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Swagelok CWS-D100-1B User Manual

Summary of CWS-D100-1B

  • Page 1

    Www.Swagelok.Com u s e r ’ s m a n u a l cws-d100-1b cws-d100-2b w e l d i n g s y s t e m.

  • Page 2

    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 warrante...

  • Page 3: Table of Contents

    2005 swagelok company, all rights reserved september 2005 toc−1 table of contents foreword registration information i . . . . . . . . . . . . . . . . . . . . . . . . Safety summary iii . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Statements iii . . . . . . . . . . . . . . . . . . . ...

  • Page 4

    Table of contents cws−d100−b welding system  2005 swagelok company, all rights reserved september 2005 toc − 2 installing the sws 2-6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installing the power supply 2-6 . . . . . . . . . . . . . . . . . . Installing the weld head 2-7 . . . . . ...

  • Page 5

    Cws − d100 − b welding system table of contents  2005 swagelok company, all rights reserved september 2005 toc − 3 entering the weld parameters 3-35 . . . . . . . . . . . . . . . . . . . Using a weld procedure guideline 3-35 . . . . . . . . . . . Effects of weld parameters 3-36 . . . . . . . . . . ...

  • Page 6

    Table of contents cws − d100 − b welding system  2005 swagelok company, all rights reserved september 2005 toc − 4 series 5/10/20 weld head 6-4 . . . . . . . . . . . . . . . . . . . . . . Daily maintenance 6-4 . . . . . . . . . . . . . . . . . . . . . . . . . Forty-hour maintenance 6-4 . . . . . . ...

  • Page 7

    Cws − d100 − b welding system table of contents  2005 swagelok company, all rights reserved september 2005 toc − 5 appendix d weld head information micro weld head − tube welding d-2 . . . . . . . . . Series 5 weld head − tube welding d-2 . . . . . . . Series 10 weld head − tube welding d-3 . . . ....

  • Page 8

    Table of contents cws − d100 − b welding system  2005 swagelok company, all rights reserved september 2005 toc − 6.

  • Page 9: Foreword

     2005 swagelok company, all rights reserved september 2005 i 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 in...

  • Page 10

    Foreword cws − d100 − b welding system  2005 swagelok company, all rights reserved september 2005 ii.

  • Page 11: Safety Summary

    Cws − d100 − b welding system foreword  2005 swagelok company, all rights reserved september 2005 iii safety summary the safety information presented here pertains to both the swagelok r welding system (sws) and the process of gas tungsten arc welding (gtaw). Read operating instructions read all of...

  • Page 12

    Foreword cws − d100 − b welding system  2005 swagelok company, all rights reserved september 2005 iv electric shock can kill. Touching live electrical parts can cause fatal shocks and severe burns. Incorrectly installed or improperly grounded equipment is a hazard. D do not touch live electrical pa...

  • Page 13

    Cws−d100−b welding system foreword 2005 swagelok company, all rights reserved september 2005 v 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. D do no...

  • Page 14

    Foreword cws − d100 − b welding system  2005 swagelok company, all rights reserved september 2005 vi 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...

  • Page 15

    Cws − d100 − b welding system foreword  2005 swagelok company, all rights reserved september 2005 vii 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. When using the sws...

  • Page 16

    Foreword cws − d100 − b welding system  2005 swagelok company, all rights reserved september 2005 viii 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. D pacemaker wearers keep ...

  • Page 17: User Precautions

    Cws − d100 − b welding system foreword  2005 swagelok company, all rights reserved september 2005 ix user precautions d 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...

  • Page 18: Power Supply Warning Label

    Foreword cws − d100 − b welding system  2005 swagelok company, all rights reserved september 2005 x power supply warning label this warning label is affixed to the power supply..

  • Page 19: Referenced Specifications

    Cws − d100 − b welding system foreword  2005 swagelok company, all rights reserved september 2005 xi referenced specifications 1. Aws f4.1, recommended safe practices for the preparation for welding and cutting of containers and piping. American welding society, 550 n.W. Lejeune rd, miami, fl 33126...

  • Page 20

    Foreword cws − d100 − b welding system  2005 swagelok company, all rights reserved september 2005 xii.

  • Page 21: Section 1

     2005 swagelok company, all rights reserved september 2005 1-1 section 1 introduction sws d100 the swagelok welding system (sws) is a versatile, portable and easy to use orbital welding system. This section includes d gas tungsten arc welding d system components d overview of sws operation d specif...

  • Page 22: Gas Tungsten Arc Welding

    Introduction cws − d100 − b welding system  2005 swagelok company, all rights reserved september 2005 1-2 the purpose of this manual is to familiarize you with the sws and to provide the reference information needed to produce high-quality, repeatable welds. While reading, you may encounter unfamil...

  • Page 23: Process Variables

    Cws − d100 − b welding system introduction  2005 swagelok company, all rights reserved september 2005 1-3 process variables the major process variables in gtaw are arc current, arc voltage, and travel speed. D arc current − the current measured between the tungsten electrode and the work. Generally...

  • Page 24: System Components

    Introduction cws − d100 − b welding system  2005 swagelok company, all rights reserved september 2005 1-4 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...

  • Page 25: The Weld Head

    Cws − d100 − b welding system introduction  2005 swagelok company, all rights reserved september 2005 1-5 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 o...

  • Page 26: Fixture Blocks

    Introduction cws − d100 − b welding system  2005 swagelok company, all rights reserved september 2005 1-6 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 ne...

  • Page 27: Overview Of Sws Operation

    Cws − d100 − b welding system introduction  2005 swagelok company, all rights reserved september 2005 1-7 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 an...

  • Page 28

    Introduction cws − d100 − b welding system  2005 swagelok company, all rights reserved september 2005 1-8 figure 1-5 sws d100 front panel controls.

  • Page 29: Specifications

    Cws−d100−b welding system introduction 2005 swagelok company, all rights reserved september 2005 1-9 specifications table 1-1 power supply model supply voltage* service amps output current (dc) cws-d100-1b 115 v (ac) 20 a 2 to 100 a cws-d100-1b 115 v (ac) 15 a 2 to 70 a cws-d100-2b 230 v (ac) 15 a 2...

  • Page 30

    Introduction cws − d100 − b welding system  2005 swagelok company, all rights reserved september 2005 1-10 table 1-5 weld heads series model od capacity 4 micro* cws-4mrh-a cws-4mfh-a 1/16 to 1/4 in. (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...

  • Page 31

    Cws − d100 − b welding system introduction  2005 swagelok company, all rights reserved september 2005 1-11 table 1-7 special purpose fixture side plates model used for comments cws-5fsp1 vcr , s type vcr , vco , b type vco fittings, and tubing weld extension length must be less than 0.75 in. (19 mm...

  • Page 32

    Introduction cws − d100 − b welding system  2005 swagelok company, all rights reserved september 2005 1-12 table 1-9 adapter inserts for cws-5fsp1 model used for comments cws-5mbvco-04 316l-4-bvco-1 316l-4-vco-1-4tb2 1/4 in. Vcr weld glands glands must have overall length of 1.12 in. (28 mm) or les...

  • Page 33: Section 2

     2005 swagelok company, all rights reserved september 2005 2-1 section 2 installation introduction this section describes the procedures necessary for installing the swagelok welding system (sws). This section includes: d tools and accessory requirements d electrical requirements d unpacking and in...

  • Page 34: Tools and Accessory

    Installation cws − d100 − b welding system  2005 swagelok company, all right reserved september 2005 2-2 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 wel...

  • Page 35: Electrical Requirements

    Cws − d100 − b welding system installation  2005 swagelok company, all rights reserved september 2005 2-3 electrical requirements input voltage table 2-1 lists the electrical requirements for the power supply. Table 2-1 power supply electrical requirements power supply model voltage requirement ser...

  • Page 36: Unpacking And Inspecting

    Installation cws − d100 − b welding system  2005 swagelok company, all right reserved september 2005 2-4 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 num...

  • Page 37

    Cws − d100 − b welding system installation  2005 swagelok company, all rights reserved september 2005 2-5 unpacking the weld head cable assembly and related components the following weld head components are packaged in a foam-lined shipping container: d weld head assembly d arc gap gage d electrode...

  • Page 38: Installing The Sws

    Installation cws − d100 − b welding system  2005 swagelok company, all right reserved september 2005 2-6 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 d install the power supply d install the ...

  • Page 39: Installing The Weld Head

    Cws − d100 − b welding system installation  2005 swagelok company, all rights reserved september 2005 2-7 installing the weld head the weld head assembly has four connectors that plug into the power supply. See figure 2-4. The four connectors on the cable are d fixture d electrode (red) d work (gre...

  • Page 40

    Installation cws − d100 − b welding system  2005 swagelok company, all right reserved september 2005 2-8 2. 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...

  • Page 41: Installing The Gas

    Cws − d100 − b welding system installation  2005 swagelok company, all rights reserved september 2005 2-9 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 ty...

  • Page 42: Gas Delivery System

    Installation cws − d100 − b welding system  2005 swagelok company, all right reserved september 2005 2-10 installing the typical shielding/purge gas delivery system install the shielding/purge gas delivery system. Figure 2-6 shows a typical system. Be sure to adhere to the following precautions: d ...

  • Page 43

    Cws − d100 − b welding system installation  2005 swagelok company, all rights reserved september 2005 2-11 inert gas cylinder high pressure gage (0 psig to 3000 psig) low pressure gage (0 psig to 150 psig) internal purge gas shut-off valve tubing to be welded sws fixture block flow meter for intern...

  • Page 44: Installing The Optional Gas

    Installation cws − d100 − b welding system  2005 swagelok company, all right reserved september 2005 2-12 installing 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. This type of system...

  • Page 45

    Cws − d100 − b welding system installation  2005 swagelok company, all rights reserved september 2005 2-13 figure 2-7 optional gas delivery system supply manifold secondary solenoid valve internal purge gas flow meter secondary solenoid bypass plug weld head shielding gas flow meter inert gas cylin...

  • Page 46: Preliminary Check

    Installation cws − d100 − b welding system  2005 swagelok company, all right reserved september 2005 2-14 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 powe...

  • Page 47

    Cws − d100 − b welding system installation  2005 swagelok company, all rights reserved september 2005 2-15 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. D for series 5, 10, and 20 weld heads, the rotor should make one-half...

  • Page 48

    Installation cws − d100 − b welding system  2005 swagelok company, all right reserved september 2005 2-16.

  • Page 49: Section 3

     2005 swagelok company, all rights reserved september 2005 3-1 section 3 operation introduction this section describes the basic operation of the swagelok welding system (sws). This section includes d front panel controls d sws modes of operation d installing the electrode in the series 5/10/20 wel...

  • Page 50: Front Panel Controls

    Operation cws − d100 − b welding system  2005 swagelok company, all rights reserved september 2005 3-2 front panel controls figure 3-1 front panel controls 1. Impulse rotary switch 2. Maintenance rotary switch 3. Impulse rate rotary switch 4. Impulse width rotary switch 5. Arc start rotary switch 6...

  • Page 51: Current Control Switches

    Cws − d100 − b welding system operation  2005 swagelok company, all rights reserved september 2005 3-3 current control switches the 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 fol...

  • Page 52: Timing Control Switches

    Operation cws − d100 − b welding system  2005 swagelok company, all rights reserved september 2005 3-4 timing control switches the timing control switch group determines the weld cycle timing. See figure 3-3. The controls function as follows: d prepurge (seconds) is the time in which shielding gas ...

  • Page 53

    Cws − d100 − b welding system operation  2005 swagelok company, all rights reserved september 2005 3-5 d 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 ...

  • Page 54: Pushbuttons

    Operation cws − d100 − b welding system  2005 swagelok company, all rights reserved september 2005 3-6 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: d start ...

  • Page 55

    Cws − d100 − b welding system operation  2005 swagelok company, all rights reserved september 2005 3-7 d 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 replac...

  • Page 56: Status Indicator Lights

    Operation cws − d100 − b welding system  2005 swagelok company, all rights reserved september 2005 3-8 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 th...

  • Page 57: Digital Displays

    Cws − d100 − b welding system operation  2005 swagelok company, all rights reserved september 2005 3-9 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: d average current indicate...

  • Page 58

    Operation cws − d100 − b welding system  2005 swagelok company, all rights reserved september 2005 3-10 table 3-3 sws message codes code no. Name normal operating range mode or setting to activate code type 01 impulse 2 a to 99.9 a disable* 02 maintenance 2 a to 99.9 a disable* 03 impulse rate 1 hz...

  • Page 59

    Cws − d100 − b welding system operation  2005 swagelok company, all rights reserved september 2005 3-11 code no. Name normal operating range mode or setting to activate code type 42 printing data is transferred to printer port information only 43 to 49 factory use not used 50 hi-temp excessive inte...

  • Page 60: Operational Mode

    Operation cws − d100 − b welding system  2005 swagelok company, all rights reserved september 2005 3-12 operational mode when 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 ...

  • Page 61

    Cws − d100 − b welding system operation  2005 swagelok company, all rights reserved september 2005 3-13 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 star...

  • Page 62

    Operation cws − d100 − b welding system  2005 swagelok company, all rights reserved september 2005 3-14 figure 3-9 digital display examples for the operator/machine interface dash on left indicates below minimum a dash on right indicates above maximum b multiple disable or caution conditions the po...

  • Page 63

    Cws − d100 − b welding system operation  2005 swagelok company, all rights reserved september 2005 3-15 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 prin...

  • Page 64

    Operation cws − d100 − b welding system  2005 swagelok company, all rights reserved september 2005 3-16 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,...

  • Page 65: Program Mode

    Cws − d100 − b welding system operation  2005 swagelok company, all rights reserved september 2005 3-17 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 mode” on page 3-...

  • Page 66

    Operation cws − d100 − b welding system  2005 swagelok company, all rights reserved september 2005 3-18 codes selected by the rotor speed switch may be able to be programmed, such as time and date information, or be a read-only parameter, such as the system serial number. See table 3-5 for a list o...

  • Page 67

    Cws − d100 − b welding system operation  2005 swagelok company, all rights reserved september 2005 3-19 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. Enter...

  • Page 68

    Operation cws − d100 − b welding system  2005 swagelok company, all rights reserved september 2005 3-20 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 f...

  • Page 69

    Cws − d100 − b welding system operation  2005 swagelok company, all rights reserved september 2005 3-21 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 use...

  • Page 70: Test Mode

    Operation cws − d100 − b welding system  2005 swagelok company, all rights reserved september 2005 3-22 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 te...

  • Page 71

    Cws − d100 − b welding system operation  2005 swagelok company, all rights reserved september 2005 3-23 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...

  • Page 72

    Operation cws − d100 − b welding system  2005 swagelok company, all rights reserved september 2005 3-24 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 repre...

  • Page 73

    Cws − d100 − b welding system operation  2005 swagelok company, all rights reserved september 2005 3-25 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...

  • Page 74: Series 5/10/20 Weld Head

    Operation cws − d100 − b welding system  2005 swagelok company, all rights reserved september 2005 3-26 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...

  • Page 75: Setting The Arc Gap

    Cws − d100 − b welding system operation  2005 swagelok company, all rights reserved september 2005 3-27 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 ...

  • Page 76: Preparing The Work

    Operation cws − d100 − b welding system  2005 swagelok company, all rights reserved september 2005 3-28 4. Restore power to the sws by turning the circuit breaker on. 5. Press stop/reset to return the rotor to the home position and visually inspect the rotor smooth rotation. Preparing the work refe...

  • Page 77: Fixturing The Work

    Cws − d100 − b welding system operation  2005 swagelok company, all rights reserved september 2005 3-29 minimize the chance of a poor quality weld by following these guidelines: d tube ends must be square. D tube ends must be burr-free. D tube ends must not have a wall thickness variation exceeding...

  • Page 78: Fixture Block

    Operation cws − d100 − b welding system  2005 swagelok company, all rights reserved september 2005 3-30 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. But...

  • Page 79

    Cws − d100 − b welding system operation  2005 swagelok company, all rights reserved september 2005 3-31 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 ° around the weld joint for fit and alignment. If the alignment is no...

  • Page 80: Conne

    Operation cws − d100 − b welding system  2005 swagelok company, all rights reserved september 2005 3-32 conne cting 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 in...

  • Page 81: Fixture Block

    Cws − d100 − b welding system operation  2005 swagelok company, all rights reserved september 2005 3-33 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....

  • Page 82: Mating The Weld Head to The

    Operation cws − d100 − b welding system  2005 swagelok company, all rights reserved september 2005 3-34 mating the weld head to the fixture block 1. Rotate the locking lever on the weld head counter-clockwise until it stops. See figure 3-26. 2. Insert the weld head into the fixture block. See figur...

  • Page 83

    Cws − d100 − b welding system operation  2005 swagelok company, all rights reserved september 2005 3-35 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 gui...

  • Page 84: Effects of Weld Parameters

    Operation cws − d100 − b welding system  2005 swagelok company, all rights reserved september 2005 3-36 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 ...

  • Page 85: Setting The Shield Gas Flow

    Cws − d100 − b welding system operation  2005 swagelok company, all rights reserved september 2005 3-37 setting the shield gas flow 1. Verify the shielding and purge gas connections to the work pieces. 2. Set the shielding gas flow meter to the proper setting. Refer to table 3-10. 3. Press purge to...

  • Page 86

    Operation cws − d100 − b welding system  2005 swagelok company, all rights reserved september 2005 3-38 2. Press start . Total time for the process is the sum of the following times: d prepurge d duration (negligible) d weld time d downslope d postpurge in the example given in table 3-9, the total ...

  • Page 87: After The Weld Is Complete

    Cws − d100 − b welding system operation  2005 swagelok company, all rights reserved september 2005 3-39 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 d electrode wear d...

  • Page 88: Operation Summary

    Operation cws − d100 − b welding system  2005 swagelok company, all rights reserved september 2005 3-40 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 f...

  • Page 89: Section 4

     2005 swagelok company, all rights reserved september 2005 4-1 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...

  • Page 90

    Micro weld heads cws − d100 − b welding system  2005 swagelok company, all rights reserved september 2005 4-2 this section presents information that is specific to the micro weld head assembly. Additional handling is necessary because the motor module and weld head are separate units. The micro wel...

  • Page 91: Using The Micro Fixture Tool

    Cws − d100 − b welding system micro weld heads  2005 swagelok company, all rights reserved september 2005 4-3 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 ...

  • Page 92

    Micro weld heads cws − d100 − b welding system  2005 swagelok company, all rights reserved september 2005 4-4 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 figur...

  • Page 93

    Cws − d100 − b welding system micro weld heads  2005 swagelok company, all rights reserved september 2005 4-5 4. Push the micro weld head onto the motor module until it is firmly seated, then lock the assembly together with the two side latches. See figure 4-6(a) and (b). 5. Press stop/reset . The ...

  • Page 94

    Micro weld heads cws − d100 − b welding system  2005 swagelok company, all rights reserved september 2005 4-6 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 el...

  • Page 95

    Cws − d100 − b welding system micro weld heads  2005 swagelok company, all rights reserved september 2005 4-7 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. Instal...

  • Page 96: Setting The Arc Gap

    Micro weld heads cws − d100 − b welding system  2005 swagelok company, all rights reserved september 2005 4-8 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 desire...

  • Page 97: Fixturing The Work

    Cws − d100 − b welding system micro weld heads  2005 swagelok company, all rights reserved september 2005 4-9 fixturing the work the work pieces must be properly prepared before fixturing. See page 3-28 in section 3, operation, for information. 1. Locate the centering gage. Turn the gage so the lab...

  • Page 98

    Micro weld heads cws − d100 − b welding system  2005 swagelok company, all rights reserved september 2005 4-10 3. Insert the first work piece, butting the weld end against the gage surface. Close and latch that side of the fixture. Make sure that the latch is fully closed against the body of the fi...

  • Page 99: To The Fixture

    Cws − d100 − b welding system micro weld heads  2005 swagelok company, all rights reserved september 2005 4-11 connecting the micro weld head to the fixture 1. Place the fixture on the micro weld head. D on the series 4 micro weld head, make sure the fixture is firmly seated. Rotate the locking lev...

  • Page 100

    Micro weld heads cws − d100 − b welding system  2005 swagelok company, all rights reserved september 2005 4-12 figure 4-15 placing the fixture on the micro weld head latch springs (2) b latch spring captures button keepers locking lever a.

  • Page 101

    Cws − d100 − b welding system micro weld heads  2005 swagelok company, all rights reserved september 2005 4-13 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 a...

  • Page 102: Using The Optional Bench

    Micro weld heads cws − d100 − b welding system  2005 swagelok company, all rights reserved september 2005 4-14 using the optional bench mounting bracket the bench mounting brackets attach series 4 and series 8 micro weld heads to a workbench. There are two mounting plates on the bracket, giving you...

  • Page 103: Series 8 Bench Mount Bracket

    Cws − d100 − b welding system micro weld heads  2005 swagelok company, all rights reserved september 2005 4-15 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 th...

  • Page 104

    Micro weld heads cws − d100 − b welding system  2005 swagelok company, all rights reserved september 2005 4-16 6. Secure the weld head using the two knurled thumb nuts supplied with the bench mounting bracket. Keep the thumb nuts on the adapter screws when not using the bench mount bracket. See fig...

  • Page 105: Section 5

     2005 swagelok company, all rights reserved september 2005 5-1 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: d developing a weld procedure guide...

  • Page 106

    Weld parameter adjustment cws − d100 − b welding system  swagelok company, all rights reserved september 2005 5-2 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 ...

  • Page 107

    Cws − d100 − b welding system weld parameter adjustment  2005 swagelok company, all rights reserved september 2005 5-3 setting the front panel switches 1. Select a travel speed (5 in./min). Average travel speeds [(od speed + wall speed) 2] = corrected travel speed table 5-1 travel speed setting cha...

  • Page 108

    Weld parameter adjustment cws − d100 − b welding system  swagelok company, all rights reserved september 2005 5-4 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 a...

  • Page 109

    Cws − d100 − b welding system weld parameter adjustment  2005 swagelok company, all rights reserved september 2005 5-5 b. Calculate the maintenance using the following formula: impulse current × “ b ” = switch setting for example, for a wall thickness of 0.049 in.: 58.8 a × 0.30 = 17.64 = 17.6 a c....

  • Page 110

    Weld parameter adjustment cws − d100 − b welding system  swagelok company, all rights reserved september 2005 5-6 7. Calculate the arc start: a. Calculate the arc start using the following formula: using the values in this example: (58.8 x 0.35) + [17.6 x (1 − 0.35)] = 32.02 = 32 a note: enter the ...

  • Page 111

    Cws − d100 − b welding system weld parameter adjustment  2005 swagelok company, all rights reserved september 2005 5-7 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). B...

  • Page 112

    Weld parameter adjustment cws − d100 − b welding system  swagelok company, all rights reserved september 2005 5-8 11. Calculate the downslope: a. Calculate the downslope using the following formula: weld time × 0.5 = switch setting for example, using the weld time of 38 in step 10.E.: 38 × 0.5 = 19...

  • Page 113: Example Weld Procedure

    Cws − d100 − b welding system weld parameter adjustment  2005 swagelok company, all rights reserved september 2005 5-9 example weld procedure guideline worksheet determine the work specifications step parameter setting 1 weld diameter 1/2 in. 2 wall thickness 0.049 in. 3 weld head model no. 5h-b 4 ...

  • Page 114

    Weld parameter adjustment cws − d100 − b welding system  swagelok company, all rights reserved september 2005 5-10 weld procedure guideline worksheet determine the work specifications step parameter setting 1 weld diameter 2 wall thickness 3 weld head model no. 4 electrode part no. 5 arc gap gage s...

  • Page 115

    Cws − d100 − b welding system weld parameter adjustment  2005 swagelok company, all rights reserved september 2005 5-11 cws-d100-1b cws-d100-2b 60 99 95 90 85 80 75 70 65 60 55 50 45 40 35 30 25 20 16 12 8 4 0 0 10 20 30 40 50 0 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 1/4 in. 3/8 in. 1/2...

  • Page 116

    Weld parameter adjustment cws − d100 − b welding system  swagelok company, all rights reserved september 2005 5-12 50 40 30 20 10 0 60 99 95 90 85 80 75 70 65 60 55 50 45 40 35 30 25 20 16 12 8 4 0 0 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 1/4 in. 3/8 in. 1/2 in. 5/8 in. 3/4 in. 7/8 in. ...

  • Page 117

    Cws − d100 − b welding system weld parameter adjustment  2005 swagelok company, all rights reserved september 2005 5-13 figure 5-3 rotor switch speed setting graphs (series 20 weld head) − fractional series 20 weld head − pipe welding travel speed (in./min) rotor speed switch setting seconds per re...

  • Page 118

    Weld parameter adjustment cws − d100 − b welding system  swagelok company, all rights reserved september 2005 5-14 figure 5-4 rotor switch speed setting graphs (micro weld head, series 5 weld head) − metric series 5 weld head − tube welding micro weld head − tube welding travel speed (mm/s) rotor s...

  • Page 119

    Cws − d100 − b welding system weld parameter adjustment  2005 swagelok company, all rights reserved september 2005 5-15 figure 5-5 rotor switch speed setting graphs (series 10 weld head, series 20 weld head) − metric series 20 weld head − tube welding series 10 weld head − tube welding travel speed...

  • Page 120: Evaluating The Weld

    Weld parameter adjustment cws − d100 − b welding system  swagelok company, all rights reserved september 2005 5-16 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 exces...

  • Page 121: Identifying Proper Welds

    Cws − d100 − b welding system weld parameter adjustment  2005 swagelok company, all rights reserved september 2005 5-17 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 parameters affects the shape of the weld....

  • Page 122

    Weld parameter adjustment cws − d100 − b welding system  swagelok company, all rights reserved september 2005 5-18 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 parameter reference setting this setting impulse (ampe...

  • Page 123

    Cws − d100 − b welding system weld parameter adjustment  2005 swagelok company, all rights reserved september 2005 5-19 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 parameter reference setting this setting maint...

  • Page 124

    Weld parameter adjustment cws − d100 − b welding system  swagelok company, all rights reserved september 2005 5-20 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 parameter reference setting this setting impulse wi...

  • Page 125

    Cws − d100 − b welding system weld parameter adjustment  2005 swagelok company, all rights reserved september 2005 5-21 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 parameter reference setting this setting speed...

  • Page 126: Adjusting Controls For

    Weld parameter adjustment cws − d100 − b welding system  swagelok company, all rights reserved september 2005 5-22 impulse rate reference weld table 5-16 lists the parameter used to create the reference weld shown in figure 5-17. Table 5-16 impulse rate reference weld parameter reference setting th...

  • Page 127

    Cws − d100 − b welding system weld parameter adjustment  2005 swagelok company, all rights reserved september 2005 5-23 figure 5-20 weld procedure guideline flowchart create a weld procedure guideline per instructions make a weld coupon is the weld penetrated is impulse width >30% of original setti...

  • Page 128

    Weld parameter adjustment cws − d100 − b welding system  swagelok company, all rights reserved september 2005 5-24.

  • Page 129: Section 6

     2005 swagelok company, all rights reserved september 2005 6-1 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...

  • Page 130: Daily Maintenance

    Maintenance cws − d100 − b welding system  2005 ‘ swagelok company, all rights reserved september 2005 6-2 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 main...

  • Page 131: Daily Maintenance

    Cws − d100 − b welding system maintenance  2005 swagelok company, all rights reserved september 2005 6-3 micro weld head fixture blocks the micro weld head fixtures require regular cleaning and maintenance. Daily maintenance 1. Clean the surfaces of the fixture that contact the work pieces. Use the...

  • Page 132: Series 5/10/20 Weld Head

    Maintenance cws − d100 − b welding system  2005 ‘ swagelok company, all rights reserved september 2005 6-4 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 ...

  • Page 133: Series 5/10/20 Weld Head

    Cws − d100 − b welding system maintenance  2005 swagelok company, all rights reserved september 2005 6-5 2. While watching the rotor status led, press and hold rotor jog and note the rotor travel time using a stopwatch. The rotor should move for 13 seconds. Repeat the test two or three times to get...

  • Page 134

    Maintenance cws − d100 − b welding system  2005 ‘ swagelok company, all rights reserved september 2005 6-6 4. 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. T...

  • Page 135

    Cws − d100 − b welding system maintenance  2005 swagelok company, all rights reserved september 2005 6-7 7. Examine the brush. See figure 6-11. Inspect and clean the brush using the following steps: a. Check the brush for excessive wear. B. Ensure the brush has a groove. Replace the brush if the gr...

  • Page 136

    Maintenance cws − d100 − b welding system  2005 ‘ swagelok company, all rights reserved september 2005 6-8 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 ...

  • Page 137

    Cws − d100 − b welding system maintenance  2005 swagelok company, all rights reserved september 2005 6-9 7. Remove the ceramic insert. See figure 6-17. 8. Inspect the ceramic insert. If it has carbon or other deposits, clean it with a fine-grit abrasive pad or soft nylon brush. 9. Remove the electr...

  • Page 138: Micro Weld Heads

    Maintenance cws − d100 − b welding system  2005 ‘ swagelok company, all rights reserved september 2005 6-10 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 ...

  • Page 139: Eight-Hour Maintenance

    Cws − d100 − b welding system maintenance  2005 swagelok company, all rights reserved september 2005 6-11 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 ...

  • Page 140

    Maintenance cws − d100 − b welding system  2005 ‘ swagelok company, all rights reserved september 2005 6-12 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...

  • Page 141

    Cws − d100 − b welding system maintenance  2005 swagelok company, all rights reserved september 2005 6-13 series 8 micro weld head disassembly and cleaning use the following instructions to disassemble the micro weld head for cleaning. See figure 6-24 and figure 6-25 for part references. 1. Remove ...

  • Page 142

    Correct idler gear placement (pressed fully into body) incorrect ÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁ figure 6-26 correct placement of idler gear in micro weld head housing ÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁ...

  • Page 143: Micro Weld Head Assembly

    Cws − d100 − b welding system maintenance  2005 swagelok company, all rights reserved september 2005 6-15 micro weld head assembly assemble the weld head by completing the steps in the appropriate weld head disassembly procedure in reverse order. Be sure to properly seat the brush spring during rea...

  • Page 144

    Maintenance cws − d100 − b welding system  2005 ‘ swagelok company, all rights reserved september 2005 6-16 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 ...

  • Page 145: Section 7

     2005 swagelok company, all rights reserved september 2005 7-1 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 gu...

  • Page 146

    Troubleshooting cws − d100 − b welding system  2005 swagelok company, all rights reserved september 2005 7-2 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 tha...

  • Page 147

    Cws − d100 − b welding system troubleshooting  2005 swagelok company, all rights reserved september 2005 7-3 power supply symptom cause remedy front panel current/voltage digital di l bl k the circuit breaker is off. Turn on circuit breaker. G g displays are blank. The power supply line cord is not...

  • Page 148

    Troubleshooting cws − d100 − b welding system  2005 swagelok company, all rights reserved september 2005 7-4 symptom cause remedy fixture indicator fails to turn off when the weld head is the weld head is not fully engaged into fixture block. Reattach the fixture block to the weld head. Weld head i...

  • Page 149

    Cws − d100 − b welding system troubleshooting  2005 swagelok company, all rights reserved september 2005 7-5 weld head symptom cause remedy rotor does not return to the home position. Fixture connector is not fully engaged. Check that the fixture connector is seated and its collar is tight. Rotor i...

  • Page 150

    Troubleshooting cws − d100 − b welding system  2005 swagelok company, all rights reserved september 2005 7-6 symptom remedy cause erratic rotor rotation/ speed control. Weld spatter on gears. Inspect the rotor primary, secondary, and drive gear(s) for damage. Replace damaged gears. Arcing damage on...

  • Page 151

    Cws − d100 − b welding system troubleshooting  2005 swagelok company, all rights reserved september 2005 7-7 electrode symptom cause remedy material found on the electrode tip. Electrode touched the weld puddle. Replace electrode and check arc gap setting. Check work pieces for out of roundness. We...

  • Page 152

    Troubleshooting cws − d100 − b welding system  2005 swagelok company, all rights reserved september 2005 7-8 fixture block symptom cause remedy when closing the fixture block side plate, the latch does not lock the latch is not inserted into the fixture block side plate completely. Reinsert the lat...

  • Page 153

    Cws − d100 − b welding system troubleshooting  2005 swagelok company, all rights reserved september 2005 7-9 welding process symptom cause remedy arc fails to start. Blown ceramic power supply fuse. Replace the ceramic power supply fuse with one of the same type and rating. Fuse not seated in fuse ...

  • Page 154

    Troubleshooting cws − d100 − b welding system  2005 swagelok company, all rights reserved september 2005 7-10 symptom remedy cause displayed average current value is much higher or lower than the expected level shown in the weld procedure guideline. Incorrect weld parameter(s) entered on the rotary...

  • Page 155

    Cws − d100 − b welding system troubleshooting  2005 swagelok company, all rights reserved september 2005 7-11 symptom cause remedy inside diameter discoloration. Insufficient internal purge gas. Increase internal purge gas flow rate and prepurge time. Contaminants in the purge line. Increase prepur...

  • Page 156

    Troubleshooting cws − d100 − b welding system  2005 swagelok company, all rights reserved september 2005 7-12 symptom remedy cause concave weld puddle. Excessive heat input. Compare the material, wall thickness and outside diameter size of the components you are welding to the weld procedure guidel...

  • Page 157

    Cws − d100 − b welding system troubleshooting  2005 swagelok company, all rights reserved september 2005 7-13 symptom remedy cause incomplete inside diameter penetration. Insufficient heat input. Compare the power supply rotary switch settings to the weld procedure guideline being used. Refer to th...

  • Page 158

    Troubleshooting cws − d100 − b welding system  2005 swagelok company, all rights reserved september 2005 7-14.

  • Page 159: Appendix A

     2005 swagelok company, all rights reserved september 2005 a-1 appendix a glossary arc the flow of electrical current between an anode and cathode. 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 ...

  • Page 160

    Glossary cws − d100 − b welding system  2005 swagelok company, all rights reserved september 2005 a-2 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 monat...

  • Page 161

    Cws − d100 − b welding system glossary  2005 swagelok company, all rights reserved september 2005 a-3 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 preven...

  • Page 162

    Glossary cws − d100 − b welding system  2005 swagelok company, all rights reserved september 2005 a-4 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 while a disable cond...

  • Page 163

    Cws − d100 − b welding system glossary  2005 swagelok company, all rights reserved september 2005 a-5 heat input the heat conducted into the weld during the weld cycle. It is generally expressed in joules or kilojoules. Impulse (high amps) the maximum current level generated during the weld cycle. ...

  • Page 164

    Glossary cws − d100 − b welding system  2005 swagelok company, all rights reserved september 2005 a-6 orbital welding a welding technique used for tubing, pipes, etc. In which the arc rotates around the weld joint circumference. Oxidation heat discoloration that occurs in the weld area caused by th...

  • Page 165

    Cws − d100 − b welding system glossary  2005 swagelok company, all rights reserved september 2005 a-7 pulse weld 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 durin...

  • Page 166

    Glossary cws − d100 − b welding system  2005 swagelok company, all rights reserved september 2005 a-8 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. Sock...

  • Page 167

    Cws − d100 − b welding system glossary  2005 swagelok company, all rights reserved september 2005 a-9 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...

  • Page 168

    Glossary cws − d100 − b welding system  2005 swagelok company, all rights reserved september 2005 a-10

  • Page 169: Appendix B

     2005 swagelok company, all rights reserved september 2005 b-1 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: d sw...

  • Page 170: Sws Remote Pendant

    Optional equipment cws − d100 − b welding system  2005 swagelok company, all rights reserved september 2005 b-2 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 indica...

  • Page 171: Weld Head Extension Cables

    Cws − d100 − b welding system optional equipment  2005 swagelok company, all rights reserved september 2005 b-3 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 extensi...

  • Page 172: Data Logging/monitoring

    Optional equipment cws − d100 − b welding system  2005 swagelok company, all rights reserved september 2005 b-4 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 sign...

  • Page 173

    Cws − d100 − b welding system optional equipment  2005 swagelok company, all rights reserved september 2005 b-5 when 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 d...

  • Page 174: Data Recording Printer

    Optional equipment cws − d100 − b welding system  2005 swagelok company, all rights reserved september 2005 b-6 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 war...

  • Page 175

    Cws − d100 − b welding system optional equipment  2005 swagelok company, all rights reserved september 2005 b-7 load the paper 1. If necessary, remove the interface cable from the rear of the printer. See figure b-11. 2. Turn the latch counter-clockwise to release the printer body from the case. Re...

  • Page 176

    Optional equipment cws − d100 − b welding system  2005 swagelok company, all rights reserved september 2005 b-8 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 tw...

  • Page 177: Operating The Printer

    Cws − d100 − b welding system optional equipment  2005 swagelok company, all rights reserved september 2005 b-9 cabling the printer cable the printer by performing the following steps: 1. Turn the sws power supply off. Turn the printer power switch off, which is the down position. 2. Plug the inter...

  • Page 178

    Optional equipment cws − d100 − b welding system  2005 swagelok company, all rights reserved september 2005 b-10 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 featur...

  • Page 179

    Cws − d100 − b welding system optional equipment  2005 swagelok company, all rights reserved september 2005 b-11 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...

  • Page 180

    Optional equipment cws − d100 − b welding system  2005 swagelok company, all rights reserved september 2005 b-12 figure b-15, labeled weld# 000028, shows that the weld cycle was interrupted by pressing downslope . Figure b-16, labeled weld# 000029, shows that the arc failed sometime during the weld...

  • Page 181

    Cws − d100 − b welding system optional equipment  2005 swagelok company, all rights reserved september 2005 b-13 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...

  • Page 182

    Optional equipment cws − d100 − b welding system  2005 swagelok company, all rights reserved september 2005 b-14 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 printo...

  • Page 183: Maintenance

    Cws − d100 − b welding system optional equipment  2005 swagelok company, all rights reserved september 2005 b-15 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 perfor...

  • Page 184

    Optional equipment cws − d100 − b welding system  2005 swagelok company, all rights reserved september 2005 b-16 using a standard rs-232 printer it is possible to interface a standard rs-232 (serial) printer to the power supply. However, specific requirements must be met by the printer to ensure co...

  • Page 185: Appendix C

     2005 swagelok company, all rights reserved september 2005 c-1 appendix c electrode selection tables and geometry cws-4mrh-a, cws-4mfh-a micro weld heads electrode part no. Component od electrode length (l) electrode diameter (d) cws-c.040-.405-p 1/8 in. 1/16 in. 3 mm 0.405 in. (10,29 mm) 0.040 in....

  • Page 186: Cws-5H-B Weld Head

    Electrode selection tables and geometry cws − d100 − b welding system  2005 swagelok company, all rights reserved september 2005 c-2 cws-5h-b weld head electrode part no. Component od electrode length (l) electrode diameter (d) cws-c.040-.705-p 1/8 in. 3/16 in. 3 mm 0.705 in. (17,90 mm) 0.040 in. (...

  • Page 187: Cws-20H-A/b Weld Head

    Electrode selection tables and geometry cws − d100 − b welding system  2005 swagelok company, all rights reserved september 2005 c-3 cws-20h-a/b weld head electrode part no. Component od pipe electrode length (l) electrode diameter (d) cws-c.062-1.630-p 1/2 in. 3/4 in. 12 mm 1/4 1/2 3/8 1.630 in. (...

  • Page 188

    Electrode selection tables and geometry cws − d100 − b welding system  2005 swagelok company, all rights reserved september 2005 c-4.

  • Page 189: Appendix D

     2005 swagelok company., all rights reserved september 2005 d-1 appendix d weld head information weld head series shield gas flow rates std ft3/hr (std l/min) prepurge and postpurge minimum time in seconds start power maximum recommended average amps 4 8 to 10 (4,7 to 4,7) continuous low 30 a 8 15 ...

  • Page 190

    Weld head information cws − d100 − b welding system  2005 swagelok company, all rights reserved september 2005 d-2 1/4 in. 1/16 in. 1/8 in. 40 30 20 10 0 1 5 15 25 35 99 95 90 85 80 75 70 65 60 55 50 45 40 35 30 25 20 16 12 8 4 0 0 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 seconds per revo...

  • Page 191

    Cws − d100 − b welding system weld head information  2005 swagelok company., all rights reserved september 2005 d-3 travel speed (in./min) rotor speed switch setting seconds per revolution vs. Vs. Curve model series 10 weld head − tube welding cws-d100-1b cws-d100-2b 1 50 40 30 20 10 0 60 99 95 90 ...

  • Page 192

    Weld head information cws − d100 − b welding system  2005 swagelok company, all rights reserved september 2005 d-4 travel speed (in./min) rotor speed switch setting seconds per revolution vs. Vs. Curve model series 20 weld head − pipe welding cws-d100-1b cws-d100-2b 1 120 0 10 20 30 40 50 60 70 80 ...

  • Page 193

    Cws − d100 − b welding system weld head information  2005 swagelok company., all rights reserved september 2005 d-5 travel speed (mm/s) rotor speed switch setting seconds per revolution vs. Vs. Series 5 weld head − tube welding curve model cws-d100-1b cws-d100-2b 10 mm 8 mm 6 mm 3 mm 12 mm 16 mm 14...

  • Page 194

    Weld head information cws − d100 − b welding system  2005 swagelok company, all rights reserved september 2005 d-6 travel speed (mm/s) rotor speed switch setting seconds per revolution vs. Vs. Series 20 weld head − tube welding curve model cws-d100-1b cws-d100-2b 120 0 10 20 30 40 50 60 70 80 90 10...

  • Page 195: Appendix E

     2005 swagelok company, all rights reserved september 2005 e-1 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 t...

  • Page 196: Weld Head Arc Gap Gage

    Arc gap gage setting tables cws − d100 − b welding system  2005 swagelok company, all rights reserved september 2005 e-2 weld head arc gap gage setting tables cws-4mrh-a, cws-4mfh-a arc gap gage dia. 0.620 in. Nominal od (in.) actual od (in.) setting for 0.020 in. Arc gap (in.) setting for 0.025 in...

  • Page 197

    Cws − d100 − b welding system arc gap gage setting tables  2005 swagelok company, all rights reserved september 2005 e-3 cws-8mrh arc gap gage dia. 0.813 in. Nominal od (in.) actual od (in.) setting for 0.020 in. Arc gap (in.) setting for 0.025 in. Arc gap (in.) setting for 0.030 in. Arc gap (in.) ...

  • Page 198

    Arc gap gage setting tables cws − d100 − b welding system  2005 swagelok company, all rights reserved september 2005 e-4 cws-8mrh arc gap gage dia. 20,65 mm nominal od (mm) actual od (mm) setting for 0,51 mm arc gap setting for 0,64 mm arc gap setting for 0,76 mm arc gap setting for 0,89 mm arc gap...

  • Page 199

    Cws − d100 − b welding system arc gap gage setting tables  2005 swagelok company, all rights reserved september 2005 e-5 cws-5h-b arc gap gage dia. 1.244 in. Nominal od (in.) actual od (in.) setting for 0.025 in. Arc gap (in.) setting for 0.030 in. Arc gap (in.) setting for 0.035 in. Arc gap (in.) ...

  • Page 200

    Arc gap gage setting tables cws − d100 − b welding system  2005 swagelok company, all rights reserved september 2005 e-6 cws-5h-b arc gap gage dia. 31,60 mm nominal od (mm) actual od (mm) setting for 0,50 mm arc gap (mm) setting for 0,64 mm arc gap (mm) setting for 0,76 mm arc gap (mm) setting for ...

  • Page 201

    Cws − d100 − b welding system arc gap gage setting tables  2005 swagelok company, all rights reserved september 2005 e-7 cws-10h-a arc gap gage dia. 1.994 in. Nominal od (in.) actual od setting for 0.025 in. Arc gap (in.) setting for 0.030 in. Arc gap (in.) setting for 0.035 in. Arc gap (in.) setti...

  • Page 202

    Arc gap gage setting tables cws − d100 − b welding system  2005 swagelok company, all rights reserved september 2005 e-8 cws-10h-a arc gap gage dia. 50,65 mm nominal od (mm) actual od (mm) setting for 0,50 mm arc gap (mm) setting for 0,64 mm arc gap (mm) setting for 0,76 mm arc gap (mm) setting for...

  • Page 203

    Cws − d100 − b welding system arc gap gage setting tables  2005 swagelok company, all rights reserved september 2005 e-9 cws-20h-a/b arc gap gage dia. 3.118 in. Nominal od (in.) actual od (in.) setting for 0.025 in. Arc gap (in.) setting for 0.030 in. Arc gap (in.) setting for 0.035 in. Arc gap (in...

  • Page 204

    Arc gap gage setting tables cws − d100 − b welding system  2005 swagelok company, all rights reserved september 2005 e-10 cws-20h-a/b arc gap gage dia. 79,23 mm nominal od (mm) actual od (mm) setting for 0,50 mm arc gap (mm) setting for 0,64 mm arc gap (mm) setting for 0,76 mm arc gap (mm) setting ...

  • Page 205: Swagelok Atw Fittings

    Cws − d100 − b welding system arc gap gage setting tables  2005 swagelok company, all rights reserved september 2005 e-11 arc gap gage setting tables for swagelok atw fittings when using swagelok atw weld fittings shown in figure e-23, measure the outside diameter of the integral filler ring or cuf...

  • Page 206

    Arc gap gage setting tables cws − d100 − b welding system  2005 swagelok company, all rights reserved september 2005 e-12 arc gap gage setting formula to determine the arc gap gage setting for a specific arc gap, use the formula below. Figure e-1 arc gap gage setting formula a 2 b 2 + ) ) c arc gap...

  • Page 207: Appendix F

     2005 swagelok company, all rights reserved september 2005 f-1 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 repre...

  • Page 208

    Parts drawings cws − d100 − b welding system  2005 swagelok company, all rights reserved september 2005 f-2 5 6 7 8 9 10 11 12 13 14 16 17 1 2 3 4 15 figure f-1 cws-5h-b weld head.

  • Page 209

    Cws − d100 − b welding system parts drawings  2005 swagelok company, all rights reserved september 2005 f-3 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...

  • Page 210

    Parts drawings cws − d100 − b welding system  2005 swagelok company, all rights reserved september 2005 f-4 figure f-2 series 5/10/20 rotor assembly 5 6 7 9 2 3 4 1 8.

  • Page 211

    Cws − d100 − b welding system parts drawings  2005 swagelok company, all rights reserved september 2005 f-5 table f-2 series 5/10/20 rotor assembly parts list reference no. Description available in kit no. [ 1 gear ring cws-11051-sub cws-11136-pkg, cws-11056-sub cws-11062-sub, cws-11304-pkg 2 dowel...

  • Page 212

    Parts drawings cws − d100 − b welding system  2005 swagelok company, all rights reserved september 2005 f-6 figure f-3 cws-5h-b motor and power block assembly 1 2 3 4 5 6 7 8 9 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 35 36 37 40 38 39 10 30 31 32 29 31 32 33 34.

  • Page 213

    Cws − d100 − b welding system parts drawings  2005 swagelok company, all rights reserved september 2005 f-7 table f-3 cws-5h-b 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 space...

  • Page 214

    Parts drawings cws − d100 − b welding system  2005 swagelok company, all rights reserved september 2005 f-8 figure f-4 cws-5tfb tube fixture block 1 2 3 4 6 5 11 9 8 7 7 5 20 21 17 18 19 19 14 13 12 15 16 10 10

  • Page 215

    Cws − d100 − b welding system parts drawings  2005 swagelok company, all rights reserved september 2005 f-9 table f-4 cws-5tfb tube fixture block parts list reference no. Description available in kit no. [ 1 latch screw cws-12132-02 cws-12131-pkg cws-5fix-pkg 2 latch cws-12131-pkg 3 lever cam assem...

  • Page 216

    Parts drawings cws − d100 − b welding system  2005 swagelok company, all rights reserved september 2005 f-10 figure f-5 cws-5fsp1 special purpose fixture block 9 11 12 7 6 5 4 3 2 1 9 7 3 4 5 8 10

  • Page 217

    Cws − d100 − b welding system parts drawings  2005 swagelok company, all rights reserved september 2005 f-11 table f-5 cws-5fsp1 special purpose fixture block parts list reference no. Description available in kit no. [ 1 locking ring tab cws-12134-pkg 2 locking ring tab screws cws-12134-pkg cws-5fi...

  • Page 218

    Parts drawings cws − d100 − b welding system  2005 swagelok company, all rights reserved september 2005 f-12 10 11 7 6 5 4 3 2 1 10 9 8 4 3 3 11 5 6 12 figure f-6 cws-5fsp2 special purpose fixture block.

  • Page 219

    Cws − d100 − b welding system parts drawings  2005 swagelok company, all rights reserved september 2005 f-13 table f-6 cws-5fsp2 special purpose fixture block parts list reference no. Description available in kit no. [ 1 locking ring tab screws cws-12134-pkg cws-13112-04 2 locking ring tab cws-1213...

  • Page 220

    Parts drawings cws − d100 − b welding system  2005 swagelok company, all rights reserved september 2005 f-14 1 2 3 4 5 6 7 8 9 10 11 12 13 14 16 18 19 17 15 figure f-7 cws-10h-a weld head.

  • Page 221

    Cws − d100 − b welding system parts drawings  2005 swagelok company, all rights reserved september 2005 f-15 table f-7 cws-10h-a 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-10wha-pkg 3 weld head housing pins ...

  • Page 222

    Parts drawings cws − d100 − b welding system  2005 swagelok company, all rights reserved september 2005 f-16 figure f-8 cws-10h-a motor and power block assembly 1 2 3 4 5 6 7 8 9 11 12 13 14 15 16 17 18 19 20 21 23 24 25 26 27 28 35 36 37 40 39 10 29 31 32 33 34 22 30 31 32 38.

  • Page 223

    Cws − d100 − b welding system parts drawings  2005 swagelok company, all rights reserved september 2005 f-17 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 spa...

  • Page 224

    Parts drawings cws − d100 − b welding system  2005 swagelok company, all rights reserved september 2005 f-18 figure f-9 cws-10tfb tube fixture block 5 6 4 11 20 15 13 14 19 18 17 21 12 22 10 16 9 8 13 13 7 14 6 5 3 2 4 1 13 7 8 11.

  • Page 225

    Cws − d100 − b welding system parts drawings  2005 swagelok company, all rights reserved september 2005 f-19 table f-9 cws-10tfb tube fixture block parts list reference no. Description available in kit no. [ 1 locking ring tab screws cws-12148-pkg cws-10fix-pkg 2 locking ring tab cws-12148-pkg 3 to...

  • Page 226

    Parts drawings cws − d100 − b welding system  2005 swagelok company, all rights reserved september 2005 f-20 3 4 1 5 6 7 8 9 10 11 12 13 14 16 18 19 17 2 15 figure f-10 cws-20h-a weld head.

  • Page 227

    Cws − d100 − b welding system parts drawings  2005 swagelok company, all rights reserved september 2005 f-21 table f-10 cws-20h-a 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-20wha-pkg 3 weld head housing pins...

  • Page 228

    Parts drawings cws − d100 − b welding system  2005 swagelok company, all rights reserved september 2005 f-22 figure f-11 cws-20h-a motor and power block assembly 1 2 3 4 5 6 7 8 9 12 13 14 15 18 19 20 21 23 24 25 26 27 28 35 36 37 40 10 29 31 32 33 34 22 30 31 32 11 16 17 39 38.

  • Page 229

    Cws − d100 − b welding system parts drawings  2005 swagelok company, all rights reserved september 2005 f-23 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 sp...

  • Page 230

    Parts drawings cws − d100 − b welding system  2005 swagelok company, all rights reserved september 2005 f-24 figure f-12 cws-20tfb tube fixture block 10 9 11 7 16 5 10 14 13 12 15 16 2 3 4 3 1 5 6 1 20 19 7 21 18 17 22 8 7 15.

  • Page 231

    Cws − d100 − b welding system parts drawings  2005 swagelok company, all rights reserved september 2005 f-25 table f-12 cws-20tfb tube fixture block parts list reference no. Description available in kit no. [ 1 latch screw cws-12306-02 cws-12307-pkg cws-20fix-pkg 2 latch cws-12307-pkg 3 lever cam a...

  • Page 232

    Parts drawings cws − d100 − b welding system  2005 swagelok company, all rights reserved september 2005 f-26 3 4 1 5 6 7 8 9 10 11 12 13 14 16 18 19 17 2 15 figure f-14 sws-20h-b weld head.

  • Page 233

    Cws − d100 − b welding system parts drawings  2005 swagelok company, all rights reserved september 2005 f-27 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-...

  • Page 234

    Parts drawings cws − d100 − b welding system  2005 swagelok company, all rights reserved september 2005 f-28 figure f-15 sws-20h-b motor and power block assembly 1 2 3 4 5 6 7 8 9 12 13 14 15 18 19 20 21 23 24 25 26 27 28 35 36 37 40 10 29 31 32 33 34 22 30 31 32 11 16 17 39 38.

  • Page 235

    Cws − d100 − b welding system parts drawings  2005 swagelok company, all rights reserved september 2005 f-29 table f-14 sws-20h-b 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 sp...

  • Page 236

    Parts drawings cws − d100 − b welding system  2005 swagelok company, all rights reserved september 2005 f-30 figure f-16 sws-20tfb-a tube fixture block 6 16 3 6 15 11 7 8 2 3 1 6 14 16 5 3 17 18 4 4 2 6 5 2 3 14 12 13 13 13 10 8 2 7 2 9 23 22 19 20 21.

  • Page 237

    Cws − d100 − b welding system parts drawings  2005 swagelok company, all rights reserved september 2005 f-31 table f-15 sws-20tfb-a tube fixture block parts list reference no. Description available in kit no. [ 1 top side plate (right) sws-20tspr-a 2 hinge and latch pin cws-20fix-pkg 3 lever cam as...

  • Page 238

    Parts drawings cws − d100 − b welding system  2005 swagelok company, all rights reserved september 2005 f-32 figure f-17 sws-20fsp1r special purpose fixture block 9 8 7 6 10 7 11 12 4 5 3 2 11 11 4 1 11 12.

  • Page 239

    Cws − d100 − b welding system parts drawings  2005 swagelok company, all rights reserved september 2005 f-33 table f-16 sws-20fsp1r special purpose fixture block parts 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...

  • Page 240

    Parts drawings cws − d100 − b welding system  2005 swagelok company, all rights reserved september 2005 f-34 6 7 5 5 8 9 4 3 3 2 3 3 1 15 14 13 12 10 10 10 10 4 figure f-18 sws-20fsp1l special purpose fixture block 11.

  • Page 241

    Cws − d100 − b welding system parts drawings  2005 swagelok company, all rights reserved september 2005 f-35 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 * 4 dowel pin cws-20fix-p...

  • Page 242

    Parts drawings cws − d100 − b welding system  2005 swagelok company, all rights reserved september 2005 f-36 figure f-19 cws-m-mtr-a motor module 5 4 3 2 1 2.

  • Page 243

    Cws − d100 − b welding system parts drawings  2005 swagelok company, all rights reserved september 2005 f-37 table f-18 cws-m-mtr-a motor module parts list reference no. Description available in kit no. [ 1 motor cover 1 cws-mp-housing 2 button head screw cws-mp-screws cws-mp-latch 3 latch cws-mp-l...

  • Page 244

    Parts drawings cws − d100 − b welding system  2005 swagelok company, all rights reserved september 2005 f-38 figure f-20 cws-4mrh-a rigid micro weld head 18 19 20 21 22 23 24 25 15 14 13 12 11 10 8 7 6 5 4 3 2 1 28 33 29 32 30 31 9 29 33 26 27 16 17 15 16 17 16 15.

  • Page 245

    Cws − d100 − b welding system parts drawings  2005 swagelok company, all rights reserved september 2005 f-39 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-g...

  • Page 246

    Parts drawings cws − d100 − b welding system  2005 swagelok company, all rights reserved september 2005 f-40 figure f-21 cws-4mfh-a flexible micro weld head 22 17 18 16 25 26 15 14 13 12 11 10 8 7 6 5 4 3 2 29 16 9 15 27 28 23 24 30 32 31 32 31 19 20 21 20 21 20 15 1 15.

  • Page 247

    Cws − d100 − b welding system parts drawings  2005 swagelok company, all rights reserved september 2005 f-41 table f-20 cws-4mfh-a flexible 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-4mh...

  • Page 248

    Parts drawings cws − d100 − b welding system  2005 swagelok company, all rights reserved september 2005 f-42 figure f-22 cws-4mfa-** micro weld head fixture 10 11 10 9 8 7 6 4 1 5 3 2.

  • Page 249

    Cws − d100 − b welding system parts drawings  2005 swagelok company, all rights reserved september 2005 f-43 table f-21 cws-4mfa-** micro weld head fixture parts list reference no. Description available in kit no. [ 1 side plate (right) * 2 side plate cam (right) cws-4mfp-latch-a 3 cam pin * 4 side...

  • Page 250

    Parts drawings cws − d100 − b welding system  2005 swagelok company, all rights reserved september 2005 f-44 figure f-23 cws-4mf-** micro weld head fixture 1 2 3 4 5 6 7 8 9 10 9.

  • Page 251

    Cws − d100 − b welding system parts drawings  2005 swagelok company, all rights reserved september 2005 f-45 table f-22 cws-4mf-** micro weld head fixture parts list reference no. Description available in kit no. [ 1 side plate (right) * 2 side plate cam (right) cws-4mfp-latch 3 dowel pin (base) * ...

  • Page 252

    Parts drawings cws − d100 − b welding system  2005 swagelok company, all rights reserved september 2005 f-46 16 17 18 37 38 20 26 25 19 28 27 17 22 21 23 39 29 32 33 40 24 14 36 35 34 13 15 5 3 2 11 4 10 9 8 12 6 7 17 1 30 18 16 31 figure f-24 cws-8mrh rigid micro weld head.

  • Page 253

    Cws − d100 − b welding system parts drawings  2005 swagelok company, all rights reserved september 2005 f-47 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/b...

  • Page 254

    Parts drawings cws − d100 − b welding system  2005 swagelok company, all rights reserved september 2005 f-48 figure f-25 sws-8mfa-** micro weld head fixture 19 18 17 16 15 1 2 3 4 5 6 7 8 9 10 11 12 13 14.

  • Page 255

    Cws − d100 − b welding system parts drawings  2005 swagelok company, all rights reserved september 2005 f-49 table f-24 sws-8mfa-** micro weld head fixture parts list reference no. Description available in kit no. [ 1 moveable side plate (right) sws-8mfp-mspr** 2 cam pin sws-8mfp-latch 3 cam latch ...

  • Page 256

    Parts drawings cws − d100 − b welding system  2005 swagelok company, all rights reserved september 2005 f-50

  • Page 257: Appendix G

     2005 swagelok company, all rights reserved september 2005 g-1 appendix g gas flow rate tables figure g-1 pressure gage purge rate and pressure tables tube size wall thickness *minimum id purge rate pressure swagelok head purge rates restrictor size 13 to 16.8 torr 1/16 in. 0.015 in. 3 std ft3/hr 7...

  • Page 258: Continued

    Gas flow rate tables cws − d100 − b welding system  2005 swagelok marketing co., all rights reserved september 2005 g-2 purge rate and pressure tables continued tube size wall thickness *minimum id purge rate pressure swagelok head purge rates restrictor size 1 to 2 torr 3/4 in. 0.065 in. 20 std ft...

  • Page 259: Appendix H

     2005 swagelok company, all rights reserved september 2005 h-1 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 pi...

  • Page 260

    Fixture block alignment cws − d100 − b welding system  2005 swagelok company, all rights reserved september 2005 h-2 tube-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 app...

  • Page 261

    Cws − d100 − b welding system fixture block alignment  2005 swagelok company, all rights reserved september 2005 h-3 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 poi...

  • Page 262

    Fixture block alignment cws − d100 − b welding system  2005 swagelok company, all rights reserved september 2005 h-4 micro-fit fitting to micro-fit fitting fixture block to align the fixture block, follow these steps: 1. Turn the fixture block over and locate the directional arrows on the plenum. T...

  • Page 263: Series 20H-B Fixture Block

    Cws − d100 − b welding system fixture block alignment  2005 swagelok company, all rights reserved september 2005 h-5 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...

  • Page 264

    Fixture block alignment cws − d100 − b welding system  2005 swagelok company, all rights reserved september 2005 h-6 series 8 micro weld head fixture to align tubing in the series 8 micro weld head fixture follow these steps: 1. Using the micro fixture tool, place the latch in the open position the...

  • Page 265: Appendix I

     2005 swagelok company, all rights reserved september 2005 i-1 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 v...

  • Page 266

    Weld parameter guidelines cws − d1200 − b welding system  2005 swagelok company, all rights reserved september 2005 i-2 table notes d all 316l material entries refer to type 316l stainless steel. D all 6lv material entries refer to type 316lv stainless steel. D tb-tb indicates a tube-to-tube weld j...

  • Page 267

    W eld procedure guidelines cws − d100 − b w elding system september 2005 i-3 2005 swagelok company , all rights reserved weld procedure guidelines - english (for reference only) w eld head joint t ype material no. Of passes od (in.) w all thickness (in.) arc gap (in.) gage setting (in.) t ravel spee...

  • Page 268

    Cws − d100 − b w elding system w eld procedure guidelines 2005 swagelok company , all rights reserved september 2005 i-4 weld procedure guidelines - english (for reference only) w eld head joint t ype material no. Of passes od (in.) w all thickness (in.) arc gap (in.) gage setting (in.) t ravel spee...

  • Page 269

    W eld procedure guidelines cws − d100 − b w elding system september 2005 i-5 2005 swagelok company , all rights reserved weld procedure guidelines - metric (for reference only) w eld head joint t ype material no. Of passes od (mm) w all thickness (mm) arc gap (mm) gage setting (mm) t ravel speed (mm...

  • Page 270

    Cws − d100 − b w elding system w eld procedure guidelines 2005 swagelok company , all rights reserved september 2005 i-6 weld procedure guidelines - english (for reference only) w eld head joint t ype material no. Of passes od (in.) w all thickness (in.) arc gap (in.) gage setting (in.) t ravel spee...

  • Page 271: Index

     2005 swagelok company, all rights reserved september 2005 index − i 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, setti...

  • Page 272

    Index cws − d100 − b welding system  2005 swagelok company, all rights reserved september 2005 index − ii 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-1...

  • Page 273

    Cws − d100 − b welding system index  2005 swagelok company, all rights reserved september 2005 index − iii gtaw advantages, 1-2 defined, a-4 variables, 1-3 h hardware installation, 2-1 heat input, defined, a-5 i identifiy proper weld, 5-17 impulse, defined, a-5 impulse rate reference weld, 5-22 inc...

  • Page 274

    Index cws − d100 − b welding system  2005 swagelok company, all rights reserved september 2005 index − iv 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, re...

  • Page 275

    Cws − d100 − b welding system index  2005 swagelok company, all rights reserved september 2005 index − v 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 guidelin...

  • Page 276

    Index cws − d100 − b welding system  2005 swagelok company, all rights reserved september 2005 index − vi 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 hea...

  • Page 277

    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.