optional fan filter in the M200 power supply Fig 55 1 Turn off the power to the M200 power supply 2 Press the latch at the side of the fan housing door and pull it open 3 Remove the fan filter cover 4 Remove the old filter and press the new filter into the cover 5 Snap the fan filter cover back into place and close the fan housing door Failure to clean or replace the fan filter periodically could result in excessive heat buildup Contact your authorized Swagelok representative for replacement filters Note Using the filter may decrease the duty cycle See Table 39 page 100 Fan housing PAM xg Filter Fan filter cover Fig 55 Installing and Replacing the Optional Fan Filter Owad Weld Parameter Development Weld parameters are the values used to create a weld procedure The shape and duration of the output current waveform a graphical representation of the weld procedure is determined by the weld parameter settings Figure 56 shows the waveform typical parameters generate during the course of a multilevel weld The weld parameter settings are Parameter 1 4 High Amps A 71 7 60 9 Low Amps A 21 7 21
120. se or decrease High Amps Width in increments of 10 up to 30 m The next three presses of the up or down button increase or decrease High Amps in increments of 10 up to 30 gm The final three presses of the up or down button increase or decrease Low Amps in increments of 10 up to 30 To return to the original values for the weld procedure you must reload the program from memory See Limits Tolerances page 30 for more information M200 Power Supply User s Manual 31 Fig 26 Process Tab vaat Time x bowes bese a Does om Laro Dhow bent resets E Pfr Tene D a paki fiw Pati fer om O fiw eet Laney k Ki yem a ete x Dest Ge F gt Dos FF J Fig 27 Purge Setup Tab Fig 28 General Setup Tab Fig 29 Levels Tab Owad 32 M200 Power Supply User s Manual Table 7 Weld Lower Section Tabs Tacks X Fig 30 The M200 power supply supports weld procedures with tacks nonpenetrating spot welds used to hold work pieces in place The number in parentheses indicates the number of tacks specified for the weld procedure To set the tack method choose from the options available in the drop down box next to the user field Automatic The entire selected weld procedure will be completed when the Start button is pressed on the Process tab Tacks Only Only the tacks portion of the selected weld procedure will be s completed When the user returns PORRO
121. sion Cords Extension cords may be used with the M200 power supply Extension cords must meet the current capacity specifications in Table 43 page 101 Owad A WARNING The M200 power supply must be grounded or electrical shock can result Setting up the M200 Power Supply 1 Position the M200 power supply so that both sides are accessible 2 Make sure the power switch on the left side of the M200 power supply is in the OFF O position 3 Connect the power cord to the power connector on the side of the unit Fig 6 Turn the connector a quarter turn clockwise to lock it in place 4 Optional Install the fan filter on the left side of the M200 power supply See page 51 Note The M200 power supply should not be operated when resting on either the left or the right side printer or fan filter side or when tilted more than 15 on its horizontal axis The MFC will not function properly in these positions NO USER SERVICEABLE COMPONE REFER SERVICE TO QUALIFIED PERS Fig 6 Connecting the Power Cord Owad Installing the Weld Head The weld head assembly attaches to the right side of the M200 power supply with four separate connectors Fig 7 E Weld head quarter turn connector E Electrode red m Work green m Weld head OD shield gas 1 Align the notch on the weld head quarter turn connector with the small tab in the M200 power supply socket labeled WELD HEAD
122. sition Purge Setup Displays the Normal Purge Blast Purge and Gas Fig 27 Type fields General Displays the Start and Finish fields Fig 28 Levels X A level is a section of the weld procedure defined by Fig 29 the parameters shown in Fig 29 Parameters can be varied by level A weld procedure can have from 1 to 99 levels The number in parentheses indicates the number of levels specified in that weld procedure Levels are shown in the process window in real time during the weld To add a level press the top of a column to highlight it then press the Add button on the right side of the window A new column containing a copy of the selected column s data will be added after the selected column Repeat for additional levels To delete one or more levels press the top of the column or columns to select them Press the Delete button on the right side of the window Adjusting Average Amps Adjust Up Down allows a user with a security password to make Average Amps adjustments within the limits and tolerances set by the owner or programmer Select the level or levels to be adjusted and press the up or down buttons to adjust Average Amps page 30 within the limits in a weld procedure defined by the programmer If no level is selected all levels are affected by Adjust Up Down Average Amps is reduced with the down button or increased with the up button gm The first three presses of the up or down button increa
123. ss the field to be filled in Depending on the information to be entered a numeric keypad alphanumeric keyboard or drop down menu will appear A USB mouse and keyboard also can be connected to the M200 power supply for data entry Numeric Keypad The valid range for the selected parameter will display at the bottom of the keypad E Press the number keys Fig 14 to enter information Press Done to save the settings and close the keypad E Press lt Bksp to erase the last character entered Press Clear to erase the entire entry Taah s eee pantani of ama a Fig 13 Calibration Target Screen Duy Orrore A Pon Delay Teme sO Olit Deg wa Fig 14 Numeric Keypad Owad 24 M200 Power Supply User s Manual Keyboard E Use the onscreen keyboard Fig 15 as you would a computer keyboard E To reposition the keyboard press the gray bar at the top of keyboard and drag it to the new position E To close the keyboard press return Note The return key will not start a new line of text Table 4 Key Functions Key Function Home Moves cursor to the beginning of the line End Moves cursor to the end of the line Prop Moves cursor to the end of the line BS Backspace Deletes character to the left of the cursor Also deletes selections that have been highlighted Tab Closes the keyboard return Closes the keyboard Ctrl Ctrl z Undo last step Ctrl
124. state to OFF will make the default for the fan button on the main screen OFF The user can not disable the fan during the weld cycle The fan is always on during the weld Fig 42 Operation Tab cycle Owad 44 M200 Power Supply User s Manual Table 14 Setup Upper Section Tabs Passwords Fig 43 Fig 44 Fig 45 Shows the current privilege level of the user screen and allows passwords to be set or reset Setting Passwords The owner password is set in the Setup Wizard the first time the M200 power supply is powered on To set security or programmer passwords m Press the Current Privilege Level button Fig 43 set by default at the Programmer level A drop down menu Fig 44 will appear on the right side of the screen that allows you to choose the level of security for the M200 power supply E Select Owner If you choose to set passwords You can now use the Change Security and Change Programmer buttons to set these passwords Fig 45 Resetting Passwords The Current Privilege Level button displays the level of security in effect gm With owner privilege you can reset any password gm With programmer privilege you can reset the programmer or security password gm With security privilege you can reset the security password Press the Change Owner Change Security or Change Programmer buttons to reset the passwords Removing Passwords Programmer and security passwords can be remove
125. t attached to the work piece Attach the correct fixture D High rotor The weld head cannot Adjust the rotor speed or speed provide the speed change the weld head programmed in the active weld procedure D Invalid The weld procedure A parameter field must be procedure selected is not filled in within tolerance executable using the Weld screen D MD failed The motor driver inside Call for service init the M200 power supply controlling weld head movement is not functioning properly D MFC no No OD shield gas flow Check gas connection flow is present The weld is and purge connector stopped immediately attachment to weld head to prevent weld head for an obstruction in the damage purge path If OD shield flow control is disabled on the Setup gt Flow Control tab this error will not display D MFC Flow has become Reduce input pressure oscillation unstable and the weld will until flow has stabilized Owad be stopped Information Pera s li aaa i Pangi tots Deowtion 0500 049 2MLV 04 03 94 Creston Game 08 12 200 Popa sow mm cree OD wan van QO Fig 82 Disable Condition Message Table 44 Disable Conditions Disable Message Description Remedy Welding can continue once the M200 power supply resets Using 230 V ac would prevent An AC input error was tuis error detected The weld The M200 power supply D AC input attempted requires more requires 90 V minimum
126. t face against electrode offset parameters are referenced from the socket centering gauge and a 0 015 in The arc gap is 0 010 in 0 25 mm from the socket OD for all 0 38 mm offset spacer e g feeler sizes and the offset is 0 015 in 0 38 mm from the socket face gauge Clamp socket in collets Fig 58 Adjustments may be necessary Push tube to the bottom of the socket then pull it back 1 16 in 1 5 mm minimum Clamp tube Note Start all socket welds between the 11 and 12 o clock positions to assist the formation of a weld pool Socket OD Socket wall thickness Arc gap 0 010 in 0 25 mm lt Electrode offset 0 015 in 1 16 in 1 5 mm minimum E 0 38 mm pull back Fig 58 Socket Weld Joint Table 19 Socket Weld Guideline Worksheet Table 16 Fractional or Example Based on Table 17 1 2 in x 0 049 in Fractional Metric or 12 0 x 1 0 mm Metric Entry Step Parameter TB TB 316LV Screen 4 For future calculations Fractional tubing Side 1 diameter Socket OD 0 73 in OD see part drawing Metric tubing 18 5 mm 16 High Amps for Level 1 1200 x Socket wall thickness _ _ Weld Fractional tubing Fractional tubing Levels 1 1200 __ 1200 x 0 115 138 0 A Metric tubing Metric tubing 47 2 x 47 2X3 2 151 0 A 17 Low Amps 0 33 x High Amps eye 1 Step 16 __ Fractional tubing Weld 0 33 xX_ 0 33 xX 138 0 455 A Levels 1 Metric tubing 0 33 x 151 0 49 8 A
127. tage of the maximum revolutions per minute rom that the rotor can attain A rotor speed setting of 99 gives the maximum rpm for the weld head Owad Z lt co m Q O ui m a m gt a ui r z D lee 6 M200 Power Supply User s Manual Single Level Weld Process Buttons The Weld Process buttons Fig 65 control the welding operation and provide some manual control functions for the weld head The buttons function as follows Electrode Change Jog Jog Back Fig 66 Start Home Print rel Ile Positions the rotor for electrode replacement and prevents to the M200 power supply from welding See the weld head user s manual for instructions on electrode replacement After replacing the electrode press Electrode Change again The rotor will move the electrode back to the true home position Press to move rotor clockwise Press again to stop The light in the corner of the button will blink while the rotor is moving The rotor will move at the speed defined as the Rotor Speed Press to move rotor counterclockwise Press again to stop The light in the corner of the button will blink while the rotor is moving The rotor will move at the speed defined as the Rotor Speed Activates the mass flow controller and starts the flow of OD shield gas to the weld head until you press the button again The button overrides prepurge and postpurge timers and allows OD shield g
128. tained in an open folder The active weld procedure will have a green icon In the Folder View press the folder name or icon to open it The weld procedures will be displayed in the File View pane in alphabetical order The Folder View will also display any subfolders contained in the original folder The buttons on the lower left Print View Delete and Load require you to select a file or folder before you press a button Press a weld procedure in the File View pane to highlight it The weld procedure name will appear in the File Name box below the File View pane Enter a file name in the File Name box before pressing the Save Rename or Create Folder buttons on the lower right of the screen When a file name is entered and saved a description that includes the OD wall thickness tubing material number of levels number of tacks and weld head model will be added automatically to the file name and displayed in the File View and whenever the weld procedure is loaded User s manual example 0 500 0 049 316LV 04 03 5H A User s manual example programmer selected file name 0 500 OD of work piece 0 049 wall thickness of work piece 316LV tubing material 04 number of levels 03 number of tacks 5H weld head model needed for weld procedure A ATW weld procedure P pipe schedule S step program The display will automatically change to the Weld Process tab after a Save has been performed Selected file with green icon F
129. the M200 power supply supply resets Using rating using 115 V ac 230 V ac would prevent input and the weld will be this error stopped Rotor jam The rotor stopped Remove obstruction from turning during the weld weld head and press Next procedure Home on the Main screen Speed The weld did not perform Attach the correct weld tolerance within the specified speed head for the loaded weld tolerance Tolerance is set on the Weld screen Limits Tolerances tab procedure Stop pressed The user pressed Stop to abort the weld Inspect work pieces and setup Start new weld Tacks not complete One or more tacks were not successful Inspect tacks and adjust weld procedure Weld head not home The weld head is not in the true home position Press Home on the touch screen Owad Weld System Hardware and Weld Process Problems Repair Replacement Instructions Certain remedies require a component such as a weld head to be disassembled cleaned or replaced For user maintenance weld procedures see the Maintenance section of the weld head user s manual www swagelok com Contact your authorized Swagelok representative with any questions Table 47 Power Supply Symptom NOTICE Do not exceed an inlet pressure of 100 psig 6 8 bar or MFC can be OD shield gas From Supply and To Weld Correct the connections visual gauge Head connections on the on the M200 power is not read
130. the U S Government Printing Office The M200 power supply has no internal serviceable parts and should not be disassembled Return the M200 power supply to an authorized Swagelok sales and service representative for service ELECTRIC SHOCK can kill 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 E Do not touch live electrical parts E Keep all panels and covers securely in place Do not touch electrode connector electrode or rotor after pressing start The electrode is electrically charged during the weld process E Follow local electrical codes and the guidelines in this manual when installing the M200 power supply 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 E Properly unplug the power cord Grasp the plug to remove it from the receptacle Owad FUMES AND GASES can be hazardous a y A Welding produces fumes and gases Breathing these fumes and gases may be hazardous to your health Build up of gases can displace oxygen and cause injury or death To avoid injury E Do not breathe fumes or gases E Ventilate the
131. the weld Table 45 Operational Conditions Operational Message Description Remedy W AC power There was an interruption See M200 Power Supply failure in the alternating current Specifications page 100 to the M200 power supply W DC power There was an interruption Call for service failure to the internal power source of the M200 power supply W Exceeding The maximum current Lower the average current weld head in the loaded weld or extend the weld time in current procedure exceeds the the weld procedure limits of the attached weld head W MD busy The motor driver inside The M200 power bit the M200 power supply supply will reset itself controlling weld head automatically movement did not accept a command from the weld procedure W MD The motor driver inside Powering off the M200 command error the M200 power supply controlling weld head movement did not accept a command from the weld procedure power supply then powering on again should correct this condition W MFC The MFC has not Wait 5 minutes after the warming up completed warmup M200 power supply is powered on to ensure accurate gas flow control W Printer The printer head is up for Close printer cutting head up loading head W Printer high temp The printer has overheated It must cool before it can print The printer will function properly when it has cooled W Printer out of paper Owad
132. to 1 91 35 110 2 2 102 19 0 to 22 0 19 0 to 22 1 20 1 92 to 2 00 35 100 2 0 91 22 5 to 25 0 22 2 to 25 3 25 2 10 to 2 16 79 0 1 8 84 25 5 to 31 5 25 4 to 31 6 2 17 to 2 29 71 0 1 6 76 32 0 to 38 0 31 7 to 38 0 32 2 30 to 2 41 71 0 1 6 66 38 5 to 44 0 38 1 to 44 3 40 2 42 to 2 77 18 110 1 3 58 44 5 to 50 5 44 4 to 50 7 50 2 78 to 3 00 18 110 1 3 51 60 0 to 76 0 50 8 to 76 1 63 Owad M200 Power Supply User s Manual 83 Owad lt x W A Ww O W gt W l W l o O 84 M200 Power Supply User s Manual Single Lewal Mode Operation In Single Level Mode single level weld procedure guidelines developed on previous power supplies can be entered using the M200 power supply touch screen Single Level Mode operation enables the user to enter either single pass or multiple pass weld procedure guidelines Single Level procedures can be entered manually or by using the Program gt Auto Create screen and choosing Levels Only in the Levels Tacks field 1 Level in the Procedure Type field and Active No Save in the Save Procedure field Single Level Mode incorporates features of the M200 power supply including the internal mass flow controller electrode position indicator Electrode Change button and the Weld Log The touch screen displays the welding process and message information Messages indicate weld parameter setup errors power supply status etc The status indicator lights on the touc
133. urge connector stopped immediately attachment to weld head to prevent weld head for an obstruction in the damage purge path If OD shield flow control is disabled on the Setup gt Flow Control tab this error will not display MFC Flow has become Reduce input pressure oscillation unstable and the weld will until flow has stabilized be stopped Owad Fig 84 Weld Error Message Table 46 Weld Error Conditions Weld Error Message Misfire Description The arc was not established Remedy Check the arc gap setting electrode and fixture Power source AC overcurrent The input current ac is above the M200 power supply rating using 115 V ac input and the weld will be stopped Welding can continue once the M200 power supply resets Using 230 V ac would prevent this error Power source AC voltage The input alternating current voltage is not allowable The M200 power supply requires 90 V minimum for 115 V and 180 V minimum for 230 V Power source high temp The M200 power supply has overheated If this occurs during a weld the M200 power supply will stop the weld immediately This condition resets automatically when the M200 power supply has cooled If welding heavy wall tubing keeping the fan on constantly could prevent this error Power source The average output Welding can continue overcurrent current dc is above once the M200 power
134. weld head user s manual for instructions on electrode replacement After replacing the electrode press Electrode Change again The rotor will move back to the home position Weld Setup Fig 22 Displays the Joint and Setup fields and allows adjustment of values Notes User Fields 1 User Fields 2 Fig 23 Fig 24 Displays an open field for entering comments and observations Press the white area once to display the onscreen keyboard Notes will be saved with the weld procedure and shown in the Weld Log as Procedure Notes Displays User Fields 1 and 2 The software will remember the eight most recent entries for each field and display them in a drop down box The owner or programmer can set data entry requirements that must be completed before a weld is performed This information is part of the weld procedure and is stored in the Weld Log Three options are available in drop down boxes next to each user field No An entry is not required for this field It may be entered at the discretion of the user Yes An entry is required for the field The entry will remain in that field until a new weld procedure is loaded Failure to enter information into this field will cause a disable code Change An entry is required in the field and must be reentered with every weld Failure to enter information into this field will cause a disable code M200 Power Supply User s Manual 29 A CAUTION The rotor will
135. x Cut and save selected highlighted text Ctrl c Copy and save elected highlighted text Ctrl v Paste saved text at cursor point del Deletes character to right of cursor Also deletes selections that have been highlighted It Moves cursor one space to the left rt Moves cursor one space to the right up Moves cursor to line above dn Moves cursor to line below pgup Moves to the preceding page pgdn Moves to the next page Drop Down Menus Drop down menus Fig 16 allow you to select entries from a list Drop down menus are indicated by a down arrow TY Press the field or arrow to display the list of selections Highlight the selection to change the value Owad Fig 15 Onscreen Keyboard Note To select text highlight it by pressing and dragging your finger over the selection Fig 16 Drop Down Menu Operation This section describes the basic operation of the M200 power supply Main Menu The Main Menu Fig 17 provides access to the M200 power supply s functions Select functions by pressing the onscreen button or by using a USB mouse to click on the selection The Main Menu buttons are described in Table 5 page 26 Welding System Owode Fig 17 Main Menu M200 Power Supply User s Manual 25 Owad Table 5 Main Menu Selections and Functions The Weld screens display detailed information about the weld and are used to input parameters start the weld and monitor the weld p
136. x 2 6 mm Entry Step Parameter Tube Tube 316LV Screen 1 Programmer Joe Welder Weld Information Programmer box 2 Joint Type Example Tube to tube Tube Tube Weld Side 1 Tube to auto tube weld Tube ATW Side 1 Tube Weld Setup Side 2 Tube to auto socket weld Tube Socket Side2 Tube Joint field 3 Material Side 1 316LV Weld Side 1 Side 2 Side 2 316LV Weld Setup Joint field 4 Work piece diameter Weld Diameter Side 1 i Side1 54 0 mm Weld Setup Diameter Side 2 Side2 540 mm Joint field For future calculations OD use larger of Side 1 and Side 2 54 0 mm 5 Wall thickness Weld Wall Side 1 use socket wall thickness for 26 mm Weld Setup socket weld Joint field Wall Side 2 26 mm For future calculations Wall use larger of side 1 and side 2 2 6 mm 6 Head weld head model Weld 40H Weld Setup Setup field 7 Electrode part number Weld see weld head user s manual SWS C 094 2 302 Weld Setup Setup field 8 Arc Gap for socket welds 0 25 mm is suggested Weld see weld head user s manual for other weld 1 52 mm Weld Setup styles Setup field 9 Arc Gauge Weld see weld head user s manual 0 00 mm Weld Setup Setup field 10 Shield Gas Weld Argon Purge Setup ID Gas Gas Type field Argon 11 PrePurge Time Continuous purge suggested for micro weld Weld heads minimum 20 second purge for all Purge Setup other heads 45 s Normal Purge PostPurge Time 20 seconds suggested purge time mo

Swagelok M200 Power Supply User's Manual, (MS-13

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