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WELDING SYSTEM USER'S MANUAL, CWS-D100-1B, CWS

1. OMAN Secondary Solenoid Valve Secondary Solenoid Bypass Plug Weld Head R SWS Fixture Block Installation 2 stage Regulator E Inert Gas TT Ne Cylinder Internal Purge Gas Flow Meter Internal Purge Gas Shut Off Valve Figure 2 7 Optional Gas Delivery System Secondary Solenoid Bypass Plug 2005 Swagelok Company All rights reserved September 2005 2 13 Installation CWS D100 B Welding System Preliminary Check Before placing the SWS into operation you should check that the power supply is operating correctly To check the system follow these steps 1 Connect the power supply power cord to an electrical outlet 2 Turn onthe power supply circuit breaker After a 2 second to 4 second delay the following is displayed e Blinking decimal point followed by a zero in the Average Current and Average Voltage displays on the power supply front panel See Figure 2 8 Figure 2 8 Average Current and e Theamber colored Fixture indicator light is Voltage Displays on indicating that the fixture block is not attached to the weld head See Figure 2 9 If the power supply does not come on refer to Section 7 Troubleshooting for a list of possi
2. 1 Encoder Board Assembly 2 Encoder Sleeve 3 Encoder Wheel 4 Motor 5 Spacer 6 Home Sensor Assembly 7 Sensor Mount 8 Sensor Mount Screws 9 Power Block Housing motor side CWS 5PBH PKG CWS 5PBH B PKG 10 Power Block Pins CWS 5PBH PKG CWS 5PBH B PKG CWS 5PBA PKG 11 Work Post 12 Drive Gear CWS 11122 P KG 13 Drive Gear Washer CWS 11122 P KG 14 Drive Gear Screw CWS 11122 P KG 15 Brush Springs CWS 11111 PKG CWS 11157 02 CWS 5PBA PKG 16 Gas Bayonet CWS 5PBH PKG CWS 5PBH B PKG 17 Thread Insert CWS 5PBH PKG CWS 5PBH B PKG 18 Power Block Screws CWS 5PBH PKG CWS 5PBH B PKG CWS 5PBA PKG 19 Work Plate CWS 11053 PKG 20 Work Plate Screw CWS 11053 PKG CWS 5PBA PKG 21 Power Strap Internal Star Washer CWS 11117 PKG CWS 5PBA PKG 22 Power Strap Screw large CWS 11117 PKG CWS 5PBA PKG 23 Power Strap Screw small CWS 11117 PKG CWS 5PBA PKG 24 Power Strap External Star Washer CWS 11117 PKG CWS 5PBA PKG 25 Power Strap CWS 11117 PKG 26 Safety Interlock Sensor 27 Power Block Housing brush side CWS 5PBH PKG CWS 5PBH B PKG 28 Brush CWS 11111 PKG 29 31 32 Secondary Gear Assy CWS 11142 PKG gear bearing gear pin 30 31 32 Primary Gear Assy gear bearing gear pin CWS 11118 PKG 33 Electrode Post 34 Drive Coupler Pins CWS 11122 PKG 35 Drive Coupler 36 Drive Coupler Motor Pin 37 Sleeve x 38 Motor Mounting Screws CW
3. Travel Speed in min Seconds per Revolution MICRO WELD HEAD TUBE WELDING Travel Speed vs Rotor Speed Switch Setting VS Seconds per Revolution in min Rotor Speed Switch Setting 1 2 in 3 8 in 1 4 in 1 8 in 3 95 i 90 r 85 SB 80 Curve Model 5 CWS D100 1B 65 CWS D100 2B 60 TS 45 40 TS I 25 20 re 3 0 20 19 18 17 16 15 14 13 1211109 876543210 0 10 20 30 40 50 60 Travel S peed in min Seconds per Revolution Figure 5 1 Rotor Switch Speed Setting Graphs Micro Weld Head Series 5 Weld Head Fractional 2005 Swagelok Company all rights reserved 5 11 September 2005 Weld Parameter Adjustment Travel Speed in min Rotor Speed Switch Setting 1 2 in 3 8 in 1 4 in 99 95 90 5 8 in 85 80 75 3 4 in 70 65 7 8 in 60 35 50 45 40 35 30 25 20 16 12 8 4 0 20 19 18 17 16 15 14 13 1211109 8 7 6 5 4 3 2 10 0 Travel Speed in min VS Rotor Speed Switch Setting 10 VS 20 CWS D100 B Welding System Seconds per Revolution Curve Model CWS D100 1B i CWS D100 2B 30 40 50 60 Seconds per Revolution SERIES 10 WELD HEAD TUBE WELDING
4. HEE EER EEE EERE EEE 0 Fa CRE MES HSA DT APT CET OS 3 1 Travel Speed mm s 20 30 40 50 60 Seconds per Revolution SERIES 10 WELD HEAD TUBE WELDING 2005 Swagelok Company all rights reserved September 2005 D 5 Weld Head Information CWS D100 B Welding System SEES vs Rotor Speed Switch Setting vs Seconds per Revolution 22mm 18mm Rotor Speed Switch Setting 25 mm 20mm 16mm 99 95 90 z Curve Model 35 mm is CWS D100 1B 70 i CWS D100 2B 65 REE 52 mm 50 45 40 28 mm 40 mm a EE 4 t t t t t t t t t t t t t t t t t 0 t t t t t t t t t t t t 8 0 7 0 6 0 5 0 4 0 3 0 2 0 1 0 0 0 10 20 30 40 50 60 70 80 90 100 110 120 8 5 18 6 5 5 5 4 5 3 5 2 5 15 0 5 Travel Speed mm s Seconds per Revolution SERIES 20 WELD HEAD TUBE WELDING D 6 2005 Swagelok Company all rights reserved September 2005 Appendix E Arc Gap Gage Setting Tables Wall Thickness and Arc Gap Material Thickness mm Arc Gap in mm in mm 0 010 to 0 020 0 25 to 0 51 0 020 0 51 0 021 to 0 030 0 52 to 0 76 0 025 0 64 0 031 to 0 045 0 77 to 1 14 0 030 0 76 0 046 to 0 055 1 15 to 1 40 0 035 0 89
5. Travel Speed i n min Seconds per Revolution SERIES 20 WELD HEAD PIPE WELDING Figure 5 3 Rotor Switch Speed Setting Graphs Series 20 Weld Head Fractional 2005 Swagelok Company all rights reserved September 2005 5 13 Weld Parameter Adjustment CWS D100 B Welding System TRS vs Rotor Speed Switch Setting vs Seconds per Revolution Rotor Speed Switch Setting 6 mm 3mm g Curve Model 95 90 8 mm 85 D CWS D100 1B CWS D100 2B 10 mm 12 mm N 55 j H 0 8 5 8 0 7 5 7 0 6 5 6 0 5 5 5 0 4 5 4 0 3 5 3 02 5 2 0 1 5 1 0 0 5 0 0 5 10 15 20 25 30 35 40 Travel Speed mm s Seconds per Revolution MICRO WELD HEAD TUBE WELDING ie ares vs Rotor Speed Switch Setting vs Seconds per Revolution Rotor Speed Switch Setting 12mm 10mm 8mm 6mm 3 mm 14 mm ame a ok til a Curve Model A 75 i CWS D100 1B le i mn CWS D100 2B aa AE AEE Ee BLE BE BE BE BLE BE BE FLE El 0 8 0_ 7 0 6 0 5 0 40 3 0 2 0 1 0 0 0 10 20 30 40 50 60 85 75 65 55 45 35 25 15 0 5 Travel Speed mm s Seconds per Revolution SERIES
6. 2005 Swagelok Company all rights reserved September 2005 F 49 Parts Drawings CWS D100 B Welding System F 50 2005 Swagelok Company all rights reserved September 2005 Appendix G Gas Flow Rate Tables Figure G 1 Pressure Gage Purge Rate and Pressure Tables Tube Wall Minimum ID Swagelok Head Restrictor Size Thickness Purge Rate Pressure Purge Rates Size 13 to 16 8 torr 1 16 in 0 015 in 3 std ft3 hr 7 to 9 iwc 10 to 20 std ft3 hr n a n a n a 1 5 std L min 175 to 230 mmwc 5 to 10 std L min 17 4 to 22 4 mb 9 3 to 16 8 torr 1 8 in 0 028 in 5 std ft3 hr 5 to 9 iwc 10 to 20 std ft3 hr 1 16 in 3mm 0 8 mm 2 3 std L min 130 to 230 mmwc 5 to 10 std L min 12 4 to 22 4 mb 5 2 to 6 3 torr 1 4 in 0 035 in 7 std ft3 hr 2 8 to 3 4 iwc 10 to 20 std ft3 hr 1 8 in 6mm 1mm 2 5 std L min 71 to 86 mmwc 5 to 10 std L min 3 mm 7 0 to 8 5 mb 2 8 to 4 7 torr 3 8 in 0 035 in 7 std ft3 hr 1 5 to 2 5 iwc 10 to 20 std ft3 hr 1 8 in 10 mm Imm 2 5 std L min 38 to 64 mmwc 5 to 10 std L min 3 mm 3 7 to 6 2 mb 1 9 to 2 8 torr 1 2 in 0 049 in 15 std ft3 hr 1 0 to 1 5 iwc 10 to 25 std ft3 hr 1 4 in 12 mm 1mm 7 std L min 25 to 38 mmwc 5 to 12 std L min 6 mm 2 5 to 3 7 mb 2005 Swagelok Company all rights reserved September 2005 G 1 Gas Flow Rate Tables CWS D100 B Welding System Purge Rate and Pressure Tables Continued Tube Wall Minimum ID Swagelok Head Restricto
7. 2005 Swagelok Company all rights reserved September 2005 CWS D100 B Welding System Eight Hour Maintenance Clean the motor module and weld head after every 8 hours of welding time Motor Module 1 Disconnect the weld head from the motor module 2 Clean the motor module power lug sockets with the provided stainless steel brush See Figure 6 20 3 Carefully remove any obstructions from the purge port See Figure 6 20 4 Clean the two power lugs on the weld head with the provided stainless steel wire brush See Figure 6 21 Maintenance Caution Do not clamp the motor module in a vise while cleaning Power Lug Sockets Purge Port Figure 6 20 Cleaning the Power Lug Sockets and the Purge Port Power Lugs Figure 6 21 Cleaning the Weld Head Power Lugs 2005 Swagelok Company all rights reserved September 2005 6 11 Maintenance Body Gear Side D Idler Gears Electrode NS Body Brush Side Figure 6 22 Removing Series 4 Micro Weld Head Components for Cleaning Insert spring Ze so ends bend toward brush Figure 6 23 Lifting the Weld Head Brush for Cleaning CWS D100 B Welding System Series 4 Micro Weld Head Disassembly and Cleaning Use the following instructions to disassemble the micro weld head for cleaning Refer to the exploded view in Figure 6 22 for part references 1 11 12 13 Lay the micro weld head down on a clean
8. Contaminants in the weld head and purge lines Increase prepurge time Check the gas source for low pressure Shielding gas line disconnected from the power supply Reconnect gas line 7 10 2005 Swagelok Company all rights reserved September 2005 CWS D100 B Welding System Symptom Inside diameter discoloration Cause Insufficient internal purge gas Remedy Increase internal purge gas flow rate and prepurge time Contaminants in the purge line Increase prepurge time Check the gas source for low pressure Migration of oxygen from the internal purge gas exit port of the work pieces to the weld joint Reduce exit port size with a purge restrictor See Note Wrong type of purge gas used Change to correct type of purge gas Contamination on work pieces Clean the work pieces before welding Nicks cuts in the internal purge Replace gas line Hole in the weld bead gas line Incorrect arc gap Resetthe arc gap with the arc gap gage Excessive internal Remove any purge gas back pressure or surge obstruction of the internal purge gas flow or reduce the flow Improper Inspect and tube preparation reface tubing Incorrect weld Check and parameter setting impulse adjust the weld parameter settings Loss of shield gas flow Check the shielding gas source for low pressure Check gas lines f
9. Locking Ring Tab Figure 7 1 Fixture Block Locking Ring Tab CWS D100 B Welding System Cause The weld head is not fully engaged into fixture block Remedy Reattach the fixture block to the weld head The fixture block locking ring tab is dirty See Figure 7 1 Clean the locking ring tab Make sure all surfaces are shiny The rear panel fixture connector is not fully engaged Check that the fixture connector is seated and its collar is tight 7 4 2005 Swagelok Company all rights reserved September 2005 CWS D100 B Welding System Weld Head Symptom Rotor does not return to the home position Cause Fixture connector is not fully engaged Remedy Check that the fixture connector is seated and its collar is tight Rotor is not atthe home position when the power supply is turned on Use ROTOR J OG to move the rotor to the home position then cycle power off and on Dirty home sensor Disassemble the weld head and check the home sensor for dirt See the appropriate motor and power block assembly drawing in Appendix F Use compressed air to blow off debris Rotor gear ring is misaligned with secondary gears Realign the rotor with the weld head opening See Section 6 Maintenance Fixture connector has broken or damaged pins wires Call for service Home sensor is damaged or misaligned Call for service Rot
10. Table F 10 CWS 20H A Weld Head P arts List Reference No Description Available in Kit No 1 Motor Cover CWS 11121 PKG 2 Motor Cover Pins CWS 11121 PKG CWS 20WHA PKG 3 Weld Head Housing Pins CWS 20HP MTRHOUSE CWS 20WHA PKG 4 Motor Cover Screws CWS 11121 PKG CWS 20WHA PKG 5 Weld Head Housing Screws long CWS 20HP LOCHOUSE CWS 20WHA PKG CWS 20HP MTRHOUSE CWS 20HP LOCHOUSEPL 6 Locking Ring Plate Pins CWS 11104 PKG CWS 20WHA PKG 7 Locking Ring with Handle CWS 11106 1 8 Locking Ring Plate CWS 11104 PKG 9 Locking Ring Plate Screws CWS 11104 PKG CWS 20WHA PKG 10 Work Extension Screw CWS 11112 PKG CWS 13101 05 11 Work Extension Washer CWS 11112 P KG 12 Work Extension CWS 11112 PKG 13 Weld Head Housing Screws short CWS 20HP LOCHOUSE CWS 20WHA PKG CWS 20HP MTRHOUSE CWS 20HP LOCHOUSEPL 14 Weld Head Housing CWS 20HP LOCHOUSE locking ring side CWS 20HP LOCHOUSEPL 15 Motor and Power Block Assembly 16 Rotor Assembly CWS 11062 SUB 17 Weld Head Housing CWS 20HP MTRHOUSE motor cover side 18 Bearing Pad Pins CWS 20HP BEARINGPAD 19 Bearing Pad CWS 20HP BEARINGPAD For part ordering information contact your Swagelok representative Not available as a field replaceable spare part 2005 Swagelok Company all rights reserved September 2005 Parts Drawings CWS D100 B Welding System Figure F 11 CWS 20H A Motor and Power Block Assembly F 22 2005 Swagelok Company all rights reserved September 2005
11. 2005 Swagelok Company all rights reserved September 2005 Swagelok VCR VCO Ultra Torr Micro Fit TM Swagelok Company 2005 Swagelok Company Printed in U S A PPI September 2005 R1 MS 13 209
12. Micro Weld Head Fixture Parts List Reference No Description Available in KitNo 1 Moveable Side Plate right SWS 8MFP MSPR 2 Cam Pin SWS 8MFP LATCH 3 Cam Latch right SWS 8MFP LATCH 4 Split Base Adjustable Side SWS 8MFP BASEPKG A 5 Split Base Fixed Side SWS 8MFP BASEPKG A 6 Button Keeper SWS 8MFP BASEPKG A SWS 8MFP SCREWS 7 Flat Head Screw SWS 8MFP BASEPKG A SWS 8MFP SCREWS 8 Cam Latch LEFT SWS 8MFP LATCH 9 Moveable Side Plate LEFT SWS 8MF P MS P L 10 Slotted Flat Head Screw SWS 8MFP ARCCVRPKG SWS 8MFP SCREWS 11 Fixed Side Plate RIGHT SWS 8MFP FSPR 12 Moveable Arc Cover SWS 8MFP ARCCVRPKG 13 Fixed Arc Cover SWS 8MFP ARCCVRPKG 14 Socket Head Screw SWS 8MFP BASEPKG A SWS 8MFP SCREWS 15 Fixed Side Plate LEFT SWS 8MFP FSPL 16 Shoulder Screw SWS 8MFP BASEPKG A SWS 8MFP SCREWS 17 Wave Spring Washer SWS 8MFP BASEPKG A SWS 8MFP SCREWS SWS 8MFP MSPR SWS 8MFP MSP L SWS 8MFP FSPR SWS 8MF P FSP L 18 Flat Washer SWS 8MFP BASEPKG A SWS 8MFP SCREWS SWS 8MFP MSPR SWS 8MFP MSPL SWS 8MFP FSPR SWS 8MFP FSPL 19 Binding Screw SWS 8MFP SCREWS SWS 8MFP MSPR SWS 8MFP MSPL SWS 8MFP FSPR SWS 8MFP FSP L 20 Tape Strips SWS 8MFP TAPE Denotes size in 1 16ths or mm includes sizes 04 06 08 6 mm 8 mm 10 mm and 12 mm For part ordering information contact your Swagelok representative Parts Drawings
13. 9 Ensure that the two power strap screws are tight A Do not damage the safety See Figure 6 12 interlock sensor while cleaning the brush 10 Ensure that the work plate screw is tight and free from See Figure 6 11 excessive oxidation See Figure 6 13 Clean the work plate with a fine grit abrasive pad if necessary 11 Inspect the gears for wear and replace if damaged by referring to the appropriate motor and power block assembly drawing in Appendix F Part Drawings Figure 6 12 Inspecting the Power Strap Screws Ce Figure 6 13 Inspecting the Work Plate and Screws 2005 Swagelok Company all rights reserved 6 7 September 2005 Maintenance Rotor Screw Electrode Sa Clamping U Plate Screw Remove Electrode our Figure 6 14 Removing the Rotor and Electrode Clamping Plate Screws Opening Brush 4 Ring Rotor Pin GearRing le Location Rotor Pin Location Figure 6 15 Placing the Rotor on the Work Surface Separate Rings Brush Ring pe eee Figure 6 16 Separating the Gear Ring from the Brush Ring Caution A Do not use a flammable liquid to clean the ball bearings CWS D100 B Welding System Rotor To disassemble the rotor follow these steps 1 Remove the rotor screws and the electrode clamping plate screws from the rotor Remove the electrode from the ceramic insert See Figure 6 14 2 Place the rotor on a clean dry surface with the rotor opening fac
14. Burrs Face Perpendicular to Axis Tube Facing Tool Square Corners Burrs 1 Rs AJ Red Result _ Burrs in m Flow Path ZZ Le tb IZ ZZ TF Le Gap Irregular Wall Thickness ee A A LE I YT OT ET OT LE 2 DL EN LIEN ART SY LA RE Reduced Flow Area Smooth Transition _ at Wall Faces N X No Gaps Figure 3 20 Tube Preparation Tubing must be square and burr free to ensure repeatable high quality autogenous fusion welds Cut the tubing to length with a hacksaw or tube cutter Face the tube ends with a lathe or a portable facing tool Deburr the ends making sure that both the inside and outside diameters are square and burr free Clean the tube ends using an appropriate solvent 2005 Swagelok Company All rights reserved September 2005 CWS D100 B Welding System M inimize the chance of a poor quality weld by following these guidelines e Tube ends must be square e Tube ends must be burr free e Tube ends must not have a wall thickness variation exceeding 15 of nominal e Tube ends must be free of any rust grease oil paint or other surface contaminates Fixturing the Work Select or configure the appropriate fixture block Select the collets to match the work outside diameter Selecting the Fixture Block and Collets 1 Select the fixture block that accepts the outside diameter of the tube to be welded See Ta
15. around the weld joint for fit and alignment If the alignment is not correct proceed to theA ppendix H Fixture Block Alignment Figure 3 25 Placing Second Work Piece 2005 Swagelok Company all rights reserved 3 31 September 2005 Operation CWS D100 B Welding System Connecting the Purge Gas Line Refer to Figure 2 6 in Section 2 Installation Connect the internal purge gas line to the work pieces 1 Set the internal purge gas flow meter depending on the inside diameter of the work pieces See A ppendix G Gas Flow Rate Tables 2 Open the shut off valve in the purge gas line The length of time for internal purge before welding depends on the internal volume and length of the work piece to be welded 3 32 2005 Swagelok Company All rights reserved September 2005 CWS D100 B Welding System Operation Connecting the Weld Head to the Fixture Block The instructions that follow refer to a Series 5 10 20 style weld head See Section 4 Micro Weld Head for instructions for using a micro weld head Safety Interlock This feature disables the power supply when the weld Note Use only safety interlock weld head is not attached to the fixture block On the front panel heads with the D100 power supply Fixture remains on until the weld head is properly attached A sensor in the weld head signals the power supply when the fixture block is connected Fixture turns off and the power supply is ready to weld
16. e baud 9600 e stop 1 e parity none e data8 e buffer gt 200 characters suggest 2000 See Figure B 22 Use the cable pin designations in the table below to create an interface cable Note that the table describes the signal wiring on the B side of the cable The B connector must have male pins to properly mate to the printer connector The A side of the cable is wired to RS 232 standards Table B 2 Interface Cable B Connector Wiring B Side Connector Pin No Signal Name from SWS D100 2 Transmit 3 Receive 5 Clear to send CTS 7 Signal ground 9 15 V dc 20 Data Transmit Ready DTR 24 Ground Power to CWS DRP Do not wire to standard printer B 16 2005 Swagelok Company all rights reserved September 2005 Appendix C Electrode Selection Tables and Geometry CWS 4MRH A CWS 4MFH A Micro Weld Heads Component Electrode Electrode Electrode Part No Length L Diameter D CWS C 040 405 P 1 8 in 0 405 in 0 040 in 1 16 in 10 29 mm 1 02 mm F L gt 3mm D gt CWS C 040 325 P 1 4 in 0 325 in 0 040 in i 6mm 8 26 mm 1 02 mm CWS 8MRH Micro Weld Head Electrode Electrode Electrode Part No Component OD Length L Diameter D CWS C 040 405 P 1 4 in 0 405 in 0 040 in 6 8 mm 10 29 mm 1 02 mm CWS C 040 325 P 3 8 in 0 325 in 0 040 in 10 mm 8 26 mm 1 02 mm CWS C 040 281 P 1 2 in 0 281 in 0 040 in 12 mm 7 14 mm 1
17. 0 056 to 0 064 1 41 to 1 63 0 040 1 02 0 065 to 0 082 1 64 to 2 28 0 045 1 14 0 083 to 0 154 2 29 to 4 00 0 050 1 39 Caution Check recommended weld arc gap ranges for each weld head Refer to the following tables Note When welding ATW fittings and weld rings be sure to add the cuff thickness to the wall thickness see Table 5 3 on page 5 4 2005 Swagelok Company all rights reserved September 2005 E 1 Arc Gap Gage Setting Tables CWS D100 B Welding System Weld Head Arc Gap Gage Setting Tables CWS 4MRH A CWS 4MFH A Arc Gap Gage Dia 0 620 in Setting Setting Setting Setting Setting Setting for for for for for for Actual 0 020 in 0 025 in 0 030 in 0 51 mm 0 64 mm 0 76 mm Nominal OD Arc Gap Arc Gap Arc Gap Arc Gap Arc Gap Arc Gap OD in in in in in mm mm mm 0 057 0 359 0 364 0 369 9 13 9 26 9 38 0 059 0 360 0 365 0 370 9 15 9 28 9 40 1 16 0 062 0 361 0 367 0 372 9 19 9 32 9 44 0 065 0 363 0 368 0 373 9 25 9 36 9 48 0 067 0 364 0 369 0 374 9 26 9 39 9 51 0 120 0 391 0 396 0 401 9 93 10 06 10 18 0 122 0 392 0 397 0 402 9 95 10 08 10 20 1 8 0 125 0 393 0 398 0 403 9 99 10 12 10 24 0 128 0 395 0 400 0 405 10 03 10 16 10 28 0 130 0396 0 401 0 406 10 06 10 19 10 31 0 245 0 453 0 458 0 463 11 52 11 65 11 77 0 247 0 454 0 459 0 464 11 54 11 67 11 79 1 4 0 250 0 456 0 461 0 466 11 58 11 71 11 83 0 253 0 457 0 462 0 467 11
18. 30 28 20 0 3 8 4 7 Notes 1 Itis suggested that a continuous shielding gas flow be used to extend the life of the micro weld head 2 On 1 4 in 3 mm and 6 mm OD tubing a restrictor with pressure gage was used Purge gas pressure was set to 2 in to 4 in of water for 1 4 in and 6 mm 6 in to 8 in of water for 3 mm SOUIEPIND 21nP3201 d PIM sooz Jequuaydes t I pouosa au6u je Aueduuod ojebems G00Z WELD PROCEDURE GUIDELINES English For Reference Only TERR JE IE ail ro v tc Er i a la ils eisalal el ela ns e Eg pa pp BE BE 3 Eg su 9 QE 2 AA id T 3 8 3 o g a g g ep 2 8 2 4 SS E DIE E E a EZIB 288 20 Sk ok 10 250 0 035 0 035 10 566 69 385 1100 10 25 20 03 10 14 7 30 36 171 15 47 Multiple 5375 0 035 0 035 10 629 71 1385 110 0 10 25 20 03 10 20110 130 25 171 15 47 TB TB 316L 0 250 0 035 0 035 70 566 51 1385 1100 5 33 35 08 10 12 4 30 27 194 15 47 Single 0 375 0 035 0 035 0 629 5 1 38 5 10 0 5 30 35 0 8 10 19 4 30 18 186 15 47 0 500 0 049 0 035 0 691 5 0 158 8 180 4138 50 0 8 10 23 30 13 323 1520 47 0 250 0 035 0 035 0 585 6 1 48 0 120 10 24 21 0 3 10 16 8 30 32 206 1
19. 32 34 Lengthening the Impulse Width raises the average current This increases the heat input per unit of electrode travel resulting in increased inside diameter dropthrough and weld bead width Swagelok Company All rights reserved September 2005 CWS D100 B Welding System Weld Parameter Adjustment Weld Example No 7 Table 5 14 lists the parameter change used to create the weld shown in Figure 5 15 Table 5 14 Weld Example No 7 P te Setti Setti i BER EEK a te Figure 5 15 Weld Example No 7 Speed s rev 26 19 33 15 Raising the Rotor Speed decreases the heat input per unit of electrode travel resulting in no inside diameter penetration Weld Example No 8 Table 5 15 lists the parameter change used to create the weld shown in Figure 5 16 Table 5 15 Weld Example No 8 Reference This parameter Seting seting Figure 5 16 Weld Example No 8 Speed s rev 26 19 19 26 Lowering the Rotor Speed increases the heat input per unit of electrode travel resulting in increased inside diameter dropthrough and weld bead width Reference Weld Illustration 2005 Swagelok Company all rights reserved 5 21 September 2005 Weld Parameter Adjustment Figure 5 17 Impulse Rate Reference Weld Figure 5 18 Impulse Rate Weld Example No 1 Figure 5 19 Impulse Rate Weld Example No 2 CWS D100 B Welding System Impulse Rate Reference Weld Table 5 16 lists the parameter used
20. AFTER WELDING IS COMPLETE USE CAUTION WHEN HANDLING 2005 Swagelok Company All rights reserved September 2005 4 13 Micro Weld Heads CWS D100 B Welding System Using the Optional Bench Mounting Bracket Caution The bench mounting brackets attach Series 4 and A Do not put the micro Series 8 Micro Weld Heads to a workbench There are weld head in a vise two mounting plates on the bracket giving you a choice Severe damage may of mounting orientations result which would void any warranty Series 4 Bench Mount Bracket 1 Determine the mounting orientation of the bracket on the workbench See Figure 4 17 Secure the bracket to the workbench M ake sure the latch is accessible 2 Open the latch on the side of the bracket 3 Slide the micro weld head into the bracket from below until the raised detent on the bracket is aligned to the machined recess of the micro weld head body Fasten the latch to secure the micro weld head to the bracket Figure 4 17 Using the Series 4 Mount Bracket 4 14 2005 Swagelok Company All rights reserved September 2005 CWS D100 B Welding System Micro Weld Heads Series 8 Bench Mount Bracket 1 Remove one of the button head screws holding the latch bracket to the weld head See Figure 4 18 A Insert one of the supplied adapter screws 2 Secure the adapter screw with a 1 4 in wrench or the micro fixture tool See Figure 4 18 B 3 Repeat steps 1 and 2
21. Arc Start Weld Procedure Guideline 5 6 Downslope Weld Procedure Guideline 5 8 Duration Weld Procedure Guideline 5 6 Impulse Weld Procedure Guideline 5 4 Impulse Width Weld Procedure Guideline 5 5 Maintenance Weld Procedure Guideline 5 4 Calculating Weld Parameter Weld Procedure Guide line Example Worksheet 5 9 Caution Condition Defined 3 13 Example of 3 16 Multiple 3 14 Centering Gage Defined A 3 Micro Weld Head Fixture Use of 4 9 Series 5 10 20 Fixture Blocks Use of 3 30 Ceramic Insert Defined A 3 Collet Defined A 3 Collets Series 5 10 20 Fixture Blocks Installing 3 29 Specifications 1 11 Concavity Defined A 3 Controlling Weld Quality 5 22 Controls Front Panel 3 2 Cracks in Weld Causes 5 17 Current Control Switches Defined 3 3 2005 Swagelok Company all rights reserved September 2005 Index Index D Data Logging B 4 Defined A 3 Data Monitoring Defined A 3 Data Recording Printer Cabling B 9 Cleaning B 15 Clearing Paper Jams B 15 Installation B 6 Loading Paper B 7 Maintenance B 15 Mounting on Power Supply B 8 Operation B 9 Performing the Self Test B 10 Unpacking and Inspection B 6 User Parameter Printout B 14 Weld Data Record Examples B 10 Dedicated Line Defined A 3 Determine Work Specification Weld Procedure Guideline Example Worksheet 5 9 Diagnostics Defined A 3 Digital Displays Defined 3 9 Disable Defined A 4 Disable Condi
22. Extension Screw CWS 11112 PKG CWS 13101 05 11 Work Extension Washer CWS 11112 PKG 12 Work Extension CWS 11112 PKG 13 Weld Head Housing Screws short CWS 10HP LOCHOUSE CWS 10WHA PKG CWS 10HP MTRHOUSE CWS 10HP LOCHOUSEPL 14 Weld Head Housing CWS 10HP LOCHOUSE locking ring side CWS 10HP LOCHOUSEPL 15 Motor and Power Block Assembly 16 Rotor Assembly CWS 11056 SUB 17 Weld Head Housing CWS 10HP MTRHOUSE motor cover side 18 Bearing Pad Pins CWS 10HP BEARINGPAD 19 Bearing Pad CWS 10HP BEARINGPAD For part ordering information contact your S wagelok representative Notavailable as a field replaceable spare part 2005 Swagelok Company all rights reserved September 2005 Parts Drawings CWS D100 B Welding System Figure F 8 CWS 10H A Motor and Power Block Assembly F 16 2005 Swagelok Company all rights reserved September 2005 CWS D100 B Welding System Parts Drawings Table F 8 CWS 10H A Motor and Power Block Assembly Parts List Reference No Description Available in Kit No 1 Encoder Board Assembly 2 Encoder Sleeve 3 Encoder Wheel 4 Motor 5 Spacer 6 Home Sensor Assembly 7 Sensor Mount 8 Sensor Mount Screws 9 Power Block Housing motor side CWS 10PBH PKG CWS 10PBH A PKG 10 Power Block Pins CWS 10PBH PKG CWS 10PBH A PKG CWS 10PBA PKG 11 Work Post 12 Drive Gear
23. Figure 6 5 Inspect Exposed Surfaces of the Weld Head Caution Do not use lubricants inside the weld head CWS D100 B Welding System Series 5 10 20 Weld Head Perform weld head maintenance daily and every 40 hours of welding time If desired maintenance may be performed before the 40 hour interval Daily Maintenance At the start of each work day 1 Inspect the weld head for cleanliness Pay close attention to the rotor area See Figure 6 5 2 Press STOP RESET Check the rotor for smooth rotation If the rotation is erratic or noisy disassemble the weld head and clean the rotor gears and brush See page 6 5 Series 5 10 20 Weld Head Disassembly and Cleaning At the end of each work day 1 Remove dirt carbon and vapor deposits from the weld head with a clean soft cloth and a solvent such as alcohol or acetone 2 Store the weld head in a clean dry place Forty Hour Maintenance Every 40 hours measure the rotor speed to ensure its accuracy For example 1 Set ROTOR SPEED to one of the following values e 19 for a micro and Series 5 10 Weld Head e 38 for a Series 20 Weld Head This sets a rotor speed of 13 seconds per revolution for the micro weld head and 26 seconds per revolution for the Series 5 10 20 Weld Head 6 4 2005 Swagelok Company all rights reserved September 2005 CWS D100 B Welding System W hile watching the rotor status LED press and hold ROTOR JOG and note the rot
24. ORIGINAL PULSE WID SETTING Y 10 0 YES IS NO DECREASE DELSE IMPULSE lt 30 OF ORIGINAL HIGH AMPS BY a SETTING 10 OF ORIGINAL SETTING MART No DECREASE MAINTENANCE OOF ORIGINAL LOW AMPS BY as 10 OF ORIGINAL SETTING CE ORIG RE EVALUATE INCREASE THE ORIGINAL WELD Egg TRAVEL SPEED BB to meet additional SUIDELINE ONMIN cleanliness requirements Figure 5 20 Weld Procedure Guideline Flowchart 2005 Swagelok Company all rights reserved 5 23 September 2005 Weld Parameter Adjustment CWS D100 B Welding System 5 24 Swagelok Company All rights reserved September 2005 Section 6 Maintenance Introduction To ensure your Swagelok Welding System SWS equipment is always in proper working order you must perform periodic maintenance on the system components This section describes the procedures necessary for maintaining the fixture blocks weld heads and power supply For detailed part drawings and information refer to Appendix F Parts Drawings Note f you experience problems while performing the procedures in this section refer to Section 7 Troubleshooting or contact your Swagelok representative Replace any defective parts Service replacement kits are available through your Swagelok representative 2005 Swagelok Company all rights reserved September 2005 6 1 Maintenance Non anodized Surfaces Under the Collets Inside Plate Surfaces
25. Table 2 2 Shipping Container Contents Part Description Part No Qty Welder Power Supply CWS D100 B 1 Power Cord CWS CORD 1 1 4 in Male QC SS QC4 S 400 1 Secondary Solenoid Bypass Plug 1 Swagelok Welding System CWS MANUAL D100B 1 User s Manual Denotes Model Denotes Language Remove the contents of the shipping container by performing the following steps 1 Remove the following items e Swagelok Welding System User s M anual e Swagelok Quick Connect stem e secondary solenoid bypass plug e power cord 2 Remove the power supply by lifting it by the handle Remove the side foam inserts Place the power supply on astable cart platform or table 3 Check the power supply and accessories for damage 4 Check that the serial number on the rear panel of the power supply matches the serial number on the shipping container label 5 Record the model and serial numbers and the delivery dates on page of the Forward section of this user s manual 2 4 2005 Swagelok Company All right reserved September 2005 CWS D100 B Welding System Installation Unpacking the Weld Head Cable Assembly and Related Components The following weld head components are packaged in a foam lined shipping container weld head assembly arc gap gage electrode package tool package 1 Inspect the container for damage 2 Remove the components from the container 3 Check the items for any damage
26. The safety interlock feature is not included on all weld heads Table 3 8 lists the first serial number of each weld head model that includes the safety interlock feature Table 3 8 Weld Heads with Safety Interlock Model No Serial No CWS M MTR A 10212 or higher CWS 4MRH A 20090 or higher CWS 4MFH A 30045 or higher CWS 8MRH all CWS 5H B 60100 or higher CWS 10H A 70033 or higher CWS 20H A 80015 or higher SWS 20H B all 2005 Swagelok Company all rights reserved 3 33 September 2005 Operation CWS D100 B Welding System Mating the Weld Head to the Figure 3 26 Releasing the Locking Lever GY g A o e 9 O JAN em LA R F Figure 3 27 Mating the Weld Head to the Fixture Block 1 Fixture Block Rotate the locking lever on the weld head counter clockwise until it stops See Figure 3 26 Insert the weld head into the fixture block See Figure 3 27 A Rotate the locking lever clockwise to secure the weld head See Figure 3 27 B Examine the Fixture light Verify that it is off 2005 Swagelok Company All rights reserved September 2005 CWS D100 B Welding System Operation Entering the Weld Parameters The following describes the parameters that are set on the SWS front panel as well as briefly discussing how the parameters are determined Using a Weld Procedure Guideline There are several reference weld procedure guideline
27. head until all status indicator lights are off CWS D100 B Welding System Status Indicator Lights The status indicator lights monitor certain elements of the power supply operation See Figure 3 6 The conditions monitored by some of the indicators are independent of the welding process M ost of the indicators light during the welding process to show the control sequence executed by the power supply The control sequence is affected by the values entered into the timing control switches The lights also notify you if any weld parameter settings exceed pre defined limits See Figure 3 8 for an example e Fixture indicates whether or not the weld head is properly attached to the fixture block If itis not connected the indicator light is on The power supply will not start a weld cycle when this indicator light is On e Prepurge indicates the prepurge cycle is active The Prepurge cycle occurs prior to arc start This light indicates that the shielding gas solenoid valve in the power supply is energized allowing the shielding gas to flow to the weld head prior to starting the welding cycle e Start indicates the power supply is in the arc start portion of the weld cycle e Weld time indicates the weld cycle is in progress e Downslope indicates the downslope cycle is in progress e Postpurge indicates the postpurge cycle is in progress The shielding gas continues to flow to the weld head and the rotor moves to the hom
28. information available in case you need to contact your Swagelok representative Power Supply Model Number Serial Number Delivery Date See rating label on the rear of the unit shown in Figure 1 Weld Head s Weld Head Model Number Serial Number Delivery Date Model Number Serial Number Delivery Date Model Number Serial Number Delivery Date Figure 1 Rating Label 2005 Swagelok Company all rights reserved September 2005 Foreword CWS D100 B Welding System ii 2005 Swagelok Company all rights reserved September 2005 CWS D100 B Welding System Foreword Safety Summary The safety information presented here pertains to both the Swagelok Welding System SWS and the process of Gas Tungsten Arc Welding GTAW Read Operating Instructions Read all of the instructions in this manual prior to operating the SWS Statements Caution Statements identify conditions or practices that could result in damage to the equipment or other property WARNINGI Statements identify conditions or practices that could result in personal injuries or loss of life Symbols The following symbols are used in this manual and on the equipment to visually identify where warning or caution information is found Consult symbols and related instructions below for necessary actions to avoid the hazards A WARNING or Caution This symbol identifie
29. is the length of time between the arc start period and the beginning of the weld time cycle e Thecurrent specified on the arc start rotary switch is maintained during this time e Therotor does not move during this time WELD TIME Seconds is the actual welding time at the average current During the weld time the output current cycles between the impulse and maintenance levels at the impulse rate and impulse width entered e During this time the rotor moves at the speed specified by the rotor speed rotary switch e Theweld time cycle forms the main body of the weld DOWNSLOPE Seconds is the time during which the average weld current uniformly decreases until the arc is extinguished e During this time the rotor continues to move at the speed specified by the rotor speed rotary switch e The downslope cycle reduces the chance of weld cracking 3 4 2005 Swagelok Company All rights reserved September 2005 CWS D100 B Welding System e POSTPURGE Seconds is the amount of time the shielding 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 is cooling e ROTOR SPEED of M ax Speed is expressed as a percentage of the maximum RPM that the rotor can attain A rotor speed setting of 99 gives the maximum RPM for the weld head See Table 3 1 Table 3 1 Maximu
30. procedure guideline CWS D100 B Welding System Cause Incorrect weld parameter s entered on the rotary switches Remedy Verify rotary switch settings match the guideline and adjust if necessary Refer to the flowchart in Figure 5 20 Adjust weld parameters as necessary using the weld procedure guideline Rotary switch settings are not giving the expected output Use test mode described in Section 3 Operation to verify proper switch operation Call for service if switches are faulty Voltage fluctuations during the weld cycle exceeding 2 V Weld head not seated properly into the fixture block Reattach the weld head to the fixture block Engage the weld head locking lever Work pieces are out of round Replace work pieces if out of standard specifications Insufficient shielding gas flow or contaminated shielding gas Check the shielding gas source for low pressure Check gas lines for leaks Change to a different gas source or change oxygen removal filter Outside diameter discoloration Insufficient shielding gas flow Increases shielding gas 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 purge gas used Change to correct type of purge gas Contamination on work pieces Clean the work pieces before welding
31. 02 mm 1 2 in 12 mm ATW fittings are outside the usable range 2005 Swagelok Company all rights reserved September 2005 C 1 Electrode Selection Tables and Geometry CWS D100 B Welding System CWS 5H B Weld Head rlo Le Electrode Electrode Electrode PartNo ComponentOD Length L Diameter D CWS C 040 705 P 1 8 in 0 705 in 0 040 in 3 16 in 17 90 mm 1 02 mm 3mm CWS C 040 605 P 1 4 in 0 605 in 0 040 in 5 16 in 15 37 mm 1 02 mm 6mm 8mm CWS C 040 555 P 3 8 in 0 555 in 0 040 in 1 2 in 14 10 mm 1 02 mm 10 mm 12 mm CWS C 040 450 P 5 8 in 0 450 in 0 040 in 15mm 11 43 mm 1 02 mm CWS C 040 405 P 16mm 0 405 in 0 040 in 10 29 mm 1 02 mm CWS 10H A Weld Head CWS C 062 1 105 P 1 4 in 1 105 in 0 062 in 3 8 in 28 07 mm 1 57 mm 1 2 in 6mm 8mm 10 mm 12 mm 14mm 15mm CWS C 062 855 P 3 4 in 0 855 in 0 062 in 7 8 in 21 72 mm 1 57 mm 18 mm 22 mm lin 23 mm 25 mm C 2 2005 Swagelok Company all rights reserved September 2005 CWS D100 B Welding System Electrode Selection Tables and Geometry CWS 20H A B Weld Head Component Electrode Electrode Electrode Part No OD Pipe Length L Diameter D CWS C 062 1 630 P 1 2 in 1 4 1 630 in 0 062 in 3 4 in 1 2 41 40 mm 1 57 mm 12 mm 3 8 18 mm 22 mm CWS C 062 1 380 P Lin 3 4 1 380 in 0 062 in 11 4 in 1 35 05 mm 1 57 m
32. 08 21 21 21 46 21 59 0 378 0 836 0 841 0 846 0 851 21 11 21 24 21 49 21 62 0 380 0 837 0 842 0 847 0 852 21 13 21 26 21 51 21 64 0 495 0 895 0 900 0 905 0 910 22 59 22 72 22 97 23 10 0 497 0 896 0 901 0 906 0 911 22 63 22 76 23 01 23 14 1 2 0 500 0 897 0 902 0 907 0 912 22 66 22 79 23 04 23 17 0 503 0 899 0 904 0 909 0 914 22 71 22 84 23 09 23 22 0 505 0 900 0 905 0 910 0 915 22 73 22 86 23 11 23 24 0 620 0 957 0 962 0 967 0 972 24 18 24 31 24 56 24 69 0 622 0 958 0 963 0 968 0 973 24 21 24 34 24 59 24 72 5 8 0 625 0 960 0 965 0 970 0 975 24 25 24 38 24 63 24 76 0 628 0 961 0 966 0 971 0 976 24 28 24 41 24 66 24 79 0 630 0 962 0 967 0 972 0 977 24 31 24 44 24 69 24 82 Arc Gap Gage Setting Tables 2005 Swagelok Company all rights reserved September 2005 E 5 Arc Gap Gage Setting Tables CWS D100 B Welding System CWS 5H B Arc Gap Gage Dia 31 60 mm Setting for Setting for Setting for Setting for Setting for 0 50 mm 0 64 mm 0 76 mm 0 89 mm 1 02 mm Nominal OD Actual OD Arc Gap Arc Gap Arc Gap Arc Gap Arc Gap mm mm mm mm mm mm mm 2 87 17 73 17 87 17 99 18 12 18 25 2 92 17 76 17 90 18 02 18 15 18 28 3 3 00 17 80 17 94 18 06 18 19 18 32 3 08 17 84 17 98 18 10 18 23 18 36 3 12 17
33. 1 Exit Test code 97 by pressing DOWNSLOPE and STOP RESET simultaneously then release both pushbuttons Enter 98 into ROTOR SPEED Test code 98 verifies the front panel lights and displays All front panel status indicator lights and all segments of the LED displays are turned on Exiting Test Mode 1 To return to the program mode press DOWNSLOPE and STOP RESET Simultaneously After releasing the pushbuttons the system will return to program mode Press STOP RESET to exit program mode and return to operational mode 2005 Swagelok Company all rights reserved 3 25 September 2005 Operation Electrode Clamping Screws Figure 3 17 Electrode Installation A WARNING TURN THE CIRCUIT BREAKER OFF WHILE INSTALLING THE ELECTRODE Caution Do not jog or move the rotor unless the electrode is clamped in place CWS D100 B Welding System Installing the Electrode in the Series 5 10 20 Weld Head Each Swagelok weld head comes with a selection of electrodes The following instructions show how to properly install the electrode in the Series 5 10 20 weld head See Section 4 Micro Weld Head for the micro weld head instructions Selecting the Proper Electrode Electrode length and diameter depend on your weld head model and the outside diameter of the work piece being welded To select the correct electrode use the Electrode Selection Table in Appendix C Electrode Selection Tables and Geometry
34. 1 fas A2 Figure F 22 CWS 4MFA Micro Weld Head Fixture F 42 2005 Swagelok Company all rights reserved September 2005 CWS D100 B Welding System Table F 21 CWS 4MFA Micro Weld Head Fixture Parts List Reference No Description Available in KitNo 1 Side Plate right 2 Side Plate Cam right CWS 4MFP LATCH A 3 Cam Pin 4 Side Plate Cam left CWS 4MFP LATCH A 5 Shoulder Screw CWS 4MFP LATCH A CWS 4MFP SCREWS 6 Binding Screw CWS 4MFP LATCH A CWS 4MFP SCREWS 7 Washer CWS 4MFP LATCH A CWS 4MFP SCREWS 8 Collet 9 Side Plate left 10 Tape Strips CWS 4MFP TAPE 11 Fixture Base Denotes size in 1 16ths or mm includes sizes 01 02 04 3 mm and 6 mm For part ordering information contact your S wagelok representative Notavailable as a field replaceable spare part Parts Drawings 2005 Swagelok Company all rights reserved September 2005 Parts Drawings CWS D100 B Welding System Figure F 23 CWS 4MF Micro Weld Head Fixture F 44 2005 Swagelok Company all rights reserved September 2005 CWS D100 B Welding System Parts Drawings Table F 22 CWS 4MF Micro Weld Head Fixture Parts List Reference No Description Available in KitNo 1 Side Plate right 2 Side Plate Cam right CWS 4MFP LATCH 3 Dowel Pin base 4 Cam Pin x 5 Side Plate Cam left CWS 4MFP LATCH 6 Shoulder Screw CWS 4MFP LATCH CWS 13
35. 1 00 6 to 12 2 96 1 04 to 1 40 16 to 19 2 12 1 42 to 1 65 22 to 25 1 69 1 66 to 2 00 25 to 38 1 69 2 03 to 2 28 40 to 52 1 27 2 30 to 2 76 2 Refer to the Rotor Speed switch setting graphs on pages 5 11 through 5 12 Calculate the R otor Speed a Locate the appropriate graph based upon the weld head model CWS 5H B b Locate the travel speed 5 in min at the bottom of the graph c From that point draw a vertical line up until the line intersects the line representing the work piece tubing outside diameter 1 2 in d From that point draw a horizontal line to the right Note The ROTOR SPEED setting is a to find the switch setting 26 percentage of the maximum weld head revolutions per minute For e Set ROTOR SPEED according to the result 26 example 25 is 25 of the in step 2 d maximum speed of the CWS 5H B weld head 2005 Swagelok Company all rights reserved 5 3 September 2005 Weld Parameter Adjustment CWS D100 B Welding System 3 Calculate the Impulse a Determine the wall thickness 0 049 in b Locate the wall thickness 0 049 in and the corresponding A factor in Table 5 3 Table 5 3 Wall Thickness and A Factor Wall Thickness Range in mm A Factor 0 015 to 0 045 0 381 to 1 143 1 1 0 046 to 0 083 1 168 to 2 108 1 2 0 084 to 0 109 2 133 to 2 769 1 3 Noter Because h POLE swich c Calculate the Impulse using the following formula accep
36. 10 Weld Example No 2 Reference Weld Illustration CWS D100 B Welding System Weld Example No 1 Table 5 8 lists the parameter change used to create the weld shown in Figure 5 9 Table 5 8 Weld Example No 1 Reference This Parameter Setting Setting Impulse Amperes 58 8 49 8 Average Current Display Amperes 32 28 87 Lowering the Impulse current lowers the average current This decreases the heat input per unit of electrode travel resulting in no inside diameter penetration Weld Example No 2 Table 5 9 lists the parameter change used to create the weld shown in Figure 5 10 Table 5 9 Weld Example No 2 Reference This Parameter Setting Setting Impulse Amperes 58 8 67 9 Average Current Display Amperes 32 35 2 Raising the Impulse current raises the average current This increases the heat input per unit of electrode travel resulting in increased inside diameter dropthrough and weld bead width 5 18 Swagelok Company All rights reserved September 2005 CWS D100 B Welding System Weld Parameter Adjustment Weld Example No 3 Table 5 10 lists the parameter change used to create the weld shown in Figure 5 11 Table 5 10 Weld Example No 3 Reference This i panies Setting Figure 5 11 Weld Example No 3 Maintenance Amperes 17 8 14 8 Average Current Display Amperes 32 30 2 Lowering the M aintenance current lowers the average current This decreases the heat input per
37. 20 Continuous Low 38 A NOTE 4 7 1 to 9 4 5 10 to 15 20 NOTE 2 Normal NOTE 3 50A 4 7 to 7 1 10 10 to 20 NOTE 1 20 NOTE 2 Normal NOTE 3 100A 4 7 to 9 4 20 A 10 to 20 NOTE 1 30 NOTE 2 Normal 100 A 4 7 to 9 4 20 B 20 to 40 NOTE 1 30 NOTE 2 Normal 100A 9 4 to 18 8 NOTE 1 Set flow to higher rates when welding at high current rates 2 Flow should be continuous for cooling when welding at high current rates 3 When welding wall thickness of 0 020 in 0 5 mm or less use low start power and an arc gap of 0 035 in 0 89 mm or less 4 When welding 1 2 in or 12 mm OD with a Series 8 weld head use the single pass one revolution weld procedure only 2005 Swagelok Company all rights reserved D 1 September 2005 Weld Head Information CWS D100 B Welding System Travel Speed h vs Rotor Speed Switch Setting vs Seconds per Revolution in min Rotor Speed Switch S etting 1 4 in 1 8 in 1 16 in g 95 Curve Model 90 Er ee ee 85 CWS D100 1B 80 7 CWS D100 2B 75 3 8 in 70 a5 60 l ee 1 2 in 50 45 40 35 30 Ts 20 ine 16 22 8 4 0 20 19 18 17 16 15 14 13 12 11109 8 7 6 5 4 3 2 1 0 0 5 0 15 20 25 30 35 40 Travel Speed in min Seconds per Revolution MICRO WELD HEAD TUBE WELDI
38. 227 2 232 56 04 56 18 56 30 56 56 56 68 495 2 332 2 337 2 342 2 347 2 352 59 09 59 23 59 35 59 61 59 73 497 2 333 2 338 2 343 2 348 2 353 59 11 59 25 59 37 59 63 59 75 11 2 500 2 334 2 339 2 344 2 349 2 354 59 15 59 29 59 41 59 67 59 79 503 2 336 2 341 2 346 2 351 2 356 59 19 59 33 59 45 59 71 59 83 505 2 337 2 342 2 347 2 352 2 357 59 22 59 36 59 48 59 74 59 86 995 2 582 2 587 2 592 2 597 2 602 65 44 65 58 65 70 65 96 66 08 997 2 583 2 588 2 593 2 598 2 603 65 46 65 60 65 72 65 98 66 10 2 2 000 2 584 2 589 2 594 2 599 2 604 65 50 65 64 65 76 66 02 66 14 2 003 2 586 2 591 2 596 2 601 2 606 65 54 65 68 65 80 66 06 66 18 2 005 2 587 2 592 2 597 2 602 2 607 65 57 65 71 65 83 66 09 66 21 Arc Gap Gage Setting Tables 2005 Swagelok Company all rights reserved September 2005 E 9 Arc Gap Gage Setting Tables CWS 20H A B CWS D100 B Welding System Arc Gap Gage Dia 79 23 mm Setting Setting Setting Setting Setting for for for for for 0 50 mm 0 64 mm 0 76 mm 1 02 mm 1 14 mm Nominal OD Actual OD Arc Gap Arc Gap Arc Gap Arc Gap Arc Gap mm mm mm mm mm mm mm 11 86 46 05 46 19 46 31 46 57 46 69 11 92 46 08 46 22 46 34 46 60 46 72 12 12 00 46 12 46 26 46 38 46 64 46 76 12 07 46 15 46 29 46 41 46 67 46 79 12 12 46 17 46 31 46 43 46 69 46 81 17 88 49 06 49 20 49 32 49 58 49 70 17 92 49 09 49 23 49 35 49 61 49 73 18 18 00 49 12 49 26 49 38 49 64 49 76 18 09 49 16 49 3
39. 4 0 78 0 230 4 35 42 0 5 30 82 41 30 12 420 15 10 20 2 000 0 065 0 045 2 605 5 0 78 0 230 4 39 42 os 30 75 38 30 13 420 15 10 20 2 000 0 083 0 045 2 605 4 0 99 6 300 4 40 54 os 30 04 47 30 11 57 8 15 17 10 20 2 000 0 109 0 045 2 605 4 0 999 570 4 50 78 10 30 94 47 30 11 785 15 20 10 20 SOUIJEPIND 21np3201 d PPM wayshs bulpjem G OOLG SMD Index A Adapter Inserts Specifications 1 12 Adjust Weld Parameters 5 1 Alignment Fixture Block H 1 Series 20H B H 5 Series 8 Micro Weld Head H 6 Arc Defined A 1 Arc Current 1 3 Arc Gap Defined A 1 Micro Weld Head Setting 4 8 Series 5 10 20 Weld Heads Setting 3 27 Arc Gap Gage Defined A 1 Micro Weld Head Setting 4 8 Series 5 10 20 Weld Head Setting 3 27 Setting Examples E 12 Setting Formula E 12 Setting Tables Series 10 Weld Head E 7 Series 20 Weld Head E 9 Series 4 Micro E 2 Series 5 Weld Head E 5 Series 8 Micro E 3 Swagelok ATW Fittings E 11 Arc Radiant Energy Defined A 1 Arc Start Defined A 1 Arc Voltage 1 3 Arc Welding Defined A 1 Arcing Defined A 2 Argon Defined A 2 Autogenous Defined A 2 Automatic Welding Defined A 2 Average Current Defined A 2 Backing Gas Defined A 2 Bench Mounting Bracket Micro Weld Head 4 14 Butt Weld Defined A 2 C Calculate
40. 5 20 Adjust weld parameters as necessary Incorrect arc gap Reset the arc gap with the arc gap gage Tip of electrode is worn or ground improperly Change the electrode Inconsistent heats of materials or changes in material chemistry Verify consistency of material with material supplier Refer to the flowchart in Figure 5 20 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 The end surfaces of the work pieces being welded are not perpendicular to their center axis Prepare the work piece weld ends properly See page 3 28 in this user s manual The fixture block side Tighten screws plate screws are as needed not tight After welding the The fitting tubing Center fitting tubing fitting tubing joint is still visible was not centered properly The electrode is bent or was not properly installed Inspect the electrode and replace if necessary Reset the arc gap with the arc gap gage Troubleshooting 2005 Swagelok Company all rights reserved September 2005 7 13 Troubleshooting CWS D100 B Welding System 7 14 2005 Swagelok Company all rights reserved September 2005 Appendix A Glossary Arc The flow of electrical current between an anode and cathode
41. 5 WELD HEAD TUBE WELDING Figure 5 4 Rotor Switch Speed Setting Graphs Micro Weld Head Series 5 Weld Head Metric 5 14 Swagelok Company All rights reserved September 2005 CWS D100 B Welding System Weld Parameter Adjustment gas vs Rotor Speed Switch Setting vs Seconds per Revolution Rotor Speed Switch Setting 12mm 10mm 8mm 6mm AN 99 14 mm 95 90 16 mm 85 80 Curve Model al E a CWS D100 1B 20 mm 70 1 65 D i CWS D100 2B 22 mm m LD 25 mm N 55 50 45 40 35 30 25 20 16 12 8 4 D A DL D D OL DOLL 0 fet st tt LE st H t 85 8 0 75 7 0 65 6 0 55 50 5 4 0 35 3 0 2520 1 510 05 0 0 10 20 30 40 50 60 Travel Speed mm s Seconds per Revolution Dares vs Rotor Speed Switch Setting vs Seconds per Revolution 22mm 18mm Rotor Speed Switch Setting 25 mm 20 mm 16 mm 28 mm 99 95 90 85 20 Curve Model 35 mm i CWS D100 1B 40 mm 70 CWS D100 2B 65 60 33 55 T mm 50 45 40 35 30 25 xX 20 16 12 8 4 t t t t t t t t t t 0 t t t t t t t t t t t 8 0 7 0 6 0 5 0 4 0 3 0 2 0 1 0 0 0 0 20 3
42. 628 15 57 15 70 15 83 15 95 3 8 0 375 0 615 0 620 0 625 0 629 15 60 15 73 15 86 15 98 0 378 0 616 0 621 0 626 0 631 15 65 15 78 15 91 16 03 0 380 0 617 0 622 0 627 0 632 15 67 15 80 15 93 16 05 0 495 0 674 0 679 0 684 0 689 17 12 17 25 17 38 17 50 0 497 0 675 0 680 0 685 0 690 17 15 17 28 17 41 17 53 1 2 0 500 0 677 0 682 0 687 0 692 17 20 17 33 17 46 17 58 0 503 0 678 0 683 0 688 0 693 17 22 17 35 17 48 17 60 0 505 0 679 0 684 0 689 0 694 17 25 17 38 17 51 17 63 2005 Swagelok Company all rights reserved E 3 September 2005 Arc Gap Gage Setting Tables CWS D100 B Welding System CWS 8MRH Arc Gap Gage Dia 20 65 mm Setting for Setting for Setting for Setting for Nominal OD Actual OD 0 51 mm 0 64 mm 0 76 mm 0 89 mm mm mm Arc Gap Arc Gap Arc Gap Arc Gap 5 87 13 77 13 90 14 02 14 15 5 92 13 79 13 92 14 04 14 17 6 6 00 13 84 13 97 14 09 14 22 6 07 13 87 14 00 14 12 14 25 6 12 13 89 14 02 14 14 14 27 7 87 14 76 14 89 15 01 15 14 7 92 14 78 14 91 15 03 15 16 8 8 00 14 83 14 96 15 08 15 21 8 08 14 86 14 99 15 11 15 24 8 13 14 89 15 02 15 14 15 27 9 88 17 12 17 25 17 37 17 50 9 93 17 15 17 28 17 40 17 53 10 10 00 17 20 17 33 17 45 17 58 10 08 17 22 17 35 17 47 17 60 10 14 17 25 17 38 17 50 17 63 11 86 16 77 16 90 17 02 17 15 11 91 16 79 16 92 1
43. 9 88 30 77 30 91 31 03 31 29 31 41 9 92 30 79 30 93 31 05 31 31 31 43 10 10 00 30 83 30 97 31 09 31 35 31 47 10 08 30 87 31 01 31 13 31 39 31 51 10 14 30 90 31 04 31 16 31 42 31 54 11 86 31 76 31 90 32 02 32 28 32 40 11 92 31 80 31 94 32 06 32 32 32 44 12 12 00 31 83 31 97 32 09 32 35 32 47 12 07 31 86 32 00 32 12 32 38 32 50 12 12 31 89 32 03 32 15 32 41 32 53 17 88 34 77 34 91 35 03 35 29 35 41 17 92 34 79 34 93 35 05 35 31 35 43 18 18 00 34 83 34 97 35 09 35 35 35 47 18 09 34 87 35 01 35 13 35 39 35 51 18 14 34 90 35 04 35 16 35 42 35 54 21 87 36 76 36 90 37 02 37 28 37 40 21 92 36 79 36 93 37 05 37 31 37 43 22 22 00 36 83 36 97 37 09 37 35 37 47 22 07 36 86 37 00 37 12 37 38 37 50 22 12 36 89 37 03 37 15 37 41 37 53 22 89 37 27 37 41 37 53 37 79 37 91 22 94 37 30 37 44 37 56 37 82 37 94 23 23 00 37 33 37 47 37 59 37 85 37 97 23 09 37 37 37 51 37 63 37 89 38 01 23 14 37 40 37 54 37 66 37 92 38 04 24 87 38 26 38 40 38 52 38 78 38 90 24 94 38 30 38 44 38 56 38 82 38 94 25 25 00 38 33 38 47 38 59 38 85 38 97 25 07 38 36 38 50 38 62 38 88 39 00 25 12 38 39 38 53 38 65 38 91 39 03 E 8 2005 Swagelok Company all rights reserved September 2005 CWS D100 B Welding System CWS 20H A B Arc Gap Gage Dia 3 118 in Setting Setting Setting Setting Setting Setting Setting Setting Setting Setting for for for for for for for for for for 0 025 in 0 030in 0 035 in 0 040in 0 045in 0
44. AVERAGE CURRENT 4 DOWNSLOPE g 20 O POSTPURGE i H L 1 3 ROTOR 4 7 La Seconds y Socords DOWNSLOPE KASSE See AVERAGE VOLTAGE IE PONN PURGE ROTOR PRINT AZ a ooo 1 Impulse rotary switch 8 Weld Time rotary switch 15 Downslope pushbutton 2 Maintenance rotary switch 9 Downslope rotary switch 16 Purge pushbutton 3 Impulse Rate rotary switch 10 Postpurge rotary switch 17 Rotor og pushbutton 4 Impulse Width rotary switch 11 Rotor Speed rotary switch 18 Print pushbutton 5 Arc Start rotary switch 12 Average Current display 19 Stop Reset pushbutton 6 Duration rotary switch 13 Average Voltage display 20 Status indicator lights 7 Prepurge rotary switch 14 Start pushbutton 21 Remote Pendant connector Figure 3 1 Front Panel Controls You operate the SWS by using pushbuttons and rotary switches on the front panel of the power supply The values you program into the rotary switches are determined by the weld procedure guidelines The front panel digital displays monitor the welding process and show message code information M essage codes are numbers that indicate weld parameter setup errors power supply status etc The status indicator lights on the front panel show the welding process sequence or flash a warning if the power supply detects that a weld parameter is set incorrectly 3 2 2005 Swagelok Company All rights reserved September 2005 CWS D100 B Welding System Operation Current Control Switches Th
45. American Welding Society 550 N W Lej eune Rd Miami FL 33126 Www aws org ANSI 249 1 Safety in Welding Cutting and Allied Processes American Welding Society 550 N W Le eune 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 Welding and Cutting Acquire from U S Government Printing Office Superintendent of Documents P O Box 371954 Pittsburgh PA 15250 www osha gov 2005 Swagelok Company all rights reserved xi September 2005 Foreword CWS D100 B Welding System xii 2005 Swagelok Company all rights reserved September 2005 Section 1 Introduction SWS D100 The Swagelok Welding System SWS is a versatile portable and easy to use orbital welding system This section includes e gas tungsten arc welding e system components e overview of SWS operation e specifications Figure 1 1 Swagelok Welding System 2005 Swagelok Company all rights reserved September 2005 1 1 Introduction CWS D100 B Welding System The purpose of this manual is to familiarize you with the SWS and to provide the reference informati
46. D100 B Welding System Exiting Program Mode Exit the program mode by pressing STOP RESET The system returns to operational mode See Caution Test Mode The power supply can be switched from the program mode to the test mode W hen selected the test mode is used to test the front panel controls displays and the optional remote operator pendant Table 3 6 TestMode Code Numbers 97 Test switches pushbuttons n a 98 Test indicator lights displays n a Test Descriptions 97 to 98 Front panel tests Code 97 is the front panel switch test code U se this test to verify the operation of all front panel rotary switches and pushbuttons Code 98 is the front panel light test U se this test to verify all front panel status indicator lights and LED displays 3 22 2005 Swagelok Company All rights reserved September 2005 CWS D100 B Welding System Entering Test Mode Refer to Figure 3 15 Enter the test mode using the following steps 1 Press and hold DOWNSLOPE 2 Press ROTOR JOG and then release both buttons at the same time The SWS is now in program mode 3 Enter 97 into ROTOR SPEED Code 97 tests front panel switches and pushbuttons 4 Press ROTOR JOG The controller changes from the program mode to the test mode Testing Rotary Switches Review the rotary switch numbers See Figure 3 1 on page 3 2 Switch one is Impulse and switch two is Maintenance etc Test code 97 displays the fir
47. KNOB 5 Latch CWS 12307 PKG 6 Latch and Hinge Screw CWS 12306 02 7 Plenum SWS 20BPLEN 8 Side Plate Screws CWS 20FIX PKG 9 Lanyard Screw long side plate SWS 20CG A 10 Bottom Side Plate left SWS 20TSPL A 1 Locking Ring Tab Screw SWS 20FP LOCKTAB 12 Helicoil 13 Insert 14 Dowel Pin 15 Locking Ring Tab SWS 20FP LOCKTAB 16 Hinge 17 Top Side Plate left SWS 20TSPL A 18 Bottom Side Plate right SWS 20TSPR A 19 Lanyard Screw short SWS 20CG A 20 Lanyard Star Washer SWS 20CG A 21 Centering Gage SWS 20CG A 22 Lanyard SWS 20CG A 23 Lanyard Star Washer SWS 20CG A For part ordering information contact your S wagelok representative Notavailable as a field replaceable spare part 2005 Swagelok Company all rights reserved September 2005 Parts Drawings CWS D100 B Welding System Figure F 17 SWS 20FSP1R Special Purpose Fixture Block F 32 2005 Swagelok Company all rights reserved September 2005 CWS D100 B Welding System Parts Drawings Table F 16 SWS 20FSP1R Special Purpose Fixture Block P arts List Reference No Description Available in Kit No 1 Bottom Side Plate 2 Top Side Plate 3 Dowel Pin 4 Knob SWS 20FP KNOB 5 Lever Cam Assembly CWS 12130 2 6 Latch Holder SWS 20FP LATCH1 7 Screw CWS 13112 04 8 Latch CWS 12146 PKG 9 Latch Screw CWS 12132 02 10 Latch Holder SWS 20FP LATCH2 1 Helicoil 12 Dowel Pin CWS 20FIX PKG For part ordering in
48. M icro Fit fitting in one of the side plates Reinstall that side plate top Insert the second M icro Fit fitting into the other side plate and close its top Align the two M icro Fit fittings by adjusting the side plate that is loose See Figure H 8 While maintaining the fitting to fitting alignment tighten the four cap screws in the adjustable side plate Take care to tighten the screws evenly to prevent the side plate from slipping H 4 2005 Swagelok Company all rights reserved September 2005 CWS D100 B Welding System Series 20H B Fixture Block The modular design of the Series 20 Fixture Block allows you to assemble the block to meet a variety of welding requirements To align tubing in the Series 20H B Fixture Block follow these steps 1 Loosen the Alignment K nobs See Figure H 9 2 Align the tubing with the fitting See Figure H 10 3 Tighten the Alignment K nobs The modular design of the Series 20 Fixture Block allows you to assemble the block to meet a variety of welding requirements Fixture Block Alignment Alignment Knobs Figure H 9 Aligning the Micro F it Fitting with the Tubing Align fitting with tubing Alignment Knob Figure H 10 Aligning the Tubing in the Series 20 Fixture Block 2005 Swagelok Company all rights reserved September 2005 H 5 Fixture Block Alignment CWS D100 B Welding System Series 8 Micro Weld Head Fixture Open Fixture To
49. Removing the Locking Ring Half ofthe Weld Head Housing Power Block SS Subassembly E N Figure 6 10 Removing the Power Block Subassembly T a Housing mo s Screws 4 Le CWS D100 B Welding System Remove the weld head housing screws from the housing Using a slight rocking motion carefully separate the locking ring half of the weld head housing from the motor half See Figure 6 8 Take care when separating the weld head housing so that internal components such as the safety interlock sensor or wiring are not damaged See Figure 6 11 Remove the rotor from the motor half of the weld head housing See Figure 6 9 Carefully lift the power block subassembly out of the motor half of the weld head housing See Figure 6 10 6 6 2005 Swagelok Company all rights reserved September 2005 CWS D100 B Welding System Maintenance 7 Examine the brush See Figure 6 11 Brush Safety Inspect and clean the brush using the following steps intenek lt 4 Sensor a Check the brush for excessive wear Groover AT b Ensure the brush has a groove Replace the brush if the groove is not present by referring to the appropriate motor and power block assembly drawing in Appendix F Part Drawings el ep c Remove any oxidation from the brush with a Figure 6 11 Inspecting the Brush fine grit abrasive pad 8 Blow any loose material from the power block assembly with clean low pressure air Caution
50. SWS 20HBP ROTOR 17 Weld Head Housing SWS 20HBP MTRHOUSE motor cover side 18 Bearing Pad Pins SWS 20HBP BEARINGPAD 19 Bearing Pad SWS 20HBP BEARINGPAD For part ordering information contact your S wagelok representative Notavailable as a field replaceable spare part 2005 Swagelok Company all rights reserved September 2005 Parts Drawings CWS D100 B Welding System Figure F 15 SWS 20H B Motor and Power Block Assembly F 28 2005 Swagelok Company all rights reserved September 2005 CWS D100 B Welding System Parts Drawings Table F 14 SWS 20H B Motor and Power Block Assembly P arts List Reference No Description Available in KitNo 1 Encoder Board Assembly 2 Encoder Sleeve 3 Encoder Wheel 4 Motor 5 Spacer 6 Home Sensor Assembly 7 Sensor Mount 8 Sensor Mount Screws K 9 Power Block Housing motor side CWS 20PBH PKG CWS 20PBH A PKG 10 Power Block Pins CWS 20PBH PKG CWS 20PBH A PKG CWS 20PBA PKG 11 Work Post 12 Drive Gear CWS 11315 PKG 13 Drive Gear Washer CWS 11315 PKG 14 Drive Gear Screw CWS 11315 PKG 15 Brush Springs CWS 11305 PKG CWS 11205 02 CWS 20PBA PKG 16 Gas Bayonet CWS 20PBH PKG CWS 20PBH A PKG 17 Thread Insert CWS 20PBH PKG CWS 20PBH A PKG 18 Power Block Screws CWS 20PBH PKG CWS 20PBH A PKG CWS 20PBA PKG 19 Work Plate CWS 11060 PKG 20 Work Pla
51. Screw CWS 4MHP SCREWS 17 Latch Keeper CWS MP LATCH 18 Motor Cover 2 19 Safety Interlock Sensor Assembly 20 Shielding Gas Tube 21 Drive Shaft Insulating Tube 22 Safety Interlock Connector Pins 23 Interface Plate 24 Drive Coupling Gear Bearing 25 Drive Coupling Gear 26 O ring CWS 4MHP CVA CWS 4MHP ORING 27 Check Valve Actuator CWS 4MHP CVA 28 Motor Cover 2A 29 Slotted Round Head Screw CWS 4MHP SCREWS CWS 4MHP BRUSH CWS 4MHP GRDPIN 30 Solid Drive Coupling 31 Solid Drive Shaft 32 Drive Clip CWS 4MHP TRANS CWS 4MHP DRVCLP 33 Star Washer CWS 4MHP SCREWS CWS 4MHP BRUSH CWS 4MHP GRDPIN For part ordering information contact your S wagelok representative Notavailable as a field replaceable spare part 2005 Swagelok Company all rights reserved September 2005 CWS D100 B Welding System Parts Drawings BOR SRK NESIS oeste sina SOO OG Figure F 21 CWS 4MFH A Flexible Micro Weld Head September 2005 2005 Swagelok Company all rights reserved F 40 CWS D100 B Welding System Parts Drawings Table F 20 CWS 4MFH A Flexible Micro Weld Head Parts List Reference No Description Available in KitNo 1 Body Brush Side CWS 4MHP BRSHHOUSE CWS 4MHP BRSHHOUSPL 2 Work Pin Stud CWS 4MHP GRDPIN 3 Brush Spring CWS 4MHP BRUSH 4 Brush and insulating co
52. System SWS The example in the following procedure is based on 1 2 in OD 0 049 in wall thickness 316L stainless steel tubing using the Series 5 Weld Head The procedure applies for all weld heads Note This procedure assumes you are fusion butt welding austenitic Stainless steel tubing Note This procedure is only a guideline The final weld quality depends on the operator s welding experience and on the proper use of welding techniques 2005 Swagelok Company all rights reserved September 2005 5 1 Weld Parameter Adjustment Note The electrode length and diameter depend on the weld head model and the outside diameter of the components Note Most applications use an arc gap of 0 035 in The proper arc gap gage setting depends on the weld head model and the outside diameter of the components CWS D100 B Welding System To develop a weld procedure guideline follow these steps Locate the Example Weld Procedure Guideline Worksheet found on page 5 9 Each of the following steps on pages 5 2 through 5 8 corresponds to the steps on the example worksheet After completing each step verify the recorded value on the example worksheet A blank worksheet is included on page 5 10 for you to use when creating your own weld procedure guidelines The values in parenthesis in the procedure correspond to the steps in the Example Weld Procedure Guideline Worksheet found on page 5 9 Determining the Work Specif
53. Travel Speed in min VS Rotor Speed Switch S etting lin 7 8in 3 4in 5 8 in 1 2 in 99 Rotor Speed Switch Setting 95 90 85 11 4 in 80 75 11 2 in 70 65 13 4 in 60 2 in 55 50 45 VS 40 Seconds per Revolution Curve Model CWS D100 1B CWS D100 2B Ne 35 30 25 20 16 12 NNO 8 F 4 201918171615141312111098765432 10 Travel Speed in min 0 0 0 20 30 40 50 60 70 80 90 100 110 120 SERIES 20 WELD HEAD TUBE WELDING Figure 5 2 Rotor Switch Speed Setting Graphs Series 10 Weld Head Series 20 Weld Head Fractional 5 12 Swagelok Company All rights reserved September 2005 CWS D100 B Welding System Travel Speed Weld Parameter Adjustment h vs Rotor Speed Switch Setting vs Seconds per Revolution in min Rotor Speed Switch Setting 3 4 in 1 2 in 3 8 in 1 4 in a 95 90 85 Curve Model en oT y a CWS D100 1B Le 70 j CWS D100 2B 1 1 4 in o3 60 112 in 55 50 45 ae 40 D 35 30 Byd 25 20 16 12 8 4 0 20 19 18 17 16 15 14 13 1211109 8 7 6 5 4 3 2 1 0 0 0 20 30 40 50 60 70 80 90 100 110 120
54. Tube Fixture Block F 24 e SWS 20H B Weld Head F 26 e SWS 20H B Motor and Power Block Assembly F 28 e SWS 20TFB A Tube Fixture Block F 30 e SWS 20FSPI1R Special Purpose Fixture Block F 32 e SWS 20FSPI1L Special Purpose Fixture Block F 34 e CWS M MTR A Motor Module F 36 e CWS 4MRH A Rigid Micro Weld Head F 38 e CWS 4MFH A FlexibleMicroWeldHead F 40 e CWS 4MFA Micro Weld Head Fixture F 42 e CWS 4MF Micro Weld Head Fixture F 44 e CWS 8MRH Rigid Micro Weld Head F 46 e SWS 8MFA Micro Weld Head Fixture F 48 2005 Swagelok Company all rights reserved September 2005 Parts Drawings CWS D100 B Welding System KSC i 2 A N Figure F 1 CWS 5H B Weld Head 2 i U F 2 2005 Swagelok Company all rights reserved September 2005 CWS D100 B Welding System Parts Drawings Table F 1 CWS 5H B Weld Head Parts List Reference No Description Available in Kit No 1 Motor Cover CWS 11121 PKG 2 Motor Cover Pins CWS 11121 PKG CWS 5WHA PKG 3 Weld Head Housing Pins CWS 5HP MTRHOUSE CWS 5WHA PKG 4 Motor Cover Screws CWS 11121 PKG CWS 5WHA PKG 5 Weld Head Housing Screws long CWS 5HP LOCHOUSE CWS 5WHA PKG CWS 5HP MTRHOUSE CWS 5HP LOCHOUSEPL 6 Locking Ring Plate Pins CWS 11104 PKG CWS 5WHA
55. V dc to 5 V dc signals drive the strip chart pens This type of recorder generally has limited memory and does not store data for future retrieval W hen the data must be captured and stored for future reference digital recording equipment is used This equipment converts the analog signals to data patterns that are stored to some device such as a memory unit or a hard disk The data can be recalled as needed and can be used for later analysis of the welding process Remember that data recording is just a method used to monitor the welding process and does not guarantee the quality of the weld 2005 Swagelok Company all rights reserved B 5 September 2005 Optional Equipment Figure B 5 CWS DRP Data Recording Printer Note For optional cable lengths add the cable length 6 12 0r 25 to the part number as a suffix For example a 25 ft cable part number is CWS DRP CABLE 25 Caution Do notuse a standard RS 232 printer cable to interface this printer Caution Do not operate the printer without paper Refer to section on paper loading CWS D100 B Welding System Data Recording Printer Introduction The optional SWS Data Recording Printer is a small size thermal printer ideal for mobile use See Figure B 5 The printer is covered under the same warranty as the power supply Unpacking and Inspection Carefully unpack and inspect the SWS printer and printer cable for any damage which may have oc
56. WELD 000026 INPUT IMP IMP ARC MNT RATE WIDTH START DUR 50 0 AQ 20 10 0 1 WELD DWN POST AVG TIME SLP PURGE SPEED CURRENT 15 3 3 10 50 0 OUTPUT AVG AVG TRAVEL WELD TIME CURRENT VOLTAGE SPEED 90 2 4 10 0 AVG AVG TRAVEL DOWNSLOPE CURRENT VOLTAGE SPEED 30 9 6 2 10 0 PERFORMANCE CONFIRMATION WELD COMPLETE PERFORMANCE ACCEPTABLE WELD ID JOB IDENT OPERATOR IDENT Figure B 13 Weld No 26 SWAGELOK WELDING SYSTEM DATA RECORD MODEL D100 1B VER 4 0 SERIAL 00000001 DATE 02 07 98 TIME 07 46 WELD 000027 INPUT IMP IMP ARC MNT RATE WIDTH START 50 0 10 20 10 WELD DWN POST AVG TIME SLP PURGE SPEED CURRENT 15 p 3 10 50 0 OUTPUT AVG AVG TRAVEL WELD TIME CURRENT VOLTAGE SPEED 50 2 9 8 10 0 AVG AVG TRAVEL DOWNSLOPE CURRENT VOLTAGE SPEED 0 0 0 0 0 0 PERFORMANCE CONFIRMATION WELD NOT COMPLETE WELD HEAD ROTOR STALLED PERFORMANCE NOT ACCEPTABLE WELD ID JOB IDENT OPERATOR IDENT Figure B 14 Weld No 27 2005 Swagelok Company all rights reserved September 2005 Optional Equipment CWS D100 B Welding System Figure B 15 labeled W ELD 000028 shows that the weld ee a CO S S ESS cycle was interrupted by pressing DOWNSLOPE SERIAL 00000001 DATE 02 07 98 TIME 07 46 WELD 000028 INPUT IMP IMP ARC MNT RATE WIDTH START DUR 50 0 10 20 10 0 1 WELD DWN POST AVG TIME SLP PURGE SPEED CURRENT so sl 3 10 5020 OUTPUT AVG AVG TRAVEL WEL
57. Worksheet Determine the Work Specifications Step Parameter Setting Weld Diameter Wall Thickness Weld Head Model No Electrode Part No Arc Gap Gage Setting Weld Head Shielding Gas Flow SLD oO HR WI Nir ID Purge Gas Flow Calculating Weld Parameters Step Parameter Setting 1 TRAVEL SPEED in min 2 ROTOR SPEED 3 IMPULSE A x Wall Thickness x 1000 IMPULSE x x 1000 4 MAINTENANCE B x Impulse MAINTENANCE x 5 IMPULSE RATE 6 IMPULSE WIDTH 7 ARC START Imp x Imp Width Maint x 1 Imp Width ARC START x x 1 8 DURATION 9 PREPURGE 10 WELD TIME If tube outside dia lt 1 2 in s rev x 2 WELD TIME e If tube outside dia gt 1 2 in s rev WELD TIME 11 DOWNSLOPE Weld Time x 0 5 DOWNSLOPE 12 POSTPURGE 5 10 Swagelok Company All rights reserved September 2005 CWS D100 B Welding System Weld Parameter Adjustment Travel Speed F VS Rotor Speed Switch Setting vs Seconds per Revolution in min Rotor Speed Switch Setting 1 4 in 1 8 in 1 16 in 99 95 90 85 Curve Model i 80 DER CWS D100 1B 75 CWS D100 2B 3 8 in 1 2 in 12 8 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 01 0 5 0 15 20 25 30 35 40
58. align tubing in the Series 8 M icro Weld Head Fixture follow these steps 1 Using the micro fixture tool place the latch in the open Loosen Screws 2 position then open the fixture See Figure H 11 A 2 Loosen the two alignment screws See Figure H 11 A Open Latch 3 Insert the tubing See Figure H 11 B 4 Close the fixture and latch then align the tubing See Insert Tube Figure H 11 C 5 Tighten the two alignment screws See Figure H 11 C Close Fixture Tighten Screws 2 Close Latch Figure H 11 Aligning the Tubing in the Series 8 Micro Weld Head Fixture H 6 2005 Swagelok Company all rights reserved September 2005 Appendix I Weld Procedure Guidelines The table in this appendix lists weld procedure guidelines developed at the factory for your use These guidelines are FOR REFERENCE ONLY The guidelines show suggested weld parameter settings for various material types and sizes M odifications of these guidelines may be necessary to achieve the desired weld results The weld procedure guideline table shows suggested parameter settings based on the following e SWS weld head used e weld joint type e material type e outside diameter and wall thickness of the weld joint The column labeled Average Current lists a calculated value based on certain weld parameters This value should approximate the value shown on the Average C urrent display during the weld cycle Because it is
59. another weld cycle that was not completed The error was caused by pressing the STOP RESET pushbutton during the weld cycle Optional Equipment SWAGELOK WELDING SYSTEM DATA RECORD MODEL D100 1B VER 4 0 SERIAL 00000001 DATE 02 07 98 TIME 07 46 WELD 000030 INPUT IMP IMP ARC MNT RATE WIDTH START DUR 00 50 10 20 10 OT WELD DWN POST AVG TIME SLP PURGE SPEED CURRENT 15 5 3 99 50 0 OUTPUT AVG AVG TRAVEL WELD TIME CURRENT VOLTAGE SPEED 5042 9 59 87 9 AVG AVG TRAVEL DOWNSLOPE CURRENT VOLTAGE SPEED 31 0 6 2 87 9 PERFORMANCE CONFIRMATION WELD COMPLETE PERFORMANCE NOT ACCEPTABLE WELD ID JOB IDENT OPERATOR IDENT Figure B 17 Weld No 30 SWAGELOK WELDING SYSTEM DATA RECORD MODEL D100 1B VER 4 0 SERIAL 00000001 DATE 02 07 98 TIME 07 46 WELD 000301 INPUT IMP IMP ARC MNT RATE WIDTH START 50 0 10 10 10 WELD DWN POST AVG TIME SLP PURGE SPEED CURRENT 15 5 10 50 50 0 OUTPUT AVG AVG TRAVEL WELD TIME CURRENT VOLTAGE SPEED 503 929 50 3 AVG AVG TRAVEL DOWNSLOPE CURRENT VOLTAGE SPEED 0 0 0 0 0 0 PERFORMANCE CONFIRMATION WELD NOT COMPLETE STOP RESET PUSHBUTTON PRESSED PERFORMANCE NOT ACCEPTABLE WELD ID JOB IDENT OPERATOR IDENT Figure B 18 Weld No 301 2005 Swagelok Company all rights reserved September 2005 Optional Equipment SWAGELOK WELDING SYSTEM USER PARAMETERS MODEL D100 1B VER 4 0 SERIAL 00000001 DATE 02 07 98 TI
60. attached to the power supply via the connector labeled Remote on the front panel See Figure B 2 Figure B 1 Remote Pendant Remote Pendant Connector Figure B 2 Remote Pendant Connector B 2 2005 Swagelok Company all rights reserved September 2005 CWS D100 B Welding System Weld Head Extension Cables The weld head extension cables increase the distance from the power supply to the weld head up to a maximum of 50 ft including the weld head cable The extension cable is placed between the power supply and weld head Install the extension cable as follows 1 Turn off the power supply circuit breaker 2 Disconnect the weld head from the power supply Plug the weld head connectors into the end of the extension cable that will accept them 3 Insert the connectors of the other end of the extension cable into the appropriate sockets on the power supply rear panel 4 Turn on the power supply 5 Locate the STOP RESET and PURGE pushbuttons on the front panel See Figure B 3 6 Press STOP RESET and check for rotor rotation Press STOP RESET again if the rotor is not at the home position 7 Press PURGE and check for gas flow through the weld head Allow the shielding gas to flow for at least 60 seconds to clear the gas lines of oxygen Press PURGE again to stop the gas flow Optional Equipment Note When using an extension cable increase the prepurge time by 1 second f
61. counter tracks any weld cycle lasting longer than 1 5 seconds Its maximum value is 999 999 Code 61 is a counter tracking arc start attempts A ny attempt to start an arc will increment the counter This counter is also not resettable The value will be greater than or equal to the weld count in item 60 Code 62 displays the serial number of the power supply The value is set at the factory and cannot be changed Code 63 displays the version of the controller software A value of 400 means version 4 00 99 Print user parameters Code 99 causes the system to output all user parameters to the optional printer See the description in A ppendix B Optional Equipment for an example of the printout A fter entry press ROTOR JOG to start the print cycle Average Voltage will show the number 42 while data is being sent to the printer 2005 Swagelok Company All rights reserved September 2005 CWS D100 B Welding System Changing Program Mode Items The ARC START and DURATION switches are used for programming values into the power supply If a code number requires a two digit value only the DURATION switch is used to input values If a data value has more than two digits ARC START is Used to set the most significant two digits and DURATION Sets the least significant two digits See Figure 3 13 The Average Current display shows the current value of the item After a new value is entered the display changes to reflect the new
62. fixture block e welding process Swagelok Welding System SWS Repair Procedure In some cases the stated remedy to a problem listed in the charts may be Call for service If so contact your Swagelok representative for over the phone troubleshooting Be prepared to give the following information to the Swagelok representative e the serial number and model number of the equipment involved e complete description of the application the product is being used in e detailed description of the symptom 2005 Swagelok Company all rights reserved 7 1 September 2005 Troubleshooting CWS D100 B Welding System Provide complete details of any problem encountered to your Swagelok representative Good information helps identify the exact problem and expedite the solution This applies to problems that are handled over the phone or those that require the unit to be returned for repair The result is faster repair times and more assurance that the repair meets with your approval M ake the Swagelok representative aware if backup equipment is needed to temporarily replace the equipment being returned for repair Repair Replacement Instructions Certain remedies require a component such as a weld head to be disassembled cleaned or replaced Section 6 Maintenance Contains user maintenance procedures If in doubt about a procedure call your Swagelok representative 7 2 2005 Swagelok Company all rights re
63. for the remaining latch bracket screw Verify the latch bracket remains securely attached to the weld head 4 Secure the bracket to any appropriate workbench 5 Position the weld head so that the exposed ends of the adapter screws slide through the holes in the bracket See Figure 4 18 C Figure 4 18 Using the Series 8 Bench Mount Bracket 2005 Swagelok Company All rights reserved 4 15 September 2005 Micro Weld Heads CWS D100 B Welding System 6 Secure the weld head using the two knurled thumb nuts supplied with the bench mounting bracket K eep the thumb nuts on the adapter screws when not using the bench mount bracket See Figure 4 19 Figure 4 19 Storing the Thumb Nuts on the Adapter Screws 4 16 2005 Swagelok Company All rights reserved September 2005 Section 5 Weld Parameter Adjustment Introduction This section describes the procedures necessary for adjusting weld parameters to create welds that meet required specifications This section includes e developing a weld procedure guideline e evaluating the weld e adjusting controls for weld quality Developing a Weld Procedure Guideline In order to create a weld that meets the required specifications you may need to adjust the welding parameters Y ou start with the weld procedure guideline worksheet found on page 5 10 The steps in the worksheet show you how to develop the speed current and timing for the Swagelok Welding
64. ft3 h L min 4MH 8 to 10 4 to 4 7 8MH 15 to 20 7 1 to 9 4 The length of time for internal purge before welding depends on the internal volume and length of the work piece to be welded See Appendix G Gas Flow Rate Tables 4 10 2005 Swagelok Company All rights reserved September 2005 CWS D100 B Welding System Connecting the Micro Weld Head to the Fixture A 1 Place the fixture on the micro weld head e Onthe Series 4 Micro Weld Head make sure the fixture is firmly seated Rotate the locking lever 90 to secure the fixture to the micro weld head See Figure 4 15 A e Onthe Series 8 Micro Weld Head engage the two latch springs over the button keepers on the sides of the fixture and close the latch levers See Figure 4 15 B A The micro weld head assembly and the work are ready for welding 2 Press PURGE to begin the shielding gas flow The shielding gas should remain on at all times when using the micro weld head 3 Program the power supply and perform the weld using the procedures established in Section 3 Operation Micro Weld Heads Caution Make sure the fixture latches are closed before attaching the fixture to the micro weld head The electrode can be damaged if the latches are left open during welding Caution Make sure that the purge line or a heavy work piece does not exert a side load force on the fixture This may cause an unacceptable weld damage to the micro weld
65. head fixtures require regular cleaning and maintenance Daily Maintenance 1 Clean the surfaces of the fixture that contact the work pieces Use the wire brush included in the micro weld head accessory package See Figure 6 3 2 If applicable check the fixture insulating tape for damage Replace the tape if it is loose or torn exposing the metal under it See Figure 6 4 To replace the tape a Remove the damaged tape from both sides of the fixture Disassembly of the CW S 8M F 08 and CWS 8MF 12MM may be necessary to assist in replacing the tape Disassemble by removing the screws which hold the arc covers on each side of the fixture Refer to page F 48 in A ppendix F Part Drawings b Clean the surfaces with alcohol or acetone c Apply one end of the pre cut tape strip to the inside edge of the underside surface The tape should wrap in the direction shown in Figure 6 4 d Wrap the tape tightly approximately 1 1 2 turns The tape should end at the outside edge of the top surface Maintenance Series 8 Fixture Series 4 Fixture Clean the surfaces Figure 6 3 Cleaning the Micro Weld Head Fixtures Outside Edge Inside Edge Figure 6 4 Checking replacing the Insulator Tape 2005 Swagelok Company all rights reserved September 2005 6 3 Maintenance WARNING Disconnect the weld head from the power supply before performing the adjustment or maintenance Rotor Area
66. head is connected 52 Rotor jam Code 52 is a disable condition The condition occurs if the power supply senses that the rotor motion is impeded The power supply monitors the rotor when a move command is given If no motion is detected the code is displayed and the system is disabled 2005 Swagelok Company all rights reserved 3 15 September 2005 Operation Figure 3 10 Display Readout for Example 1 Figure 3 11 Display Readout for Example 2 CWS D100 B Welding System Let s look at two examples EXAMPLE 1 Disable Condition Suppose a weld procedure guideline is keyed in and IMPULSE is set to 1 A The minimum allowable Impulse setting message code 01 is 2 A so the power supply is disabled and the status indicator lights begin to flash Pressing START has no effect The rotor can still be moved with ROTOR JOG Or STOP RESET The digital displays read as shown in Figure 3 10 The Average Voltage display shows that switch one Impulse is below its minimum allowable setting dash on left The Average Current display shows the minimum limitis 2A By changing the value of the Impulse switch to 2A or greater the condition is corrected and the Operation can proceed The correct Impulse value can only be determined by developing a proper weld procedure guideline EXAMPLE 2 Caution Condition A weld procedure guideline is keyed in and Prepurge is set to zero seconds You may wish to use a co
67. limited to the selection of an electrode and setting the arc gap The arc gap setting depends on the characteristics of the work pieces A gage is provided with the weld head to assist in setting the arc gap After the arc gap is set the weld head attaches to the fixture block and is secured with a locking ring The power supply uses rotary switches for weld parameter control See Figure 1 5 The appropriate switch settings are generally defined by the work pieces to be welded and are refined using test welds The correct settings used for a specific job are developed into a weld procedure guideline The guideline is used to maintain repeatability and quality control for subsequent jobs of the same type 2005 Swagelok Company all rights reserved 1 7 September 2005 Introduction CWS D100 B Welding System Figure 1 5 SWS D100 Front Panel Controls 1 8 2005 Swagelok Company all rights reserved September 2005 CWS D100 B Welding System Introduction Specifications Table 1 1 Power Supply Model Supply Voltage Service Amps Output Current dc CWS D100 1B 115 V ac 20 A 2 to 100A CWS D100 1B 115 V ac 15 A 2to70A CWS D100 2B 230 V ac 15 2 to 100A 10 input voltage tolerance frequency range 50 Hz to 60 Hz Table 1 2 Duty Cycle Model 100 CWS D100 1B 100 Amps 32 3 Amps 25 Amps 14 Volts 11 3 Volts 11 Volts CWS D100 2B 100 Amps 32 3 Amps 25 Amps 14 Volts 11 3 Volts 11 Volts Duty cycle is t
68. power cord Grasp the plug to remove it from the receptacle Do not use extension cords that are in poor physical condition or have insufficient current capacity Failure to do so can pose fire and shock hazards 2005 Swagelok Company all rights reserved September 2005 CWS D100 B Welding System Foreword FUMES AND GASES can be hazardous Welding produces fumes and gases Breathing these fumes and gases can be hazardous to your health Build up of gases can displace oxygen and cause injury or death Do not breathe fumes or gases If inside ventilate the area and or use exhaust at the arc to remove welding fumes and gases If ventilation is poor use an approved air supplied respirator Read the Material Safety Data Sheets MSDSs and the manufacturer s instructions for metals consumables coatings cleaners and degreasers Work in a confined space only if it is well ventilated or while 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 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 Do not weld on coated metals such as galvanized lead or cadmium plated steel unless the coating is removed from the weld area the area is well v
69. program mode the ROTOR SPEED rotary switch is the code number selector Enter a number into the switch and the code number is shown on the Average Voltage display Data associated with the code number will be displayed on the Average Current display Operation Figure 3 12 Entering Program Mode 2005 Swagelok Company all rights reserved September 2005 3 17 Operation CWS D100 B Welding System Codes selected by the ROTOR SPEED switch May be able to be programmed such as time and date information or bea read only parameter such as the system serial number See Table 3 5 for a list of all code numbers Table 3 5 Program Mode Code Numbers Code No Description Programmable 720 Resettable weld counter Ys 21 Automatic print counter Yes 22 Enable signal polarity Yes 23 Arc Start power Yes 30 Time hours Yes 31 Time minutes Yes 32 Date month Yes 33 Date day Yes 34 Date year Yes 35 Date printing format Yes 60 Nonresettable weld counter No 61 Arc start attempts No 62 System serial number No 63 System software version No 99 Print user parameters No Code Number Descriptions 20 Resettable weld counter The resettable weld counter counts the number of valid weld cycles completed The counter can be preset to any number from 0 to 9999 The controller increments the counter each time a valid weld cycle occurs A weld cycle must last longer than 1 5
70. the same way as a Series 5 10 20 Weld Head 1 Turn off the power supply circuit breaker on the rear panel See Figure 4 3 2 Connect the motor module to the power supply See page 2 7 in Section 2 Installation for instructions 3 Turn on the power supply 4 Press STOP RESET The motor moves the rotor drive gear to its home position Micro Weld Heads Tabs to Engage the Rotor Drive Gear N Wrench Opening for S Bench Mount Bracket lt Adapter Screws Slots Used to Open 7 and Close Fixtures Figure 4 2 Micro Fixture Tool Figure 4 3 Power Supply Circuit Breaker 2005 Swagelok Company All rights reserved September 2005 4 3 Micro Weld Heads Drive Gear Figure 4 4 Rotor Manual Adjustment CWS D100 B Welding System Installing the Micro Weld Head 1 Using the micro fixture tool turn the drive gear on the base of the micro weld head to align the rotor opening to the weld head housing opening See Figure 4 4 A and Figure 4 4 B showing views of the rotor misaligned and in proper alignment The drive gear on the base of the micro weld head must be aligned so that it meshes with the drive pins on the motor module housing Locate the shielding gas port on the micro weld head and verify that the O ring is in place See Figure 4 5 The O ring seals the gas port A valve in the port opens the gas flow through the motor module The valve opens when the micro weld head is properly conne
71. unit of electrode travel resulting in no inside diameter penetration Weld Example No 4 Table 5 11 lists the parameter change used to create the weld shown in Figure 5 12 Table 5 11 Weld Example No 4 Reference This Parameter Setting Setting Figure 5 12 Weld Example No 4 Maintenance Amperes 17 8 20 8 Average Current Display Amperes 32 34 1 Raising the M aintenance current raises the average current This increases the heat input per unit of electrode travel resulting in increased inside diameter dropthrough and weld bead width Reference Weld Illustration 2005 Swagelok Company all rights reserved 5 19 September 2005 Weld Parameter Adjustment Figure 5 13 Weld Example No 5 Figure 5 14 Weld Example No 6 Reference Weld Illustration CWS D100 B Welding System Weld Example No 5 Table 5 12 lists the parameter change used to create the weld shown in Figure 5 13 Table 5 12 Weld Example No 5 Reference This Parameter Setting Setting Impulse Width 30 Average Current Display Amperes 32 30 Shortening the Impulse W idth lowers the average current This decreases the heat input per unit of electrode travel resulting in no inside diameter penetration Weld Example No 6 Table 5 13 lists the parameter change used to create the weld shown in Figure 5 14 Table 5 13 Weld Example No 6 Reference This Parameter Setting Setting Impulse Width Average Current Display Amperes
72. valve The secondary valve is controlled by the power supply Straight Polarity The electrical configuration which makes the electrode the negative lead and the work the positive lead Travel Speed The speed of the electrode as it passes over the weld joint usually expressed in inches per minute or centimeters per second Tungsten The material used to make the electrode Tungsten is typically alloyed with rare earth metals to enhance its current carrying capacity UCI An acronym used for universal collet insert the exchangeable component used in the fixture block to hold the work pieces The patented design inserts come in various sizes to match the outside diameter of the work pieces A 8 2005 Swagelok Company all rights reserved September 2005 CWS D100 B Welding System Glossary Watt A unit of electrical power measurement One ampere times one volt equals one watt Weld Coupon A sample weld made for evaluation purposes The weld is used for both visual and physical testing Weld Data Record A printout used for data recording purposes listing weld parameter inputs power supply outputs and performance confirmation Weld Procedure Guideline The term used to describe a custom set of weld parameter values used to program the SWS for a particular welding job The parameter settings are based on the characteristics of the work and the SWS configuration It is sometimes called the weld schedule Weld Pool
73. with the tubing See Figure H 5 W hile maintaining the fitting to tubing alignment tighten the four cap screws in the adjustable side plate Take care to tighten the screws evenly to prevent the side plate from slipping Fixture Block Alignment CWS 5FSP2 Plenum se 3 Side Plate Centering Gage Figure H 4 Removing the Top of the Side Plate Align fitting with tubing Figure H 5 Aligning the Micro Fit Fitting With the Tubing 2005 Swagelok Company all rights reserved September 2005 H 3 Fixture Block Alignment Plenum rr Directional s Arrows 9 Pct i Cap Screws bo Side Plate TT gt 3 4 5 6 7 Side Plate Centering Gage Figure H 7 Removing the Top of the Side Plate Align fitting with fitting Figure H 8 Aligning the Micro Fit Fittings CWS D100 B Welding System Micro Fit Fitting to Micro Fit Fitting Fixture Block To align the fixture block follow these steps Turn the fixture block over and locate the directional arrows on the plenum The arrows point to the appropriate side plate See Figure H 6 Using the provided 3 32 in hex wrench unscrew the four cap screws in the appropriate side plate just enough to loosen it from the plenum See Figure H 6 to locate the appropriate side plate Turn the fixture block upright and remove the tops of the CW S 5F SP2 Side Plates See Figure H 7 Using the centering gage place one
74. 0 4 7 to 9 4 20 A 10 to 20 4 7 to 9 4 20 B 20 to 40 9 4 to 18 8 4MH 8 to 10 4 to 4 7 8MH 15 to 20 7 1 to 9 4 Set the flow to the higher rates when welding at high current levels G 2 2005 Swagelok Marketing Co all rights reserved September 2005 Appendix H Fixture Block Alignment Series 5 Fixture Block The modular design of the Series 5 Fixture Block allows you to assemble the block to meet a variety of welding requirements In order to maintain precise alignment of the work pieces in the fixture block the side plates must be periodically aligned This section covers e tube to tube e Micro Fit fitting to tube e Micro Fit fitting to M icro Fit fitting 2005 Swagelok Company all rights reserved September 2005 H 1 Fixture Block Alignment CWS D100 B Welding System Tube to Tube Fixture Block To align the fixture block follow these steps Plenum Figure H 2 Placing the Tubing 1 4 Turn the fixture block over and locate the directional arrows on the plenum The arrows point to the appropriate side plate See Figure H 1 Using the provided 3 32 in hex wrench unscrew the four cap screws in the appropriate side plate just enough to loosen it from the plenum See Figure H 1 to locate the appropriate side plate Turn the fixture block upright and release both levers and open both sides of the fixture block Place a straight length of tubing minimum length 1 50 i
75. 0 40 50 60 70 80 90 100 110 120 8 5 75 6 5 5 5 45 3 5 2 5 15 0 5 Travel Speed mm s Seconds per Revolution SERIES 20 WELD HEAD TUBE WELDING Figure 5 5 Rotor Switch Speed Setting Graphs Series 10 Weld Head Series 20 Weld Head Metric 2005 Swagelok Company all rights reserved September 2005 5 15 Weld Parameter Adjustment oe ns es el Figure 5 6 Good Weld CWS D100 B Welding System Evaluating the Weld A completed weld must meet structural and metallurgical requirements The weld must be uniform be free from cracks porosity and undercuts It must not have excessive oxidation And if itis a butt weld it must have full penetration from the outside diameter to the inside diameter See Figure 5 6 Identifying Typical Weld Discontinuities Figure 5 7 shows typical weld discontinuities TYPICAL WELD DISCONTINUITIES 727777 SSSSS a Incomplete Penetration Partial Penetration Concavity WA 7 ZAR LIZZ LOR A 77777 EENEN E Seem ERE Excessive Drop Through Weld Pool Shift Axial Misalignment Angular Misalignment Figure 5 7 Typical Weld Discontinuities Swagelok Company All rights reserved September 2005 CWS D100 B Welding System Weld Parameter Adjustment Identifying Proper Welds The cross sectional welds in Figure 5 8 through Figure 5 19 on pages 5 17 through 5 22 show how changing various paramet
76. 0 49 42 49 68 49 80 18 14 49 18 49 32 49 44 49 70 49 82 21 87 51 05 51 19 51 31 51 57 51 69 21 92 51 08 51 22 51 34 51 60 51 72 22 22 00 51 12 51 26 51 38 51 64 51 76 22 07 51 15 51 29 51 41 51 67 51 79 22 12 51 18 51 32 51 44 51 70 51 82 22 87 51 56 51 70 51 82 52 08 52 20 22 92 51 58 51 72 51 84 52 10 52 22 23 23 00 51 62 51 76 51 88 52 14 52 26 23 09 51 66 51 80 51 92 52 18 52 30 21 14 51 69 51 83 51 95 52 21 52 33 24 87 52 55 52 69 52 81 53 07 53 19 24 92 52 59 52 73 52 85 53 11 53 23 25 25 00 52 62 52 76 52 88 53 14 53 26 25 07 52 65 52 79 52 91 53 17 53 29 25 12 52 68 52 82 52 94 53 20 53 32 27 86 54 05 54 19 54 31 54 57 54 69 27 92 54 07 54 21 54 33 54 59 54 71 28 28 00 54 12 54 26 54 38 54 64 54 76 28 07 54 15 54 29 54 41 54 67 54 79 28 12 54 17 54 31 54 43 54 69 54 81 34 87 57 55 57 69 57 81 58 07 58 19 34 93 57 58 57 72 57 84 58 10 58 22 35 35 00 57 62 57 76 57 88 58 14 58 26 35 08 57 65 57 79 57 91 58 17 58 29 35 13 57 68 57 82 57 94 58 20 58 32 51 87 66 05 66 19 66 31 66 57 66 69 51 92 66 08 66 22 66 34 66 60 66 72 52 52 00 66 12 66 26 66 38 66 64 66 76 52 08 66 15 66 29 66 41 66 67 66 79 52 13 66 18 66 32 66 44 66 70 66 82 2005 Swagelok Company all rights reserved September 2005 CWS D100 B Welding System Arc Gap Gage Setting Tables Arc Gap Gage Setting Tables for Swagelok ATW Fittings W hen using Swagelok ATW weld fittings shown in Figure E 23 measure the outside diameter of the integral f
77. 1 Program Programmable mode 34 Date year 2 digit Program Programmable 00 2000 mode 35 Date printing O mm dd yy Program Programmable format 1 dd mm yy mode 36 to 40 Factory use Notused 41 Paper out No paper Caution installed with printer power on 3 10 2005 Swagelok Company All rights reserved September 2005 CWS D100 B Welding System Operation Normal Mode or Operating Setting to Code No Name Range Activate Code Type 42 Printing Data is Information only transferred to printer port 43 to 49 Factory use Notused 50 Hi temp Excessive Disable internal power supply temperature 51 Old head type No weld Disable head or non safety interlocked weld head connected 52 Rotor jam Rotor motion Disable impeded See Note A 53 to 59 Factory use Not used 60 Non resettable Program Information only weld counter mode 61 Arc start Program Information only attempts mode 62 System serial Program Information only number mode 63 System Program Information only software mode version 64 to 96 Factory use See Note B 97 Test switches Test mode pushbuttons 98 Test indicator Test mode lights dis plays 99 Print user Program parameters mode The Prepurge Start Weld Time Downslope and Postpurge status indicator lights are flashing Note A Press STOP RESET to clear the error Rotor will not move again unless STOP RESET is pressed a second time Note B Service may be necessary Ca
78. 1153 16 CWS 11136 PKG CWS 11056 SUB CWS 11154 16 CWS 11304 PKG CWS 11062 SUB CWS 11154 20 Brush Ring CWS 11051 SUB CWS 11136 PKG CWS 11056 SUB CWS 11062 SUB CWS 11304 PKG Rotor Screws CWS 11051 SUB CWS 5ROTOR PKG CWS 13111 10 CWS 10ROTOR PKG CWS 11056 SUB CWS 20ROTOR PKG CWS 11062 SUB Electrode Clamping Plate Screws CWS 11051 SUB CWS 13110 06 CWS 11108 PKG CWS 5ROTOR PKG CWS 13176 06 CWS 11056 SUB CWS 11204 PKG CWS 10ROTOR PKG CWS 13176 06 CWS 11062 SUB CWS 11306 PKG CWS 20ROTOR PKG Electrode Clamping Plate CWS 11051 SUB CWS 11108 PKG CWS 11204 PKG CWS 11056 SUB CWS 11062 SUB CWS 11306 PKG Electrode CWS C 040 705 P CWS C 040 605 P CWS C 040 555 P CWS C 062 1 105 P CWS C 062 855 P CWS C 062 1 630 P CWS C 062 1 380 P CWS C 062 1 105 P Ceramic Insert CWS 11051 SUB CWS 11132 CWS 11136 P KG CWS 11056 SUB CWS 11210 CWS 11062 SUB CWS 11304 PKG CWS 11210 For part ordering information contact your S wagelok representative 2005 Swagelok Company all rights reserved September 2005 F 5 Parts Drawings CWS D100 B Welding System Figure F 3 CWS 5H B Motor and Power Block Assembly F 6 2005 Swagelok Company all rights reserved September 2005 CWS D100 B Welding System Table F 3 Reference No Parts Drawings CWS 5H B Motor and Power Block Assembly P arts List Description Available in Kit No
79. 15 5 10 CWS 10H A TB TB 316L 0 500 0 049 0 035 1 282 7 0 58 8 18 0 10 35 32 os 20 27 14 30 37 320 12 15 5 10 0 750 0 049 0 045 1 417 5 5 58 8 18 0 35 32 05 20 26 13 30 19 32 0 12 15 5 10 Single 1 000 0 065 0 045 1 542 5 0 78 0 23 0 35 41 05 20 38 19 30 13 aro 15 7 15 1 000 0 083 0 045 1 542 5 0 99 6 30 0 39 54 05 20 38 19 30 13 57 1 15 17 7 15 _ 0 500 0 035 0 040 1 849 7 0 385 10 0 10 27 20 0 3 30 28 14 30 74 18 0 12 15 5 10 Multiple 3590 0 049 0 040 1 849 6 0 588 18 0 10 25 40 os 30 31 16 30 65 280 12 15 5 10 0 750 0 049 0 045 1 980 5 0 58 8 180 6 43 32 0 5 30 28 14 30 36 35 0 12 15 5 10 1 000 0 065 0 045 2 105 5 0 78 0 23 0 6 35 42 0 5 30 38 19 30 26 420 12 15 7 15 1 000 0 083 0 045 2 105 4 0 99 6 300 6 35 54 0 5 30 47124 30 21 540 15 7 15 1 250 0 065 0 045 2 230 5 0 78 0 230 4 35 42 10 5 30 47 24 30 21 420 15 7 15 a cn TETE 316L 1 250 0 083 0 045 2 230 4 0 99 6 30 0 4 35 54 05 30 59 30 30 17 1540 15 7 15 Single 1 500 0 065 0 045 2 355 5 0 78 0 230 4 43 42 05 30 57 29 30 18 470 15 7 15 1 500 0 083 0 045 2 355 4 0 99 6 300 4 50 54 0 5 30 711 36 30 14 648 15 7 15 1 750 0 065 0 045 2 480
80. 19 b Set DOWNSLOPE 19 according to the result of the formula in step 11 a 12 Set POSTPURGE to 20 5 8 Swagelok Company All rights reserved September 2005 CWS D100 B Welding System Example Weld Procedure Guideline Worksheet Determine the Work Specifications Weld Parameter Adjustment Step Parameter Setting 1 Weld Diameter 1 2 in 2 Wall Thickness 0 049 in 3 Weld Head Model No 5H B 4 Electrode Part No CWS C 040 605 P 5 Arc Gap Gage Setting 0 907 in 6 Weld Head Shielding Gas Flow 12 7 ID Purge Gas Flow 4 Calculating Weld Parameters Step Parameter Setting 1 TRAVEL SPEED in min 5 in min 2 ROTOR SPEED 26 3 IMPULSE 58 8A A x wall thickness x 1000 IMPULSE 1 2 x 0 049 in x 1000 58 8 4 MAINTENANCE 17 6A B x Impulse MAINTENANCE 0 30 x 58 8 17 64 17 6 5 IMPULSE RATE 10 cycles s 6 IMPULSE WIDTH 35 7 ARC START 32A imp x imp width maint x 1 imp width ARC START 58 8 x 0 35 17 6 x 1 0 35 32 02 32 8 DURATION 0 55 9 PREPURGE 10s 10 WELD TIME 385s lf tube outside dia lt 1 2 in s rev x 2 WELD TIME 19 x 2 38 lf tube outside dia gt 1 2 in s rev WELD TIME 11 DOWNSLOPE 195 Weld Time x 0 5 DOWNSLOPE 38 x 0 5 19 12 POSTPURGE 205s 2005 Swagelok Company all rights reserved September 2005 5 9 Weld Parameter Adjustment CWS D100 B Welding System Weld Procedure Guideline
81. 198 02 7 Collet 8 Side Plate left 9 Tape Strips CWS 4MFP TAPE 10 Fixture Base Denotes size in 1 16ths or mm includes sizes 01 02 04 3 mm and 6 mm For part ordering information contact your S wagelok representative Notavailable as a field replaceable spare part 2005 Swagelok Company all rights reserved September 2005 Parts Drawings CWS D100 B Welding System Figure F 24 CWS 8MRH Rigid Micro Weld Head F 46 2005 Swagelok Company all rights reserved September 2005 CWS D100 B Welding System Parts Drawings Table F 23 CWS 8MRH Rigid Micro Weld Head Parts List Reference No Description Available in Kit No 1 Body Brush Side CWS 8MHP BRSHHOUSE 2 Power Brush Spring CWS 8MHP BRUSH 3 Power Brush Buss Bar CWS 8MHP BRUSH 4 Idler Gear Assembly CWS 8MHP IDLER 5 Rotor CWS 8MHP ROTOR 6 Latch Bracket CWS 8MHP BRACKET 7 Draw Latch CWS 8MHP BRACKET CWS 8MHP LATCH 8 Electrode CWS C 040 405 P CWS C 040 325 P CWS C 040 281 P CWS C 040 450 P 9 Electrode Screw CWS 8MHP ROTOR CWS 8MHP CERAMIC CWS 8MHP SCREWS 10 Ceramic Insert CWS 8MHP ROTOR CWS 8MHP CERAMIC 1 Transmission Assembly CWS 8MHP TRANS 12 Slotted Flat Head Screw CWS 8MHP SCREWS CWS 8MHP BRSHHOUSE CWS 8MHP GEARHOUSE CWS 13157 10 13 Socket Head Cap Screw CWS 8MHP SCREWS CWS 8MHP BRSHHOUSE CWS 8MHP GEARHOUSE 14 B
82. 29 3 30 3 32 3 33 3 33 3 34 TOC 2 2005 Swagelok Company all rights reserved September 2005 CWS D100 B Welding System Entering the Weld Parameters 3 35 Using a Weld Procedure Guideline 3 35 Effects of Weld Parameters 3 36 Setting the Shield Gas Flow 3 37 Starting and Completing the Weld 3 37 Display Indications During Welding 3 38 After the Weld is Complete 3 39 Operation Summary 3 40 Section 4 Micro Weld Heads CWS 4MRH A CWS 4MFH A CWS 8MRH Introduction se raa ed ae tinapa te kiaat eaaa 4 1 Using the Micro Fixture Tool 4 3 Installing the Motor Module 4 3 Installing the Micro Weld Head 4 4 Installing Replacing the Electrode 4 6 Setting the Arc Gap 4 8 Fixturing the Work 4 9 Connecting the Micro Weld Head to the Fixture 4 11 Considerations During Welding 4 13 Using the Optional Bench Mounting Bracket 4 14 Series 4 Bench Mount Bracket 4 14 Series 8 Bench Mount Bracket 4 15 Section 5 Weld Parameter Adjustment INntrOdUCHON saisan draen t pak es eee iS 5 1 Developing a Weld Procedure Guideline 5 1 Determining the Work Specifications 5 2 Setting t
83. 3 1 148 1 153 1 158 1 163 1 168 29 04 29 18 29 30 29 56 29 68 0 255 1 149 1 154 1 159 1 164 1 169 29 07 29 21 29 33 29 59 29 71 0 370 1 207 1 212 1 217 1 222 1 227 30 53 30 67 30 79 31 05 31 17 0 372 1 208 1 213 1 218 1 223 1 228 30 55 30 69 30 81 31 07 31 19 3 8 0 375 1 209 1 214 1 219 1 224 1 229 30 58 30 72 30 84 31 10 31 22 0 378 1 211 1 216 1 221 1 226 1 231 30 63 30 77 30 89 31 15 31 27 0 380 1 212 1 217 1 222 1 227 1 232 30 65 30 79 30 91 31 17 31 29 0 495 1 269 1 274 1 279 1 284 1 289 32 10 32 24 32 36 32 62 32 74 0 497 1 270 1 275 1 280 1 285 1 290 32 13 32 27 32 39 32 65 32 77 1 2 0 500 1 272 1 277 1 282 1 287 1 292 32 18 32 32 32 44 32 70 32 82 0 503 1 273 1 278 1 283 1 288 1 293 32 20 32 34 32 46 32 72 32 84 0 505 1 274 1 279 1 284 1 289 1 294 32 23 32 37 32 49 32 75 32 87 0 620 1 332 1 337 1 342 1 347 1 352 33 70 33 84 33 96 34 22 34 34 0 622 1 333 1 338 1 343 1 348 1 353 33 73 33 87 33 99 34 25 34 37 5 8 0 625 1 335 1 340 1 345 1 350 1 355 33 76 33 90 34 02 34 28 34 40 0 628 1 336 1 341 1 346 1 351 1 356 33 80 33 94 34 06 34 32 34 44 0 630 1 337 1 342 1 347 1 352 1 357 33 83 33 97 34 09 34 35 34 47 0 745 1 394 1 399 1 404 1 409 1 414 35 28 35 42 35 54 35 80 35 92 0 747 1 395 1 400 1 405 1 410 1 415 35 30 35 44 35 56 35 82 35 94 3 4 0 750 1 397 1 402 1 407 1 412 1 417 35 35 35 49 35 61 35 87 35 99 0 753 1 398 1 403 1 408 1 413 1 418 35 38 35 52 35 64 35 90 36 02 0 755 1 399 1 404 1 409 1 414 1 419 35 42 35 56 35 68 35 94 36 06 0 870 1 457 1
84. 4 Verify that the weld head serial number matches the serial number on the shipping container 5 Record the model and serial numbers and the delivery dates on page i of the Forward section of this user s manual 2005 Swagelok Company All rights reserved 2 5 September 2005 Installation Figure 2 2 Power Cord Receptacle Figure 2 3 Power Supply Circuit Breaker in the OFF Position 1 CWS D100 B Welding System Installing the SWS To get the maximum performance and reliability from your SWS it must be set up and installed properly This section describes how to e install the power supply e install the weld head Installing the Power Supply To install the power supply follow these steps Place the power supply in a position such that the front and rear panel controls are easily accessible Locate the power cord Insert the cord into the polarized receptacle on the rear of the power supply See Figure 2 2 Tighten the connector lock at the base of the receptacle to secure the cord in the receptacle Ensure that the power cord reaches an electrical outlet Do not connect the power cord to the outlet at this time Turn off the circuit breaker Refer to Figure 2 3 2 6 2005 Swagelok Company All right reserved September 2005 CWS D100 B Welding System Installation Fixture Electrode Installing the Weld Head The weld head assembly has four connectors that plug into the po
85. 45 40 35 30 gt 25 20 16 12 8 4 HH 0 8 5 8 0 7 5 7 0 6 5 6 0 5 5 5 0 4 5 4 0 3 5 3 02 5 2 0 1 5 1 0 0 5 0 0 5 0 15 20 25 30 35 40 8mm 1 Travel Speed mm s Seconds per Revolution MICRO WELD HEAD TUBE WELDING D 4 2005 Swagelok Company all rights reserved September 2005 Weld Head Information CWS D100 B Welding System Travel Speed mm s vs Rotor Speed Switch Setting Rotor Speed Switch Setting 12mm 10mm 8mm 6mm 3mm 14mm 95 iein N Seconds per Revolution Curve Model CWS D100 1B CWS D100 2B t 8 0 7 0 6 0 5 0 4 0 3 0 2 0 1 0 0 0 10 85725 GI 555 455 a 25 5 105 Travel Speed mm s 20 30 40 50 60 Seconds per Revolution SERIES 5 WELD HEAD TUBE WELDING Travel Speed mm s VS Rotor Speed Switch Setting Rotor Speed Switch Setting 12mm 10mm 8mm 6mm 14mm 95 16mm 85 18 mm 20 mm 22 mm vs 25mm Seconds per Revolution Curve Model CWS D100 1B CWS D100 2B
86. 462 1 467 1 472 1 477 36 88 37 02 37 14 37 40 37 52 0 872 1 458 1 463 1 468 1 473 1 478 36 90 37 04 37 16 37 42 37 54 7 8 0 875 1 460 1 465 1 470 1 475 1 480 36 94 37 08 37 20 37 46 37 58 0 878 1 461 1 466 1 471 1 476 1 481 36 98 37 12 37 24 37 50 37 62 0 880 1 462 1 467 1 472 1 477 1 482 37 00 37 14 37 26 37 52 37 64 0 995 1 519 1 524 1 529 1 534 1 539 38 45 38 59 38 71 38 97 39 09 0 997 1 520 1 525 1 530 1 535 1 540 38 48 38 62 38 74 39 00 39 12 1 1 000 1 522 1 527 1 532 1 537 1 542 38 53 38 67 38 79 39 05 39 17 1 003 1 523 1 528 1 533 1 538 1 543 38 55 38 69 38 81 39 07 39 19 1 005 1 524 1 529 1 534 1 539 1 544 38 58 38 72 38 84 39 10 39 22 Arc Gap Gage Setting Tables 2005 Swagelok Company all rights reserved September 2005 E 7 Arc Gap Gage Setting Tables CWS 10H A Arc Gap Gage Dia 50 65 mm CWS D100 B Welding System Setting Setting Setting Setting Setting for for for for for 0 50 mm 0 64mm 0 76 mm 1 02 mm 1 14 mm Nominal Actual OD Arc Gap Arc Gap Arc Gap Arc Gap Arc Gap OD mm mm mm mm mm mm mm 5 87 28 76 28 90 29 02 29 28 29 40 5 94 28 80 28 94 29 06 29 32 29 44 6 6 00 28 83 28 97 29 09 29 35 29 47 6 05 28 85 28 99 29 11 29 37 29 49 6 12 28 89 29 03 29 15 29 41 29 53 7 87 29 76 29 90 30 02 30 28 30 40 7 92 29 80 29 94 30 06 30 32 30 44 8 8 00 29 83 29 97 30 09 30 35 30 47 8 08 29 87 30 01 30 13 30 39 30 51 8 13 29 89 30 03 30 15 30 41 30 53
87. 5 G Gas Delivery System Installing 2 9 Installing Optional Type 2 12 Installing Typical Shielding Purge Type 2 10 Gas Flow Rates Internal Purge Gas G 1 Shielding Gas 3 37 G 2 Gas Tungsten Arc Welding Principles 1 2 Index ii 2005 Swagelok Company all rights reserved September 2005 CWS D100 B Welding System Index GTAW Message Codes Interpreting 3 13 Advantages 1 2 Micro Fixture Tool Micro Weld Head 4 3 Defined A 4 Variables 1 3 Micro Weld Head 4 1 Bench Mounting Bracket 4 14 Connecting to Fixture 4 11 H Connecting to Motor Module 4 4 Fixturing Work 4 9 Hardware Installation 2 1 ae AR a is nstallin otor Module 4 Heat Input Defined A 5 Micro as Tool 4 3 Series 4 Bench Mount Bracket 4 14 Series 4 Electrode Selection Table and Geometry C 1 pe Series 8 Bench Mount Bracket 4 15 identity ans NER sele Series 8 Electrode Selection Table and Impulse Defined A 5 Geometry C 1 Impulse Rate Reference Weld 5 22 Setting Arc Gap 4 8 Inclusion Defined A 5 Travel Speed Switch Setting Seconds per Inside Diameter Dropthrough Weld Parameter ans oes DADS Correction 5 19 5 20 5 21 Inside Diameter Penetration Weld Parameter Correc Micro Weld Heads Maintenance 6 10 tion 5 19 5 20 5 21 Misfire Defined A 5 Inspection Components Installation 2 4 p Monitor Performance Data Logging B 4 Installation 2 1 Data Recording Printer B 6 Motor Module Micro Weld Head Electrical Require
88. 5 20 4 7 CWS 8MRH Multiple 5375 0 035 0 035 10 648 63 148 0 1 120 8 32 121103 10 24112 30 22 235 1520 47 RENE 0 250 0 035 0 035 0585 44 148 0 120 6 28 35 08 10 14 4 30 23 221 1520 47 Single 9375 10 035 0 035 10 648 46 1480 11201 8 34 35 08 10 20 6 30 16 242 1520 47 10 250 I mm 0 030 0 561 6 9 435 110 10 34 21 0 3 10 14 7 30 36 221 12 47 Multiple S375 mm 0 035 10629 63 435 110 8 40 22 03 10 231 11 30 2 1240 12 47 JTBTE RSR 0 250 I mm 0 030 0561 69 455 110 10 34 35 08 10 10 30 36 227 12 T T Single 9375 imm 0 035 0 629 63 1455 TOT 8 30 35 06 10 16 30 22 245 12 47 Notes 1 The maximum suggested weld rate on 1 2 in x 0 049 in components is 12 welds per hour This rate can be increased to 15 welds per hour on smaller diameter parts 2 Itis suggested that a continuous shielding gas flow be used to extend the life of the micro weld head SOUIJEPIND 21nP3201 d PIM wayshs bulpjem G OOLG SMD S00Z Jequuaydes pe ssai au u e Xuedwo 4ojebems Go0z S I WELD PROCEDURE GUIDELINES Metric For Reference Only Weld Head CWS 8MRH N otes 1 The maximum suggested weld rate on 12 mm x 1 0 mm components is 12 welds per hour This rate can be increased to 15 welds per hour on smaller diameter parts 2 Itis suggested that a continuous shi
89. 50 mm 0 64 mm 0 76 mm 1 02 mm 1 14 mm Nominal Actual Arc Gap Arc Gap Arc Gap Arc Gap Arc Gap Arc Gap Arc Gap Arc Gap Arc Gap Arc Gap OD in OD in in in in in in mm mm mm mm mm 0 495 1 832 837 1 842 847 1 852 46 39 46 53 46 65 46 91 47 03 0 497 1 833 838 1 843 848 1 853 46 41 46 55 46 67 46 93 47 05 1 2 0 500 1 834 839 1 844 849 1 854 46 45 46 59 46 71 46 97 47 09 0 503 1 836 841 1 846 851 1 856 46 49 46 63 46 75 47 01 47 13 0 505 1 837 842 1 847 852 1 857 46 52 46 66 46 78 47 04 47 16 0 745 1 957 962 1 967 972 1 977 49 56 49 70 49 82 50 08 50 20 0 747 1 958 963 1 968 973 1 978 49 59 49 73 49 85 50 11 50 23 3 4 0 750 1 959 964 1 969 974 1 979 49 63 49 77 49 89 50 15 50 27 0 753 1 961 966 1 971 976 1 981 49 66 49 80 49 92 50 18 50 30 0 755 1 962 967 1 972 977 1 982 49 69 49 83 49 95 50 21 50 33 0 995 2 082 2 087 2 092 2 097 2 102 52 74 52 88 53 00 53 26 53 38 0 997 2 083 2 088 2 093 2 098 2 103 52 76 52 90 53 02 53 28 53 40 1 000 2 084 2 089 2 094 2 099 2 104 52 80 52 94 53 06 53 32 53 44 003 2 086 2 091 2 096 2 101 2 106 52 84 52 98 53 10 53 36 53 48 005 2 087 2 092 2 097 2 102 2 107 52 87 53 01 53 13 53 39 53 51 245 2 207 2 212 2 217 2 222 2 227 55 91 56 05 56 17 56 43 56 55 247 2 208 2 213 2 218 2 223 2 228 55 94 56 08 56 20 56 46 56 58 11 4 250 2 209 2 214 2 219 2 224 2 229 55 98 56 12 56 24 56 50 56 62 253 2 211 2 216 2 221 2 226 2 231 56 01 56 15 56 27 56 53 56 65 255 2 212 2 217 2 222 2
90. 6 to 0 083 1 168 to 2 108 35 0 084 to 0 109 2 133 to 2 769 50 b Set IMPULSE WIDTH 35 according to Table 5 5 Weld Parameter Adjustment Note f the IMPULSE is greater than 99 9 A set the IMPULSE to 99 9 However use the actual value to calculate the Maintenance For example if the IMPULSE is 102 A set the IMPULSE to 99 9 but use 102 to calculate the Maintenance Note Because the MAINTENANCE switch accepts values to only one decimal place you may need to round off the number For example 17 64 is rounded off to 17 6 Note As a general guideline set the IMPULSE RATE between 5 cycles per second to 25 cycles per second A setting of ten is a general starting point However as the tube outside diameter decreases the Impulse Rate value increases Refer to identifying Proper Welds on page 5 17 to see the effect of the Impulse Rate on the weld 2005 Swagelok Company all rights reserved September 2005 5 5 Weld Parameter Adjustment CWS D100 B Welding System 7 Calculate the Arc Start Note The minimum START a Calculate the Arc Start using the setting is 2 following formula Impulse x Impulse Width maint x 1 Impulse Width Arc Start Note Enter the Impulse Width in the formula as a percentage Using the values in this example 58 8 x 0 35 17 6 x 1 0 35 32 02 32 A b Set ARC START 32 according to the results of the formula in step 7 a 8 Calculate t
91. 62 11 75 11 87 0 255 0 458 0 463 0 468 11 64 11 77 11 89 CWS 4MRH A CWS 4MFH A Arc Gap Gage Dia 15 75 mm Setting for Setting for Setting for 0 51 mm 0 64 mm 0 76 mm Nominal OD Actual OD Arc Gap Arc Gap Arc Gap mm mm mm mm mm 2 87 9 84 9 97 10 09 2 92 9 87 10 00 10 12 3 3 00 9 91 10 04 10 16 3 05 9 93 10 06 10 18 3 12 9 97 10 10 10 22 5 87 11 34 11 47 11 59 5 94 11 38 11 51 11 63 6 6 00 11 41 11 54 11 66 6 05 11 43 11 56 11 68 6 12 11 47 11 60 11 72 E 2 2005 Swagelok Company all rights reserved September 2005 CWS D100 B Welding System Arc Gap Gage Setting Tables CWS 8MRH Arc Gap Gage Dia 0 813 in Setting Setting Setting Setting Setting Setting Setting Setting for for for for for for for for Nominal Actual 0 020 in 0 025 in 0 030in 0 035 in 0 51 mm 0 64 mm 0 77 mm 0 89 mm OD OD Arc Gap Arc Gap Arc Gap Arc Gap Arc Gap Arc Gap Arc Gap Arc Gap in in in in in in mm mm mm mm 0 245 0 549 0 554 0 559 0 564 13 95 14 08 14 21 14 33 0 247 0 550 0 555 0 560 0 565 13 97 14 10 14 23 14 35 1 4 0 250 0 552 0 557 0 562 0 567 14 02 14 15 14 28 14 40 0 253 0 553 0 558 0 563 0 568 14 05 14 18 14 31 14 43 0 255 0 554 0 559 0 564 0 569 14 07 14 20 14 33 14 45 0 370 0 612 0 617 0 622 0 627 15 55 15 68 15 81 15 93 0 372 0 613 0 618 0 623 0
92. 7 04 17 17 12 12 00 16 84 16 97 17 09 17 22 12 07 16 87 17 00 17 12 17 25 12 12 16 89 17 02 17 14 17 27 E 4 2005 Swagelok Company all rights reserved September 2005 CWS D100 B Welding System CWS 5H B Arc Gap Gage Dia 1 244 in Setting Setting Setting Setting Setting Setting Setting Setting Nominal Actual 0 025 in 0 030 in 0 035 in 0 040 in O81 mm oven ra 0 69 mm Loam oD OD Arc Gap Arc Gap Arc Gap Arc Gap Arc Gap Arc Gap Arc Gap Arc Gap in in in in in in mm mm mm mm 0 120 0 707 0 712 0 717 0 722 17 83 17 96 18 21 18 34 0 122 0 708 0 713 0 718 0 723 17 86 17 99 18 24 18 37 1 8 0 125 0 710 0 715 0 720 0 725 17 91 18 04 18 29 18 42 0 128 0 711 0 716 0 721 0 726 17 93 18 06 18 31 18 44 0 130 0 712 0 717 0 722 0 727 17 96 18 09 18 34 18 47 0 245 0 770 0 775 0 780 0 785 19 43 19 56 19 81 19 94 0 247 0 771 0 776 0 781 0 786 19 44 19 57 19 82 19 95 1 4 0 250 0 772 0 777 0 782 0 787 19 48 19 61 19 86 19 99 0 253 0 774 0 779 0 784 0 789 19 53 19 66 19 91 20 04 0 255 0 775 0 780 0 785 0 790 19 56 19 69 19 94 20 07 0 370 0 832 0 837 0 842 0 847 21 01 21 14 21 39 21 52 0 372 0 833 0 838 0 843 0 848 21 03 21 16 21 41 21 54 3 8 0 375 0 835 0 840 0 845 0 850 21
93. 86 18 00 18 12 18 25 18 38 5 87 19 23 19 37 19 49 19 62 19 75 5 92 19 27 19 41 19 53 19 66 19 79 6 6 00 19 30 19 44 19 56 19 69 19 82 6 08 19 34 19 48 19 60 19 73 19 86 6 12 19 36 19 50 19 62 19 75 19 88 7 87 20 24 20 38 20 50 20 63 20 76 7 92 20 27 20 41 20 53 20 66 20 79 8 8 00 20 30 20 44 20 56 20 69 20 82 8 08 20 34 20 48 20 60 20 73 20 86 8 13 20 36 20 50 20 62 20 75 20 88 9 88 21 24 21 38 21 50 21 63 21 76 9 92 21 27 21 41 21 53 21 66 21 79 10 10 00 21 30 21 44 21 56 21 69 21 82 10 08 21 34 21 48 21 60 21 73 21 86 10 14 21 37 21 51 21 63 21 76 21 89 11 87 22 24 22 38 22 50 22 63 22 76 11 92 22 26 22 40 22 52 22 65 22 78 12 12 00 22 30 22 44 22 56 22 69 22 82 12 07 22 33 22 47 22 59 22 72 22 85 12 13 22 36 22 50 22 62 22 75 22 88 E 6 2005 Swagelok Company all rights reserved September 2005 CWS D100 B Welding System CWS 10H A Arc Gap Gage Dia 1 994 in Setting Setting Setting Setting Setting Setting Setting Setting Setting Setting Game in ao in asin Par AS ena ibe tak ae aint dou LE Nominal Actual Arc Gap Arc Gap Arc Gap Arc Gap Arc Gap Arc Gap Arc Gap Arc Gap Arc Gap Arc Gap OD in OD in in in in in mm mm mm mm mm 0 245 1 144 1 149 1 154 1 159 1 164 28 93 29 07 29 19 29 45 29 57 0 247 1 145 1 150 1 155 1 160 1 165 28 95 29 09 29 21 29 47 29 59 1 4 0 250 1 147 1 152 1 157 1 162 1 167 29 00 29 14 29 26 29 52 29 64 0 25
94. CWS 11156 PKG 13 Drive Gear Washer CWS 11156 PKG 14 Drive Gear Screw CWS 11156 PKG 15 Brush Springs CWS 11137 PKG CWS 11157 02 CWS 10PBA PKG 16 Gas Bayonet CWS 10PBH PKG CWS 10PBH A PKG 17 Thread Insert CWS 10PBH PKG CWS 10PBH A PKG 18 Power Block Screws CWS 10PBH PKG CWS 10PBH A PKG CWS 10PBA PKG 19 Work Plate CWS 11054 PKG 20 Work Plate Screw CWS 11054 PKG CWS 10PBA PKG 21 Power Strap Internal Star Washer CWS 11117 PKG CWS 10PBA PKG 22 Power Strap Screw large CWS 11117 P KG CWS 10PBA PKG 23 Power Strap Screw small CWS 11117 PKG CWS 10PBA PKG 24 Power Strap External Star Washer CWS 11117 PKG CWS 10PBA PKG 25 Power Strap CWS 11117 PKG 26 Safety Interlock Sensor 27 Power Block Housing brush side CWS 10PBH PKG CWS 10PBH A PKG 28 Brush CWS 11137 PKG 29 31 32 Secondary Gear Assy CWS 11141 PKG gear bearing gear pin 30 31 32 Primary Gear Assy CWS 11142 PKG gear bearing gear pin 33 Electrode Post 34 Drive Coupler Pins CWS 11156 PKG 35 Drive Coupler 36 Drive Coupler Motor Pin 37 Sleeve 38 Motor Mounting Screws CWS 10PBA PKG 39 Encoder Board Mount Screws 40 Motor Ground Lug For part ordering information contact your Swagelok representative Not available as a field replaceable spare part 2005 Swagelok Company all rights reserved September 2005 CWS D100 B Welding System Parts Drawings Figure F 9 CWS 10TFB Tube Fixture Block September 2005 2005 Swagelok Co
95. CWS 5UCI 1 8 in to 5 8 in tubing 3 mm to 16 mm add mm suffix for metric sizes CWS 5UFCI 95 n a fixture collets to hold adapter inserts for CWS 5FSP1 side plate CWS 5UFCI 1 8 in to 5 8 in tube collet for special purpose side plates 3 mm to 16 mm CWS 5MWCI 04 1 8 in 1 4 in 6 mm for Micro Fit fittings CWS 5MWCI 06 3 8 in 8 mm 10mm for Micro Fit fittings CWS 5MWCI 08 1 2 in 12 mm for Micro Fit fittings CWS I1OUCI 1 4 in to 1 in tubing 6 mm to 25 mm CWS 20UCI 1 2 in to 2 in tubing 12 mm to 52 mm CWS 20UCI P 1 4 in to 1 1 2 in pipe 10 2 mm to 48 3 mm addJ suffix for IS pipe P add MMP suffix for metric pipe MMP SWS 20UCI TN 1 2 in to 2 in tubular weld fitting collet for 12 mm to 52 mm SWS 20FSP1L and SWS 20FSP1R add MM MMTN suffix for metric sizes SWS 20UCI MC n a collet to hold ferrule mandrels for SWS 20TFB A fixture block x _ Identifies the collet size in 1 16ths or metric MM suffix 2005 Swagelok Company all rights reserved 1 11 September 2005 Introduction WARNING DO NOT USE EXTENSION CORDS THAT ARE IN POOR PHYSICAL CONDITION OR HAVE INSUFFICIENT CURRENT CAPACITY FAILURE TO DO SO CAN POSE FIRE AND SHOCK HAZARDS Table 1 9 Model CWS 5MBVCO 04 CWS D100 B Welding System Used for 316L 4 BVCO 1 316L 4 VCO 1 4TB2 Adapter Inserts for CWS 5FSP1 Comments glands must have overall length of 1 4 in VCR 1 12 in 28 mm weld glands or le
96. CWS D100 B Welding System Parts Drawings Table F 11 CWS 20H A Motor and Power Block Assembly Parts List Reference No Description Available in Kit No 1 Encoder Board Assembly 2 Encoder Sleeve 3 Encoder Wheel 4 Motor 5 Spacer 6 Home Sensor Assembly 7 Sensor Mount 8 Sensor Mount Screws K 9 Power Block Housing motor side CWS 20PBH PKG CWS 20PBH A PKG 10 Power Block Pins CWS 20PBH PKG CWS 20PBH A PKG CWS 20PBA PKG 11 Work Post 12 Drive Gear CWS 11315 PKG 13 Drive Gear Washer CWS 11315 PKG 14 Drive Gear Screw CWS 11315 PKG 15 Brush Springs CWS 11305 PKG CWS 11205 02 CWS 20PBA PKG 16 Gas Bayonet CWS 20PBH PKG CWS 20PBH A PKG 17 Thread Insert CWS 20PBH PKG CWS 20PBH A PKG 18 Power Block Screws CWS 20PBH PKG CWS 20PBH A PKG CWS 20PBA PKG 19 Work Plate CWS 11060 PKG 20 Work Plate Screw CWS 11060 PKG CWS 20PBA PKG 21 Power Strap Internal Star Washer CWS 11117 PKG 22 Power Strap Screw large CWS 11117 PKG CWS 20PBA PKG 23 Power Strap Screw small CWS 11117 PKG CWS 20PBA PKG 24 Power Strap External Star Washer CWS 11117 PKG 25 Power Strap CWS 11117 PKG 26 Safety Interlock Sensor 27 Power Block Housing brush side CWS 20PBH PKG CWS 20PBH A PKG 28 Brush CWS 11305 PKG 29 31 32 Secondary Gear Assy CWS 11313 PKG gear bearing gear pin 30 31 32 Primary Gear Assy CWS 11141 PKG gear bearing
97. Cover 1 CWS MP HOUSING 2 Button Head Screw CWS MP SCREWS CWS MP LATCH 3 Latch CWS MP LATCH 4 Motor Cover 1A CWS MP HOUSING 5 Socket Head Cap Screw CWS MP SCREWS For part ordering information contact your S wagelok representative 2005 Swagelok Company all rights reserved September 2005 Parts Drawings CWS D100 B Welding System Figure F 20 CWS 4MRH A Rigid Micro Weld Head F 38 2005 Swagelok Company all rights reserved September 2005 CWS D100 B Welding System Parts Drawings Table F 19 CWS 4MRH A Rigid Micro Weld Head Parts List Reference No Description Available in Kit No 1 Body Brush Side CWS 4MHP BRSHHOUSE CWS 4MHP BRSHHOUSPL 2 Work Pin Stud CWS 4MHP GRDPIN 3 Brush Spring CWS 4MHP BRUSH 4 Brush and insulating cover CWS 4MHP BRUSH 5 Rotor CWS 4MHP ROTOR 6 Electrode CWS C 040 405 P CWS C 040 325 P 7 Ceramic Insert CWS 4MHP ROTOR CWS 4MHP CERAMIC 8 Electrode Screw CWS 4MHP ROTOR CWS 4MHP CERAMIC 9 Idler Gear Assembly CWS 4MHP IDLER 10 Transmission Assembly CWS 4MHP TRANS 11 Dowel Pin CWS 4MHP LEVER 12 Locking Lever CWS 4MHP LEVER 13 Slotted Flat Head Screw CWS 4MHP SCREWS CWS 4MHP BRSHHOUSE CWS 4MHP BRSHHOUSPL CWS 4MHP GEARHOUSE CWS 13157 10 14 Body Gear Side CWS 4MHP GEARHOUSE 15 Socket Head Cap Screw CWS 4MHP SCREWS CWS 4MHP BRSHHOUSE CWS 4MHP BRSHHOUSPL CWS 4MHP GEARHOUSE 16 Button Head
98. D TIME CURRENT VOLTAGE SPEED 50 1 9 8 10 1 AVG AVG TRAVEL DOWNSLOPE CURRENT VOLTAGE SPEED 31 42 6 2 10 1 PERFORMANCE CONFIRMATION WELD NOT COMPLETE DOWNSLOPE PUSHBUTTON PRESSED PERFORMANCE NOT ACCEPTABLE WELD ID JOB IDENT OPERATOR IDENT Figure B 15 Weld No 28 Figure B 16 labeled WELD 000029 shows that the arc Cais ae dd RT failed sometime during the weld cycle A gain note that the DATE 00 07 98 TIME 07 46 FREE weld time output readings seem normal but the downslope fe nie ke readings are zero This indicates that the arc failed during MNT RATE WIDTH START DUR 50 0 10 20 10 0 1 weld time WELD DWN POST AVG TIME SLP PURGE SPEED CURRENT 15 5 3 10 50 0 OUTPUT AVG AVG TRAVEL WELD TIME CURRENT VOLTAGE SPEED 50 2 9 8 10 1 AVG AVG TRAVEL DOWNSLOPE CURRENT VOLTAGE SPEED 0 0 0 0 0 0 PERFORMANCE CONFIRMATION WELD NOT COMPLETE ARC FAILURE PERFORMANCE NOT ACCEPTABLE WELD ID JOB IDENT OPERATOR IDENT Figure B 16 Weld No 29 B 12 2005 Swagelok Company all rights reserved September 2005 CWS D100 B Welding System Figure B 17 labeled WELD 000030 shows a weld cycle that was not acceptable Although the power supply did complete the cycle the rotor speed output did not match the programmed value The weld may in fact be acceptable in this case but the condition is flagged nonetheless Figure B 18 labeled WELD 000301 shows
99. Figure 6 1 Cleaning the Collets and Collet Mounting S urfaces Figure 6 2 Lever Cam and Latch CWS D100 B Welding System Series 5 10 20 Fixture Blocks Perform fixture block maintenance daily and after every 40 hours of welding time If desired maintenance may be performed before the 40 hour interval Daily Maintenance Atthe start of each work day 1 2 Inspect the fixture block for cleanliness Remove dirt carbon and vapor deposits from the fixture block with aclean soft cloth A solvent such as alcohol or acetone can be used Remove heavier deposits with a fine grit abrasive pad At the end of each work day clean and then store the fixture block in a dry place Forty Hour Maintenance Every 40 hours 1 Inspect and clean the collets See Figure 6 1 A a Check for scratches and dents b Remove dirt and oxides from all surfaces of the collet with the a soft stainless steel wire brush Remove any oxides from the non anodized mating surfaces of the side plates with a fine grit abrasive pad See Figure 6 1 B Remove any dirt and oxides from the inside surfaces of the side plates with a clean soft cloth See Figure 6 1 C Remove heavier deposits with a fine grit abrasive pad Check the lever cam and latch for smooth operation See Figure 6 2 6 2 2005 Swagelok Company all rights reserved September 2005 CWS D100 B Welding System Micro Weld Head Fixture Blocks The micro weld
100. Hinge worn out Replace the hinge and dowel pins Worn out latch cam Replace the latch cam The latch does A burr is in the slot or on Use a fine file to not fit into the latch remove burrs SORE The latch is bent Remove the latch fixture block or damaged and replace all side plate damaged parts The hinge is bent Remove the hinge or damaged and replace all damaged parts The fixture The arc gap is incorrect Reset arc gap block does not according to the Weld fit onto the Procedure Guideline weld head The locking ring tab is broken or damaged Replace the locking ring tab The weld head is incorrectly assembled Reassemble using the instructions found in Section 6 Maintenance Arc damage on fixture Clean fixture Remove and replace any damaged parts 7 8 2005 Swagelok Company all rights reserved September 2005 CWS D100 B Welding System Welding Process Symptom Arc fails to start Cause Blown ceramic power supply fuse Remedy Replace the ceramic power supply fuse with one of the same type and rating Fuse not seated in fuse holder properly or fuse spring is missing Insert fuse properly Replace fuse spring if necessary Incorrect arc gap setting Reset the arc gap with the arc gap gage Either ARC START DURATION or both settings are incorrect Refer to the weld procedure guideline established for
101. In pulse welding high current is maintained for some fraction of each output cycle and low current is maintained for the remainder of the cycle The average current is the sum of these fractional components that occur during each cycle Backing Gas The gas used at the back of a weld joint or within a tube or vessel to prevent oxidation and undercut Butt Weld A weld joint where two work pieces are welded together with their long axes concentric and in line The joint can have various configurations such as square groove v groove j groove double v groove etc A 2 2005 Swagelok Company all rights reserved September 2005 CWS D100 B Welding System Glossary Centering Gage Gage used to center the work pieces in the fixture block Ceramic Insert A ceramic insulator used in the rotor to isolate the electrode from the weld head The insert helps to prevent arcing Collet A device used to hold the work pieces in the fixture Collets are made to hold work pieces of various diameters and shapes Concavity In welding the condition where the weld profile extends below the outside surface of the work Data Logging Collecting welding parameter data without regard to faults or alarms Data Monitoring Collecting data and comparing it to preset conditions Alarm triggering can be enabled if the data is outside normal limits Dedicated Line An electrical service line used for only one device The devic
102. In welding the flow of current between an electrode and the work Arc Gap The distance between the electrode and the work Arc Gap Gage The gage used to set the arc gap in the weld head rotor Arc Radiant Energy The ultra violet light emitted from the welding arc Arc Start The period of the welding cycle following prepurge During this short period of time approximately 0 01 second high voltage is applied between the electrode and workpiece initiating the arc The only control of this period is with arc start power Code 23 in program mode Arc Welding A type of welding process that uses an electrical arc as a source of heat to melt and join metals 2005 Swagelok Company all rights reserved A 1 September 2005 Glossary CWS D100 B Welding System Arcing A condition in welding where the arc follows another path instead of from the the electrode to the work This can cause damage to the weld head and fixturing components Argon An inert monatomic gas used as a shielding and purge gas for gas tungsten arc welding Autogenous In orbital welding autogenous describes the process of welding two parts together using the fusion process without the use of filler material Automatic Welding A welding process in which all of the parameters are controlled by the welding machine during the weld cycle The process may or may not perform the loading and unloading of the work pieces Average Current
103. ME 07 46 resettable weld counter 29 Automatic print count 5 Monitor Polarity ACTIVE HIGH 1 Arc Start Power 0 Date format DD MM YY 1 Non resettable weld count 1217 Non resettable arc starts 1239 Configuration dipswitch 00 Figure B 19 User Parameter Printout CWS D100 B Welding System User Parameter Printout The power supply can print a record showing the state of various programmable counters the date format and other system information See Figure B 19 The printout is initiated by accessing item 99 in the program mode of operation See the description in Section 3 Operation for user instructions for the program mode 2005 Swagelok Company all rights reserved September 2005 CWS D100 B Welding System Optional Equipment Maintenance The SWS printer is designed to require a minimum of maintenance and service Contact your Swagelok representative for any electrical or mechanical repairs that must be performed Clearing Paper J ams In the event of a paper jam condition do not force paper into the unit or try to pry the paper out of the unit This may damage the thermal print mechanism 1 Turn off the printer power switch and disconnect the Figure B 20 Removing the Printer printer cable from the rear of the printer from its Case 2 Turn the latch counter clockwise to release the printer body from the case Remove the printer body from the case by pulling it forward See F
104. NG es vs Rotor Speed Switch Setting vs Seconds per Revolution Rotor Speed Switch S etting 1 2 in 3 8 in 1 4 in 1 8 in od 95 i 90 5 8 in 85 80 75 70 65 60 55 50 45 40 35 30 25 20 16 12 8 4 0 20 19 18 17 16 15 14 13 1211109 876543210 0 10 20 30 40 50 60 Cure Model CWS D100 1B i CWS D100 2B Travel Speed in min Seconds per Revolution SERIES 5 WELD HEAD TUBE WELDING D 2 2005 Swagelok Company all rights reserved September 2005 CWS D100 B Welding System Travel Speed Weld Head Information vs Rotor Speed Switch Setting VS Seconds per Revolution in min Rotor Speed Switch Setting 1 2 in 3 8 in 1 4 in 99 95 Curve Model 5 8 in 85 80 z 75 D CWS D100 1B 3 4 in 70 CWS D100 2B 65 7 8 in 60 lin KH 45 40 35 30 25 20 16 12 8 4 0 20 19 18 17 16 15 14 13 1211109 8 76543210 0 10 20 30 40 50 60 Travel Speed in min Seconds per Revolution Pere vs Rotor Speed Switch Setting vs Seconds
105. Note lf the arc fails to start the power supply enters the idle state See Section 7 Troubleshooting for possible causes and corrective actions CWS D100 B Welding System Press START Total time for the process is the sum of the following times e prepurge e duration negligible e weld time e downslope e postpurge In the example given in Table 3 9 the total process would be 84 5 seconds Display Indications During Welding During welding the status indicator lights on the front panel light in the following sequence Prepurge Start Weld Time and R otor Downslope Postpurge Rotor remains on during Weld Time and Downslope and until the rotor returns to the home position after welding Average Current LED Display Compare the value shown on the display with the average current value listed under Arc Start on the weld procedure guideline The Arc Start value is calculated during the development of the guideline The value displayed during welding is generally within 10 of the calculated value 3 38 2005 Swagelok Company All rights reserved September 2005 Operation CWS D100 B Welding System Average Voltage LED Display The value displayed during weld time is typically between 5 V and 15 V The display may be used to monitor voltage fluctuations that can result from e electrode wear e out of round tubing e contamination of shielding gas After the Weld is Complete 1 Wait f
106. PKG 7 Locking Ring with Handle CWS 11106 1 8 Locking Ring Plate CWS 11104 PKG 9 Locking Ring Screws CWS 11104 PKG CWS 5WHA PKG 10 Work Extension Screw CWS 11112 PKG CWS 5WHA PKG CWS 13101 05 11 Work Extension Washer CWS 11112 PKG 12 Work Extension CWS 11112 PKG 13 Weld Head Housing Screws short CWS 5HP LOCHOUSE CWS 5WHA PKG CWS 5HP MTRHOUSE CWS 5HP LOCHOUSEPL 14 Weld Head Housing locking ring side CWS 5HP LOCHOUSE CWS 5HP LOCHOUSEPL 15 Motor and Power Block Assembly 16 Rotor Assembly CWS 11051 SUB 17 Weld Head Housing motor cover side CWS 5HP MTRHOUSE For part ordering information contact your S wagelok representative Notavailable as a field replaceable spare part 2005 Swagelok Company all rights reserved September 2005 F 3 Parts Drawings CWS D100 B Welding System A E E N amp i 2 7 Ss v g 7 S7 Ug i Sy D S amp Figure F 2 Series 5 10 20 Rotor Assembly 2005 Swagelok Company all rights reserved F 4 September 2005 CWS D100 B Welding System Table F 2 Reference No 1 Parts Drawings Series 5 10 20 Rotor Assembly Parts List Description Gear Ring Available in KitNo CWS 11051 SUB CWS 11136 PKG CWS 11056 SUB CWS 11062 SUB CWS 11304 PKG Dowel Pins CWS 11051 SUB CWS 5ROTOR PKG CWS 10ROTOR PKG CWS 11136 PKG CWS 11056 SUB CWS 20ROTOR PKG CWS 11304 PKG CWS 11062 SUB Ball Bearings CWS 11051 SUB CWS 1
107. Replacement Instructions Appendix A Glossary Appendix B Optional Equipment SWS Remote Pendant Weld Head Extension Cables Data Logging Monitoring Data Recording Printer Introduction sperme ns le huh Unpacking and Inspection Installation vs jie Re ops ak Dose OL Di Operating the Printer Maintenance peona us armani Using a Standard RS 232 Printer Appendix C Electrode Selection Tables and Geometry CWS 4MRH A CWS 4MFH A Micro Weld Heads CWS 8MRH Micro Weld Head CWS 5H B Weld Head CWS 10H A Weld Head CWS 20H A B Weld Head Electrode Geometry 0 cece cece ee eee eee 6 4 6 4 6 4 6 5 6 9 6 10 6 10 6 11 6 15 6 15 6 15 7 1 7 1 7 2 B 2 B 3 B 4 B 6 B 6 B 6 B 6 B 9 B 15 B 16 C 1 C 1 C 2 C 2 C 3 C 3 TOC 4 2005 Swagelok Company all rights reserved September 2005 CWS D100 B Welding System Appendix D Weld Head Information MICRO WELD HEAD TUBE WELDING SERIES 5 WELD HEAD TUBE WELDING SERIES 10 WELD HEAD TUBE WELDING SERIES 20 WELD HEAD TUBE WELDING SERIES 20 WELD HEAD PIPE WELDING MICRO WELD HEAD TUBE WELDING SERIES 5 WELD HEAD
108. S 5PBA PKG 39 Encoder Board Mount Screws 40 Motor Ground Lug For part ordering information contact your S wagelok representative Notavailable as a field replaceable spare part 2005 Swagelok Company all rights reserved September 2005 F 7 Parts Drawings CWS D100 B Welding System Figure F 4 CWS 5TFB Tube Fixture Block F 8 2005 Swagelok Company all rights reserved September 2005 CWS D100 B Welding System Parts Drawings Table F 4 CWS 5TFB Tube Fixture Block Parts List Reference No Description Available in KitNo 1 Latch Screw CWS 12132 02 CWS 12131 PKG CWS 5FIX PKG 2 Latch CWS 12131 PKG 3 Lever Cam Assembly CWS 12130 2 4 Top Side Plate right 5 Hinge and Latch Pins CWS 5FIX PKG 6 Hinge 7 Side Plate Screws CWS 5FIX PKG 8 Bottom Side Plate right 9 Plenum CWS 5PLEN 10 Plenum Pins CWS 5FIX PKG 11 Bottom Side Plate left 12 Locking Ring Tab Screws CWS 12134 PKG CWS 5FIX PKG 13 Locking Ring Tab CWS 12134 PKG 14 Top Side Plate left 15 Collet Insert Screws CWS 5FIX PKG CWS 13112 04 16 Collet Insert 17 Lanyard Screw long side plate CWS 5CG 18 Lanyard Screw short centering gage CWS 5CG 19 Lanyard Star Washer CWS 5CG 20 Centering Gage CWS 5CG 21 Lanyard CWS 5CG For part ordering information contact your Swagelok representative Not available as a field replac
109. Shift A welding condition in which the weld puddle is displaced to one side of the weld joint due to differences in the active surface elements of the metals to be welded Weld Puddle The portion of the weld that is molten Weld Time The portion of the weld cycle in which the current is at the level needed to fully penetrate the weld joint The current will pulse between Impulse and M aintenance levels 2005 Swagelok Company all rights reserved A 9 September 2005 Glossary CWS D100 B Welding System A 10 2005 Swagelok Company all rights reserved September 2005 Appendix B Optional Equipment This appendix lists the optional equipment available for your Swagelok Welding System SWS Contact your Swagelok representative for additional information on any listed option This section includes e SWS Remote Pendant e weld head extension cables e data logging monitoring e SWS Data Recording Printer 2005 Swagelok Company all rights reserved September 2005 B 1 Optional Equipment CWS D100 B Welding System SWS Remote Pendant See Figure B 1 The SWS Remote Pendant allows you to control the SWS operation from up to 25 ft away The remote pendant contains the same pushbuttons and status indicator lights as the power supply front panel with the exception of the PRINT pushbutton Cable extensions are available to increase the overall length to 100 ft The unit is
110. Status Indicator Lights In Test code 97 the pushbuttons and status indicator lights can also be functionally tested on both the front panel of the power supply and on the remote pendant W hen the pushbuttons are pressed a specific status indicator light turns on Pressing a pushbutton and seeing an indicator light turn on checks both for proper operation The pushbuttons and corresponding status indicator lights are shown in Table 3 7 Table 3 7 Pushbutton Test Reference Pushbutton Lights Illuminated Start Fixture and Rotor Downslope Prepurge Purge Start Rotor J og Weld Time Print Downslope Stop Reset Postpurge The remote pendant pushbuttons and status indicator lights can also be tested Plug in the remote pendant and follow the same procedure as before Note that the PRINT pushbutton is not on the remote pendant When testing the remote pendant pushbuttons the status indicator light that turns on may not be adjacent to the pushbutton The order is established by the button positions on the power supply front panel See Table 3 7 for all pushbutton indicator light pairings 3 24 2005 Swagelok Company All rights reserved September 2005 CWS D100 B Welding System Operation Testing Front Panel Lights Displays The tests executed in Test code 97 assume that the front panel status indicator lights and LED displays are functional If you are in doubt Test code 98 tests the lights and displays
111. TUBE WELDING SERIES 10 WELD HEAD TUBE WELDING SERIES 20 WELD HEAD TUBE WELDING Appendix E Arc Gap Gage Setting Tables Wall Thickness and Arc Gap Weld Head Arc Gap Gage Setting Tables Arc Gap Gage Setting Tables for Swagelok ATW Fittings Arc Gap Gage Setting Formula Appendix F Parts Drawings Appendix G Gas Flow Rate Tables Purge Rate and Pressure Tables Purge Rate and Pressure Tables Continued General Suggested Shielding Gas Flow Rates Argon Appendix H Fixture Block Alignment Series 5 Fixture Block Series 20H B Fixture Block Series 8 Micro Weld Head Fixture Appendix I Weld Procedure Guidelines Index D 2 D 2 D 3 D 3 D 4 D 4 D 5 D 5 D 6 E 1 E 2 E 11 E 12 G 1 G 2 G 2 H 1 H 5 H 6 Table of Contents 2005 Swagelok Company all rights reserved September 2005 TOC 5 Table of Contents CWS D100 B Welding System _ 2005 Swagelok Company all rights reserved TOC 6 September 2005 Foreword Registration Information Your Swagelok representative can provide support and service of your Swagelok Welding System SWS as well as local stock of precision fittings and valves Please take a moment to fill out the warranty information form as well as the information listed below Keep this
112. WS D100 B Welding System Tools and Accessory Requirements You need the following tools and accessories to install and operate your SWS Tool Accessory Included Provided With Hex Wrenches 0 050 in to 5 32 in Yes Weld Head Electrode Package Yes Weld Head Arc Gap Gage Yes Weld Head Flat Blade Screw Driver Yes Weld Head Centering Gage Yes Fixture Block Quick Connect Stem Yes Power Supply Secondary Solenoid Bypass Plug Yes Power Supply Dial Digital Calipers or Micrometer No Purge Connector s No Shielding P urge gas lines No Shielding P urge Gas Sourcel2 No Pressure Regulator No Internal Purge Gas Flow Meter No Shielding Gas Flow Meter No 1 All lines used for shielding purge gas should be the low moisture absorption type 2 A compressed gas bottle or liquid Dewar source can be used Argon is the gas most frequently used 3 A two stage gas regulator is suggested The regulator should reduce the source pressure to 25 psig to 50 psig 1 9 bar to 3 5 bar for the arc shielding and internal backing purge flow meters 2 2 2005 Swagelok Company All right reserved September 2005 CWS D100 B Welding System Installation Electrical Requirements Input Voltage Table 2 1 lists the electrical requirements for the power supply Table 2 1 Power Supply Electrical Requirements Power Supply Voltage Model Requirement Service Current CWS D100 1B 115 V ac 20A CWS D100 2B 230 V ac 15A If the input vol
113. a calculated value some variation may be seen based on the welding conditions These guidelines were developed using the same techniques outlined in Section 5 Weld Parameter Adjustment If you need assistance developing additional guidelines please contact your Swagelok representative 2005 Swagelok Company all rights reserved l 1 September 2005 Weld Parameter Guidelines CWS D1200 B Welding System Table notes All 316L material entries refer to type 316L stainless steel All 6LV material entries refer to type 316LV stainless steel TB TB indicates a tube to tube weld joint ATW TB indicates an ATW fitting to tube joint JTB JTB indicates a Japanese butt end fractional outside diameter and metric wall thickness tube to tube weld joint MTB MTB indicates a metric tube to tube weld joint MATW MTB indicates an metric ATW fitting to tube joint All outside diameter and wall thickness measurements are in inches if the chart is labeled English and in millimeters if the chart is labeled M etric unless otherwise noted 2005 Swagelok Company all rights reserved September 2005 S00Z Jequuaydes pe ssai au u e Xuedwo ojebems Go0z E I WELD PROCEDURE GUIDELINES English For Reference Only Wa S S builpjem G OOLG SMD o lz 2 3 olgj r v Yn c i lt j fd 2 Pex fj tlela glg DPeolo
114. alling the Optional Gas Delivery System The optional gas delivery system is generally used in Ultra High Purity UHP gas systems where quick connects are not permitted T his type of system uses an external 12 V dc secondary solenoid valve instead of using the solenoid valve located inside the power supply If necessary the secondary solenoid valve may be the high purity type A secondary solenoid bypass plug is inserted in the EXT GAS CONTROL connector on the rear panel to disable the solenoid inside the power supply and provide 12 V to control the secondary solenoid For the gas delivery system using a secondary shielding gas solenoid valve locate the e secondary solenoid bypass plug e secondary shielding gas solenoid valve e 1 4 turn internal purge gas shut off valve Refer to Figure 2 7 Install the optional gas delivery system Be sure to adhere to the following precautions e Ensure that the gas storage container s are secured before using them e Ensure all connections are tight and do not leak e Observe correct polarity on the secondary solenoid bypass plug e Adjust the low pressure regulator gage to reduce the gas storage container source pressure to 25 psig to 50 psig 2005 Swagelok Company All right reserved September 2005 CWS D100 B Welding System Shielding Gas Flow Meter SWS Power AS Supply Va
115. amp 24 135108 10 131 4130 26 254 71 11933 10 10 0 89 1671 19 1544 162 8124 135 70 8 10 18 6130 15 254 71 11933 Wa S S BUIPIBM G OOLG SMD SOUIEPIND 21nP3201 d PIM S00Z Jaquadas 9 1 pe ssai au6u je Aueduuod xoje6ems 6007 WELD PROCEDURE GUIDELINES English For Reference Only g E 3 3 2 g o v u BES RS j r 3 fl lels ils 49 8 sg BE a elie FE BE 3 te D 5 Eg VOR IDE ESV EIELE E Ela i Salt Se 2 8 SE amp lonlr 4 4 i ala g a ud 22 0 125 0 028 0 030 0 715 4 7 21 5 56 25 17 20 0 3 10 10 5 30 99 86 12 1 4 0 250 0 035 0 030 0 777 7 0 38 5 10 0 10 22 20 0 3 10 13 7 30 77 170 12 4 7 CWS 5H B TB TB 316L Multiple 0 375 0 035 0 035 0 845 7 0 385 10 0 10 31 40 0 3 10 20 10 30 50 190 12 5 10 0 500 0 035 0 035 0 907 7 0 425 100 10 28 20 0 3 10 27 14 30 37 191 12 5 10 0 500 0 049 0 035 0 907 7 0 58 8 18 0 10 35 32 os 10 27 14 30 37 320 12 5 10 0 250 0 035 0 035 1 157 7 0 38 5 10 0 10 25 20 0 3 20 13 7 30 77 17 0 12 15 4 7 0 375 0 035 0 035 1 219 7 0 40 5 10 0 10 29 20 0 3 20 20 10 30 50 19 0 12 15 5 10 Multiple 9 500 0 035 0 035 1282 7 0 420 10 0 10 34 20 os 20 27 14 30 37 209 12
116. been printed For the highest quality output and maximum thermal head life it is recommended that a premium quality thermal paper be used Swagelok part number CW S DRP PA PER Using the Printer A ctivate the printer from the power supply by one of two methods e Press PRINT On the power supply front panel e Establish an automatic print cycle by setting the automatic print counter program mode item 21 The printer will always print the last valid weld data record If no valid data exists the average current display will show three dashes Weld Data Record Examples The example printouts in this section show the SWS weld data record format Note the WELD on each data record This number is the resettable weld counter value program mode item 20 B 10 2005 Swagelok Company all rights reserved September 2005 CWS D100 B Welding System Figure B 13 labeled WELD 000026 is an example record of an acceptable weld cycle The power supply controller determines acceptability depending on comparisons of feedback readings of voltage current and rotor speed against expected values Figure B 14 labeled WELD 000027 shows an unacceptable weld cycle caused by a stalled rotor Note the zero values for the downslope cycle indicating that the rotor stalled during weld time Optional Equipment SWAGELOK WELDING SYSTEM DATA RECORD MODEL D100 1B VER 4 0 SERIAL 00000001 DATE 02 07 98 TIME 07 46
117. ble 06 Duration 0 0 to 5 0 gt 5 Disable 07 Prepurge 1s to 99s lt 1 Caution 08 Weld Time 1sto99s lt 1 Disable 09 Downslope 1sto99s lt 1 Disable 10 Postpurge 1sto99s lt 1 Caution 11 Rotor Speed 5 to 99 gt lor lt 5 Caution lt 1 Disable The Prepurge Start Weld Time Downslope and Postpurge status indicator lights are flashing 3 12 2005 Swagelok Company All rights reserved September 2005 CWS D100 B Welding System Operation Disable Condition The power supply enters a disable condition when a serious fault exists or a front panel control is set to a value that could damage the system The power supply will not start in a disable condition The rotor can still be moved while the disable condition exists using STOP RESET or ROTOR JOG The power supply shows the disable condition by flashing the status indicator lights shown in Figure 3 8 and flashing a message code on the Average Current and Average Voltage displays The code shows you what rotary switch is misprogrammed Caution Condition A caution condition indicates that a front panel parameter setting is questionable The power supply is not disabled and can weld if a caution exists The front panel indicates a caution condition by flashing a message code on the Average Current and Average Voltage displays The code shows you which rotary switch has the questionable value Figure 3 8 Disable Condition Int
118. ble 1 6 in Section 1 Introduction 2 Select the proper collets for the diameter of the parts being welded See Table 1 8 in Section 1 Introduction Installing the Collets in a Tube Fixture Block 1 Release both levers and open the tube fixture block See Figure 3 21 2 Install the collet halves in both the top and bottom side plates and tighten the collet screws M ake sure the collet shoulder is flush against the fixture side plate See Figure 3 22 Operation Fixture 2 gt an a Side Plate Figure 3 22 Installing Collets 2005 Swagelok Company all rights reserved September 2005 Operation CWS D100 B Welding System Aligning the Work Pieces in the Tube Fixture Block 1 Place the centering gage in one side of the tube fixture block The centering gage must span the width of the collet See Figure 3 23 2 Butt one work piece against the centering gage See Figure 3 24 A 3 Lock down the top side plate See Figure 3 24 B 4 Remove the centering gage Figure 3 23 Place the Centering Gage Note When welding a Swagelok ATW fitting to tubing butt the tubing against the centering gage first Figure 3 24 Placing First Work Piece in the Fixture Block 3 30 2005 Swagelok Company All rights reserved September 2005 CWS D100 B Welding System Operation 5 Butt the second work piece against the first work piece and lock down the top side plate See Figure 3 25 6 Inspect 360
119. ble causes and corrective actions Figure 2 9 Weld Status Indicator Lights 2 14 2005 Swagelok Company All right reserved September 2005 CWS D100 B Welding System 3 Position the weld head such that the rotor can be easily seen See Figure 2 10 4 Press STOP RESET On the front panel e For series 5 10 and 20 Weld Heads the rotor should make one half of a rotation 180 position in the head See Figure 2 11 e For the micro head the rotor should make one complete rotation in the head 5 Press STOP RESET on the front panel to return the rotor to its home position 6 Turn off the power supply If problems occur refer to Section 7 Troubleshooting for a list of possible causes and corrective actions Installation Figure 2 10 Positioning the Weld Head to View the Rotor Rotation Note The rotor must be returned to its home position before welding Figure 2 11 Checking the Rotor Rotation 2005 Swagelok Company All rights reserved September 2005 Installation CWS D100 B Welding System 2 16 2005 Swagelok Company All right reserved September 2005 Section 3 Operation Introduction This section describes the basic operation of the Swagelok Welding System SWS This section includes e front panel controls e SWS modes of operation e installing the electrode in the Series 5 10 20 Weld Head e Setting the arc gap e preparing the work e fixturing the work e connec
120. bly A dditional handling is necessary because the motor module and weld head are separate units The micro weld head fixtures do not use separate collets so fixture setup differs slightly from the Series 5 10 20 fixture block procedures The procedures unless noted are the same for all micro weld heads M ost figures in this section show the Series 4 Rigid Drive Micro Weld Head Topics common to all weld heads are not covered in this section See Sections 2 3 and 5 for information on power supply setup and weld procedure guidelines The section includes e micro fixture tool installing the motor module e installing the micro weld head e installing replacing the electrode e setting the arc gap e fixturing the work e connecting the micro weld head to the fixture e considerations during welding e using the optional bench mounting bracket 4 2 2005 Swagelok Company All rights reserved September 2005 CWS D100 B Welding System Using the Micro Fixture Tool Each micro weld head includes a micro fixture tool See Figure 4 2 The primary purpose of the tool is to latch and unlatch the fixtures In addition the tool can be used for the following e aligning the micro weld head rotor e attaching the optional bench mount bracket Series 8 only The micro fixture tool has a hole that allows the tool to be secured by a key chain Installing the Motor Module Connect the motor module to the power supply
121. c Insert Figure 6 17 Removing the Ceramic Insert Electrode Clamping Plate Figure 6 18 Removing the Electrode Clamping Plate Caution Do not pinch any internal wiring or damage the safety interlock sensor during reassembly 2005 Swagelok Company all rights reserved September 2005 6 9 Maintenance WARNING Disconnect the weld head from the power supply before performing the adjustment and maintenance procedures Caution Do not use any lubricants inside the weld head Figure 6 19 Inspect Exposed Surfaces of the Weld Head CWS D100 B Welding System Micro Weld Heads Perform weld head maintenance daily and every 8 hours of welding time If desired maintenance may be performed before the 8 hour interval Daily Maintenance At the start of each work day 1 Inspect the micro weld head for cleanliness focusing attention on the rotor area See Figure 6 19 Press STOP RESET Check the rotor for smooth rotation If the rotation is erratic or noisy disassemble the micro weld head and clean the rotor idler gears and brush See page 6 12 Series 4 Micro Weld Head Disassembly and Cleaning or page 6 13 Series 8 Micro Weld Head Disassembly and Cleaning At the end of each work day 1 Remove dirt carbon and vapor deposits from the weld head with a clean soft cloth and a solvent such as alcohol See Figure 6 19 Store the micro weld head in a clean dry place
122. cro Weld Head Disassembly 6 12 Series 5 10 20 Fixture Block Maintenance 6 2 6 3 Series 5 10 20 Weld Head Disassembly and Cleaning 6 5 Maintenance 6 4 Series 8 Micro Weld Head Disassembly 6 13 Shielding Gas Defined A 7 Flow Settings 3 37 Side Plates Fixture Specifications 1 11 Single Level Defined A 8 Single Pass Defined A 8 Index iv 2005 Swagelok Company all rights reserved September 2005 CWS D100 B Welding System Socket Defined A 8 Solenoid Bypass Defined A 8 Specifications 1 9 Status Indicator lights Defined 3 8 Testing 3 24 Straight Polarity Defined A 8 Switch Settings Weld Procedure Guideline 5 3 SWS Data Recording Printer B 6 Installing Components 2 6 Optional Equipment B 1 Registration Information i Repair Procedure 7 1 System Components 1 4 System Status Fault Codes 3 15 T Test Mode 3 22 Entering 3 23 Exiting 3 25 Test Descriptions 3 22 Testing Front Panel Lights Displays 3 25 Testing Pushbuttons and Status Indicators 3 24 Testing Rotary Switches 3 23 Timing Control Switches Defined 3 4 Tools Installation 2 2 Travel Speed 1 3 Defined A 8 Troubleshooting 7 1 Electrode 7 7 Fixture Block 7 8 Power Supply 7 3 Weld Head 7 5 Welding Process 7 9 Tungsten Defined A 8 U UCI Defined A 8 Undercuts in Weld Causes 5 17 Unpacking Components Installation 2 4 Unpacking Weld Head Assembly 2 5 Index W Watt Defin
123. cted to the motor module Align the connecting surfaces of the micro weld head and motor module See Figure 4 5 Mating Connections Figure 4 5 O ring and Mating Connections 4 4 2005 Swagelok Company All rights reserved September 2005 CWS D100 B Welding System A 4 Push the micro weld head onto the motor module until itis firmly seated then lock the assembly together with the two side latches See Figure 4 6 A and B 5 Press STOP RESET The rotor turns one revolution and stops at the home position The opening in the rotor aligns to the opening in the micro weld head housing If not disconnect the weld head and repeat the procedure Micro Weld Heads Caution Do not force the micro weld head and motor module together The drive gears of the micro weld head and motor module must be aligned for the pieces to mate correctly If you have problems mating the components rotate the micro weld head drive gear a small amount and try again Refer to step 1 on page 4 4 Figure 4 6 Connecting Weld Head and Motor Module 2005 Swagelok Company All rights reserved September 2005 4 5 Micro Weld Heads WARNING TURN OFF THE POWER SUPPLY BEFORE INSTALLING AN ELECTRODE Note Experience suggests replacement of the electrode when itshows signs of deterioration Electrode Clamping Screw Figure 4 7 Electrode Clamping Screw Location Caution Do not
124. curred in shipping If the printer or cable is damaged contact your Swagelok Representative Installation The printer mounts on the top of the power supply The printer requires a special interface cable CWS DRP CABLE The cable supplies both power and data to the printer The standard cable length is 2 ft 61 cm With an optional interface cable the unit can be placed up to 25 ft away from the power supply Before operating your printer do the following e Install the printer using the instructions provided in this section e Ensure that the printer mechanism and paper path are clear of any packing materials or foreign matter B 6 2005 Swagelok Company all rights reserved September 2005 CWS D100 B Welding System Load the Paper 1 If necessary remove the interface cable from the rear of the printer See Figure B 11 Turn the latch counter clockwise to release the printer body from the case Remove the printer body from the case by pulling it forward See Figure B 6 Remove the paper roll spindle pin and used paper spindle Install the new roll of thermal paper and load the paper into the feed mechanism See Figure B 7 a Place the roll between the support brackets in the position so that the paper feeds from the top Hold the paper roll so that the hole in the paper spindle is aligned with the holes in the support brackets b Fold about 1 2 in of the leading edge of the paper back over its
125. d head drives a rotor which carries the tungsten electrode around the weld joint Optical circuitry in the weld head sends precise feedback to the power supply to control the speed of the rotor All moving parts in the weld head mount in low friction devices to provide smooth consistent operation A spring loaded floating brush continuously contacts approximately one third of the circumference of the rotor at all times This configuration ensures consistent uniform electrical conductance to the rotor and electrode See Table 1 5 on page 1 10 for the weld head specifications Series 5 Series Micro Motor Module Series Micro Motor Module Series 4 Micro Series 4 Micro Rigid Flexible Series 8 Micro Figure 1 3 Weld Heads 2005 Swagelok Company all rights reserved 1 5 September 2005 Introduction CWS D100 B Welding System Fixture Blocks The SWS fixture blocks accurately align and hold tubing fittings and valve bodies The modular design allows you to select different side plates and create the configuration needed for the job The fixture block is separate from the weld head allowing work pieces to be easily aligned and fixtured before welding The use of multiple fixture blocks offers increased productivity Each fixture block is designed to accommodate a range of work piece sizes A unique and patented Universal Collet Insert UCI fits into the fixture block to match the diameter of the w
126. de and the work Arc length is important with this process because it affects the width of the weld puddle puddle width is proportional to arc length The desired arc length is as short as possible e Travel Speed The speed that the electrode moves over the work while welding Travel speed affects both the width and weld penetration of GTAW Its effect on width is more pronounced than on penetration Increasing travel speed decreases the width of the weld Travel speed generally is fixed in mechanized welding Other variables such as current or voltage are varied to maintain control of the weld 2005 Swagelok Company all rights reserved 1 3 September 2005 Introduction CWS D100 B Welding System System Components The SWS D100 Power Supply The power supply features microcontroller electronics and closed loop circuitry to precisely control output current Simplified controls and displays provide efficient programming and monitoring of the welding process See Table 1 1 on page 1 9 for the power supply specifications Figure 1 2 SWS D100 Power Supply 1 4 2005 Swagelok Company all rights reserved September 2005 CWS D100 B Welding System Introduction The Weld Head The SWS weld heads deliver consistent precise welds for outside diameters from 1 16 in to 2 in 3 mm to 52 mm There are six weld heads to choose from depending on the size of the work pieces See Figure 1 3 A dc motor in the wel
127. dry surface with the model and serial numbers facing up Remove the five screws from the weld head housing See Figure 6 22 A Rock the housing gently to loosen it from the rest of the assembly Lift and remove the housing Remove the rotor by lifting it clear of the lower portion of the micro weld head housing See Figure 6 22 B Loosen the electrode clamping screw then remove the electrode and ceramic insert See Figure 6 22 C Clean the rotor with the provided stainless steel wire brush Clean the ceramic insert with the provided nylon brush Remove and inspect the two idler gears for damage Replace if necessary See Figure 6 22 D Clean the two idler gears with a solvent and a soft cloth See Figure 6 23 A Hold the micro weld head as shown Gently lift the brush from the side noted in the figure and rotate it outward a few degrees Note the position of the spring in the groove in the weld head brush The spring ends bend toward the brush when the spring lays in the groove Remove the spring See Figure 6 23 B Clean any oxide deposits from the weld head brush with the provided stainless steel wire brush Inspect all other weld head components and clean any that are dirty Blow any loose dirt from the weld head with clean dry low pressure air 6 12 2005 Swagelok Company all rights reserved September 2005 CWS D100 B Welding System Series 8 Micro Weld Head Disassembly and Cleaning Us
128. e current control switch group determines the characteristics of the current output of the power supply during a weld cycle See Figure 3 2 The controls function as follows e IMPULSE High Amps sets the maximum current output used during the weld cycle The impulse setting affects the depth of penetration of the weld profile e MAINTENANCE Low Amps sets the minimum current output used during the weld cycle This is the current level required to e maintain the arc e provide enough background heat to maintain the weld puddle e IMPULSE RATE Pulses Sec sets the number of changes per second between the Impulse and M aintenance current levels during the weld cycle e IMPULSE WIDTH of Impulse sets the percentage of time the current is at the Impulse current level for each Impulse M aintenance cycle Figure 3 2 Current Controls e ARC START Amps sets the output current during the duration period This current level e helps stabilize the initiated arc e develops the weld puddle 2005 Swagelok Company all rights reserved 3 3 September 2005 Operation CWS D100 B Welding System Timing Control Switches Figure 3 3 Timing Controls The timing control switch group determines the weld cycle timing See Figure 3 3 The controls function as follows PREPURGE Seconds is the time in which shielding gas flows through the weld head and around the weld joint before the arc is initiated DURATION Seconds
129. e is isolated from interference created by other equipment and can utilize the full current capacity of the line breaker Diagnostics A built in program that checks the function of the front panel controls and indicators of the SWS power supply Errors are shown on the front panel digital displays 2005 Swagelok Company all rights reserved A 3 September 2005 Glossary CWS D100 B Welding System Disable An error condition created by a mis programmed front panel rotary switch The switch value is outside the safe operating range of the weld system The SWS will not weld whilea Disable condition exists Discontinuity The characteristic of a weld bead marked by breaks or interruptions in the typical structure causing a lack of homogeneity A discontinuity is not necessarily a defect Downslope The portion of the welding cycle when the weld current is decreased from the welding level to zero over a specific period of time Downslope time is used to prevent weld bead cracking Drop Through A condition where the weld puddle extends into the inside diameter of the weldment Duration The period following arc start during which the arc stabilizes and the weld puddle develops The current set on ARC START is Maintained for the time set on DURATION The rotor does not move during this period Electrode A pointed cylindrical rod made from a nonconsumable tungsten alloy which is used as a conductor for the arc in t
130. e position e Rotor indicates the rotor is in motion 3 8 2005 Swagelok Company All rights reserved September 2005 CWS D100 B Welding System Digital Displays The digital displays monitor system operation during welding and provide message code information See Figure 3 7 The display functions are as follows e Average Current indicates the average arc current measured during the weld sequence e Average Voltage indicates the average arc voltage measured during the weld sequence The average voltage displayed during a weld cycle varies with the arc gap type of shielding gas current output etc but typically is in the 5 V to 15 V range The Average Current and Average Voltage displays are also used for programming and displaying message codes See SWS Modes of Operation SWS Modes of Operation The front panel controls serve two purposes In addition to controlling the weld parameters and weld sequences the controls are used to access the modes of the power supply The power supply has three modes of operation e operational e program e test Each mode uses message codes to perform a variety of functions Generally the message codes are grouped by mode Operational mode uses codes 1 to 11 41 42 50 and 51 Program mode uses 20 to 23 30 to 35 60 to 63 and 99 Test mode uses 97 and 98 The message codes are explained in detail later in this section Table 3 3 shows all the message codes used b
131. e the following instructions to disassemble the micro weld head for cleaning See Figure 6 24 and Figure 6 25 for part references 1 Remove the two screws securing the latch bracket and remove it from the weld head See Figure 6 24 2 Lay the micro weld head down on a clean dry surface with the model and serial numbers facing up 3 Remove the seven screws from the weld head housing See Figure 6 25 A 4 Rock the housing gently to loosen it from the rest of the assembly Lift and remove the housing 5 Remove the rotor by lifting it clear of the lower portion of the micro weld head housing See Figure 6 25 B 6 Loosen the electrode clamping screw then remove the electrode and ceramic insert See Figure 6 25 C 7 Clean the rotor with the provided stainless steel wire brush 8 Clean the ceramic insert with the provided nylon brush 9 Remove and inspect the four idler gears for damage Replace if necessary See Figure 6 25 D 10 Clean the idler gears with a solvent and a soft cloth Maintenance Latch Bracket Figure 6 24 Removing Series 8 Micro Weld Head Latch Bracket A Housing Screws Body Gear Side aan Ceramic Insert A aa nn Electrode Screw rd as Idler D gt TT Co Gears Figure 6 25 Removing Series 8 Micro Weld Head Components for Cleaning 2005 Swagelok Company all rights reserved September 2005 6 13 Maintenance CWS D100 B Welding Syste
132. eable spare part 2005 Swagelok Company all rights reserved September 2005 F 9 Parts Drawings CWS D100 B Welding System Figure F 5 CWS 5FSP1 Special Purpose Fixture Block F 10 2005 Swagelok Company all rights reserved September 2005 CWS D100 B Welding System Table F 5 CWS 5FSP1 Special Purpose Fixture Block Parts List Reference No Description Available in KitNo 1 Locking Ring Tab CWS 12134 PKG 2 Locking Ring Tab Screws CWS 12134 PKG CWS 5FIX PKG CWS 13112 04 3 Socket Head Screw CWS 12158L PKG CWS 12159R PKG CWS 13112 04 4 Spacer 5 Spring Washers 6 Top Side Plate 7 Latch Cam Pin CWS 12158L PKG CWS 12159R PKG 8 Right Latch Cam CWS 12159R PKG CWS 5FIX PKG 9 Latch Cam Set Screw CWS 12158L PKG CWS 12159R PKG 10 Side Plate Screws CWS 5FIX PKG 11 Bottom Side Plate 12 Left Latch Cam CWS 12158L PKG For part ordering information contact your S wagelok representative Notavailable as a field replaceable spare part Parts Drawings 2005 Swagelok Company all rights reserved September 2005 Parts Drawings CWS D100 B Welding System Le Crs Wi Figure F 6 CWS 5FSP2 Special Purpose Fixture Block F 12 2005 Swagelok Company all rights reserved September 2005 CWS D100 B Welding System Parts Drawings Table F 6 CWS 5FSP2 Special Purpose Fixture Block Parts List Reference No Description Available in Ki
133. ed A 9 Weld Examples Bead Width 5 18 5 19 Inside Diameter Dropthrough 5 18 5 19 Inside Diameter Penetration 5 18 Identify Proper 5 17 Weld Bead Width Weld Parameter Correction 5 19 5 20 5 21 Weld Coupon Defined A 9 Weld Data Record Defined A 9 Examples of B 10 Weld Discontinuities Typical 5 16 Weld Head 1 5 Arc Gap Gage Setting Formula E 12 Arc Gap Gage Setting Tables E 2 CWS 10 Electrode Selection and Geometry C 2 CWS 20 Electrode Selection and Geometry C 3 CWS 4 Electrode Selection and Geometry C 1 CWS 5 Electrode Selection and Geometry C 2 CWS 8MRH Electrode Selection and Geometry C 1 Extension Cables B 3 Installing 2 7 Micro 4 1 Bench Mounting Bracket 4 14 Connecting to Fixture 4 11 Fixturing Work 4 9 Installing Electrode 4 6 Micro Fixture Tool 4 3 Setting Arc Gap 4 8 Welding Considerations 4 13 Series 4 Micro Disassembly 6 12 Series 5 10 20 Connecting to Fixture Block 3 33 Disassembly and Cleaning 6 5 Fixturing Work 3 29 Installing Electrode 3 26 Maintenance 6 4 Safety Interlock 3 33 Selecting Electrode 3 26 Setting Arc Gap 3 27 Series 8 Micro Disassembly 6 13 Specifications 1 10 Troubleshooting 7 5 Unpacking 2 5 Weld Head Series 10 Travel Speed Switch Setting Seconds per Revolution Chart 5 12 5 15 D 3 D 5 Weld Head Series 20 Pipe Travel Speed Switch Setting Seconds per Revolution Chart 5 12 5 13 5 15 D 4 2005 Swagelok Company a
134. elding gas flow be used to extend the life of the micro weld head Ela g E 9 g v U un ul capt sees g 8 o 6 y fe elie v o D D o 7 A o auy f q f 5 DE 5 0 D g al a 5 n LU 5 5 u re E 6 E 3 0 0 19 gt 5 3 44 8 vll GE 8 8 g 9 Sz 8 RE 6 BIS E E 8 2 f i 8 8 eae ee ce F 2 Fi lt Un FE EE 4 6 0 dun 40 nd ad 6 TO 0 76 1408 21 1433 1140 81 26 120103 10 18 8 130 28 1216 71 119 33 Multiple 8 1 0 0 76 15 08 21 1433 140 8 28 20 03 10 23 11 30 21 222 71 1933 10 10 1089 leon ls 130 8 138 120 703 10 301 15 130 1 17 245 71 1933 MTB MTB 316L 5 TO 0 76 140 21 1433 1130 8129 135 108 10 12 4 130 28 TET 71 119 33 ar 8 10 10 76 15 08 21 1433 1401 8 30 35 10 8 10 141 4130 21 1228 71 1933 nge Mg 10 089 11621 22 1433 11401 8 40 35 08 10 197 5130 17 25 7 71 11933 12 10 0 89 1721 21 1433 160 8142135 108 10 22 6 30 14 269 Toe 1933 6 1 0 0 76 14 58 2 6 1544 16 2 10 20 32 05 10 151 7 30 34 1238 71 1 9 3 3 Multiple 8 10 10 76 15 58 26 1544 1621 amp 8 21132105 10 201 9130 26 12421 71 1933 EEN ER 10 10 0 89 1671 19 1544 162 8 17 32 105 10 33 16 30 15 12277 71 11933 i 6 10 0 76 1458 2 6 1544 16 2 10 24 35 08 10 10 3130 34 1254 71 11533 Single 8 1 0 10 76 15 58 26 1544 1621
135. elf so that folded portion is facing up c Insert the paper under the silver pin and under the top half of the paper sensor Push the leading edge of the paper forward into the feed mechanism d Insert the paper spindle pin in through the paper spindle M ake sure the paper spindle pin is installed in the orientation shown in the figure e Advance the paper with the thumbwheel until it comes out of the front panel slot Slide the printer back into its case Turn the latch clockwise to secure the printer to the case Connect the printer cable to the connector on the rear of the printer See Cabling the Printer on page B 9 Run the self test described on page B 10 to ensure the paper is installed correctly Optional Equipment Figure B 6 Removing the Printer from its Case A Spindle l Note Paper Path Figure B 7 Install Paper Caution Once the paper enters the feed mechanism do not pull it back in the direction of the paper roll Always feed the paper with the thumbwheel 2005 Swagelok Company all rights reserved September 2005 B 7 Optional Equipment CWS D100 B Welding System Plastic Screws Mounting the Printer to the Power Supply The SWS printer attaches to the top surface of the power supply using a mounting bracket To mount the printer do the following 1 Remove the two 1 4 20 pan head plastic screws from the top panel of the power supply See Figure B 8 2 Remove the
136. enous manual welds of the process industry The process can be used to weld almost all metals GTAW can be used to weld all types of joint geometries in tubing pipe or other structural shapes It is particularly appropriate for welding wall sections less than 3 8 in 9 5 mm thick GTAW Process Advantages The GTAW process has the following advantages e produces superior quality welds e allows excellent control of weld penetration e welds almost all metals e produces autogenous welds at high speeds e allows precise control of the welding variables e welds with or without filler metal e eliminates spatter 1 2 2005 Swagelok Company all rights reserved September 2005 CWS D100 B Welding System Introduction Process Variables The major process variables in GTAW are arc current arc voltage and travel speed e Arc Current The current measured between the tungsten electrode and the work Generally stated arc current controls the weld penetration Direct Current Electrode Negative DCEN is common for GTAW It offers the advantages of deep penetration and fast welding speeds because most of the heat generated in the welding process is transferred to the work e Arc Voltage The voltage measured between the tungsten electrode and the work Arc voltage is affected by the following e arc current e Shape of the tungsten electrode tip e type and purity of shielding gas e arc length distance between the electro
137. ension Length CWS 4MFA 1 16 to 1 4 in 1 4 in 6 mm 3 to 6 mm SWS 8MFA 1 4 to 1 2 in 1 4 in 6 mm 6 to 12 mm CWS 5TFB 1 8 to 5 8 in 3 4 in 19 mm 3 to 16 mm CWS 10TFB 1 4 to 1 in 3 4 in 19 mm 6 to 25 mm recessed 15 16 in 24 mm no recess CWS 20TFB 1 2 to 2 in 1 3 8 in 35 mm 12 to 52 mm SWS 20TFB A 1 2 to 2 in 1 45 in 37 mm 12 to 52 mm Designates size in 1 16ths or mm 4MFA includes sizes 01 02 04 3 mm and 6 mm 8MF includes sizes 04 06 08 6 mm 8 mm 10 mm and 12 mm 1 10 2005 Swagelok Company all rights reserved September 2005 CWS D100 B Welding System Introduction Table 1 7 Special Purpose Fixture Side Plates Model Used for Comments CWS 5FSP1 VCR S Type weld extension length must be VCR VCO less than 0 75 in 19 mm B Type VCO fittings requires adapter inserts and tubing CWS 5FSP2 Micro F it fittings requires Micro F it fitting collets and tubing CWS 5HBDA BW4 BN DL DS 1 4 in 3 8 in or 6 mm CWS 5HBDA BW6 HD HB DA style tubular weld fittings and tubing butt CWS 5HBDA BW6MM valve bodies weld ends SWS 20FSP1L tubular weld fittings 0 80 in 20 mm weld and tubing extension length requires SWS 20UCI XXTN collets SWS 20FSP1R tubular weld fittings 0 80 in 20 mm weld and tubing extension length requires SWS 20UCI XXTN collets DA manual actuator only Table 1 8 Collets Model OD Capacity Comments
138. entilated and if necessary while wearing an air supplied respirator The coatings and any metals containing these elements can give off toxic fumes if welded 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 1 WELDING HANDBOOK VOLUME 2 8TH EDITION AMERICAN WELDING SOCIETY Shut off shielding gas supply when not in use 2005 Swagelok Company all rights reserved September 2005 Foreword A CWS D100 B Welding System ARC RAYS can burn eyes NOISE can damage hearing Arc rays from the welding process produce intense visible and invisible ultraviolet and infrared rays that can burn eyes The SWS is meant for use only with enclosed weld heads which minimize exposure to these harmful rays Do not look at welding arc Use protective screens or barriers to protect others from flash and glare warn others not to watch the arc Wear approved ear protection if noise level is high WELDING can cause fire or explosion Welding on closed containers such as tanks drums or pipes can cause them to blow up The hot work piece and hot equipment can cause fires and burns Check and be sure the area is safe before doing any welding Protect
139. ered on the SWS front panel The lei EST values from the weld procedure guideline in Table 3 9 50 7 Downslope__ Create a current waveform as shown in Figure 3 28 lt LA s i During a typical weld the power supply pulses between OHHH AE EAA AA A D high amp current and low amp current In the example 20 LEE shown at the right the current control settings are AR e IMPULSE 58 8 A ls Time e MAINTENANCE 17 6A Figure 3 28 Weld Current Waveform e IMPULSE RATE 10 pulses per second e IMPULSE WIDTH 35 In this case the current pulses between the high and the low levels 10 times per second The current is at the high level 35 of the time and at the low level 65 of the time Effects of Weld Parameter Changes Impulse and Rotor Speed affect the depth of penetration of the weld Impulse Width also affects weld penetration The control allows fine tuning of the weld penetration level Pulse rate is typically set so that each weld spot overlaps the previous one by at least 60 3 36 2005 Swagelok Company All rights reserved September 2005 CWS D100 B Welding System Setting the Shield Gas Flow T Verify the shielding and purge gas connections to the work pieces Set the shielding gas flow meter to the proper setting Refer to Table 3 10 Press PURGE to operate the shielding gas solenoid valve and to start the shielding gas flow A
140. erpreting the Message Codes The power supply shows the switch setting problem by displaying the switch code on the Average Voltage display Codes 1 to 11 use the Average Current display to show the limit for the switch identified by the Average Voltage display Code numbers 41 and above in the Average Voltage display are system status information or errors detected by the power supply See Figure 3 9 The Average Voltage display shows that rotary switch position 04 has an incorrect value Refer to Figure 3 1 and note that the switch labeled 04 is the IMPULSE WIDTH switch The position of the dash indicates which limit is exceeded minimum or maximum Figure 3 9 A shows the dash on the left indicating that the setting is too low Figure 3 9 B shows the dash on the right indicating the setting is too high The Average Current display shows the limit for the parameter Whether the limit displayed is a minimum or maximum depends on the position of the dash in the other display Figure 3 9 A shows the low limit for IMPULSE WIDTH is 5 Figure 3 9 B shows the high limit for IMPULSE WIDTH S 95 2005 Swagelok Company all rights reserved 3 13 September 2005 Operation CWS D100 B Welding System a Dash on left indicates below minimum Dash on right indicates above maximum Figure 3 9 Digital Display Examples for the Operator Machine Interface Multiple Disable or Caution Conditions The power supply displays multiple er
141. ers affects the shape of the weld To check the weld follow these steps 1 Inspect the weld on the outside of the tube Check for e uniformity e Cracks e undercuts e excessive oxide 2 Inspect the weld on the inside of the tube Check for e uniformity cracks undercuts and excessive oxidation e full penetration e excessive weld bead width variations e excessive weld spot overlap Reference Weld Figure 5 8 shows a cross section of a proper weld The weld Note The welds are made with a shows full penetration from the outside diameter to the 316L stainless steel tube with the inside diameter a crown on the outside diameter and following dimensions 1 2 in OD minimal weld bead dropthrough on the inside diameter 0 049 in wall thickness Table 5 7 lists the parameters used to create the weld Compare welds with Figure 5 8 OD Weld Table 5 7 Reference Weld Parameters Bead Parameter Setting Impulse Amperes 58 8 Weld Zone Maintenance Amperes 17 6 Impulse Rat 1 ID mpulse e 0 a Impulse Width 35 Dropthrough Speed s rev 26 19 ID Weld Bead Arc Gap 0 035 in Avg Current Display Amperes 32 Figure 5 8 Reference Weld Illustration The following examples show how changes in various parameters can affect the weld shape 2005 Swagelok Company all rights reserved 5 17 September 2005 Weld Parameter Adjustment Figure 5 9 Weld Example No 1 Figure 5
142. et WELD TIME according to that result For example since the tubing in this example has an outside diameter of 1 2 in the Weld Time is 19x 2 38 greater than 1 2 in Set WELD TIME according to the result in step 10 d For example the Weld Time is 19 for a single pass weld and 38 for a two pass weld based upon the following criteria ROTOR SPEED 25 Seconds per revolution 19 Seconds per revolution for a single pass weld 19 Seconds per revolution for a two pass weld 19 x 2 38 Weld Parameter Adjustment Note Experience suggests that tubing with an outside diameter of less than or equal to 1 2 in typically requires two revolutions two passes Tubing with a larger outside diameter requires one revolution one pass Caution When welding 1 2 in or 12 mm outside diameters with the 8MRH Weld Head use a single pass one revolution weld procedure only 2005 Swagelok Company all rights reserved September 2005 5 7 Weld Parameter Adjustment Note The suggested minimum Postpurge time is 20 seconds This time allows for sufficient cooling of the electrode and weld zone Additional Postpurge time may be necessary for a weld made with a high average current setting CWS D100 B Welding System 11 Calculate the Downslope a Calculate the Downslope using the following formula Weld Time x 0 5 switch setting For example using the Weld Time of 38 in Step 10 e 38 x 0 5
143. et i a izlitje o 9 og i S Bl el 3 5 SE 5 be Lula HR NT Ia ES 6 Q BE p Cc G 2i 5 o 5 3 g oe 2 fe SE 4 On FS lt Ala g A a ad ulan 0 062 0 020 0 020 0 364 4 7 22 0 60 10 25 20 0 3 10 5 3130 99 100 810 AEA 316 Multiple 0125 0 028 0 030 0 405 68 308 8 0 10 25 203 0 7 4 71 137 8 10 0 250 0 035 0 035 0 473 7 2 38 5 10 0 10 25 20 0 3 10 13 7 30 38 17 1 8 10 CWS 4MRH A Single 0 250 0 035 0 030 0 468 5 1 38 5 10 0 10 24 35 0 8 10 12 4 30 27 16 8 8 10 sors ley Multiple 0 250 1mm 0 030 0468 70 435 110 10 26 20 03 10 13 7 30 37 195 810 JTBJ Single 0 250 1mm 0 030 0 468 7 0 145 5 11 0 10 28 35 0 8 10 9 3 30 37 20 7 8 10 See table on page G 1 WELD PROCEDURE GUIDELINES Metric For Reference Only 4 E E zl g r v ri amp 2 o F Le En v t Q g D 2 o f z s E ELE BSS Saf fl BE Sl El el a apt sgle T E 5 5 v y 5 5 5 un ig ke g JE S g 3 amp 9 dele BRIERE Bla e El ela if 3 B S R95 SE ILE F Z E q UWIFE ENE L Bl eu qu 2 od Mue Lm 08 0 640 10 08 34 310 78 12 32 20 03 10 6 3 30 90 15 2 3847 e CWS 4MRH A TB TB 316 mm 10 10 760 1170 21 1433 130 10 25 20 03 10 18 8 30 28 206 3 847 Single 6mm 1 0 0760 1170 2 1 43 3 13 0 10 23 35 0 8 10 12 4
144. formation contact your Swagelok representative Not available as a field replaceable spare part 2005 Swagelok Company all rights reserved September 2005 Parts Drawings CWS D100 B Welding System Figure F 18 SWS 20FSP1L Special Purpose Fixture Block F 34 2005 Swagelok Company all rights reserved September 2005 CWS D100 B Welding System Parts Drawings Table F 17 SWS 20FSP1L Special Purpose Fixture Block Parts List Reference No Description Available in Kit No 1 Bottom Side Plate 2 Top Side Plate 3 Helicoil x 4 Dowel Pin CWS 20FIX PKG 5 Screw CWS 13112 04 6 Latch Screw CWS 12132 02 7 Latch CWS 12146 PKG 8 Latch Holder SWS 20FP LATCH3 9 Latch Holder SWS 20F P LATCH4 10 Screw CWS 10FIX PKG 1 Locking Ring Tab Screw CWS 13174 10 12 Dowel Pin 13 Locking Ring Tab SWS 20FP LOCKTAB 14 Lever Cam Assembly CWS 12308 1 15 Helicoil For part ordering information contact your S wagelok representative Notavailable as a field replaceable spare part 2005 Swagelok Company all rights reserved September 2005 Parts Drawings CWS D100 B Welding System Figure F 19 CWS M MTR A Motor Module F 36 2005 Swagelok Company all rights reserved September 2005 CWS D100 B Welding System Parts Drawings Table F 18 CWS M MTR A Motor Module P arts List Reference No Description Available in Kit No 1 Motor
145. ge CWS 20CG 20 Lanyard Star Washer CWS 20CG 21 Centering Gage CWS 20CG 22 Lanyard CWS 20CG For part ordering information contact your S wagelok representative Notavailable as a field replaceable spare part Parts Drawings 2005 Swagelok Company all rights reserved September 2005 Parts Drawings CWS D100 B Welding System Figure F 14 SWS 20H B Weld Head F 26 2005 Swagelok Company all rights reserved September 2005 CWS D100 B Welding System Parts Drawings Table F 13 SWS 20H B Weld Head Parts List Reference No Description Available in Kit No 1 Motor Cover CWS 11121 PKG 2 Motor Pins CWS 11121 PKG CWS 20WHA PKG 3 Weld Head Housing Pins CWS 20HP MTRHOUSE CWS 20WHA PKG 4 Motor Cover Screws CWS 11121 PKG CWS 20WHA PKG 5 Weld Head Housing Screws long CWS 20WHA PKG SWS 20HBP MTRHOUSE SWS 20HBP LOCHOUSE 6 Locking Ring Plate Pins CWS 11104 PKG CWS 20WHA PKG 7 Locking Ring with Handle CWS 11106 1 8 Locking Ring Plate CWS 11104 PKG 9 Locking Ring Plate Screws CWS 11104 PKG CWS 20WHA PKG 10 Work Extension Screw CWS 11112 PKG CWS 13101 05 11 Work Extension Washer CWS 11112 PKG 12 Work Extension CWS 11112 PKG 13 Weld Head Housing Screws short CWS 20WHA PKG SWS 20HBP MTRHOUSE SWS 20HBP LOCHOUSE 14 Weld Head Housing SWS 20HBP LOCHOUSE locking ring side 15 Motor and Power Block Assembly 16 Rotor Assembly
146. gear pin 33 Electrode Post 34 Drive Coupler Pins CWS 11315 PKG 35 Drive Coupler 36 Drive Coupler Motor Pin 37 Sleeve 38 Motor Mounting Screws CWS 20PBA PKG 39 Encoder Board Mount Screws 40 Motor Ground Lug For part ordering information contact your Swagelok representative Not available as a field replaceable spare part 2005 Swagelok Company all rights reserved September 2005 Parts Drawings CWS D100 B Welding System 22 Figure F 12 CWS 20TFB Tube Fixture Block F 24 2005 Swagelok Company all rights reserved September 2005 CWS D100 B Welding System Table F 12 CWS 20TFB Tube Fixture Block Parts List Reference No Description Available in KitNo 1 Latch Screw CWS 12306 02 CWS 12307 PKG CWS 20FIX PKG 2 Latch CWS 12307 PKG 3 Lever Cam Assembly CWS 12308 1 4 Top Side Plate right 5 Hinge and Latch Pins CWS 20FIX PKG 6 Hinge 7 Side Plate Screws CWS 20FIX PKG 8 Bottom Side Plate right 9 Plenum CWS 20PLEN 10 Plenum Pins CWS 20FIX PKG 11 Bottom Side Plate left 12 Locking Ring Tab Screws CWS 12309 PKG CWS 20FIX PKG 13 Locking Ring Tab CWS 12309 PKG 14 Top Side Plate left 15 Collet Insert Screws CWS 20FIX PKG CWS 13112 04 16 Collet Insert 17 Lanyard Star Washer CWS 20CG 18 Lanyard Screw long side plate CWS 20CG 19 Lanyard Screw short centering ga
147. he GTAW process GTAW An acronym for gas tungsten arc welding the process used in the Swagelok Welding System SWS A 4 2005 Swagelok Company all rights reserved September 2005 CWS D100 B Welding System Glossary Heat Input The heat conducted into the weld during the weld cycle Itis generally expressed in J oules or kilo oules Impulse High Amps The maximum current level generated during the weld cycle Also referred to as high amps Inclusion A defect or discontinuity in the work material or weld that could become a site for stress or corrosion Internal Purge Gas The gas used at the back of a weld joint or within a tube or vessel to prevent oxidation and undercut Jog The term used when positioning the rotor with the Rotor og pushbutton before or after the weld cycle Joule A unit of energy One joule is equal to one ampere times one volt for one second Also termed a watt second Maintenance Low Amps The minimum current level generated during the weld cycle Also referred to as background current or low amps Misfire An action that occurs when the arc fails to start or sustain itself Multiple Pass A welding technique in which the rotor moves more than one revolution during the weld time The technique is most helpful when fusion welding small diameter parts 2005 Swagelok Company all rights reserved A 5 September 2005 Glossary CWS D100 B Welding System Orb
148. he Duration a Locate the wall thickness 0 049 in and the corresponding D factor in Table 5 6 Table 5 6 Wall Thickness and D Factor Wall Thickness Range in mm D Factor 0 015 to 0 045 0 381 to 1 143 0 3 0 046 to 0 083 1 168 to 2 108 0 5 0 084 to 0 109 2 133 to 2 769 1 0 b Set DURATION 0 5 according to Table 5 6 Note The suggested minimum 9 Set PREPURGE to 10 Prepurge time is 10 seconds for all weld heads Higher Prepurge times may be necessary for certain applications Use a continuous purge when using the micro weld head by pressing the PURGE pushbutton When using a weld head extension cable increase the Prepurge time one second for each foot of extension length 5 6 Swagelok Company All rights reserved September 2005 CWS D100 B Welding System 10 Refer to the Rotor Speed switch setting graphs on pages 5 11 through 5 12 Calculate the Weld Time a Locate the appropriate graph based upon the weld head model CWS 5H B Locate the R otor Speed 26 from step 2 e on page 5 3 on the graph From that point extend a horizontal line to the right until it intersects the seconds revolution curve Drop a vertical line down from that point on the curve to find the seconds per revolution 19 The Weld Time setting depends on the tubing outside diameter If the outside diameter is less than or equal to 1 2 in multiply the seconds per revolution by two and s
149. he Front Panel Switches 5 3 Example Weld Procedure Guideline Worksheet 5 9 Weld Procedure Guideline Worksheet 5 10 Evaluating the Weld 5 16 Identifying Typical Weld Discontinuities 5 16 Identifying Proper Welds 5 17 Adjusting Controls for Weld Quality 5 22 Section 6 Maintenance Introduction 2s dace eset he men Mmes LA 6 1 Series 5 10 20 Fixture Blocks 6 2 Daily Maintenance 6 2 Forty Hour Maintenance 6 2 Micro Weld Head Fixture Blocks 6 3 Daily Maintenance 6 3 Table of Contents 2005 Swagelok Company all rights reserved September 2005 TOC 3 Table of Contents CWS D100 B Welding System Series 5 10 20 Weld Head Daily Maintenance Forty Hour Maintenance Series 5 10 20 Weld Head Disassembly and Cleaning 114 8 ck eee ore an Series 5 10 20 Weld Head Assembly Micro Weld Heads Daily Maintenance Eight Hour Maintenance Micro Weld Head Assembly Power Supply Fuse Inspection and Replacement Section 7 Troubleshooting INtrOMUCHON 3 05 ie ste ed a hats ste Swagelok Welding System SWS Repair Procedure Repair
150. he ratio of time the power supply can weld to the time the power supply must remain 1dle to cool The 10 minute cycle is a recognized welding industry standard It represents the maximum weld time allowed with the balance of the 10 minute cycle required for cooling Table 1 3 10 Minute Cycle Times Maximum Weld Time Required Idle Time Duty Cycle Rating Minutes Minutes 30 3 7 60 6 4 100 10 0 Continually exceeding the duty cycle may activate an internal thermal protector that will disable the power supply and display message code 50 Refer to pages 3 13 and 3 15 Table 1 4 Power Supply Dimensions and Weight Model Dimensions overall Weight CWS D100 1B 15 1 2 in 39 cm wide 42 Ibs 19 kg 20 in 51 cm deep 9 in 23 cm high without handle CWS D100 2B 15 1 2 in 39 cm wide 45 lbs 20 4 kg 20 in 51 cm deep 9 in 23 cm high without handle 2005 Swagelok Company all rights reserved 1 9 September 2005 Introduction CWS D100 B Welding System Table 1 5 Weld Heads Series Model OD Capacity 4 Micro CWS 4MRH A 1 16 to 1 4 in CWS 4MFH A 3 to 6 mm 8 Micro CWS 8MRH 1 4 to 1 2 in 6 to 12 mm 5 CWS 5H B 1 8 to 5 8 in 3 to 16 mm 10 CWS 10H A 1 4 to Lin 6 to 25 mm 20 SWS 20H B 1 2 to 2 in 12 to 52 mm Requires CWS M MTR A motor module Requires SWS 20TFB A Table 1 6 Standard Fixture Blocks Minimum Weld Model OD Capacity Ext
151. head or both 2005 Swagelok Company All rights reserved September 2005 4 11 Micro Weld Heads CWS D100 B Welding System o LT Latch Spring Captures Button Keepers Latch Springs 2 Lever Figure 4 15 Placing the Fixture on the Micro Weld Head 4 12 2005 Swagelok Company All rights reserved September 2005 Micro Weld Heads CWS D100 B Welding System Considerations During Welding The approach to welding using the micro weld head is similar to that used for other Swagelok weld heads Develop a weld procedure guideline as you would for any job The power supply controls and indicators work the same However the unique qualities of the micro weld head and its fixtures cause some noticeable differences during welding The sound of the weld is slightly louder compared to other Swagelok weld heads This is due to the reduced size of the fixture You may notice a clicking sound during the downslope cycle This is normal The fixture contracts slightly due to heat dissipation producing the sound Because the fixture is small heat build up may make the device too hot to handle immediately after welding Hold the fixture in the base areas shown in Figure 4 16 Use the optional aluminum cooling plate to hold the fixture and allow it to cool faster See Figure 4 16 Extended internal purging assists the cooling process Hold Here Figure 4 16 Cooling Plate WARNING THE FIXTURE MAY BE HOT
152. ications 1 Determine the outside diameter 1 2 in of the tubing or fitting at the weld joint 2 Determine the wall thickness 0 049 in of the tubing or fitting at the weld joint 3 Select the weld head model CWS 5H B 4 Refer to the Electrode Selection Tables in Appendix C Electrode Selection Tables and Geometry Select the proper electrode CW S C 040 605 P 5 Refer to the Weld Head Arc Gap Gage tables in Appendix E Arc Gap Gage Setting Tables Set the arc gap 0 907 in in the arc gap gage with either a caliper or micrometer 5 2 Swagelok Company All rights reserved September 2005 CWS D100 B Welding System Weld Parameter Adjustment Setting the Front Panel Switches 1 Select a travel speed 5 in min Note A travel speed of 3 in min to 15 in min is a general range for Average Travel Speeds OD Speed Wall Speed 2 9 p K p peed l GTAW welding Corrected Travel Speed Table 5 1 Travel Speed Setting Chart Fractional Wall Thickness Travel Speed OD Size Travel Speed in in per min in in per min 015 to 030 1 16 to 3 16 8 031 to 040 1 4 to 1 2 7 041 to 055 5 8 to 3 4 5 056 to 065 7 8 to 1 4 066 to 079 1 to 11 2 4 3 080 to 090 15 8 to 2 091 to 109 Table 5 2 Travel Speed Setting Chart Metric Wall Thickness Travel Speed OD Size Travel Speed mm mm per sec mm mm per sec 0 38 to 0 76 3 to 6 3 39 0 78 to
153. igure B 20 3 Cut the paper off at the roll Carefully remove the Caution paper in the printer mechanism by advancing the A Do not pull the paper thumbwheel or using tweezers or small needle nose backwards toward the paper pliers Remove the paper through the front of the roll This can damage the printer See Figure B 21 print head mechanism 4 Reload the paper after the jam has been cleared 5 Slide the printer back into the printer case and tighten the latch 6 Connect the printer cable to the connector on the rear of the printer 7 Run a self test to verify that the paper is installed correctly Figure B 21 Clearing a Paper am Cleaning The exterior SWS printer cabinet may be cleaned with a non abrasive cleaner Take care to prevent liquids from entering the mechanical assembly 2005 Swagelok Company all rights reserved B 15 September 2005 Optional Equipment Caution A The CWS DRP printer interface supplies 15 V power on the interface cable Some Serial printers could be damaged by this power supply voltage To Printer Cable Pinout CWS D100 B Welding System Using a Standard RS 232 Printer Itis possible to interface a standard RS 232 serial printer to the power supply However specific requirements must be met by the printer to ensure compatibility The serial printer must have the following minimum capabilities e printing ASCII characters e havea 40 character column width
154. iller ring or cuff Use this cuff dimension in the proper table for Swagelok ATW fittings below to determine the setting for the weld head model you are using i Reference Diameter CWS 5H B Arc Gap Gage Dia 1 244 in 31 60 mm Setting for 0 035 in 0 89 mm ATW Size Cuff OD Arc Gap 1 4 in 0 29 in 0 801 in i 5 8 her 3 8 in 0 41 in 0 863 in us ee Fitting 1 2 in 0 55 in 0 931 in 6mm 7mm 20 19 mm 8mm 9mm 21 20 mm 10 mm 11 mm 22 20 mm 12 mm 13 2 mm 23 32 mm CWS 10H A Arc Gap Gage Dia 1 944 in 50 65 mm Setting for 0 045 in 1 14 mm ATW Size Cuff OD Arc Gap 1 4 in 0 29 in 1 186 in 3 8 in 0 41 in 1 248 in 1 2 in 0 55 in 1 316 in 3 4 in 0 8 in 1 441 in lin 1 06 in 1 571 in 6 mm 7 0 mm 29 97 mm 8 mm 9 0 mm 30 98 mm 10 mm 11 0 mm 31 98 mm 12 mm 13 2 mm 33 10 mm 18 mm 19 2 mm 36 11 mm 23 mm 25 4 mm 38 5 mm 2005 Swagelok Company all rights reserved E 11 September 2005 Arc Gap Gage Setting Tables CWS D100 B Welding System Arc Gap Gage Setting Formula To determine the arc gap gage setting for a specific arc gap use the formula below A B C f Weld Aj 7 CR OD ig 7 f Arc Gap o CC Arc Gap ni Gage Setting P A B c ARC GAP zo vr 2 KR GAGE Where S E TT N G A largest OD on the weld end of the tubing or fitting weldi
155. ing up Separate the gear ring from the brush ring enough to clear the two rotor pins See Figure 6 15 3 Completely separate the gear ring from the brush ring as shown in Figure 6 16 Lay the rings flat on the work surface 4 Remove the ball bearings from the gear and brush rings See Figure 6 16 5 Inspect the ball bearings for wear and damage Replace if necessary 6 If the ball bearings are dirty clean them with a mild solvent or cleaning solution Dry the balls thoroughly 6 8 2005 Swagelok Company all rights reserved September 2005 CWS D100 B Welding System 10 11 Remove the ceramic insert See Figure 6 17 Inspect the ceramic insert If it has carbon or other deposits clean it with a fine grit abrasive pad or soft nylon brush Remove the electrode clamping plate Clean it with a fine grit abrasive pad See Figure 6 18 Inspect the brush and gear rings for dirt or other deposits Clean the rings with a fine grit abrasive pad or soft stainless steel wire brush Dry all parts with clean low pressure air before reassembly Series 5 10 20 Weld Head Assembly Assembly of the weld head and rotor is the reverse of the disassembly procedures To assemble the weld head follow these steps 1 Complete the steps in reverse order in the rotor disassembly procedure on page 6 8 Complete the steps in reverse order in the weld head disassembly procedure on page 6 5 Maintenance Cerami
156. ings It uses the basic parameters of IMPULSE MAINTENANCE and IMPULSE WIDTH There are other parameters that can be used to control weld quality such as gas purge arc gap weld speed joint preparation ARE ALL OTHER QC REQ MET etc These issues can be WELD OK addressed after the basic ERE DURE criteria have been met GUIDELINE NUMBER NOTE The welds must meet the basic criteria of being structurally and metallurgically sound The weld must be 100 WELD penetrated to the inside SOUIDELINE diameter surface without XXXXXX reducing the flow path The weld may also have IS IMPULSE IS IMPULSE WIDTH gt 30 OF WIDTH ORIGINAL SETTING gt 50 19 SETTING INCREASE THE IMPULSE WIDTH BY OF ORIGINAL SETTING IS THE NO INCREASE IMPULSE IMPULSE gt 30 HIGH AMPS BY OF ORIGINAL 10 OF ORIGINAL SETTING SETTING IMPULSE BE gt 99 9 WILLTHE AMPS IS THIS THE FIRST TIME AT 99 9 AMPS SET THE IMPULSE HIGH AMPS AT 99 9 el INCREASE MAINTENANCE LOW AMPS BY pe RNCS 10 OF ORIGINAL SETTING RE EVALUATE ORIGINAL WELD DECREASE THE TRAVEL SPEED PROCEDURE GUIDELINE IN MIN IS a WIDTH 230 OF DECREASE THE GINA IMPULSE WIDTH ge
157. ital Welding A welding technique used for tubing pipes etc in which the arc rotates around the weld joint circumference Oxidation H eat discoloration that occurs in the weld area 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 can be detrimental to high purity systems and increase the chances of weld joint corrosion Ozone A gas produced from the disassociation of oxygen in the presence of the electric arc Penetration The term used to describe the depth of the weld The common usage to describe the correct level of penetration for tube and pipe welds is full penetration weld This means the weld has penetrated completely from the outside diameter to the inside diameter of the weld joint There are no portions of the weld joint that are visibly unfused Plenum A device that separates the fixture block side plates providing space for the weld head and forming a chamber for the shielding gas Power Supply The device that produces the electrical power for the welding process The SWS power supply is a constant current power supply Pulse Rate The rate at which the output current level is changed between the high Impulse and low M aintenance settings The rate is expressed as pulses per second A 6 2005 Swagelok Company all rights reserved September 2005 CWS D100 B Welding System Glossary Pulse We
158. ld A weld current that varies between a high level and a low level at a specific rate The technique reduces the heat input to the weld Pulse Width Impulse The percentage of time during one cycle that the weld current is at the Impulse High A mps level Purge Gas The gas used at the back of a weld joint or within a tube or vessel to prevent oxidation and undercut Remote Pendant A hand held control device that allows remote operation of the SWS power supply Re enforcement The excess metal on the outside surface of the weld that extends above the surface of the work It is sometimes referred to as the crown or bead Rotor The device that holds the tungsten electrode and moves around the weld joint during orbital welding SCFH The acronym for standard cubic feet per hour This is the unit used to measure the flow rate of shielding and purge gases Shielding Gas The gas used to shield the tungsten electrode and work pieces during the welding cycle It also cools the weld head 2005 Swagelok Company all rights reserved A 7 September 2005 Glossary CWS D100 B Welding System Single Level A welding technique in which a single value of current is used during the weld cycle Single Pass A welding technique in which the rotor moves one revolution during the weld time Socket A type of weld joint Solenoid Bypass An option that bypasses the internal gas solenoid in favor of a secondary
159. ll rights reserved September 2005 Index v Index Weld Head Series 20 Tube Travel Speed Switch Setting Seconds per Revolution Chart D 3 D 6 Weld Head Series 5 Travel Speed Switch Setting Seconds per Revolution Chart D 2 D 5 Weld Head Series 5 10 20 Connecting to Fixture Block 3 33 Fixturing Work 3 29 Installing Electrode 3 26 Maintenance 6 4 Safety Interlock 3 33 Selecting Electrode 3 26 Setting Arc Gap 3 27 Weld Heads Micro Maintenance 6 10 Weld Parameter Adjust 5 1 Effects of 3 36 Entry 3 35 Weld Parameter limits Defined 3 12 Weld Pool Shift Defined A 9 Weld Procedure Guideline Blank Worksheet 5 10 Defined A 9 Determine Work Specification 5 2 Develop a 5 1 Example Worksheet 5 9 CWS D100 B Welding System Front Panel Switch Settings 5 3 Calculate Arc Start 5 6 Downslope 5 8 Duration 5 6 Impulse 5 4 Impulse Width 5 5 Maintenance 5 4 Use of 3 35 Weld Puddle Defined A 9 Weld Quality Adjusting Controls 5 22 Weld Time Defined A 9 Welding Checklist before Starting 3 37 Completion Steps 3 39 Display Indications during 3 38 Principles 1 2 Welding Considerations Micro Weld Head 4 13 Welding Process Troubleshooting 7 9 Weld Spot Overlap Weld Parameter Correction 5 22 Work Piece Micro Weld Head Alignment 4 9 Preparation 3 28 Series 5 10 20 Fixture Block Alignment 3 30 Series 5 10 20 Weld Head Purge Gas Connection 3 32 Index vi
160. ll your Swagelok representative 2005 Swagelok Company all rights reserved 3 11 September 2005 Operation CWS D100 B Welding System Operational Mode W hen the power supply is turned on it enters the operational mode The Average Current and Average Voltage displays show a blinking decimal point and a zero If the weld head is not attached to a fixture block Fixture is on The power supply is ready to be used Weld Parameter Limits Message codes 1 to 11 Each front panel rotary switch controls a part of the welding process The power supply operates normally as long as each switch setting is within certain limits If the limits are exceeded the power supply reacts to the condition and shows a message code on the front panel displays If the code display is accompanied by flashing status indicator lights a disable condition exists If not the code display indicates a caution condition M essage codes 1 to 11 refer to the front panel rotary switches by number See Table 3 4 See Figure 3 1 to cross reference the switch position numbers Table 3 4 Weld Parameter Limit Message Codes Normal Mode or Operating Setting to Code No Name Range Activate Code Type 01 Impulse 2A to 99 9 A lt 2 Disable 02 Maintenance 2 A to 99 9 A lt 2 Disable 03 Impulse Rate 1 Hz to 99 Hz lt 1 Caution 04 Impulse Width 5 to 95 lt 5or gt 95 Disable 05 Arc Start 2A to 99 A lt 2 Disa
161. llow the system to purge for several minutes on initial setup to clear the shielding gas system of oxygen Press PURGE again to close the shield gas solenoid valve Table 3 10 Shield Gas Flow Rates Argon Weld Head Series std ft3 h L min 5 10 to 15 4 7 to 7 1 10 10 to 20 4 7 to 9 4 20 A 10 to 20 4 7 to 9 4 20 B 20 to 40 9 4 to 18 8 et the flow to the higher rates when welding at high current levels Starting and Completing the Weld 1 Check the following before starting the weld e All rear panel connections are complete e Shielding and purge gas lines are properly connected e The inert gas source is on e Correct gas flow rates are set e Weld pieces are properly aligned and clamped in the fixture block e The proper arc gap is set e Theweld head is connected to the fixture block e The proper weld procedure guideline settings have been entered e All status indicator lights are off e Theinternal purge gas is flowing Operation Caution Excessive or insufficient flow rates may affect arc start and arc stability Note Although the power supply welds in any orientation it is recommended that it be placed in the upright position before welding 2005 Swagelok Company all rights reserved September 2005 Operation WARNING Do not touch the cable connectors during arc start If the cables have been damaged a potential for electric shock exists
162. m Correct idler Gear Placement 11 Replace the idler gears in the micro weld head housing Pressed Fully into Body ka Verify the idler gear axle is pressed into the body See Figure 6 26 12 Clean any oxide deposits from the exposed surface of the weld head brush with the provided stainless steel wire brush 13 Verify that the spring under the weld head brush is not exposed See Figure 6 27 If necessary reposition the spring under the weld head brush Figure 6 26 Correct Placement of Idler Oar Mero MC Hea touslag 14 Inspect all other weld head components and clean any that are dirty Blow any loose dirt from the weld head with clean dry low pressure air Correct Position Incorrect Position Spring Covered by Brush Spring Exposed Under Brush Figure 6 27 Spring Position 6 14 2005 Swagelok Company all rights reserved September 2005 CWS D100 B Welding System Maintenance Micro Weld Head Assembly Caution A Do not pinch the internal Assemble the weld head by completing the steps in the wiring during reassembly of appropriate weld head disassembly procedure in the micro weld head reverse order Be sure to properly seat the brush spring during reassembly See Figure 6 23 B or Figure 6 27 If the spring is not seated properly the rotor will not move A fter reassembly check the rotor for smooth motion by turning the drive gear by hand Power Supply VAR NING The user should not service The powe
163. m 23 mm 25 mm 28 mm 35 mm CWS C 062 1 105 P 11 2in 1 105 in 0 062 in 35 mm 28 07 mm 1 57 mm CWS C 062 855 P 1 3 4 in 11 4 0 855 in 0 062 in 2 in 11 2 21 72 mm 1 57 mm 35mm 40 mm 52mm Electrode Geometry This illustration shows the electrode shape Swagelok suggests Properly ground electrodes provide consistent repeatable welds Pre ground electrodes are available from your Swagelok representative See your parts list for ordering information The electrode part numbers are assigned as follows CWS X 744 44 P Package Designator Electrode Length Electrode Diameter Material Designator C Ceriated T Thoriated The ceriated electrode material type is a mixture of 98 tungsten and 2 cerium and is commonly referred to as 2 ceriated This electrode type has demonstrated improved arc starting performance over the 2 thoriated type particularly when using purified shielding gas 2005 Swagelok Company all rights reserved C 3 September 2005 Electrode Selection Tables and Geometry CWS D100 B Welding System C 4 2005 Swagelok Company all rights reserved September 2005 Appendix D Weld Head Information i Prepurge and Weld Shield Gas Flow Rates Postpurge Maximum Head std ft3 hr minimum time Recommended Series std L min in seconds Start Power Average Amps 4 8 to 10 Continuous Low 30A 4 7 to 4 7 8 15 to
164. m Rotor Speed by Weld Head Model Maximum Rotor Speed Seconds Weld Head Model RPM Revolution Micro Weld Head 24 2 5 Series 5 10 Weld Head 12 5 Series 20 Weld Head 6 10 Operation Note A minimum of 10 seconds PREPURGE is recommended for all SWS Weld Head models If Weld Head extension cables are used add one second for each foot of cable added 2005 Swagelok Company all rights reserved September 2005 3 5 Operation CWS D100 B Welding System Pushbuttons The front panel pushbuttons control the welding operation and provide some manual control functions for the weld head See Figure 3 4 The pushbutton functions are as follows Figure 3 4 Pushbuttons Note The external gas solenoid referenced here may be used in place of the internal solenoid at the users option See Section 2 Installation for installation information START initiates the welding sequence DOWNSLOPE initiates the downslope cycle when pressed during the weld time cycle The downslope cycle reduces the output current levels from the weld time levels to zero during the time specified STOP RESET aborts the weld and halts the rotor if pressed during the weld cycle Push STOP RESET again to return the rotor to its home position as shown in Figure 3 5 on page 3 7 The rotor will move at maximum speed when traveling to the home position regardless of the programmed rotor speed W hen not welding pushing STOP RESET cau
165. ments 2 3 Installing 4 3 Installing Gas Delivery System 2 9 Maintenance 6 11 a ee ni a Multiple Pass Defined A 5 Tools and Accessories 2 2 Unpacking and Inspecting Components 2 4 Installing Electrode O Micro Weld Head 4 6 Series 5 10 20 Weld Heads 3 26 Operation 3 1 Data Recording Printer B 9 Internal Purge Gas Defined A 5 Micro Weld Head 4 1 Modes of 3 9 J Overview 1 7 Program Mode 3 17 Jog Defined A 5 Changing Items 3 21 Joule Defined A 5 Entering 3 17 Exiting 3 22 M Selecting Program Items 3 17 Specifications 1 9 i Summary 3 40 Maintenance 6 1 Test Mode 3 22 Data Recording Printer B 15 Entering 3 23 Defined A 5 Exiting 3 25 Micro Weld Head Motor Module 6 11 z Micro Weld Heads 6 10 Operational Mode Power Supply 6 15 Defined 3 12 Series 5 10 20 Fixture Blocks 6 2 6 3 Disable Caution examples 3 16 Series 5 10 20 Weld Heads 6 4 Table of Message Codes 3 10 2005 Swagelok Company all rights reserved Index iii September 2005 Index Optional Equipment B 1 SWS Data Recording Printer B 6 Orbital Welding Defined A 6 Oxidation Defined A 6 Ozone Defined A 6 P Parts Drawings F 1 Parts Lists Replacement F 1 Pendant Remote Operator B 2 Penetration Defined A 6 Performance Tracking Data Logging B 4 Plenum Defined A 6 Power Supply 1 4 Current Control Switches 3 3 Defined A 6 Digital Displays 3 9 Entering Weld Parameters 3 35 Front Panel Controls 3 2 Fu
166. mounting bracket from the printer by removing the two black knobs The bracket must be pulled apart somewhat to free the printer due to the serrated mating surfaces See Figure B 9 3 Attach the mounting bracket to the power supply by tightening the two captive thumbscrews in the base of the bracket See Figure B 10 4 Install the printer in the mounting bracket and rotate the unit to an appropriate viewing angle Insert and tighten the two black Knobs to secure the printer Figure B 9 Separating the Printer from the Mounting Bracket O Figure B 10 Mount the Bracket to the Power Supply B 8 2005 Swagelok Company all rights reserved September 2005 CWS D100 B Welding System Optional Equipment Cabling the Printer Cable the printer by performing the following steps 1 Turnthe SWS power supply off Turn the printer power switch off which is the down position 2 Plug the interface cable into the 25 pin connector on the back of the printer The connectors are polarized so only one end of the cable will match the printer connector Connect the other end of the cable to the printer connector on the rear of the power supply See Figure B 11 3 Turn on the power supply Do not apply power to the printer at this time W ry ON Operating the Printer a CA 9 The controls used to operate the CWS DRP have been kept S g to a minimum See Figure B 12 The front panel components and their functions are lis
167. mpany all rights reserved F 18 CWS D100 B Welding System Table F 9 CWS 10TFB Tube Fixture Block Parts List Reference No Description Available in KitNo 1 Locking Ring Tab Screws CWS 12148 PKG CWS 10FIX PKG 2 Locking Ring Tab CWS 12148 PKG 3 Top Side Plate left 4 Lever Cam Assembly CWS 12130 2 5 Latch Screw CWS 12132 02 CWS 12146 PKG CWS 10FIX PKG 6 Latch CWS 12146 PKG 7 Collet Insert Screws CWS 10FIX PKG CWS 13112 04 8 Collet Insert F 9 Bottom Side Plate left 10 Plenum CWS 10PLEN 11 Side Plate Screws CWS 10FIX PKG 12 Bottom Side Plate right 13 Hinge and Latch Pins CWS 10FIX PKG 14 Hinge 15 Top Side Plate right 16 Plenum Pins CWS 10FIX PKG 17 Lanyard Screw short centering gage CWS 10CG 18 Lanyard Star Washer CWS 10CG 19 Lanyard CWS 10CG 20 Centering Gage CWS 10CG 21 Lanyard Screw long side plate CWS 10CG 22 Lanyard Star Washer CWS 10CG For part ordering information contact your Swagelok representative Not available as a field replaceable spare part Parts Drawings 2005 Swagelok Company all rights reserved September 2005 F 19 Parts Drawings CWS D100 B Welding System Figure F 10 CWS 20H A Weld Head F 20 2005 Swagelok Company all rights reserved September 2005 CWS D100 B Welding System Parts Drawings
168. mping screw to allow the electrode to fall against the arc gap gage See Figure 4 10 7 Tighten the electrode clamping screw to hold the electrode in place Do not overtighten Remove the arc gap gage The rotor may move due to the torque of tightening the clamping screw Use your finger to hold the rotor in place 8 If the micro weld head is disconnected from the motor module attach it to the motor module Complete the steps in Installing the Micro Weld Head beginning on page 4 4 When complete return here 9 Turn on the power supply 10 Press STOP RESET The rotor starts moving and stops at the home position 4 8 2005 Swagelok Company All rights reserved September 2005 CWS D100 B Welding System Micro Weld Heads Fixturing the Work The work pieces must be properly prepared before fixturing See page 3 28 in Section 3 Operation for information 1 Locatethe centering gage Turn the gage so the labeled side is face up Insert the gage into the fixture See Figure 4 11 The orientation of the fixture does not matter 2 Open the fixture side facing the labeled side of the centering gage by rotating the latch 90 See Figure 4 12 The fixture opens with a scissors type action Figure 4 12 shows how to use the micro fixture tool on both the Series 4 and Series 8 fixtures Figure 4 11 Inserting Centering Gage Opening the Note Use the micro fixture tool for Fixture Series 4 and Series 8 fixture
169. n 38 1 mm in the collets such that it rests across both side plates Close and lock the side plate that is not adjustable See Figure H 2 Lock down the top of the loosened side plate Tighten the four cap screws in the loosened side plate Take care to tighten the screws evenly to prevent the side plate from slipping Open the side plates and remove the tubing H 2 2005 Swagelok Company all rights reserved September 2005 CWS D100 B Welding System Micro Fit Fitting to Tube Fixture Block To align the fixture block follow these steps 1 Turn the fixture block over and locate the directional arrows on the plenum The arrows point to the appropriate side plate See Figure H 3 U sing the provided 3 32 in hex wrench unscrew the four cap screws in the appropriate side plate just enough to loosen it from the plenum See Figure H 3 to locate the appropriate side plate Turn the fixture block upright and release the lever and open the top of the tube side plate Choose and install a collet that holds tubing that matches the outside diameter of the M icro Fit fitting Unlatch and remove the top of the CW S 5FSP2 Side Plate See Figure H 4 Using the centering gage place a straight length of tubing minimum length 1 50 in 38 1 mm in the tube side plate and lock down the top of the plate Place the M icro Fit fitting in the fitting side plate and close and latch the top Align the M icro Fit fitting
170. ng diameter B Arc gap gage diameter C _ desired arc gap Figure E 1 Arc Gap Gage Setting Formula Example No 1 Series 5 Weld Head 1 4 to 1 4 in tube butt weld A 0 253 in largest outside diameter Arc gap gage diameter B 1 244 in Desired arc gap C 0 028 in O 253in LAN 4 0 028in 0 777 in Example No 2 Series 5 Weld Head 6 to 6 mm tube butt weld A 6 081 mm largest outside diameter Arc gap gage diameter B 31 60 mm Desired arc gap C 0 71 mm 603i mm SLEMM 4 071mm 19 551 mm E 12 2005 Swagelok Company all rights reserved September 2005 Appendix F Parts Drawings This section includes exploded assembly drawings and associated parts lists These drawings are provided as a guide to identifying part names For specific part ordering information contact your Swagelok representative The parts identified in this section include e CWS 5H B Weld Heads s as se a F 2 e Series 5 10 20 Rotor Assembly F 4 e CWS 5H B Motor and Power Block Assembly F 6 e CWS 5TFB Tube Fixture Block F 8 e CWS 5FSP1 Special Purpose Fixture Block F 10 e CWS 5FSP2 Special Purpose Fixture Block F 12 e CWS 10H A WeldHead F 14 e CWS 10H A Motor and Power Block Assembly F 16 e CWS 10TFB Tube Fixture Block F 18 e CWS 20H A WeldHead F 20 e CWS 20H A Motor and Power Block Assembly F 22 e CWS 20TFB
171. nges the Arc Start power level The default setting for Arc Start power is one normal power This setting is recommended for all tubing with an OD greater than 1 16 in 1 5 mm or a wall thickness greater than 0 020 in 0 5 mm Set the Arc Start power to zero low power for tubing with a 1 16 in 1 5 mm OD or wall thickness under 0 020 in 0 5 mm Using the normal power setting for work of this size can affect the integrity of the weld The ARC START and DURATION rotary switch settings may have to be increased when Arc Start power is set to zero 2005 Swagelok Company all rights reserved 3 19 September 2005 Operation Note The controller does not check the state of the printer during execution of a print cycle The user parameters are sent to the printer port when ROTOR JOG is pressed CWS D100 B Welding System 30 35 Time and date The controller in the power supply keeps track of the time and date Display or change the current settings using items 30 through 35 Code 30 is the hour using the 24 hour format Code 31 is the minutes 32 is the month 33 is the day and 34 is the year Each item is a two digit value A 00 entered for the year indicates the year 2000 Code 35 sets the date format for a printout A value of zero which is the default sets the date to the mm dd yy format A value of one sets the format to dd mm yy 60 63 Weld system information Code 60 is a non resettable weld counter This
172. ntinuous purge so the prepurge timer is not needed The minimum prepurge setting message code 07 is one second According to Table 3 3 code 07 will not disable the power supply so entering zero creates a caution condition The digital displays read as shown in Figure 3 11 The Average Voltage display shows that switch 7 Prepurge is below its normal limit dash on left The Average Current display shows the minimum limitis one The unit is still functional This condition only serves to show that there is a questionable setting If START is pushed the system begins welding and the weld current and voltage are displayed After completing the weld the digital displays again indicate the caution condition W hen Prepurge is changed to one second or greater the displays return to normal 2005 Swagelok Company All rights reserved September 2005 CWS D100 B Welding System Program Mode The program mode accesses setup parameters for the power supply and the optional printer The program mode also serves as an access path for the test mode See Test M ode on page 3 22 Entering Program Mode Refer to Figure 3 12 Do the following to enter program mode 1 Press and hold DOWNSLOPE 2 Press and hold ROTOR JOG 3 Release both pushbuttons at the same time The status indicator lights begin to sequence up and down indicating that the program mode has been successfully entered Selecting Program Items In
173. oduction Front Panel Controls Current Control Switches Timing Control Switches Pushbuttons Status Indicator Lights Digital Displays SWS Modes of Operation Operational Mode Program Mode Test Mode Installing the Electrode in the Series 5 10 20 Weld Head Selecting the Proper Electrode Inserting the Electrode into a Rotor Setting the Arc Gap Setting the Arc Gap Gage Setting the Arc Gap Preparing the Work Fixturing the Work Selecting the Fixture Block and Collets Installing the Collets in a Tube Fixture Block Aligning the Work Pieces in the Tube Fixture Block Connecting the Purge Gas Line Connecting the Weld Head to the Fixture Block Safety Interlock Mating the Weld Head to the Fixture Block 2 6 2 6 2 7 2 9 2 9 2 10 2 12 2 14 3 1 3 2 3 3 3 4 3 6 3 8 3 9 3 9 3 12 3 17 3 22 3 26 3 26 3 26 3 27 3 27 3 27 3 28 3 29 3 29 3
174. ody Gear Side CWS 8MHP GEARHOUSE 15 Socket Head Cap Screw CWS 8MHP SCREWS CWS 8MHP BRSHHOUSE CWS 8MHP GEARHOUSE 16 Socket Head Cap Screw CWS 8MHP SCREWS CWS 8MHP BRSHHOUSE CWS 8MHP GEARHOUSE 17 Button Head Screw CWS 8MHP SCREWS CWS 8MHP BRSHHOUSE CWS 8MHP GEARHOUSE 18 Latch Keeper 19 Motor Cover 2 20 Drive Clip CWS 8MHP TRANS CWS 8MHP DRVCLP 21 Shielding Gas Tube 22 Drive Shaft Insulating Tube 23 Safety Interlock Conn Pins 24 Interface Plate 25 Drive Coupling Gear Bearing 26 Drive Coupling Gear 27 O ring CWS 8MHP CVA CWS 8MHP ORING 28 Check Valve Actuator CWS 8MHP CVA 29 Micro Coupling Collar CWS 8MHP BRSHHOUSE 30 Motor Cover 2A 31 Button Head Cap Screw CWS 8MHP SCREWS CWS 8MHP BRSHHOUSE CWS 8MHP GEARHOUSE CWS 8MHP BRACKET 32 Work Cable 33 Electrode Cable 34 Brush O Ring Spacer 35 Star Washer CWS 8MHP SCREWS CWS 8MHP BRUSH 36 Slotted Pan Head Screw CWS 8MHP SCREWS CWS 8MHP BRUSH 37 Solid Drive Coupling 38 Solid Drive S haft 39 Safety Interlock Sensor Assy 40 Shrink Tubing For part ordering information contact your Swagelok representative Not available as a field replaceable spare part 2005 Swagelok Company all rights reserved September 2005 Parts Drawings CWS D100 B Welding System Figure F 25 SWS 8MFA Micro Weld Head Fixture F 48 2005 Swagelok Company all rights reserved September 2005 CWS D100 B Welding System Table F 24 SWS 8MFA
175. of this manual or the appropriate weld procedure guideline Inserting the Electrode into a Rotor 1 Press STOP RESET The rotor makes one half of a revolution 180 for the Series 5 10 and 20 weld head assuming that the weld head is not attached to a fixture block 2 Verify that the rotor is in the correct position to install the electrode See Figure 3 17 If the rotor position is not as shown press STOP RESET again The micro weld head setup is different The procedures are covered in Section 4 Micro Weld Head 3 On the rear panel turn off the circuit breaker 4 Loosen the two electrode clamping screws If you are replacing the electrode remove the electrode 5 Insert the new electrode with the sharp tip pointing out Tighten the electrode clamping screws slightly to temporarily hold in place 2005 Swagelok Company All rights reserved September 2005 CWS D100 B Welding System Setting the Arc Gap The proper arc gap setting facilitates control of the weld and improves consistency The following steps cover how to set the arc gap The arc gap is set by using the arc gap gage provided with the weld head The gage is adjusted for the desired arc gap and then installed in the rotor aperture With the gage in place the electrode can be positioned with reasonable accuracy Setting the Arc Gap Gage 1 Measure the outside diameters of the work pieces being welded using a caliper or micrometer See Fig
176. on needed to produce high quality repeatable welds W hile reading you May encounter unfamiliar terminology Some terms are common to the welding industry and others particular to the SWS Refer to Appendix A Glossary if necessary Gas Tungsten Arc Welding Principles of the GTAW Process Gas Tungsten Arc Welding GTAW is a welding process that creates an arc between a nonconsumable tungsten or tungsten alloy electrode and the work The electrode is held in a torch rotor or other device GTAW uses a shielding gas most commonly Argon that is delivered to the weld area The shielding gas envelops the weld joint and electrode protecting both from contamination by the atmosphere The electric arc which creates the weld is produced by the passage of current through the conductive ionized shielding gas The arc is established between the tip of the electrode and the work Heat generated by the arc melts the base metal Once the arc and weld puddle are established the electrode moves along the joint and the arc progressively melts the joint surface Filler wire if used is added to the leading edge of the weld puddle to fill the joint GTAW provides precise control of heat input to the weld joint For this reason it is preferred for joining thin gage metals and for making welds close to heat sensitive components The process offers advantages to many industries ranging from the high purity required in the semiconductor industry to autog
177. or all status indicator lights to go off 2 Check if the fixture block has cooled enough to be safely handled Allow additional cooling time if necessary before handling If necessary increase postpurge time to aid cooling 3 Release the locking lever on the weld head housing 4 Remove the weld head from the fixture block If itis difficult to remove the weld head release one of the side plate lever cams 5 Remove the internal purge gas lines from the welded assembly 6 Release the levers on the fixture block 7 Open the side plates of the fixture block 8 Remove the welded assembly A WARNING USE GLOVES OR OTHER PROTECTIVE DEVICES IF YOU MUST HANDLE PARTS IMMEDIATELY AFTER WELDING THE PARTS CAN BE EXTREMELY HOT AND MAY CAUSE BURNS Caution Do not immerse the hot fixture block in water after welding If using only one fixture block allow it to cool before performing the next weld More than one fixture block can be used for repetitive welding Note Inspect and clean the electrode after each weld Look for oxidation wear or weld material on the tip 2005 Swagelok Company all rights reserved September 2005 Operation CWS D100 B Welding System Operation Summary 1 Install the electrode 2 Set the arc gap using the arc gap gage 3 Prepare the work pieces 4 Select the correct fixture block and collets 5 Install the collets in the fixture block 6 Align the work piece
178. or each foot of extension cable Figure B 3 Pushbutton Locations 2005 Swagelok Company all rights reserved September 2005 B 3 Optional Equipment Data output connectors Figure B 4 Data Logging Outputs Note The data recorder must have high impedance inputs greater than 1 MQ Note Variables such as material chemistry weld end preparation electrode condition and shielding gas may also affect the weld quality The user must decide how to use the information provided by this feature CWS D100 B Welding System Data Logging Monitoring The power supply has four Bayonetted N Style connectors BNC on the lower portion of the rear panel that provide analog data outputs The data outputs have a signal range from 0 V dc to 5 V dc See Figure B 4 Connect a chart recorder or other recording device to these outputs to monitor the SW S during welding The BNC connectors output the following signals e current e voltage e rotor travel speed e enable The current voltage and rotor speed outputs are used to monitor the performance of the SWS Table B 19 Data Output References Output Function 0 V Reference 4 V Reference current OA 100A voltage OV 20 V travel speed 0 of max RPM 100 of max RPM Enable is a control signal for the external recorder Equipment with the capability to start and stop data recording can use this signal as the trigger to control the recording f
179. or gage to reduce the gas storage container source pressure to 25 psig to 50 psig W hen complete continue to the Preliminary Check procedure beginning on page 2 14 2 10 2005 Swagelok Company All right reserved September 2005 CWS D100 B Welding System Installation 2 Flow Meter for Internal 2 stage Regulator Purge Gas Range Flow Meter for Shielding Gas High Pressure Gage Low Pressure Gage 0 std ft3 h to 30 std ft3 h Range 0 std ft h to 50 std ft3 h 0 psig to 3000 psig 0 psig to 150 psig i Supply Manifold Internal Purge Gas Shut Off Valve Gas Cylinder Tubing to be Welded R Shielding Gas Supply Inlet Purge Fitting N Swagelok Union or ies Reducing Union with Nylon Purge Fitting SW9 P ower Supply Ferrules or Ultra Torr Swagelok Union or Reducing Union with Nylon Ferrules or Ultra Torr for P Gas Restricti SWS Fixture Block or Purge Gas Restriction Figure 2 6 Typical Gas Delivery System 2005 Swagelok Company All rights reserved 2 11 September 2005 Installation Caution Do not insert the secondary solenoid bypass plug into the connector unless you are using a secondary solenoid Inserting the plug disables the power supply solenoid CWS D100 B Welding System Inst
180. or leaks Change to a different gas source or change oxygen removal filter Troubleshooting Note The purge restrictor must be of adequate size to prevent excessive inside diameter back pressure 2005 Swagelok Company all rights reserved September 2005 7 11 Troubleshooting Symptom Concave weld puddle CWS D100 B Welding System Cause Excessive heat input Remedy Compare the material wall thickness and outside diameter size of the components you are welding to the weld procedure guideline being used Verify rotary switch settings match the guideline and adjust if necessary Refer to the flow chart in Figure 5 17 Adjust weld parameters as necessary Insufficient inside diameter purge gas flow Compare flowmeter settings to the weld procedure guideline being used Adjust if necessary 7 12 2005 Swagelok Company all rights reserved September 2005 CWS D100 B Welding System Symptom Incomplete inside diameter penetration Cause Insufficient heat input Remedy Compare the power supply rotary switch settings to the weld procedure guideline being used Refer to the flowchart in Figure 5 20 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 Refer to the flowchart in Figure
181. or squeaks when turning Dirty or worn weld head body halves Disassemble the weld head and clean replace components Gear bearings worn or dirty Clean or replace bearing assemblies as needed Dirty ball bearings in rotor Disassemble rotor and clean or replace ball bearings as needed Rotor does not move or makes a clicking noise when turning Debris on gears Check for weld spatter or debris on gears Loose drive clip in the micro weld head Check and replace drive clip if needed See the appropriate micro weld head assembly drawing in Appendix F Brush spring is installed incorrectly in micro weld head Install the brush spring in the correct orientation See Section 6 Maintenance Bent motor shaft Call for service Troubleshooting 2005 Swagelok Company all rights reserved September 2005 7 5 Troubleshooting Symptom Erratic rotor rotation speed control Cause Weld spatter on gears CWS D100 B Welding System Remedy Inspect the rotor primary secondary and drive gear s for damage Replace damaged gears Arcing damage on rotor gear teeth Inspect rotor and replace if damaged Dirty weld head debris on encoder sensor or encoder wheel Disassemble the weld head and clean thoroughly Encoder wheel slips on motor shaft Call for service Sticky rotary switches Use test mode to isola
182. or travel time using a stopwatch The rotor should move for 13 seconds Repeat the test two or three times to get an accurate average travel time The travel distance for Series 5 10 20 Weld Heads is one half revolution The micro weld head moves one revolution Compare the actual rotor travel time to the 13 second reference If the measured speed differs more than one second from the reference contact your Swagelok representative Series 5 10 20 Weld Head Disassembly and Cleaning This section describes the procedures necessary for disassembling the weld head and rotor Weld Head To disassemble the weld head follow these steps 1 Blow any loose material from the weld head assembly with clean low pressure air Remove the four screws locking ring and locking ring plate See Figure 6 6 Remove the work extension screw with lock washer and the work extension Inspect the work extension for pitting wear or damage See Figure 6 7 Maintenance Screws LT Ta T Locking po ST Ring Plate Z y Locking Ring i Zz he Figure 6 6 Removing the Locking Ring and Locking Ring Plate Screw and a Lock Washer pa ic Work Extension Work Extension SEN Se Hs Figure 6 7 Removing the Work Extension 2005 Swagelok Company all rights reserved September 2005 6 5 Maintenance Housing e Locking VP Weld Head Housing Motor Half Figure 6 8
183. ork piece The collet design firmly holds tubing and fittings that vary 0 005 in 0 13 mm from nominal outside diameter Collets are also available for thin wall pipe The collets exchange quickly making the fixture block very adaptable to changing work requirements Tables 1 6 1 7 and 1 8 list the available fixtures and collets Series 5 Series 8 Series 4 Figure 1 4 Standard Fixtures 1 6 2005 Swagelok Company all rights reserved September 2005 CWS D100 B Welding System Introduction Overview of SWS Operation GTAW Orbital welding is a proven method for welding cylindrical shapes such as tubes fittings and pipe The SWS design makes the orbital welding process efficient and effective The SWS provides an advanced method of autogenous GTAW The system uses a fixture block and associated weld head to provide precise fixturing of the work pieces The welding parameters are controlled by the SWS power supply and are programmed by the operator Operating the SWS is uncomplicated The work piece sizes define the fixture block configuration collets and weld head to be used The fixture block quickly clamps onto the work pieces The weld joint is centered in the fixture block using a centering gage Since the fixture block is not part of the weld head multiple fixture blocks can be used to maximize weld setup efficiency The weld head cable assembly attaches quickly to the power supply Setup of the weld head is
184. pecific application maintain them and associated parts in good condition e Turn face away from valve outlet when opening cylinder valve e Keep protective cap in place over valve except when cylinder is in use or connected for use e Read and follow instructions on compressed gas cylinders associated equipment and CGA publication P 1 listed in Safety Standards A Foreword WARNING SHIELDING GAS CYLINDERS CAN EXPLODE IF DAMAGED OR IMPROPERLY TREATED 2005 Swagelok Company all rights reserved September 2005 vii Foreword WARNING A SHIELDING GAS CYLINDERS CAN EXPLODE IF DAMAGED OR IMPROPERLY TREATED WARNING PACEMAKER WEARERS KEEP AWAY CWS D100 B Welding System HOT PARTS can cause severe burns After welding the work piece weld head and electrode can be extremely hot and may cause burns MAGNETIC FIELDS can affect pacemakers e Pacemaker wearers keep away e Wearers should consult their doctor before going near welding operations viii 2005 Swagelok Company all rights reserved September 2005 CWS D100 B Welding System User Precautions Power Supply Grounding The power supply is grounded through the ground connector of the power cord Avoid electrical shock by making sure the power cord is plugged into a properly wired and grounded receptacle before turning the unit on Water and Moisture System components are not waterproof Do not expose the SWS equipmen
185. per Revolution Rotor Speed Switch Setting lin 7 8in 3 4in 5 8 in 1 2 in 99 95 90 85 LH a Curve Model 75 a CWS D100 1B 11 2 in 70 S CWS D100 2B 65 1 3 4 in 60 2 in 35 i 50 45 An 40 iD 35 30 25 xx 20 16 d 12 8 4 0 20 19 18 17 16 15 14 13 12 11109 8 7 6 5 4 3 2 10 0 0 20 30 40 50 60 70 80 90 100 110 120 Travel Speed in min Seconds per Revolution SERIES 20 WELD HEAD TUBE WELDING 2005 Swagelok Company all rights reserved September 2005 D 3 Weld Head Information CWS D100 B Welding System peer vs Rotor Speed Switch Setting vs Seconds per Revolution l i Rotor Speed Switch Setting 3 4 in 1 2in 3 8 in 1 4 in og 95 90 85 lin 80 Curve Model 13 D CWS D100 1B is CWS D100 2B 11 4 in 65 60 11 2 in 55 50 45 40 35 30 25 ie 20 16 12 8 4 0 20 19 18 17 16 15 14 13 12 1110 9 8 7 6 5 4 3 2 10 0 0 20 30 40 50 60 70 80 90 100 110 120 T Travel Speed in min Seconds per Revolution SERIES 20 WELD HEAD PIPE WELDING Travel Speed vs Rotor Speed Switch Setting VS Seconds per Revolution mm s Rotor Speed Switch Setting 6mm 3mm g 95 Curve Model KH D CWS D100 1B i CWS D100 2B N 75 70 10 mm 65 A 12 mm 55 a
186. r Size Thickness Purge Rate Pressure Purge Rates Size 1 to 2 torr 3 4 in 0 065 in 20 std ft3 hr 0 5 to 1 1 iwc 15 to 30 std ft3 hr 1 4 in 20 mm 1 5 mm 10 std L min 13 to 28 mmwc 7 to 14 std L min 6 mm 1 2 to 2 7 mb 1 to 1 9 torr Lin 0 065 in 40 std ft3 hr 0 5 to 1 0 iwc 15 to 30 std ft3 hr 1 4 in 25 mm 1 5 mm 20 std L min 13 to 25 mmwc 7 to 14 std L min 6 mm 1 2 to 2 5 mb 1 to 1 3 torr 11 2 in 0 065 in 80 std ft3 hr 0 5 to 0 7 iwc 15 to 25 std ft3 hr 1 4 in 38 mm 1 5 mm 40 std L min 13 to 18 mmwc 7 to 12 std L min 6 mm 1 2 to 1 7 mb 0 7 to 1 3 torr 2 in 0 065 in 150 std ft3 hr 0 4 to 0 7 iwc 15 to 25 std ft3 hr 3 8 in 50 mm 1 5 mm 70 std L min 13 to 18 mmwc 7 to 12 std L min 10 mm 1 0 to 1 7 mb These tables for use on butt welds only ATW welds and Weld Ring welds typically will require approximately 15 more purge pressure Head purge rates exceed Swagelok recommendations Be cautious of arc wander For best results use constant head purge between welding cycles Pressures must be adjusted for ID encroachment of 0 to 10 of wall thickness atthe bottom of the weld ndicated purge rates are for minimum color line ID purge rates shall be adjusted to the desired ID color line Restrictor sizes are approximate purge rate amp pressure are critical parameters General Suggested Shielding Gas Flow Rates Argon Weld Head Series std ft3 h L min 5 10 to 15 4 7 to 7 1 10 10 to 2
187. r supply has no internal serviceable parts and the power supply should not be disassembled Fuse Inspection and Replacement Note The fuse can be checked A 20 110 V ac system or a 10 A 220 V ac with an ohmmeter system ceramic fuse is on the rear panel of the power supply A blown fuse does not permit an arc to start To inspect the fuse 1 Turn off the power supply See Figure 6 28 2 Unplug the power cord Figure 6 28 Power Supply Circuit Breaker in the OFF position 2005 Swagelok Company all rights reserved 6 15 September 2005 Maintenance CWS D100 B Welding System 3 Inspect the fuse and fuse cap a Unscrew the fuse cap using a flat blade screwdriver See Figure 6 29 b Inspect the fuse cap for damage overheating burning etc Replace the cap if necessary Caution inui A EEN i c Using an ohmmeter check the continuity of the Use only insulated pliers to fuse If itis blown replace it with a fuse of the remove fuse same type and rating 4 Turn on the power supply Figure 6 29 Ceramic Fuse Location 6 16 2005 Swagelok Company all rights reserved September 2005 Section 7 Troubleshooting Introduction This section contains troubleshooting charts to assist you if a problem is encountered Information is included for both hardware and weld process problems This section contains troubleshooting guidelines for e power supply e weld head e electrode e
188. rode cleaning tool Note Clean the electrode before every weld to ensure Push the electrode into the electrode cleaning tool and PAM enone nce rotate back and forth two to three times Figure 4 8 Installing the Electrode 2005 Swagelok Company All rights reserved 4 7 September 2005 Micro Weld Heads Figure 4 10 Setting the Arc Gap A Caution Make sure the electrode is secure but do not overtighten The electrode could be damaged as a result CWS D100 B Welding System Setting the Arc Gap The micro weld head accessory package also includes an arc gap gage The gage is required to set the arc gap The gage fits the rotor aperture and adjusts for the desired arc gap 1 Measure the OD of the work to be welded with a caliper or micrometer and record the value See Figure 4 9 A 2 Refer to the CWS 4M RH A CWS 4M FH A or CWS 8M RH tables in Appendix E Arc Gap Gage Setting Tables Find the Actual OD column 3 Locate the OD value in the table that matches the OD of the work Find the arc gap gage setting listed for that OD and record it 4 Set the arc gap gage to the value from the table using the provided 3 32 in hex wrench M easure from the bottom of the arc gap gage to the top of the adjustment screw See Figure 4 9 B 5 Insert the arc gap gage into the micro weld head rotor opening 6 Hold the micro weld head so that the electrode tip is pointing down Loosen the electrode cla
189. rors on the digital displays one after another Each message code is displayed for a moment followed by the next until all are shown The sequence repeats continuously until the errors are cleared If the message code is caused by a disable condition the status indicator lights blink as the code is displayed 3 14 2005 Swagelok Company All rights reserved September 2005 CWS D100 B Welding System Operation System Status Faults Message codes 41 to 52 41 Paper out Code 41 indicates that the optional printer is out of paper See Appendix B Optional Equipment for information on the printer 42 Printing Code 42 appears when a print cycle is started The power supply outputs data to the optional printer This code only shows that the data is being sent to the printer The power supply does not monitor the printer operation 50 Hi temp Code 50 is a disable condition that is not resettable The condition occurs when a temperature sensor inside the power supply detects a buildup of heat that exceeds a predefined limit The power supply is disabled until the internal temperature drops to a safe level Allow the power supply to cool After the condition clears welding can resume 51 Old head type Code 51 is a disable condition The code is displayed if the power supply does not detect a safety interlocked weld head The code is displayed if no weld head is connected or if a nonsafety interlocked weld
190. rotate the rotor with the electrode clamping screw loose Damage to the micro weld head housing may result CWS D100 B Welding System Installing Replacing the Electrode The micro weld head accessory package includes a screwdriver tweezers and an electrode cleaning tool Use these tools for installing or replacing the electrode 1 Select the proper electrode for the job to be performed See A ppendix C Electrode Selection Tables and Geometry Turn off the power supply circuit breaker on the rear panel See Figure 4 3 Disconnect the micro weld head from the motor module M anually turn the rotor drive gear shown in Figure 4 4 until the electrode clamping screw is exposed See Figure 4 7 4 6 2005 Swagelok Company All rights reserved September 2005 CWS D100 B Welding System Micro Weld Heads 5 Loosen the electrode clamping screw holding the micro weld head as shown in Figure 4 8 A This orientation helps to prevent the electrode from falling out during installation 6 Install a new electrode with the tweezers to avoid contamination Insert the electrode through the ceramic insulator and into the rotor to its full insertion depth M ake sure the sharp tip of the electrode is pointing out See Figure 4 8 B 7 Tighten the clamping screw sufficiently to prevent the electrode from falling out of the rotor Do not overtighten the clamping screw 8 Clean the electrode with the provided elect
191. rtially blocked or cut shielding gas line Check for leaks and or blockage Replace purge lines if needed O ring missing between the weld head and motor module Micro Weld Head Only Check and install O ring if necessary Shielding gas line disconnected inside weld head Disassemble weld head and reconnect the line Bent or broken electrodes Electrode was not secured in the rotor Replace the electrode Tighten electrode clamping screws Weld head not correctly attached to the fixture block Replace the electrode Reattach the weld head to 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 electrode No shielding gas Check for shielding gas flow and set the proper flow rate Troubleshooting 2005 Swagelok Company all rights reserved September 2005 7 7 Troubleshooting Fixture Block Symptom When closing the fixture block side plate the latch does not lock CWS D100 B Welding System 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 fitting tubing with the correct size Wrong size collets Replace with the correct size collet
192. s Figure 4 12 Insert First Work Piece 2005 Swagelok Company All rights reserved 4 9 September 2005 Micro Weld Heads Caution When closing the fixture be sure the moving side of the fixture engages into the small groove on the stationary side of the fixture an Correct Wrong Figure 4 13 Checking the Weld J oint Series 4 Fixture Figure 4 14 Proper Latch Position Series 8 Fixture CWS D100 B Welding System Insert the first work piece butting the weld end against the gage surface Close and latch that side of the fixture M ake sure that the latch is fully closed against the body of the fixture See Figure 4 13 Remove the centering gage Open the other side of the fixture and insert the second work piece Butt the weld ends together Close and latch that side Check the weld joint for proper fit and alignment See Figure 4 13 Verify that the latches are fully closed See Figure 4 13 Series 4 or Figure 4 14 Series 8 Connect the purge gas line to the work pieces See Figure 2 6 in Section 2 Installation Open the shut off valve in the purge gas line Set the flow meters according to the weld procedure guideline for both the shielding and internal purge gas Table 4 1 Shield Gas Flow Rates Argon Weld Head Series std
193. s included in Appendix Weld Procedure Guidelines of this manual If assistance is needed in obtaining more Weld Procedure Guidelines please provide your Swagelok representative with your specific requirements The weld procedure guideline listed in Table 3 9 is based on 1 2 in tubing with a 0 049 in wall thickness Table 3 9 Sample Weld Procedure Guideline Weld Parameter Setting Impulse 58 8 Maintenance 17 6 Impulse Rate 10 Impulse Width 35 Arc Start 32 Duration 0 5 Prepurge 10 Weld Time 2 revolutions 36 Downslope 18 Postpurge 20 Rotor Speed 26 Using the weld procedure guideline in Table 3 9 enter the Note If the displays do not read listed values on the front panel rotary switches Once this is zero please refer to Operational done the digital display windows should read a zero with a Mode on page 3 12 flashing decimal point The unit is ready for operation 2005 Swagelok Company all rights reserved 3 35 September 2005 Operation CWS D100 B Welding System Effects of Weld Parameters The following text briefly discusses how the weld parameters relate to the current waveform and the effects of any parameter changes Weld Parameters Affect the Output Waveform WELD CURRENT PARAMETERS The shape and duration of the output current waveform RE ARMENE r RUSE Daten e MpulsE created during the weld cycle is determined by the weld Weld Time parameter settings ent
194. s in the fixture block 7 Connect the internal purge gas line to the work piece to be welded and set the flow meter 8 Press PURGE and Set the shield gas flow 9 Press PURGE to stop the shielding gas flow prior to starting the weld 10 Connect the weld head to the fixture block 11 Program the welder 12 Press START and complete the weld 13 Remove the weld head from the tube fixture block 14 Remove the welded assembly from the tube fixture block 3 40 2005 Swagelok Company All rights reserved September 2005 Section 4 Micro Weld Heads CWS 4MRH A CWS 4MFH A CWS 8MRH Introduction The micro weld heads are used to weld work pieces from 1 16 in to 1 2 in 3 mm to 12 mm OD The Series 4 Micro Weld Head can weld work pieces from 1 16 in to 1 4 in 3 mm to 6 mm OD and is available in both rigid drive and flexible drive configurations The Series 8 Micro Weld Head can weld work pieces from 1 4 in to 1 2 in 6 mm to 12 mm OD and is available in a rigid drive configuration All micro weld heads operate with a detachable motor module See Figure 4 1 Series 8 Rigid Drive jf Series 4 Flexible Drive Motor Module Series 4 Rigid Drive Figure 4 1 Rigid Drive and Flexible Drive Micro Weld Heads 2005 Swagelok Company All rights reserved 4 1 September 2005 Micro Weld Heads CWS D100 B Welding System This section presents information that is specific to the micro weld head assem
195. s the location of all other types of warning or caution information which don t have specific symbols Accompanying text will identify the specific nature of the condition and if the condition is a warning or caution 2005 Swagelok Company all rights reserved iii September 2005 Foreword A CWS D100 B Welding System ELECTRIC SHOCK can kill Touching live electrical parts can cause fatal shocks and severe burns Incorrectly installed or improperly grounded equipment is a hazard Do not touch live electrical parts No user serviceable parts in the power supply other than a fuse Refer all other power supply servicing to your Authorized Swagelok representative K eep all panels and covers securely in place Do not touch electrode connector electrode or rotor after pressing start The electrode is live during the weld cycle Verify that the power supply is properly grounded before use M ake sure the power cord is plugged into a properly wired and grounded receptacle Follow local electrical codes and the guidelines in the manual when installing the SWS Failure to do so may create an electrical shock hazard Shock hazards can exist even when equipment is properly installed so itis important that the operator be trained in the proper use of the equipment and follow established safety practices Frequently inspect input power cord for damage or bare wiring replace immediately if damaged Properly unplug the
196. se Inspection and Replacement 6 15 Input Voltage Requirement 2 3 Installing 2 6 Maintenance 6 15 Modes of Operation 3 9 Operation 3 1 Operational Mode 3 12 Program Mode 3 17 Pushbuttons 3 6 Specifications 1 9 Status Indicator lights 3 8 System Status Faults 3 15 Test Mode 3 22 Timing Control Switches 3 4 Troubleshooting 7 3 Unpacking 2 4 Weld Parameter limits 3 12 Printer SWS Data Recording B 6 Process Variables GTAW 1 3 Program Mode 3 17 Changing Items 3 21 Code Number Descriptions 3 18 Entering 3 17 Exiting 3 22 Selecting Program Items 3 17 Table of Code Numbers 3 18 Proper Weld Identify 5 17 Pulse Rate Defined A 6 Pulse Weld Defined A 7 CWS D100 B Welding System Pulse Width Defined A 7 Purge Gas Defined A 7 Series 5 10 20 Weld Head Connection to Work Pieces 3 32 Pushbutton Switches Defined 3 6 Pushbuttons Testing 3 24 Q Quality Adjusting controls 5 22 R Recording Data B 4 Re enforcement Defined A 7 Reference Weld 5 17 Remote Operator Pendant B 2 Remote Pendant Defined A 7 Rotary Switches Testing 3 23 Rotor Defined A 7 Series 5 10 20 Weld Head Disassembly 6 8 Rotor Speed Maximum by Weld Head Model 3 5 RS 232 Printer Connecting to SWS B 16 S Safety Interlock Series 5 10 20 Weld Head Serial Number Effectiv ity 3 33 Series 5 10 20 Weld Heads 3 33 Safety Summary General iii User Precautions ix SCFH Defined A 7 Series 4 Mi
197. seconds to be considered valid The counter number will be printed on the weld data record See the description of the optional printer in Appendix B Optional Equipment 2005 Swagelok Company All rights reserved September 2005 CWS D100 B Welding System Operation 21 Automatic print counter The print counter allows the power supply to automatically print a weld data record at regular intervals The interval is set by the value entered in the counter Entering a value of ten for example causes the power supply to print a weld data record for weld cycle 10 20 30 and so on The power supply stores the weld count in memory The weld count will be reset if a new print count value is entered The weld count is also reset when the power supply is turned off The default print counter value is zero Zero in the counter disables the feature A weld data record printout can be accomplished at any time by pushing PRINT on the front panel See the printer description in Appendix B Optional Equipment for an example of the printout 22 Enable signal polarity The Enable signal one of the BNC data recording outputs described in Appendix B Optional Equipment has a selectable polarity Set item 22 to a value of 1 to make the signal active HIGH A value of 0 in item 22 causes the signal to be active LOW See Appendix B Optional Equipment for more information on data recording 23 Arc Start power The Arc Start power setting cha
198. served September 2005 CWS D100 B Welding System Power Supply Symptom Front panel current voltage digital displays are blank Cause The circuit breaker is off Remedy Turn on circuit breaker The power supply line cord is not plugged in Plug power cord into the wall outlet STOP RESET has been pushed with no weld head connected Press STOP RESET again The replaced or new ceramic fuse fails immediately when power is turned on Internal component failure Call for service Power supply fan does not operate Internal component failure Call for service A status indicator light does not function Burnt out indicator light Internal component failure Use test mode described in Section 3 Operation to isolate the problem Call for service if the light is faulty Pushbutton does not function Dirty electrical contacts Switch failure Use test mode described in Section 3 Operation to verify switch operation Call for service if the pushbutton switch is faulty Troubleshooting Note The circuit breaker is of the type that must be reset if it trips Reset the breaker by setting it to the OFF position before turning it on 2005 Swagelok Company all rights reserved September 2005 7 3 Troubleshooting Symptom Fixture indicator fails to turn off when the weld head is connected to a fixture block
199. ses the rotor to rotate as shown in Table 3 2 Table 3 2 Stop Reset Rotor Travel Weld Head Model Rotor Travel Micro Weld Head 1 Revolution Series 5 10 20 1 2 Revolution no Fixture Block connected 1 Revolution with Fixture Block connected PURGE activates the internal solenoid valve or the optional external gas solenoid valve and starts the flow of shielding gas to the weld head See Note W hen PURGE is depressed shielding gas flows to the weld head until you press the pushbutton again The pushbutton overrides the prepurge and postpurge timers and allows shielding gas to continuously flow through the weld head 3 6 2005 Swagelok Company All rights reserved September 2005 CWS D100 B Welding System Operation e ROTOR JOG advances the rotor manually Press and hold the pushbutton to move the rotor Release the pushbutton to stop the rotor ROTOR JOG can be used to position the rotor for electrode replacement or adjustment The rotor will move at the speed defined by the ROTOR SPEED rotary switches e PRINT Causes the power supply controller to transmit weld data to the printer port on the rear of the unit The optional CWS DRP printer accepts the data and prints the record Figure 3 5 Rotor Home Position 2005 Swagelok Company all rights reserved 3 7 September 2005 Operation Figure 3 6 Status Indicator Lights A Caution DO NOT try to remove the fixture block from the weld
200. ss with captured male nut SS 4 SVCR 4 CWS 5FVCR 04 1 4 in VCR glands must have weld glands overall length of 0 72 in 18 mm or less with captured female nut SS 4 VCR 1 CWS 5FBVCO 04 316L 4 BVCO 3 glands must have 1 4 in VCR overall length of weld glands 0 77 in 20 mm or less with captured female nut SS 4 VCR 1 CWS 5MSVCR 04 6LV 4 SVCR 3 with captured male nut SS 4 SVCR 4 CWS 5FSVCR 04 6LV 4 SVCR 3S 6LV 4 SVCR 3 Table 1 10 Extension Cords with captured female nut SS 4 SVCR 1 Wire gauge Wire gauge 0 ft to 50 ft 50 ft to 100 ft Model Supply Voltage Omto15m 15m to 30 m CWS D100 1B 115 V ac 12 AWG 10 AWG 2 5 mm 4 0 mm CWS D100 2B 230 V ac 12 AWG 10 AWG 2 5 mm 4 0 mm Some power loss will occur depending on the length of the extension cord See Table 1 10 to determine the minimum wire size to use 2005 Swagelok Company all rights reserved September 2005 Section 2 Installation Introduction This section describes the procedures necessary for installing the Swagelok Welding System SWS This section includes e tools and accessory requirements e electrical requirements e unpacking and inspecting system components e installing the SWS e installing the gas delivery system e preliminary check 2005 Swagelok Company All rights reserved September 2005 2 1 Installation C
201. st switch that has a non zero value When the power supply is switched to the test mode the digital displays indicate the value keyed into IMPULSE For example if IMPULSE is set to 45 0 the display appears as shown in Figure 3 16 Average Voltage shows that switch one Impulse is being tested and Average C urrent shows its present setting of 45 0 At this point IMPULSE can be rotated and the numerical values of each switch position are displayed in Average Current This exercise shows that the switches are working properly Once the operation of IMPULSE is verified the switch must be set to zero to allow the diagnostic to look to the next switch With IMPULSE Set to 0 the unit displays the values in switch two MAINTENANCE Use the same method described earlier to verify the operation of this switch Operation Figure 3 15 Entering Test Mode Figure 3 16 LED Test Display 2005 Swagelok Company all rights reserved September 2005 Operation Note The remote pendant is an optional feature See Appendix B Optional Equipment for more information Note The postpurge and rotor indicator lights are not tested on the remote pendant CWS D100 B Welding System After verification of MAINTENANCE Set its value to zero and move to switch three and so on If a switch displays an incorrect value it may be damaged or defective Contact your Swagelok representative for service Testing Pushbuttons and
202. t to water Proper Use and Storage Do not store or use near hazardous materials Store indoors and cover the system when not in use Weld Heads Disconnect the weld head completely from the power supply prior to servicing User service including cleaning or component replacement is limited to those operations identified in this manual Fixture Blocks Disconnect the fixture block from the weld head prior to servicing User service including cleaning or component replacement is limited to those operations identified in this manual Power Supply Service There are no user serviceable parts in the power supply other than a fuse Refer all other servicing to your Authorized Swagelok sales and service representative A A Foreword WARNING VERIFY THAT THE SYSTEM IS PROPERLY GROUNDED BEFORE USE WARNING USERS SHOULD NOT SERVICE THE POWER SUPPLY 2005 Swagelok Company all rights reserved September 2005 Foreword CWS D100 B Welding System Power Supply Warning Label This warning label is affixed to the power supply ARC WELDING can be hazardous Read and follow this label and the User s Manual Only qualified persons are to install and operate this unit Pacemaker wearers keep away Return to authorized sales and service center for service Do Not Remove Destroy or Cover This Label ELECTRIC SHOCK can kill WELDING can cause fire or explosion Do not touch live electrical par
203. tNo Locking Ring Tab Screws 1 CWS 12134 PKG CWS 13112 04 2 Locking Ring Tab CWS 12134 PKG 3 Screw Retainer CWS 5FP FSP2RETAIN 4 Top Side Plate 5 Dowel Pin 6 Locator Pin 7 Latch Cam Set Screw CWS 12132 02 CWS 5FP FSP2LATCH 8 Bottom Side Plate 9 Latch CWS 5FP FSP2LATCH 10 Lever Cam Assembly CWS 12130 2 11 Socket Head Screw CWS 13112 04 12 Socket Head Screw CWS 5FIX PKG For part ordering information contact your S wagelok representative Notavailable as a field replaceable spare part 2005 Swagelok Company all rights reserved September 2005 Parts Drawings CWS D100 B Welding System Figure F 7 CWS 10H A Weld Head F 14 2005 Swagelok Company all rights reserved September 2005 CWS D100 B Welding System Table F 7 CWS 10H A Weld Head Parts List Parts Drawings Reference No Description Available in KitNo 1 Motor Cover CWS 11121 PKG 2 Motor Cover Pins CWS 11121 PKG CWS 10WHA PKG 3 Weld Head Housing Pins CWS 10HP MTRHOUSE CWS 10WHA PKG 4 Motor Cover Screws CWS 11121 PKG CWS 10WHA PKG 5 Weld Head Housing Screws long CWS 10HP LOCHOUSE CWS 10WHA PKG CWS 10HP MTRHOUSE CWS 10HP LOCHOUSEPL 6 Locking Ring Plate Pins CWS 11104 PKG CWS 10WHA PKG 7 Locking Ring with Handle CWS 11106 1 8 Locking Ring Plate CWS 11104 PKG 9 Locking Ring Plate Screws CWS 11104 PKG CWS 10WHA PKG 10 Work
204. tage is 100 V or less the output power capabilities may be reduced Ensure that the following guidelines are adhered to when considering the electrical requirements for the power supply e All wiring and related components must WARNING be installed according to local and THE POWER SUPPLY MUST National Electrical Codes BE GROUNDED IF IT IS NOT GROUNDED ELECTRIC e The power supply must be grounded SHOCK CAN OCCUR e A dedicated electrical circuit must be used Using an Extension Cord If itis necessary to use an extension cord follow these guidelines e The wire size must meet the specifications indicated in Table 1 10 located in Section 1 Introduction e f the length of the cord is greater than 100 ft Note The voltage drop in an call your Swagelok representative for extension cord 100 ft long may recommended guidelines affect the output performance of the SWS 2005 Swagelok Company All rights reserved 2 3 September 2005 Installation Note Keep the shipping container and the foam inserts for storing and or shipping Figure 2 1 Shipping Container CWS D100 B Welding System Unpacking and Inspecting System Components Unpacking the Power Supply The SWS power supply is packaged in a wooden shipping container See Figure 2 1 The power supply part number and serial number are located on a label on the outside of the container Table 2 2 lists the contents of the shipping container
205. te Screw CWS 11060 PKG CWS 20PBA PKG 21 Power Strap Internal Star Washer CWS 11117 PKG 22 Power Strap Screw large CWS 11117 PKG CWS 20PBA PKG 23 Power Strap Screw small CWS 11117 PKG CWS 20PBA PKG 24 Power Strap External Star Washer CWS 11117 PKG 25 Power Strap CWS 11117 PKG 26 Safety Interlock Sensor 27 Power Block Housing brush side CWS 20PBH PKG CWS 20PBH A PKG 28 Brush CWS 11305 PKG 29 31 32 Secondary Gear Assy CWS 11313 PKG gear bearing gear pin 30 31 32 Primary Gear Assy CWS 11141 PKG gear bearing gear pin 33 Electrode Post 34 Drive Coupler Pins CWS 11315 PKG 35 Drive Coupler 36 Drive Coupler Motor Pin 37 Sleeve 38 Motor Mounting Screws CWS 20PBA PKG 39 Encoder Board Mount Screws 40 Motor Ground Lug For part ordering information contact your Swagelok representative Not available as a field replaceable spare part 2005 Swagelok Company all rights reserved September 2005 F 29 Parts Drawings CWS D100 B Welding System Figure F 16 SWS 20TFB A Tube Fixture Block F 30 2005 Swagelok Company all rights reserved September 2005 CWS D100 B Welding System Parts Drawings Table F 15 SWS 20TFB A Tube Fixture Block Parts List Reference No Description Available in KitNo 1 Top Side Plate right SWS 20TSPR A 2 Hinge and Latch Pin CWS 20FIX PKG 3 Lever Cam Assembly CWS 12308 1 4 Knob SWS 20FP
206. te the problem Call for service Fixture connector has broken wire Call for service Arc damage on rotor gear Arcing from rotor Clean gear or replace if necessary Damage to weld head body halves Arcing Disassemble the weld head Clean replace parts as needed Follow the recommended maintenance schedule outlined in Section 6 Maintenance Excessive heat from welding Check weld procedure guideline Use a larger weld head allow a cooling period between welds or allow continuous shielding gas flow when welding Weld head was dropped Check for damage and replace parts as necessary Check rotor for smooth operation Call for service if damage is severe 7 6 2005 Swagelok Company all rights reserved September 2005 CWS D100 B Welding System 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 internal purge gas flow rate for excessive back pressure Weld head is not properly attached to the fixture block Reattach the weld head to fixture block Engage the weld head locking lever Oxidation film on the electrode Insufficient shielding gas Increase shielding gas flow rate Insufficient post purge time Increase post purge time Pa
207. ted in Table B 1 Figure B 11 Connecting the Printer Table B 1 Printer Front Panel Controls Control Function THUMBWHEEL Used to manually advance the paper The thumbwheel can be advanced in one direction only indicated by the arrow Thumbwheel LED Indicates the power is on when green indicates paper is out when flashing red yellow green SWITCH Down position power off Middle position power on Top position paper advance spring loaded momentary LATCH Locks the printer inside the case Latch Switch Figure B 12 Printer Front Panel Controls 2005 Swagelok Company all rights reserved B 9 September 2005 Optional Equipment Note See page 3 17 for descriptions of the program mode items referenced in this section CWS D100 B Welding System Performing the Self Test The printer has a convenient self test feature This feature is used to quickly determine if the printer is operating correctly To activate the self test feature 1 Locate the power switch on the front panel See Figure B 12 2 Move the power switch from off to the paper advance position and hold it there The paper advance position is the point when the switch is pressed upward to the limit of its travel 3 Release the power switch once the self test routine begins The printout is a recurring pattern of symbols numbers and letters 4 Turn off the power switch after several lines of the test pattern have
208. the job Adjust start and duration settings as necessary Excessive purge gas flow Reduce flow to the value shown on the weld procedure guideline Insufficient shielding Check the shielding gas gas flow or source for low pressure contaminated Check gas lines for shielding gas leaks Change to a different gas source or change oxygen removal filter Electrode in Replace electrode poor condition Damaged electrical connections in the Weld head needs repair weld head Call for service Poor contact Inspect and clean all between locking contact surfaces ring tab and ground extension Poor contact Inspect and clean all between rotor contact surfaces and brush Poor contact Inspect and clean all between tubing contact surfaces collet and fixture block Arc start power set to zero Set Arc Start power menu item 23 to one See page 3 19 for details Troubleshooting Note All fuses should be rated at 250 V ac 110 V ac power Supplies use a 20 A fuse 1 4 in x 1 1 4 in 220 V units use a 10 A fuse 5 mm x 20 mm Note The ceramic fuse is located on the rear panel of the power supply See Figure 7 2 Figure 7 2 Ceramic Fuse Location 2005 Swagelok Company all rights reserved September 2005 7 9 Troubleshooting Symptom Displayed average current value is much higher or lower than the expected level shown in the weld
209. ting the weld head to the fixture block e entering the weld parameters e Setting the shield gas flow e Starting and completing the weld The description of the welding process in this section uses a weld procedure guideline based on tubing witha 1 2 in OD and 0 049 in wall thickness Remember that a weld procedure guideline is a list of weld parameter settings that have been determined for a particular job K eep in mind that the weld parameters listed in this section may not produce an optimum weld since the purpose of this section is to demonstrate the operation of the SWS Section 5 Weld Parameter Adjustment describes how to optimize welding parameters 2005 Swagelok Company all rights reserved 3 1 September 2005 Operation CWS D100 B Welding System Front Panel Controls s Y Y O FIXTURE d PREPURGE i FK l NJ pai IMPULSE IAINTENANCE IMPULSE RATE IMPULSE WIDTH ARC START DURATION BY Oa O WELD TIME High Amps MANTENA S Pulses See Ge at Impulse Amps Seconds
210. tion Defined 3 13 Example of 3 16 Multiple 3 14 Disassembly Rotor Series 5 10 20 Weld Head 6 8 Series 4 Micro Weld Head 6 12 Series 8 Micro Weld Head 6 13 Weld Head Series 5 10 20 6 5 Discontinuities Typical 5 16 Discontinuity Defined A 4 Downslope Defined A 4 Dropthrough Defined A 4 Duration Defined A 4 E Electrical Requirements Installation 2 3 Electrode Defined A 4 Shape C 3 Troubleshooting 7 7 CWS D100 B Welding System Electrode Geometry C 3 Electrode Selecting Micro Weld Head 4 6 Series 5 10 20 Weld Heads 3 26 Evaluating Weld 5 16 Excessive Oxide Causes 5 17 Excessive Weld Bead Dropthrough Causes 5 17 Excessive Weld Spot Overlap Causes 5 17 Extension Cables Weld Head B 3 Extension Cord Guidelines 2 3 Extention Cord Specifications 1 12 F Fixture Micro Weld Head Centering Gage Using 4 9 Connection 4 11 Fixture Block 1 6 Alignment H 1 H 5 Micro Fit to Micro Fit H 4 Micro Fit to Tubing H 3 Connecting to Series 5 10 20 Weld Head 3 33 Series 5 10 20 Maintenance 6 2 6 3 Series 5 10 20 Weld Head Centering Gage Using 3 30 Installing Collets 3 29 Specifications 1 10 Troubleshooting 7 8 Fixture Side Plates Specifications 1 11 Fixturing Work Micro Weld Head 4 9 Series 5 10 20 Weld Head 3 29 Front Panel Lights Displays Testing 3 25 Front Panel Switch Settings Weld Procedure Guide line 5 3 Fuse Inspection and Replacement 6 1
211. to create the reference weld shown in Figure 5 17 Table 5 16 Impulse Rate Reference Weld Reference This Parameter Setting Setting Impulse R ate 10 Impulse Rate Weld Example No 1 Table 5 17 lists the parameter change used to create the weld shown in Figure 5 18 Table 5 17 Weld Example No 1 Reference This Parameter Setting Setting Impulse R ate 05 Lowering the frequency reduces weld spot overlap Impulse Rate Weld Example No 2 Table 5 18 lists the parameter change used to create the weld shown in Figure 5 19 Table 5 18 Weld Example No 2 Reference This Parameter Setting Setting Impulse R ate 25 Raising the frequency increases weld spot overlap Adjusting Controls for Weld Quality Attimes the welding parameters as described on page 5 9 must be adjusted to create an acceptable weld Usethe flow chart in Figure 5 20 to assist in adjusting the weld parameters 5 22 Swagelok Company All rights reserved September 2005 CWS D100 B Welding System START HERE CREATE A WELD Weld Parameter Adjustment PROCEDURE GUIDELINE PER INSTRUCTIONS MAKE A WELD COUPON IS THE WELD PENETRATED IS THE WELD OVER PENETRATED IS THE WELD CONCAVE IS DROP THROUGH This chartis an aid ROUGH for reference only to help meet general requirements for 100 autogenous fusion butt welds in stainless steel tubing and fitt
212. ts Do not locate unit over combustible surfaces Electrode and rotor are live during Do not weld on closed containers weld cycle Keep all panels and covers securely in place FUMES AND GASES can be hazardous ARC RAYS can burn eyes Do not breathe fumes or gases NOISE can damage hearing Ventilate area or use breathing device s Do not look at welding arc Read Material Safety Data Sheets MSDS s if dar are ant rh LEE and manufacturer s instructions for the Proper EN p material used 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 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 UN CHOC ELECTRIQUE peut tre mortel Ne posez pas l appareil sur des surfaces combustibles Seules des personnes qualifi es peuvent Ne touchez pas les parties lectriques sous tension installer et utiliser cet appareil L lectrode et le rotor sont sous tension pendant le soudage 14326 E X 2005 Swagelok Company all rights reserved September 2005 CWS D100 B Welding System Foreword Referenced Specifications 1 AWS F4 1 Recommended Safe Practices for the Preparation for Welding and Cutting of Containers and Piping
213. ts values to only one decimal place you may need to round off the number Since 58 8 is already to one decimal place it does not need rounding A x wall thickness x 1000 switch setting For example for a wall thickness of 0 049 in 1 2 x 0 049 in x 1000 58 8 A Note f the IMPULSE calculation result is equal to or greater than d Set IMPULSE 58 8 according to the result of the 99 9 A set the IMPULSE to 99 9 formula in step 3 c 4 Calculate the M aintenance a Locate the wall thickness 0 049 in and the corresponding B factor in Table 5 4 Table 5 4 Wall Thickness and B Factor Wall Thickness Range in mm B Factor 0 015 to 0 045 0 381 to 1 143 0 25 0 046 to 0 083 1 168 to 2 108 0 30 0 084 to 0 109 2 133 to 2 769 0 40 5 4 Swagelok Company All rights reserved September 2005 CWS D100 B Welding System b Calculate the M aintenance using the following formula Impulse current x B switch setting For example for a wall thickness of 0 049 in 58 8 x 0 30 17 64 17 6A c Set MAINTENANCE 17 6 according to the result of the formula in step 4 b 5 Set IMPULSE RATE to 10 6 Calculate the Impulse Width a Locate the wall thickness 0 049 in and the corresponding C factor in Table 5 5 Table 5 5 Wall Thickness and C Factor Wall Thickness Range in mm C Factor 0 015 to 0 045 0 381 to 1 143 25 0 04
214. unction The polarity of the enable signal is selectable See Program M ode Operation in Section 3 Operation The data from these outputs does not indicate whether the weld is acceptable but instead provides a record of the equipment performance during the welding process The data can be compared to the weld procedure guideline as a method of quality control Visual mechanical and other testing must also be done to verify the weld integrity As with any connection proper leak testing should be performed once the weld is completed B 4 2005 Swagelok Company all rights reserved September 2005 CWS D100 B Welding System Optional Equipment W hen selecting data recording equipment consider the accuracy of the printout required The frequency response of a recorder determines its ability to respond to a signal change which determines printout accuracy To record accurate data during the welding process it is suggested that the data collecting device have a sampling rate ten times faster than the maximum weld impulse rate If the sampling rate is not sufficient the data is not recorded accurately The SWS maximum pulse frequency is 99 pulses per second This pulse rate suggests a minimum sample rate of 1000 samples per second In addition to the sampling rate the equipment must also have the capability to gather data over the longest programmed weld time 198 seconds W hen an analog strip chart recorder is used the 0
215. ure 3 18 A 2 Refer to the tables for your weld head model in Appendix E Arc Gap Gage Setting Tables Find the actual outside diameter nearest to your measurement 3 Adjust the arc gap gage to match the setting from the table or weld procedure guideline See Figure 3 18 B 4 To calculate arc gap gage settings for other arc gaps see the arc gap gage setting formula in Appendix E Arc Gap Gage Setting Tables 5 Gage settings for Swagelok ATW fittings are in the tables in Appendix E Arc Gap Gage Setting Tables Setting the Arc Gap 1 Insert the arc gap gage into the rotor See Figure 3 19 A 2 Tilt the weld head upward Loosen the electrode screw allowing the electrode to drop onto the gage surface See Figure 3 19 B 3 Tighten the electrode clamping screws just enough to secure the electrode Remove the arc gap gage Operation Figure 3 19 Setting the Arc Gap A Caution Do not jog or move the rotor unless the electrode is clamped in place 2005 Swagelok Company all rights reserved September 2005 Operation CWS D100 B Welding System Restore power to the SWS by turning the circuit breaker on Press STOP RESET to return the rotor to the home position and visually inspect the rotor smooth rotation Preparing the Work Refer to Figure 3 20 Prepare the tube pieces to be welded Method Hack Saw Cut End Roller in by Cutter Blade and PS Tube Cutter Ss LN A
216. ut terminal of the weld head Insert the weld head shielding gas connector into the Swagelok Quick Connect stem labelled TO WELD HEAD Ensure that the connector is firmly attached This connection provides shielding gas to the weld head through a solenoid valve in the power supply 2 8 2005 Swagelok Company All right reserved September 2005 CWS D100 B Welding System Installation Installing the Gas Delivery System Introduction The Gas Delivery System reduces oxidation or contamination to the weld puddle tungsten electrode and Heat Affected Zone HAZ There are two types of gas delivery systems commonly used e typical Gas Delivery System Refer to the installation procedure beginning on page 2 10 e gas delivery system using a secondary shielding gas solenoid valve Refer to the installation procedure beginning on page 2 12 2005 Swagelok Company All rights reserved 2 9 September 2005 Installation CWS D100 B Welding System Installing the Typical Shielding Purge Gas Delivery System Install the Shielding Purge Gas Delivery System Figure 2 6 shows atypical system Be sure to adhere to the following precautions e Ensure that the gas storage container s are secured before using them e Ensure all connections are tight and do not leak e Useonly a Swagelok single ended shut off Quick Connect stem on the shield purge line for the shielding gas connector e Adjust the low pressure regulat
217. value The following example uses the resettable weld counter code 20 to illustrate how a code value is changed The example shows how to set the weld counter to a value of 1000 Do the following to modify the value 1 Press and hold DOWNSLOPE 2 Press and hold ROTOR JOG 3 Release both pushbuttons at the same time The SWS is now in program mode 4 Enter 20 into ROTOR SPEED 5 Enter 10 into ARC START Enter 00 into DURATION 6 Press and hold Rotor JOG for 2 seconds to 3 seconds to enter the new value When the status indicator lights begin to flash release the pushbutton When Rotor JOG is pressed all the status indicator lights will turn on After a small delay the lights start to flash indicating the change has been completed The Average C urrent display now shows the new value Since the Average Current display is limited to three digits values greater than 999 must be displayed in two parts First the most significant digits are displayed After a moment the three least significant digits are displayed with a decimal point by the last digit For this example 1 would be displayed first followed by 000 to show the value of 1000 See Figure 3 14 Operation Figure 3 14 Data Display for Values Above 999 2005 Swagelok Company all rights reserved September 2005 3 21 Operation A Caution Return the rotary switch settings to normal welding values after exiting program mode CWS
218. vantages Process Variables System Components The SWS D100 Power Supply The Weld Head Fixture Blocks Overview of SWS Operation Specifications Lutter ardent ood toa Section 2 Installation Introduction Tools and Accessory Requirements Electrical Requirements Input Voltage Using an Extension Cord Unpacking and Inspecting System Components Unpacking the Power Supply Unpacking the Weld Head Cable Assembly and Related Components iii iii iii vii xi 1 2 1 2 1 2 1 3 1 4 1 5 1 6 1 7 1 9 2 1 2 2 2 3 2 3 2 3 2 4 2 5 2005 Swagelok Company all rights reserved September 2005 TOC 1 Table of Contents CWS D100 B Welding System Installing the SWS Installing the Power Supply Installing the Weld Head Installing the Gas Delivery System Introduction Installing the Typical Shielding Purge Gas Delivery System Installing the Optional Gas Delivery System Preliminary Check Section 3 Operation Intr
219. ver CWS 4MHP BRUSH 5 Rotor CWS 4MHP ROTOR 6 Electrode CWS C 040 405 P CWS C 040 325 P 7 Ceramic Insert CWS 4MHP ROTOR CWS 4MHP CERAMIC 8 Electrode Screw CWS 4MHP ROTOR CWS 4MHP CERAMIC 9 Idler Gear Assembly CWS 4MHP IDLER 10 Transmission Assembly CWS 4MHP TRANS 11 Dowel Pin CWS 4MHP LEVER 12 Locking Lever CWS 4MHP LEVER 13 Slotted Flat Head Screw CWS 4MHP SCREWS CWS 4MHP BRSHHOUSE CWS 4MHP BRSHHOUSPL CWS 4MHP GEARHOUSE CWS 13157 10 14 Body Gear Side CWS 4MHP GEARHOUSE 15 Socket Head Cap Screw CWS 4MHP SCREWS CWS 4MHP BRSHHOUSE CWS 4MHP BRSHHOUSPL CWS 4MHP GEARHOUSE 16 Drive Clip CWS 4MHP TRANS CWS 4MHP DRVCLP 17 Safety Interlock Sensor Assembly 18 Shielding Gas Tube 19 Flexible Drive Coupling Assembly 20 Button Head Screw CWS 4MHP SCREWS 21 Latch Keeper CWS MP LATCH 22 Motor Cover 2 23 Safety Interlock Connector Pins 24 Interface Plate 25 Drive Coupling Gear Bearing 26 Drive Coupling Gear 27 O ring CWS 4MHP CVA CWS 4MHP ORING 28 Check Valve Actuator CWS 4MHP CVA 29 Motor Cover 2A 30 Flexible Drive Shaft 31 Star Washer CWS 4MHP SCREWS CWS 4MHP BRUSH CWS 4MHP GRDPIN 32 Slotted Round Head Screw CWS 4MHP SCREWS CWS 4MHP BRUSH CWS 4MHP GRDPIN For part ordering information contact your Swagelok representative Not available as a field replaceable spare part 2005 Swagelok Company all rights reserved September 2005 Parts Drawings CWS D100 B Welding System
220. wer supply See Figure 2 4 The four connectors on the cable are fixture Weld Head Shielding Gas e electrode red e work green e weld head shielding gas Connect the four connectors to the rear panel of the power supply by performing the following steps see Figure 2 5 1 Locate the weld head assembly Figure 2 4 Weld Head Assembly Figure 2 5 Weld Head Connectors 2005 Swagelok Company All rights reserved 2 7 September 2005 Installation Caution Ensure that the fixture connector is fully seated in the mating socket and the threaded sleeve is tight Note The weld head shielding gas connector must be a single end shut off SESO Swagelok Quick Connect stem SS QC4 S 400 CWS D100 B Welding System Align the notch on the multi pin connector with the small tab in the mating socket on the rear panel labelled FIXTURE Insert the connector in the socket Turn the connector sleeve clockwise by hand until it is tight This connection provides the control signals to drive the weld head Insert and fully seat the red connector into the socket on the rear panel labelled ELECTRODE Twist the connector 1 4 turn clockwise to lock it into place This connection is the negative output terminal of the weld head Insert the green connector into the socket on the rear panel labelled WORK Twist the connector 1 4 turn clockwise to lock it into place This connection is the positive outp
221. www swagelok com WELDING SYSTEM USER S MANUAL CWS D100 1B CWS D100 2B ON The Swagelok Limited Lifetime Warranty Swagelok hereby warrants to the purchaser of this Product that the non electrical components of the Product shall be free from defects in material and workmanship for the life of the Product All electrical components installed in or on the Product are warranted to be free from defects in material and workmanship for twelve months from the date of purchase The purchaser s remedies shall be limited to replacement and installation of any parts that fail through a defect in material or workmanship MANUFACTURER SPECIFICALLY DISAVOWS ANY OTHER REPRESENTATION EXPRESS OR IMPLIED WARRANTY OR LIABILITY RELATING TO THE CONDITION OF USE OF THE PRODUCT AND IN NO EVENT SHALL SWAGELOK BE LIABLE TO PURCHASER OR ANY THIRD PARTY FOR ANY DIRECT OR INDIRECT CONSEQUENTIAL OR INCIDENTAL DAMAGES Table of Contents Foreword Registration Information Safety Summary Statements OYMPOISE se Lt mers Lea Mir Rachat Safe Practices and Safety Precautions User Precautions Power Supply Warning Label Referenced Specifications Section 1 Introduction SWS D100 Gas Tungsten Arc Welding Principles of the GTAW Process GTAW Process Ad
222. y the power supply Note that certain code ranges are marked Factory Use These codes except for 64 to 96 are normally not used which is noted in the table Operation Figure 3 7 Digital Displays 2005 Swagelok Company all rights reserved September 2005 3 9 Operation CWS D100 B Welding System Table 3 3 SWS Message Codes Normal Mode or Operating Setting to Code No Name Range Activate Code Type 01 Impulse 2 to 99 9 A lt 2 Disable 02 Maintenance 2 A to 99 9 A lt 2 Disable 03 Impulse Rate 1 Hz to 99 Hz lt 1 Caution 04 Impulse Width 5 to 95 lt 5 or gt 95 Disable 05 Arc Start 2 A to 99 A lt 2 Disable 06 Duration 0 0 to 5 0 gt 5 0 Disable 07 Prepurge 1sto99s lt 1 Caution 08 Weld Time 1s to 99s lt 1 Disable 09 Downslope 1sto99s lt 1 Disable 10 Postpurge 1sto99s lt 1 Caution 11 Rotor Speed 5 to 99 gt lor lt 5 Caution lt 1 Disable 12 to 19 Factory use Notused 20 Resettable weld 0 to 9999 Program Programmable counter mode 21 Automatic print 0 to 99 Program Programmable counter mode 22 Enable signal 0 low Program Programmable polarity 1 high mode 23 Arc Start power 0 low Program Programmable 1 normal mode 24 to 29 Factory use Notused 30 Time hours 0 to 24 Program Programmable mode 31 Time minutes 0 to 59 Program Programmable mode 32 Date month l to 12 Program Programmable mode 33 Date day 1 to 3
223. yourself and others from the hot work piece Watch for fire and keep a fire extinguisher nearby Do not weld on closed containers such as tanks drums or pipes unless they are properly prepared according to AWS F4 1 Do not use welder to thaw frozen pipes Do not use extension cords that are in poor physical condition or have insufficient current capacity Failure to do so can pose fire and shock hazards vi 2005 Swagelok Company all rights reserved September 2005 CWS D100 B Welding System Safe Practices and Safety Precautions READ ANSI Z49 1 Safety and safe practices in welding cutting and allied processes are covered in ANSI Z49 1 SAFETY IN WELDING AND CUTTING W hen using the SWS follow all basic safety practices CYLINDERS can explode if damaged Shielding gas cylinders contain gas under high pressure If damaged a cylinder can explode Since gas cylinders are normally part of the welding process be sure to treat them carefully e Protect compressed gas cylinders from excessive heat mechanical shocks slag open flames sparks and arcs e Install cylinders in an upright position by securing to a stationary support or cylinder rack to prevent falling or tipping e Keep cylinders away from any welding or other electrical circuits e Never weld on a pressurized cylinder explosion will result e Useonly correct shielding gas cylinders regulators hoses and fittings designed for the s

WELDING SYSTEM USER'S MANUAL, CWS-D100-1B, CWS

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