Optional Mounting of the Series 8HPH Weld Head
Contents
1. Burrs Reduced Flow Area Face Perpendicular to Axis Tube Facing Tool Square Corners Figure 18 No Gaps Preparing the Tube 2004 2005 2006 Swagelok Company all rights reserved May 2006 Series 8HPH Weld Head Fixturing the Work Pieces It is very important that the work pieces are aligned so that the electrode is in the seam of the joint and that the ends are butted squarely If the work pieces are out of alignment you may experience angular or axial misalignment weld defects See Figure 19 and Figure 20 Visual Alignment To secure a work piece into the fixture the user actuates WE the right movable clamp with the left handle The left movable clamp is actuated in a similar fashion See Figure 21 This method of operation allows the user to operate the fixture with one hand while holding and aligning the work piece with the other Electrode 1 Insert the first work piece into either side of the fixture and visually align the end of the work piece with the electrode tip Tube 2 Clamp the work piece by placing the handle in the not locked closed position 3 Insert the other work piece and butt it up to the Movable Side Plate clamped work piece Clamp the second work piece 4 Place both handles in the locked closed position gege Aere the Tube End and Clamping the First Work Piece 2004 2005 2006 Swagelok Company all rights reserved 13 May 2002. Remove the brush wave spring and curved disc springs as shown in Figure 48 and discard See the spare parts list in Table 3 for ordering information and contact your authorized Swagelok sales and service representative for replacement parts Figure 48 Removing the Brush and Springs 8 Remove the rotor See Figure 49 Figure 49 Removing the Rotor 2004 2005 2006 Swagelok Company all rights reserved 27 May 2006 Series 8HPH Weld Head 9 Clean the teeth of the gears with the nylon brush included with the weld head See Figure 50 10 Clean the gear surfaces with a swab and isopropyl alcohol See Figure 50 11 Clean the track area of the weld head body with a swab and isopropyl alcohol Clean the Track with Isopropyl Alcohol Figure 50 Cleaning the Guideway of the Rotor Track with Isopropyl Alcohol 12 Remove the electrode and ceramic insert and inspect around the electrode hole for damage Note The ceramic insert is fragile and will crack if not handled properly 13 Use a wire brush to eliminate discoloration Replace the rotor if arcing damage prevents normal operation 14 Clean the rotor with a swab and isopropyl alcohol 15 Check the ceramic insert for damage If it is damaged replace it according to the Ceramic Insert Replacement instructions in this manual Figure 51 Inspecting the Ceramic Insert for Damage 28 2004 2005 2006 Swagelok Company all rights reserved May 2006
3. 30 Tool Arc Shield Arc Shield Return Spring Figure 20 Removing the Arc Shield Return Spring from the Movable Plate Assembly 2 Push and hold the tool change lever back while pushing each handle to its rear most position Once Actuator each handle is back release the tool change lever to ee lock the handles in the tool change position See Figure 31 Figure 31 Positioning the Weld Head for a Tool Change 18 2004 2005 2006 Swagelok Company all rights reserved May 2006 Series 8HPH Weld Head 3 Remove the cap screw and washer See Figure 32 4 Remove outer movable side plate arc shield assembly adapter hub thrust bearing and inner movable side plate See Figure 33 5 Set aside the inner and outer movable side plates Keep the thrust bearing adapter hub and arc shield assembly nearby for reinstallation 6 Release the side plate latch 7 Remove the two shoulder screws from the fixed side plate 8 Pull the fixed side plate off of the fixture See Figure 34 2004 2005 2006 Swagelok Company all rights reserved May 2006 Figure 32 Removing the Cap Screw and Washer Inner Movable Side Plate r Hub lt gt me og 4 y apte ead GN Thrust Bearing m Q Arc Shield Assembly a Outer Movable Side Plate Figure 33 Removing the Movable Side Figure 34 Removing the Fixed Side Plate Series 8HPH Weld Head Side Plate Installation 1 Select the required side plate
4. Series 8HPH Weld Head Weld Head Reassembly 1 Replace the ceramic insert on the rotor and secure it with flathead screws 2 Install the new electrode and secure it with a set screw See Figure 52 Note If you are reassembling following a rotor jam indicated by the power supply first reconnect the power supply and press HOME Otherwise after you have reassembled the weld head the rotor will remember what position it was in when it jammed and will not return to its proper home position Disconnect the power supply before reassembly D WARNING Figure 52 Installing the Ceramic PINCH POINTS elas Caution KEEP HANDS LOOSE p SE Do not use lubricants inside CLOTHING AND LONG HAIR AWAY FROM MOVING PARTS SERIOUS INJURY CAN OCCUR 3 Reposition the rotor in the drive gear insert of the weld head Seat the rotor so that the track fits over the ridge of the insert Make sure the rotor is flush with the ends of the rotor track the weld head 4 Install a new brush with the three pockets facing upward Align the holes of the brush with the screw gt o 2 holes in the weld head body assembly j 5 Install the new wave spring and two curved disc Ste springs into the brush pockets making sure they are Here positioned as shown See Figure 53 A Caution Be sure that the cover is lined up correctly or the springs will shift Figure 53 Installing the Brush and Disc Springs 2004 2005
5. WS LT SWS 8HPH WS RT Description Ordering No Full Left Right 8 in Work Support Rail 21634 4 3 5 in Work Support Rail 21635 1 10 32 Knurled Thumb Screw 21636 6 Work Support Slide Base 21638 2 Work Support Right Brace 21640 1 Work Support Left Brace 21641 1 1 21642 75 1 1 N A 7 Plastic Head Screw 21642 1 00 1 d N A 21642 1 50 1 1 N A 36 2004 2005 2006 Swagelok Company all rights reserved May 2006 Series 8HPH Weld Head 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 authorized Swagelok sales and service representative The parts identified in this section include SWS 8HPH Weld Head Assembly SWS 8HPH Fixture Assembly 2004 2005 2006 Swagelok Company all rights reserved May 2006 37 Series 8HPH Weld Head Figure 64 SWS 8HPH Weld Head Assembly 38 2004 2005 2006 Swagelok Company all rights reserved May 2006 Table 3 SWS 8HPH Weld Head Assembly Parts List Reference No Description Series 8HPH Weld Head Ordering No Minimum Order Qty 1 Encoder Circuit Board Home Sensor Mount Shim N A N A Home Sensor Home Sensor Mount SS Socket Head Cap Screw 2 56 x 0 375 in SS Socket Head Cap Screw 2 56 x 0 187 in Weld Head Body Assembly Cover Motor Side Motor Mount Co
6. of the weld head work cable green with the arrow on the female socket green of the extension cable With the arrows aligned insert and fully seat the green male connector of the weld head cable into the green female socket of the extension cable Twist the connector one quarter turn clockwise to lock into place 4 Insert the male shielding gas connector of the weld head cable into the female Swagelok quick connect body of the extension cable Align bodies and stems when coupling or uncoupling Figure 5 Connecting the Weld Head to the Extension Cable Figure 6 Connecting the Weld Head to the Extension Cable Caution Do not rotate quick connects while coupled Do not insert foreign object into uncoupled bodies or stems A 2004 2005 2006 Swagelok Company all rights reserved May 2006 Series 8HPH Weld Head Connecting the Weld Head Extension Cable to the Power Supply The weld head extension cable has four connectors that plug into the power supply See Figure 7 1 Attach the threaded multi pin connector of the extension cable to the mating socket on the rear panel of the power supply labeled FIXTURE Turn the connector sleeve clockwise by hand until it is tight This connection provides the control signals to drive the weld head Figure 7 Connecting the Weld Head Caution Extension Cable to the Power A Ensure that the threaded Supply multi pin connector is fully seated in the mating socket and the
7. plates by pushing each actuator handle Figure 12 Pressing SETUP on the back to the open position See Figure 13 Operator Panel Figure 13 Pushing Actuator Handles to the Open Position 2004 2005 2006 Swagelok Company all rights reserved 9 May 2006 Series 8HPH Weld Head 5 With the weld head in the open position press JOG on the operator panel see Figure 14 until the tungsten electrode is in the position shown in Figure 15 Figure 14 Pressing JOG on the Operator Panel Electrode Figure 15 Jogging the Rotor until the Electrode is Accessible 10 2004 2005 2006 Swagelok Company all rights reserved May 2006 Series 8HPH Weld Head 6 Loosen the electrode set screw with the hex drive See Figure 16 Caution Hold on to the electrode with tweezers so that the electrode does not fall into the weld head gear assembly 7 Remove and discard the old electrode 8 Install a new electrode using the tweezers Insert the electrode through the ceramic insulator and into the rotor to its full insertion depth Make sure the sharp tip of the electrode is pointing out See Figure 16 9 Tighten the set screw sufficiently to prevent the electrode from falling out of the rotor A Caution Do not overtighten the set screw as it could damage the electrode screw or Set Screw rotor threads Note Replace the electrode set screw if any sign of stripping is observed Figure 1
8. screws holding the metal shroud in place 4 Push the handles to the not locked closed position 5 Remove the tool change knob by turning it counterclockwise 6 Remove the metal shroud by lifting it straight up off of the base See Figure 42 7 Push the handles and tool change lever to the tool change position 8 Remove the movable side plates thrust bearing adapter hub and arc shield assembly 24 Tool Change Knob Handles Screws Qty 8 Figure 42 Removing the Metal Shroud 2004 2005 2006 Swagelok Company all rights reserved May 2006 Series 8HPH Weld Head 9 Remove the fixed side plate screws 10 Release the fixed side plate latch 11 Pull the fixed side plate off of the weld head See Changing the Side Plates for detailed instructions 12 Clean the surfaces of fixed side plate and the movable side plates that contact the work with a wire brush 13 Wipe the surfaces of the fixed and movable side plates with isopropyl alcohol 14 Remove the two locating shoulder screws and Screws Securing the button head screw to remove the weld head Weld Head to the assembly See Figure 43 Housing Figure 43 Removing the Weld Head Assembly 15 Disconnect the motor control connector 16 Unscrew the nut and disconnect the purge gas line GT 17 Pull the weld head assembly straight out from the EES base to access the power cable See Figure 44 Figure 44 Removing the Weld
9. the operator panel of the power supply until the electrode is at the twelve o clock position Remove the electrode set screw See Figure 60 Remove the electrode Remove the ceramic insert Figure 60 Removing the Electrode 2004 2005 2006 Swagelok Company all rights reserved 33 May 2006 Series 8HPH Weld Head 7 Seat the new ceramic insert into the pocket in the Caution track of the rotor with the beveled edge facing out Excessive force can break See Figure 61 the ceramic insert 8 Install a new electrode using the tweezers Insert the electrode through the ceramic insulator and into the rotor to its full insertion depth Make sure the sharp tip of the electrode is pointing out of the rotor hole 9 Tighten the set screw sufficiently to prevent the electrode from falling out of the rotor 10 Reinstall the two flathead screws to secure the ceramic insert a Jog the rotor until you can install one of the screws b Jog the rotor 300 until you can install the remaining flat head screw Caution Figure 61 Replacing the Ceramic Insert Make sure that the ceramic and electrode screws are snug before operation 11 Press HOME to return the rotor to the home position Arc Shield Replacement If there is physical damage to the arc shield it should be replaced 1 Remove the four flathead screws securing the arc shield to the movable clamp See Figure 62 Flathead Screws 2 Remove t
10. threaded sleeve is tight 2 Insert and fully seat the red connector of the extension cable into the socket on the rear panel of the power supply labeled ELECTRODE Twist the connector one quarter turn clockwise to lock into place This connection is the negative terminal of the weld head 3 Insert and fully seat the green connector of the extension cable into the socket on the rear panel of the power supply labeled WORK Twist the connector one quarter turn clockwise to lock into place This connection is the positive terminal ey 77 Ka of the weld head 4 Insert the shielding gas connector stem into Figure 8 Turning the Power the Swagelok quick connect body labeled Supply ON TO WELD HEAD Caution Ensure the connector is firmly attached This connection provides shielding gas to the weld head through a solenoid valve in the power supply 5 Turn the power ON See Figure 8 2004 2005 2006 Swagelok Company all rights reserved 5 May 2006 Series 8HPH Weld Head 6 Press HOME to return the rotor to the home position See Figure 9 7 Check that the rotor returns to the appropriate home positions See Figure 10 Caution The weld head should not be started in any rotor position except home Arc start in any other location may cause weld head damage Figure 9 Power Supply Operator Panel 8 Ifthe rotor does not return to the home position see the Fixture Disas
11. 2006 Swagelok Company all rights reserved 29 May 2006 Series 8HPH Weld Head 6 Reinstall the brush side cover 7 Insert the four plastic flathead screws to secure the brush side cover See Figure 54 A WARNING DO NOT REPLACE PLASTIC FLATHEAD SCREWS WITH METAL FLATHEAD SCREWS THIS COULD EXPOSE THE WELDING OPERATOR TO WELDING ARC START VOLTAGES Figure 54 Installing the Brush Side Cover 8 Position the hooked end of the side shield into the recess at the top of the insert and clamp the side shield down See Figure 55 9 Reinstall the plastic flathead screws and metal flathead screws to secure the side shields WARNING Plastic Screw Lee A DO NOT REPLACE PLASTIC FLATHEAD SCREWS WITH METAL FLATHEAD SCREWS n ee etal Screw THIS COULD EXPOSE THE Figure 55 Installing Side Shields WELDING OPERATOR TO WELDING ARC START VOLTAGES 30 2004 2005 2006 Swagelok Company all rights reserved May 2006 10 11 12 13 14 15 16 17 18 Reconnect the power cable to the weld head Slide the weld head into the base and align the screw holes Insert the shoulder screws and the button head screw to secure the weld head in place Reconnect the motor control connector Reconnect the purge gas line See Figure 56 Slide the fixed side plate over the weld head assembly Secure the fixed side plate with two shoulder screws Reinstall the movable side plate assembly Se
12. 6 Series 8HPH Weld Head Alignment Using the Centering Gauge The centering gauge is supplied attached to the weld head ecking and must be adjusted before use The following steps refer Screw to the left movable clamp Note The centering gauge can be set for use with either the left or right movable clamp Note In order to use the centering gauge in the right movable clamp the gauge must first be adjusted to work with the right movable clamp The centering gauge adjustment procedure is the same for both the left and right Figure 22 Loosening the Locking Screw movable clamps 1 Loosen the locking screw using the supplied hex key See Figure 22 2 Clamp the centering gauge around the circular surface shown in Figure 23 using the left movable clamp See Figure 24 Figure 24 Centering Gauge Clamped into Position 14 2004 2005 2006 Swagelok Company all rights reserved May 2006 Series 8HPH Weld Head 3 Ensure that the centering gauge is pushed against the side plate 4 Adjust the centering gauge so that the right edge is centered on the electrode See Figure 25 Electrode 5 Tighten the centering gauge locking screw Locking Screw Right Edge of Centering Gauge Figure 25 Adjusting the Centering Gauge 6 Insert the work piece into the other side of the fixture and butt it squarely against the end of the centering gauge See Figure 26 7 Clamp the work piece into plac
13. 6 Loosening the Electrode 10 Press HOME to return the rotor to the home position as shown in Figure 17 Incorrect Correct Figure 17 Home Position of Rotor 2004 2005 2006 Swagelok Company all rights reserved 11 May 2006 Series 8HPH Weld Head Operation Preparing the Work It is important to prepare the components properly before welding See Figure 18 Components must be square and burr free to ensure repeatable high quality autogenous fusion welds Follow these steps to achieve square and burr free tubing 1 Cut the tubing to length with a hacksaw or tube cutter 2 Face the tube ends with a lathe or a portable facing tool 3 Deburr the ends making sure that both the inside and outside diameters are square and burr free 4 Clean the tube ends using an appropriate solvent Minimize the chance of a poor quality weld by following these guidelines e Tube ends must be square e Tube ends must not have a wall thickness variation exceeding 15 of nominal e Tube ends must be burr free e Tube ends must be free of any rust grease oil paint or other surface contaminants Method Result Burrs in Burrs Flow Path Hacksaw Cut End Rolled by Cutter Irregular Tube Blade and Roller Diameter Tube Cutter ZZ Zz Smooth Transition at Wall Faces
14. D mm Electrode Length mm Electrode Ordering Number 13 61 SWS C 040 536 012 P 13 49 SWS C 040 531 012 P 13 36 SWS C 040 526 012 P 13 23 SWS C 040 521 012 P SWS C 040 472 012 P SWS C 040 467 012 P SWS C 040 462 012 P SWS C 040 457 012 P SWS C 040 433 012 P SWS C 040 428 012 P SWS C 040 423 012 P SWS C 040 418 012 P SWS C 040 388 012 P SWS C 040 383 012 P SWS C 040 378 012 P SWS C 040 373 012 P SWS C 040 349 012 P SWS C 040 344 012 P SWS C 040 339 012 P SWS C 040 334 012 P Note The electrodes listed in Table 1 and Table 2 are for argon shielding gas only 2004 2005 2006 Swagelok Company all rights reserved May 2006 Series 8HPH Weld Head Installing or Replacing the Electrode The series 8HPH weld head tool package includes A Caution Do not press JOG or move the rotor unless the electrode e wire brushes is clamped in place e aminiature hex drive e tweezers e ahex wrench set Use these tools for installing a new size of electrode or for replacing the electrode when it shows signs of deterioration Reducing the jog speed may be helpful for correct positioning of the rotor 1 To reduce jog speed press SETUP on the operator panel 2 Select CONFIG from the setup options 3 Select a jog speed of 50 or less 4 Open the side
15. Head Assembly 2004 2005 2006 Swagelok Company all rights reserved 25 May 2006 Series 8HPH Weld Head 18 Disconnect the power cable from the plastic motor drive housing See Figure 45 19 Remove the weld head from the base Figure 45 Disconnecting the Power Cable Weld Head Disassembly and Cleaning WARNING gt DO NOT REPLACE PLASTIC A new brush ceramic insert and curved disc springs will FLATHEAD SCREWS WITH need to be ordered prior to performing this procedure These METAL FLATHEAD SCREWS items should be replaced during periodic maintenance THIS COULD EXPOSE THE WELDING OPERATOR TO WELDING ARC START VOLTAGES 1 Remove the screws securing the side shields of the weld head 2 Loosen the two flathead screws at the top of the brush side cover to remove tension on the side shield pieces 3 Lift the bottom of the side shield to unhook it from the metal insert See Figure 46 Loosen to Remove Tension to Allow Side Shield Removal 4 Wipe the surfaces of the side shields and covers with isopropyl alcohol Plastic Screw Metal Screw Sage Figure 46 Removing the Side Shields 26 2004 2005 2006 Swagelok Company all rights reserved May 2006 Series 8HPH Weld Head 5 Remove the four plastic flathead screws securing the brush side cover See Figure 47 6 Clean the inside surface of brush side cover with isopropyl alcohol Figure 47 Removing the Brush Side Cover 7
16. M Clamp Stop Assembly Clamp Block Adapter Hub 1 25 in OD 0 56 in ID Bronze Washer 1 25 in OD 0 75 in ID Bronze Washer 10 32 0 500 in Socket head Cap Screw 10 32 0 69 in dia Black Knob 5 16 18 3 8 2 5 in LG Socket head Shoulder Screw 0 750 in OD 0 375 in ID Thrust Washer Left Handle Assembly Right Handle Assembly Nylon Washer 3 16 in dia Left Spring Link Right Spring Link Spring Eyelet 1 4 20 Hex Nut E clip Strut Actuator Extension Spring 8 32 3 16 x 1 4 in LG Socket head Shoulder Screw Wave Coil Spring Clamp Stop Extension Spring Fixture Feet 8 32 5 8 x 3 16 in LG Socket head Shoulder Screw Actuator Assembly Outer Clamp Actuator Assembly Inner Clamp Needle Roller Thrust Bearing 1 000 in OD 10 Fender Washer 10 32 x 3 8 in Button head Cap Screw Metal Shroud Arc Shield Hub Arc Shield Arc Shield Return Spring 2004 2005 2006 Swagelok Company all rights reserved 41 May 2006 Series 8HPH Weld Head Reference No Description Ordering No Minimum Order Qty 1 8 in Movable Side Plate 21543 02 1 4 in Movable Side Plate 21543 04 3 8 in Movable Side Plate 21543 06 1 2 in Movable Side Plate 21543 08 3 mm Movable Side Plate 21543 3MM 6 mm Movable Side Plate 21543 6MM 8 mm Movable Side Plate 21543 8MM 10mm Movable Side P
17. Unpacking the Weld Head Components The following weld head components are packaged in a foam lined shipping container e weld head e electrode package e centering gauge e series SHPH tool package e extension cable e user s manual The series 8HPH weld head has size specific side plates and the order number specifies which set will be installed upon receipt Other side plate sizes are optional accessories The side plate size ordered will determine the electrode package that is delivered with the weld head Perform the following steps when your Swagelok series SHPH weld head arrives 1 Inspect the container for damage 2 Remove the components from the container 3 Check the items for any damage 4 Verify that the weld head serial number matches the serial number on the shipping container 5 Record the model and serial numbers and the delivery date on the Warranty Information form Figure 2 Shipping Container 2004 2005 2006 Swagelok Company all rights reserved May 2006 Series 8HPH Weld Head Optional Mounting of the Series 8HPH Weld Head The series SHPH weld head comes with predrilled holes for optional bench top mounting 1 Determine the mounting orientation of the weld 4 in a S See head on the workbench RES 2 Use the integral mounting holes on the bottom of the unit to secure the unit to the workbench SEENEN 1 3 Drill holes in workbench using the dimension gu
18. ameters from Open 1 8 to 1 2 in and 3 to 12 mm Designed for the rigors of the production environment and for cleanroom compliance the series 8HPH is encased in a metal shroud It is capable of performing up to four times as many welds as the traditional micro weld head in the same amount of time The series 8HPH also provides the benefit of enhanced operator comfort as the actuator handles allow the operator to fixture work pieces without touching the fixture plates Not Locked Closed Tool A dc motor in the weld head drives a rotor which revolves 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 The electrode is positioned in the eight o clock position to facilitate visual joint alignment Figure 1 Series SHPH Weld Head A spring loaded floating brush maintains contact with approximately two thirds of the circumference of the rotor This configuration ensures consistent uniform electrical conductance to the rotor and electrode This manual presents information that is specific to the high performance weld head The weld head fixtures do not use separate collets but rather have separate side plates with integral collet features Formal training on the operation fixture plate installation and maintenance is recommended 2004 2005 2006 Swagelok Company all rights reserved 1 May 2006 Series 8HPH Weld Head
19. ck while pulling each actuator handle to the locked closed position Once each handle is forward release the tool change lever 13 Reattach the arc shield spring Figure 39 Locking the Actuator Handles in the Operation Position 22 2004 2005 2006 Swagelok Company all rights reserved May 2006 Series 8HPH Weld Head Performing Daily Maintenance To keep your Swagelok welding system equipment in Caution ki der t perform dail int AN 2 EC EE WE Do not use lubricants inside f the weld head Daily Fixture Maintenance TE Surfaces of the Movable Side Plates Clean the At the beginning of each workday Arc Shield 1 Place the handles in the tool change position 2 Use a stainless steel wire brush to clean the collet surfaces of the side plates that contact the work See Figure 40 3 Remove dirt carbon and vapor deposits from the arc shield and movable side plates with a swab and isopropyl alcohol Clean Fixed Side Plates Figure 40 Inspecting Side Plates and Arc Shield Daily Weld Head Maintenance 1 Remove dirt carbon and vapor deposits from the weld head rotor area with a clean soft cloth or swab and a 90 or greater isopropyl alcohol solvent 2 Clean the exposed areas of the ceramic insert with isopropyl alcohol and inspect for cracks or arcing damage If the ceramic insert is damaged follow the instructions in Ceramic Insert Replacement to replace it 3 In
20. crementally jog the rotor and clean both sides of the rotor with a swab and isopropyl alcohol See Figure 41 Figure 41 Jogging and Cleaning Both Store the weld head in a clean dry place at the end of Sides of the Rotor each workday 2004 2005 2006 Swagelok Company all rights reserved 23 May 2006 Series 8HPH Weld Head Performing Periodic Maintenance As the weld head is repeatedly used parts will begin to wear Extensive testing has identified these baseline maintenance parameters which can be used to approximate when certain tasks will need to be done This is dependent on the size of work pieces typically being welded with the machine For series SHPH machines being used primarily to weld 1 4 in 6 35 mm or smaller tubing periodic maintenance should be conducted every 10 000 welds For series SHPH machines being used primarily to weld larger than 1 4 in 6 35 mm tubing periodic maintenance should be conducted every 3 000 welds Replace all worn parts Brush and curved disc springs must be ordered for periodic maintenance For detailed part drawings and ordering information see the Parts Drawings at the end of this manual Spare parts are available through your authorized Swagelok sales and service representative Series 8HPH Cleaning and Inspection Fixture Disassembly and Cleaning 1 Verify the rotor is in the home position 2 Disconnect the unit from the power supply 3 Loosen the eight
21. e Changing the Side Plates for detailed instructions Move the handles from the tool change to the not locked closed position See Figure 57 2004 2005 2006 Swagelok Company all rights reserved May 2006 Series 8HPH Weld Head Motor Control 10 pin Connector Purge Gas Line Figure 56 Reconnect the Internal Cabling Figure 57 Reinstalling the Side Plates 31 Series 8HPH Weld Head 19 Reinstall the metal shroud straight down 20 Align the tool change lever with the housing slot using a screwdriver 21 Tighten the eight screws that hold the metal shroud in position See Figure 58 Figure 58 Reinstalling the Metal Shroud 22 Reinstall the tool change knob See Figure 59 23 Reconnect the power and turn on the power supply 24 Press HOME to verify the rotor rotates smoothly and stops in home position Figure 59 Reinstalling the Tool Change Knob 32 2004 2005 2006 Swagelok Company all rights reserved May 2006 Series 8HPH Weld Head Ceramic Insert Replacement l Press JOG on the operator panel of the power supply until the first ceramic flathead screw is exposed Remove the first ceramic flathead screw Caution When removing screws be careful not to drop them into the weld head gear assembly Press JOG on the operator panel of the power supply until the second ceramic flathead screw is exposed Remove the second ceramic flathead screw Press JOG on
22. e See Figure 27 8 Remove the centering gauge and insert the other work piece to be welded butting it up against the first work piece Clamp the second work piece in place Note At the start of every shift or whenever the electrode is changed ensure the centering gauge is re centered Figure 27 Clamping the Work Piece 2004 2005 2006 Swagelok Company all rights reserved 15 May 2006 Series 8HPH Weld Head Performing a Weld Operate the weld head using the following parameters Caution e Do not use tack programs Series 8HPH or programs that include Shield gas flow rate std ft hr 10 to 150 tacks with the series 8HPH std L min 4 7 to 7 1 weld head Prepurge and Postpurge Continuous minimum time in seconds Caution Start Power U low Low Norme Do not use step programs with the series 8HPH Maximum Recommended 40 Amps weld head Average Amps Set flow to higher rates when welding at high current rates M100 1 Power Supplies with serial numbers before 2802 D100 1 Power Supplies with serial numbers before 1425 D100 2 Power Supplies with serial numbers before 3267 or M100 2 Power Supplies with serial numbers before 3464 and ac arc start should use Low or U low arc starts All D 100 1A and D 75 units should use Low or U low arc starts Power supplies with dc arc starts should use Normal for wall thickness above 0 030 in 16 2004 2005 2006 Swagelok Company all rights reserved May 2006 Se
23. en it is ordered based on the diameter of the tubing being welded S Figure 11 Tungsten Electrode Caution A Only ceriated tungsten should be used in the weld head The use of other types of tungsten may cause weld head damage Electrode Length 0 615 Component OD 2 Arc Gap Example For a 0 500 in component with a 0 035 in arc gap 0 615 0 500 2 0 035 0 330 in This value is inserted into the Swagelok electrode ordering number as follows SWS C 040 330 P See your authorized Swagelok sales and service representative if custom arc gaps or tip diameters are desired which are not listed in Table 1 or Table 2 2004 2005 2006 Swagelok Company all rights reserved May 2006 Series 8HPH Weld Head Table 1 Series SHPH Electrode Selection Fractional Component OD in Electrode Length in Electrode Ordering Number 1 8 0 533 SWS C 040 533 012 P 0 528 SWS C 040 528 012 P 0 523 SWS C 040 523 012 P 0 518 SWS C 040 518 012 P SWS C 040 465 012 P SWS C 040 460 012 P SWS C 040 455 012 P SWS C 040 450 012 P 0 025 0 403 SWS C 040 403 012 P SWS C 040 398 012 P SWS C 040 393 012 P SWS C 040 388 012 P SWS C 040 335 012 P 0 035 0 330 SWS C 040 330 012 P SWS C 040 325 012 P 0 040 0 045 SWS C 040 320 012 P Table 2 Series 8HPH Electrode Selection Metric Component O
24. he old arc shield 3 Install a new arc shield 4 Reinstall the four flathead screws Figure 62 Replacing the Arc Shield 34 2004 2005 2006 Swagelok Company all rights reserved May 2006 Series 8HPH Weld Head Work Support System Note The work support is sold separately Right Left Work Support Instructions 1 Attach the 8 in work support rails to the series SHPH weld head unit See Figure 63 2 Slide the base onto the rails Set the base to the desired position and secure with the knurled thumb screws 4 Attach and set the right and or left brace to the appropriate height on the base Lock in place using the knurled thumb screw Note The right or left brace can be used with the V notch for tubing or the flat side as needed e For the left work support use the plastic head screw for fine adjustments in height and for additional support as needed 5 Additional work supports can be attached to the base of the left or right work supports as needed 6 An additional work support base can be used as a free standing work support Attach the 3 5 in work support rail to the top surface of the support base Secure the right brace to the appropriate height and angle using the knurled thumb screw 2004 2005 2006 Swagelok Company all rights reserved 35 May 2006 Series 8HPH Weld Head Figure 63 Work Support System SWS 8HPH WS SWS 8HPH
25. ide in Figure 3 Ge 102 mm Caution Do not drill into the weld head The mounting holes O on the unit are a specific depth to prevent damage to Figure 3 Series SHPH Mounting internal parts Dimension Guide 4 Align holes on bottom of weld head unit to holes in workbench 5 Insert four 1 4 in x 20 machine screws of appropriate length not included through the workbench into the weld head unit See Figure 4 Figure 4 Optional Mounting of the Weld Head to the Bench 2004 2005 2006 Swagelok Company all rights reserved 3 May 2006 Series 8HPH Weld Head Installing the Weld Head Connecting the Extension Cable to the Weld Head The four connectors on the cable are 1 threaded multi pin connector 2 electrode red 3 work green 4 weld head shielding gas 1 Align the notch on the threaded multi pin connector of the weld head cable with the small tab in the mating socket of the extension cable Insert the threaded connector and screw on the weld head cable by turning clockwise until it is tight 2 Align the arrow on the female socket of the weld head electrode cable red with the arrow on the male connector red of the extension cable With the arrows aligned insert and fully seat the red male connector of the extension cable into the red female socket of the weld head cable Twist the connector one quarter turn clockwise to lock into place 3 Align the arrow on the male connector
26. late 21543 10MM 12mm Movable Side Plate 21543 12MM Motor Wire Harness N A Strain Relief Assembly N A Handle Cover 21601 S S Button Head Screws 1 4 20 x 2 00 in N A Flathead S S 2 56 x 0 188 in Screws Backing Plate 21606 Cable tie Mount Spring Link Pin 10 24 1 4 x 3 4 in LG Socket Head Shoulder Screw S S Button Head Screws 8 32 x 1 00 in S S Flathead Screw 4 40 x 0 250 in 21517 Latch Catch 21643 4 40 Star Lock Nut 13103 Latch 11520 52 Not Shown 42 1 8 in Centering Gauge SWS 8HPCG 02 1 4 in Centering Gauge SWS 8HPCG 04 3 8 in Centering Gauge SWS 8HPCG 06 1 2 in Centering Gauge SWS 8HPCG 08 3 mm Centering Gauge SWS 8HPCG 3MM 6mm Centering Gauge SWS 8HPCG 6MM 8 mm Centering Gauge SWS 8HPCG 8MM 10 mm Centering Gauge 12 mm Centering Gauge SWS 8HPCG 10MM SWS 8HPCG 12MM 2004 2005 2006 Swagelok Company all rights reserved May 2006 Warranty Information Swagelok products are backed by The Swagelok Limited Lifetime Warranty For a copy visit swagelok com or contact your authorized Swagelok representative Swagelok TM Swagelok Company 2004 2005 2006 Swagelok Company Printed in U S A OM May 2006 R2 MS 13 170
27. ries 8HPH Weld Head Verify the Alignment of the Work The series 8HPH weld head allows the user to verify work piece alignment while fixtured To check the weld joint BEFORE initiating the weld sequence 1 Open the arc shield by pushing down on the thumb tab See Figure 28 2 Release the tab to have the arc shield return to the closed position 3 Program the power supply as instructed in the power supply manual 4 Press PURGE to begin shielding gas flow The shielding gas should remain on at all times when using the weld head 5 Check the shielding gas flow rate Proper shielding gas flow for this weld head is 10 to 15 std ft hr 4 7 to 7 1 std L min 6 Verify the arc shield is in the closed position See Figure 29 WARNING CLOSE ARC SHIELD BEFORE BEGINNING WELD USER COULD BE EXPOSED TO THE UV RAYS OF THE ARC IF THE ARC SHIELD IS NOT CLOSED DURING WELDING Caution Quality of the weld could be affected by an open arc shield during welding 2004 2005 2006 Swagelok Company all rights reserved May 2006 Caution Provide support to the purge tube and heavy work pieces to prevent an unacceptable weld damage to the series 8HPH weld head or both Figure 28 Arc Shield Open Figure 29 Arc Shield Closed Series 8HPH Weld Head Changing the Side Plates Side Plate Removal 1 Unhook the arc shield return spring that is holding the arc shield assembly in place See Figure
28. sembly procedure in Performing Periodic Maintenance Incorrect Correct Figure 10 Home Position of Rotor 6 2004 2005 2006 Swagelok Company all rights reserved May 2006 Series 8HPH Weld Head Electrode Selection and Installation Inspecting the Electrode This illustration shows the electrode shape Swagelok recommends Properly ground electrodes provide consistent repeatable welds Pre ground electrodes are available from your Swagelok sales and service representative See Table 1 and Table 2 for ordering information Tip diameters listed in the tables are for argon only Other shielding gases may require different tip diameters The electrode ordering numbers are assigned as follows SWS X 040 HHH P Electrode Length in Electrode Diameter in Tip Piece vaere Design Diameter in 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 Calculating Electrode Length Electrode length depends on the desired arc gap and outside diameter of the work piece being welded The series SHPH comes with electrodes machined to specific arc gaps Certain electrodes will automatically be selected for inclusion with the series 8HPH wh
29. size 2 Slide the fixed side plate over the weld head 3 Insert the shoulder screws in the fixed side plate but do not tighten 4 Secure the side plate latch 5 Secure the fixed side plate with screws Tighten the fasteners 1 8 to 1 4 of a turn past finger tight See Figure 35 Figure 35 Installing the Fixed Side Plate 20 2004 2005 2006 Swagelok Company all rights reserved May 2006 Series 8HPH Weld Head 6 Align the keyed inner plate of the movable side plate with the notches in the shaft See Figure 36 7 Install the inner movable side plate 8 Reinstall the thrust bearing and adapter hub on the shaft Align them with the notched shaft See Figure 37 9 Install the arc shield assembly on hub Note Make sure that the thrust bearing and adapter hub remain aligned 10 Install the outer plate of the movable side plate over the notch of the adapter hub Figure 36 Aligning the Keyed Inner Clamp with the Notched Shaft Figure 37 Installing the Movable Clamp Assembly 2004 2005 2006 Swagelok Company all rights reserved 21 May 2006 Series 8HPH Weld Head 11 Reinstall the washer and the screw to secure the movable clamp assembly Tighten the fasteners 1 8 to 1 4 of a turn past finger tight Figure 38 Reinstalling Washer and Screw Note The movable side plate assembly should be flush with the weld head when properly installed 12 Push and hold the tool change lever ba
30. ver Brush Side Rotor Ceramic Insert Motor Mount Side Cover Side Shield Purge Bayonet SS Socket Head Cap Screw 4 40 x 0 250 in Quick connect Tab Insulating Drive Gear Drive Gear Retaining Washer Plastic Flathead Screw 2 56 x 0 219 in S S Flathead Screw 4 40 x 0 250 in SS Electrode Set Screw 3 48 x 0 063 in Electrode Brush SS Shoulder Screw 4 40 x 0 375 in Curved Disc Spring SS Socket Head Cap Screw 6 32 x 0 250 in SS Flathead Screw 1 64 x 1 25 in Encoder Wheel Motor Drive Coupler Pin Drive Coupler Pin Sleeve Sleeve Sensor Mount Drive Coupler SS Dowel Pin 0 093 x 0 125 in Wave Spring 2004 2005 2006 Swagelok Company all rights reserved May 2006 39 I K Z E D SR co A bp Figure 65 SWS 8HPH Housing May 2006 2004 2005 2006 Swagelok Company all rights reserved 40 Series 8HPH Weld Head Table A SWS 8HPH Housing Reference No Description Ordering No Minimum Order Qty 1 Top Platform N A N A Outer Support Plate N A 1 8 in Fixed Side Plate 21539 02 1 4 in Fixed Side Plate 21539 04 3 8 in Fixed Side Plate 21539 06 1 2 in Fixed Side Plate 21539 08 3 mm Fixed Side Plate 21539 3MM 6 mm Fixed Side Plate 21539 6MM 8 mm Fixed Side Plate 21539 8MM 10 mm Fixed Side Plate 21539 10MM 12 mm Fixed Side Plate 21539 12M
31. www swagelok com SERIES 8 HPH WELD HEAD USER S MANUAL Unpacking the Weld Head Components ri 2 Optional Mounting of the Series 8HPH Weld Head 3 Installing the Weld Head 4 Connecting the Extension Cable to the Weld Head 4 Connecting the Weld Head Extension Cable to the Power Supply sseseseeseseeseseesesesessensresnsrernsnsrnens 5 Electrode Selection and Installaton eeen 7 Inspecting the Electrode AAA 7 Calculating Electrode Length ii 7 Installing or Replacing the Electrode 9 Operation sessions ee eee 12 Preparing the Work eeceseeseeseeeeeeeeeeeeeeaeeeaeeeaeeeas 12 Fixturing the Work Dieces uaa raniranananaanaaneans 13 Performing a Weld sinss R 16 Changing the Side Plates uae 18 Performing Daily Maintenance A 23 Daily Fixture Maintenance seeen 23 Daily Weld Head Maintenance A 23 Performing Periodic Maintenance uae 24 Series 8HPH Cleaning and Inspection 24 Ceramic Insert PBeplacement uae 33 Arc Shield Replacement 34 Work Support System ccecccccesceeeeeeeeceeseeeeeeeeeateneneeseateas 35 Right Left Work Support Instructions 35 Parts DIaWingS sie sehen Hees 37 OWING Series 8HPH Weld Head SERIES 8HPH WELD HEAD Swagelok series 8HPH high performance weld heads deliver consistent precise welds for outside di
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