Series 20 Weld Head User`s Manual (SWS-MANUAL
Contents
1. A Caution Do not jog or move the rotor unless the electrode is clamped in place 2001 2004 Swagelok Company all rights reserved 9 April 2004 Series 20 Weld Head Setting the Arc Gap 1 Use JOG to position the rotor as shown This allows access to the electrode clamping screws 2 Insert the arc gap gage into the rotor See Figure 9 A Tilt the weld head upward Loosen the electrode screw allowing the electrode to drop onto the gage surface See Figure 9 B 4 Tighten the electrode clamping screws just enough to secure the electrode Remove the arc gap gage 5 Press HOME to return the rotor to the home position Figure 9 Setting the Arc Gap A Caution Do not jog or move the rotor unless the electrode is clamped in place 10 2001 2004 Swagelok Company all rights reserved April 2004 Series 20 Weld Head Preparing the Work It is important to prepare the tube pieces properly before welding Refer to Figure 10 Tubing must be square and burr free to ensure repeatable high quality autogenous fusion welds Cut the tubing to length with a hacksaw or tube cutter Face the tube ends with a lathe or a portable facing tool Deburr the ends making sure that both the inside and outside diameters are square and burr free Clean the tube ends using an appropriate solvent Minimize the chance of a poor quality weld by following these guidelines e Tube ends must be square e Tube ends must not2. MANUAL ENTRY then press ENTER the weld head Select LEVELS ONLY then press ENTER Enter 2 levels then press ENTER a a al ac Enter the programmer name Typically it would be your name S Enter the Side 1 Tube Diameter 20 then press ENTER 7 Select 20 from the Weld Head pick list 2001 2004 Swagelok Company all rights reserved 21 April 2004 Series 20 Weld Head 8 Using Table 8 enter the following parameters Table Parameters Parameter Ent Start Power Normal Start Current 20 Rotor Delay 0 Prepurge 5 Postpurge 5 Downslope 0 9 Using Table 9 enter the following parameters for level 1 and level 2 Table 9 Level I and Level 2 Parameters Parameter Level 2 Setting Impulse 2 0 Maintenance 2 0 Weld Time 15 Ramp o ooo 0 Pulse Rate 1 Pulse Width 50 Speed Hi 4 00 Speed Lo 4 00 10 Press the WELD mode key 11 Select SAVE TO MEMORY then press ENTER 12 Enter the procedure name Timing Test then press ENTER Checking the Weld Head Timing 1 Select WELD TEST 2 Press START 3 After verifying the screen displays WELD HEAD IS CLEAR TO ROTATE press ENTER Wrong Correct 4 Verify the rotor completes two revolutions then check that no part of the rotor is exposed after it stops See Figure 23 Figure 23 Rotor Position i WARNING If the rotor does not complete the revolutions and stop correctly contact your Swagelok representative THE ROTOR WILL ROTATE ONE REVOLUT
3. 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 contaminates Method Result Burrs in Burrs Flow Path Hack Saw Cut i p ane ae End Rolled by Cutter Irregular Tube Blade and Roller Diameter Tube Cutter Burrs Reduced Flow Area Face Perpendicular Smooth Transition to Axis at Wall Faces Tube Facing Tool Square Corners No Gaps Figure 10 Tube Preparation 2001 2004 Swagelok Company all rights reserved 11 April 2004 Series 20 Weld Head Fixturing the Work Select or configure the appropriate fixture block Select the collets to match the work outside diameter Selecting the Fixture Block and Collets 1 Select the fixture block that accepts the outside diameter of the tube to be welded Refer to Table 6 Table 6 Fixture Blocks Minimum Weld Model OD Capacity Extension Length SWS 20TFB A 1 2 to 2 in 1 45 in 12 to 52 mm 36 83 mm SWS 20FSP1L or 1 2 to 2 in 0 80 in SWS 20FSP1R 12 to 52 mm 20 32 mm 2 Select the proper collets for the diameter of the parts being welded Refer to Table 7 Table 7 Collets Model OD Capacit Comments CWS 20UCI x 1 2 in to 2 in Tubing tube fittings 7 12 mm to 48 3 mm CWS 20UCI XP 1 4 to 1 1 2 Pipe Add J suffix for JIS p
4. 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 2001 2004 Swagelok Company all rights reserved 5 April 2004 Series 20 Weld Head Calculating Arc Gap Gage Settings To determine the arc gap gage setting for a specific arc gap use the formula below i I l 7 p 9 of C Ld A B ARC GAP gt ED gt ag C GAGE SETTING Where A largest OD on the weld end of the tubing or fitting welding diameter B Arc gap gage diameter C desired arc gap Figure 6 Arc Gap Gage Setting Formula Example No 1 Series 20 Weld Head 1 to 1 in tube butt weld A 1 000 in largest outside diameter Arc gap gage diameter B 3 118 in Desired arc gap C 0 025 in L000in in 0 025in 2084in Example No 2 Series 20 Weld Head 25 to 25 mm tube butt weld A 25 00 mm largest outside diameter Arc gap gage diameter B 79 20 mm Desired arc gap C 0 50 mm n 220mm 050mm 52 60 mm 6 2001 2004 Swagelok Company all rights reserved April 2004 Series 20 Weld Head Setting the Arc Gap The proper arc gap setting facilitates control of the weld and improves consistency The following steps cover how to set the arc gap The arc gap is set by using the arc gap gage provided with the weld head The gage is a
5. ordering information contact your Swagelok representative The parts identified in this section include SWS 20H C Weld Head SWS 20H C Motor and Power Block Assembly SWS 20H C Rotor Assembly SWS 20TFB A Tube Fixture Block SWS 20FSPI1R Special Purpose Side Plate SWS 20FSPI1L Special Purpose Side Plate 2001 2004 Swagelok Company all rights reserved April 2004 29 some 20 Weld Head Figure 37 SWS 20H C Weld Head 30 2001 2004 Swagelok Company all rights reserved April 2004 Series 20 Weld Head Table 10 SWS 20H C Weld Head Parts List No Order Quantity N A i i 10 N A SS Socket Head Cap Screw 13254 10 6 32 x 0 312 in 10 SS Dowel Pin 0 125 x 0 375 in 13135 10 11 SS Socket Head Cap Screw 13162 10 4 40 x 1 250 in CO 00 N 03 AI BY ONJ gt oa 12 SS Socket Head Cap Screw 13161 10 4 40 x 0 812 in 13 Work Extension Bar 21054 1 14 Brass Button Head Screw 21066 10 4 40 x 0 250 in w nylon 15 Locking Ring 21065 1 16 Locking Ring Plate 11104 A 1 17 Plastic Socket Head Cap Screw 13105 10 6 32 x 0 437 in 18 SS Dowel Pin 0 125 x 0 250 in 13134 10 For part ordering information contact your Swagelok representative 2001 2004 Swagelok Company all rights reserved 31 April 2004 Series 20 Weld Head Figure 38 SWS 20H C Motor and Power Block Assembly 32 2001 2004 Swagelok Company all rights reserved April 2004 Series 20 Weld Head Table 11 SWS 2
6. 0H C Motor and Power Block Assembly Parts List No Order Quantity i 10 N A N A N A T i 12 i 13 10 14 10 15 N A 16 i 17 i 18 10 19 i 20 N A 21 10 22 i 23 10 24 i 25 10 26 i 27 N A 28 10 29 N A 30 31 N A 32 10 33 10 34 Wire Ring Terminal NA 35 Brass Slotted Head Screw 4 40 x 0 250 in 21066 10 For part ordering information contact your Swagelok representative CO Ni OI BY GD PN gt a ow o 2001 2004 Swagelok Company all rights reserved 33 April 2004 Series 20 Weld Head Figure 39 SWS 20H C Rotor Assembly 34 2001 2004 Swagelok Company all rights reserved April 2004 Series 20 Weld Head Table 12 SWS 20H C Rotor Assembly Parts List No Order Quantity i i 10 N A 10 10 i i N A CO CO N 03 017 AI GW P gt 2001 2004 Swagelok Company all rights reserved 35 April 2004 Series 20 Weld Head Figure 40 SWS 20TFB A Tube Fixture Block 36 2001 2004 Swagelok Company all rights reserved April 2004 Series 20 Weld Head Table 13 SWS 20TFB A Tube Fixture Block Parts List Reference Description Part No Minimum No Order Quantity i 1 2 N A 3 i 4 5 i 6 10 7 i 8 10 9 10 10 Side Plate Assembly left 1 11 10 12 N A N A 13 N A 14 N A N A 15 16 N A N A 17 i 18 i 19 10 20 10 21 i 22 i 23 10 For part ordering information contact your Swagelok representative 2001 2004 Swagelok Company a
7. Company all rights reserved April 2004 Series 20 Weld Head 7 Remove the ceramic insert See Figure 35 Ceramic Insert 8 Inspect the ceramic insert If it has carbon or other a deposits clean it with a fine grit abrasive pad or soft nylon brush 9 Remove the electrode clamping plate Clean it with a fine grit abrasive pad See Figure 36 10 Inspect the brush and gear rings for dirt or other deposits Clean the rings with a fine grit abrasive pad or soft stainless steel wire brush Figure 35 Removing the 11 Dry all parts with clean low pressure air Ceramice sen before reassembly Electrod ectrode E Pe Clamping Plate Weld Head Assembly Assembly of the weld head and rotor is the reverse of the disassembly procedures To assemble the weld head follow these steps 1 Complete the steps in reverse order in Rotor on page 26 Figure 36 Removing the Electrode Clamping Plate 2 Complete the steps in reverse order in Weld Head Disassembly and Cleaning on page 23 A Caution Do not pinch any internal wiring during reassembly 2001 2004 Swagelok Company all rights reserved 27 April 2004 Series 20 Weld Head 28 2001 2004 Swagelok Company all rights reserved April 2004 Series 20 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
8. ION TO HOME POSITION 15 SECONDS AFTER COMPLETING THE TWO REVOLUTIONS 22 2001 2004 Swagelok Company all rights reserved April 2004 Series 20 Weld Head Weld Head Disassembly and Cleaning This section describes how to disassemble the weld head ats and rotor N Locking Ring a Locking Weld Head i Ring Plate To disassemble the weld head follow these steps 1 Blow any loose material from the weld head assembly with clean low pressure air 2 Remove the four screws locking ring and locking ring ER plate See Figure 24 gt 3 Remove the work extension screw lock washer and the work extension Inspect the work extension for pitting wear or damage See Figure 25 4 Replace work extension if necessary Refer to the Parts Drawings at the end of this manual for part O ordering information Figure 24 Removing the Locking Ring and Locking Ring Plate Work 7 Extension a i Work Extension Screw Figure 25 Removing the Work Extension 2001 2004 Swagelok Company all rights reserved 23 April 2004 Series 20 Weld Head 5 Remove the weld head housing screws from the housing Housing Using a slight rocking motion carefully separate the in locking ring half of the weld head housing from the motor half See Figure 26 a i 6 Carefully separate the weld head housing halves so that Weld Head i internal compo
9. Lock down the top side plate See Figure 14 B 4 Remove the centering gage Figure 13 Place the Centering Gage Note When welding a Swagelok ATW fitting to tubing butt the tubing against the centering gage first Figure 14 Placing First Work Piece in the Fixture Block 2001 2004 Swagelok Company all rights reserved 15 April 2004 Series 20 Weld Head 5 Butt the second work piece against the first work piece and lock down the top side plate See Figure 15 6 Inspect 360 around the weld joint for fit and alignment If the alignment is not correct proceed to the next section for alignment adjustment instructions YS Vf LA gt N Figure 15 Placing Second Work Piece 16 2001 2004 Swagelok Company all rights reserved April 2004 Series 20 Weld Head Adjusting the 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 SWS 20TFB A Fixture Block follow these steps 1 Loosen the alignment knobs See Figure 16 2 Align the tubing with the fitting See Figure 17 3 Tighten the alignment knobs 2001 2004 Swagelok Company all rights reserved April 2004 Alignment Knobs Figure 16 Loosen the Alignment Knobs Align Fitting with Tubing Alignment Knob Figure 17 Aligning the Tubing Se
10. VENT SHALL SWAGELOK BE LIABLE TO PURCHASER OR ANY THIRD PARTY FOR ANY DIRECT OR INDIRECT CONSEQUENTIAL OR INCIDENTAL DAMAGES Series 20 Weld Head SERIES 20 WELD HEAD Weld Head The Series 20 SWS weld head delivers consistent precise welds for outside diameters from 1 2 to 2 in 12 to 52 mm A DC motor in the weld head drives a rotor which carries the tungsten electrode around the weld joint Optical circuitry in the weld head sends precise feedback to the power supply to control the speed of the rotor All moving parts in the weld head are mounted in low friction devices to provide smooth consistent operation Q A spring loaded floating brush continuously contacts Figure 1 Series 20 Weld Head approximately one third of the circumference of the rotor This configuration ensures consistent uniform electrical conductance to the rotor and electrode Fixture Block The Series 20 SWS fixture block accurately aligns and IN holds tubing fittings and valve bodies The modular gt design allows you to select different side plates and create Ki the configuration needed for the job Ly Y N before welding Using multiple fixture blocks can increase productivity Bs The fixture block is separate from the weld head LONG o allowing work pieces to be easily aligned and fixtured Ne kd hs Each fixture block is designed to accommodate a range of LNA work piece sizes A unique and patented Universa
11. awings at the end of this manual for part ordering information 2001 2004 Swagelok Company all rights reserved April 2004 Brush Groove Figure 29 Inspecting the Brush Power 4 ue Strap Screws Figure 30 Inspecting the Power Strap Screws Figure 31 Inspecting the Work Plate and Screws 25 Series 20 Weld Head Rotor as Rotor Screw Electrode 2 To disassemble the rotor follow these steps Clamping U a 1 Remove the rotor screws and the electrode clamping ie i plate screws from the rotor Remove the electrode from the ceramic insert See Figure 32 2 Place the rotor on a clean dry surface with the rotor Ceramic opening facing up Separate the gear ring from the brush nsen ring See Figure 33 Electrode Figure 32 Removing the Rotor and 3 Completely separate the gear ring from the brush ring as shown in Figure 34 Lay the rings flat on Electrode Clamping Plate Screws the work surface Opening Brush 4 Remove the ball bearings from the gear and a tha gt brush rings Gear Ring eue oe 5 Inspect the ball bearings for wear and damage hus Replace if necessary 6 Ifthe ball bearings are dirty clean them with isopropyl alcohol or cleaning solution Dry the Rotor Pin balls thoroughly Location Figure 33 Placing the Rotor on the Work Surface Separate Gear Ring Ball Brush Ring Figure 34 Separating the Gear Ring from the Brush Ring 26 2001 2004 Swagelok
12. djusted for the desired arc gap and then installed in the rotor With the gage in place the electrode can be positioned with reasonable accuracy Setting the Arc Gap Gage 1 Measure the outside diameters of the work pieces being welded using a caliper or micrometer See Figure 7 A The M100 will calculate the arc gap gage setting automatically when using the Auto Entry feature 2 Refer to the table for your nominal OD Find the Figure 7 Setting an Arc Gap gage actual outside diameter nearest to your measurement 2001 2004 Swagelok Company all rights reserved 7 April 2004 Series 20 Weld Head Table 2 SWS 20H C Arc Gap Gage Dia 3 118 in Setting Setting Setting Setting Setting Setting Setting Setting Setting Setting for for for for for for for 0 030 in 0 040 in 0 050 in 0 060 in 0 070 in 0 5 mm 1 14 mm Nominal Actual Arc Gap Arc Gap Arc Gap Arc Gap Arc Gap Arc Gap Arc Gap OD in OD in in in in in in mm mm 112 47 08 si 50 27 53 44 114 56 62 12 59 79 2 66 14 Table 3 SWS 20H C Arc Gap Gage Dia 79 20 mm Actual 00 Setting for Setting for Setting for Setting for Setting for Nominal OD Actual OD 0 50 mm Arc 0 64 mm Arc 0 76 mm Arc 1 02 mm Arc 1 14 mm Arc mm mm Gap mm Gap mm Gap mm Gap mm Gap mm 12 16 76 18 49 76 22 51 76 23 51 76 25 53 26 8 54 76 35 58 26 52 66 76 Table4 SWS 20H C Pipe Arc Gap Gage Settings standard ae Setting for Setting for Se
13. eld Head This Swagelok weld head comes with a selection of electrodes The following instructions show how to properly install an electrode in the weld head Selecting the Proper Electrode Electrode length and diameter depend on your weld head L model and the outside diameter of the work piece being i Coes welded To select the correct electrode use the Electrode Selection Table Table 1 Electrode Selection Table Electrode Part No OD Length L Diameter D CWS C 062 1 630 P 1 4 1 630 in 0 062 in 1 2 41 40 mm 1 57 mm 3 8 CWS C 062 1 380 P 1 in 3 4 1 380 in 0 062 in 1 1 4 in 1 35 05 mm 1 57 mm 23 mm 25mm 28 mm 35 mm CWS C 062 1 105 P 1 1 2 in 1 105 in 0 062 in wae 28 07 mm 1 57 mm CWS C 062 855 P 1 1 4 0 855 in 0 062 in 1 1 2 21 72 mm 1 57 mm 4 2001 2004 Swagelok Company all rights reserved April 2004 Series 20 Weld Head Electrode Geometry This illustration shows the electrode shape Swagelok suggests Properly ground electrodes provide consistent repeatable welds Pre ground electrodes are available from j your Swagelok representative See your parts list for ordering information The electrode part numbers are assigned as follows SWS X HHH P Figure 5 Tungsten Electrode Electrode Package Diameter Designator Material Designator Electrode lP Diameter C Ceriated Length T Thoriated The ceriated electrode material type
14. eplace the set screw and verify that it is locked tightly in position Non Anodized Surfaces B Under the Collets Inside Plate Surfaces A Collets Figure 20 Cleaning the Collets and Collet Mounting Surfaces Figure 21 Lever Cam and Latch 2001 2004 Swagelok Company all rights reserved April 2004 Series 20 Weld Head Weld Head Daily Maintenance Perform weld head maintenance daily and every 500 to 700 WARNING welds Depending on usage and wear maintenance may be DISCONNECT THE performed before the 500 weld mark WELD HEAD FROM THE POWER SUPPLY At the start of each work day BEFORE PERFORMING 1 Inspect the weld head for cleanliness Pay close attention THE ADJUSTMENT to the rotor area OR MAINTENANCE 2 Press HOME Check the rotor for smooth rotation If the rotation is erratic or noisy disassemble the weld head and clean the rotor gears and brush See Weld Head Disassembly and Cleaning on page 23 At the end of each work day 1 Remove dirt carbon and vapor deposits from the weld head with a clean soft cloth and a solvent such as isopropyl alcohol 2 Store the weld head in a clean dry place Weld Head Periodic Maintenance Aner Every 500 to 700 welds measure the rotor speed to verify Figure 22 Inspect Exposed Surfaces of its accuracy the Weld Head Creating the Weld Head Timing Check Program Caution 1 Select PROG CREATE A Do not use lubricants inside Select
15. head 2 Align the notch on the multi pin connector with the small tab in the mating socket on the rear panel labeled FIXTURE Insert the connector in the socket Turn the connector sleeve clockwise by hand until it is tight This connection provides the control signals to drive the weld head 3 Insert and fully seat the red connector into the socket on the rear panel labeled ELECTRODE Twist the connector 1 4 turn clockwise to lock it into place This connection is the negative terminal of the weld head 4 Insert the green connector into the socket on the rear panel labeled WORK Twist the connector 1 4 turn clockwise to lock it into place This connection is the positive terminal of the weld head 5 Insert the weld head shielding gas connector into the Swagelok Quick Connect stem labeled TO WELD HEAD Ensure that the connector is firmly attached This connection provides shielding gas to the weld head through a solenoid valve in the power supply 2001 2004 Swagelok Company all rights reserved April 2004 Fixture Electrode Weld Head Shielding Gas Figure 4 Weld Head Connectors A Caution Ensure that the fixture connector is fully seated in the mating socket and the threaded sleeve is tight Note The weld head shielding gas connector must be a single end shut off SESO Swagelok Quick Connect stem SS QC4 S 400 Series 20 Weld Head Installing the Electrode in the W
16. ipe XPJ Add MMP suffix for metric pipe XMMP SWS 20UCI XTN 1 2 in to 2 in Tubular weld fitting p 12 mm to 52 mm collet for SWS 20FSP1L and SWS 20FSP1R Add MM XMMTN suffix for metric sizes SWS 20UCI MC N A Collet to hold ferrule mandrels for SWS 20TFB A fixture block Where X identifies the collet size in 1 16ths or metric MM suffix 12 2001 2004 Swagelok Company all rights reserved April 2004 Series 20 Weld Head Installing the Collets in a Tube Fixture Block 1 Release both levers and open the tube fixture block See Figure 11 Figure 11 Opening the Fixture Block 2001 2004 Swagelok Company all rights reserved 13 April 2004 Series 20 Weld Head 2 Install the collet halves in both the top and bottom side plates and tighten the collet screws Make sure the collet shoulder is flush against the fixture side plate See Figure 12 Fixture Side Plate Collet Shoulder Figure 12 Installing Collets 2001 2004 Swagelok Company all rights reserved April 2004 Series 20 Weld Head 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 Verify that the centering gage is positioned correctly for either the thick or thin side plate See Figure 13 2 Butt one work piece against the centering gage See Figure 14 A 3
17. l Collet WS Insert UCI fits into the fixture block to match the Coe diameter of the work piece The collet design firmly holds OM tubing and fittings that vary 0 005 in 0 13 mm from nominal outside diameter Collets are also available for thin Figure 2 Series 20 Fixture Block wall pipe The collets exchange quickly making the fixture block very adaptable to changing work requirements 2001 2004 Swagelok Company all rights reserved 1 April 2004 Series 20 Weld Head Unpacking the Weld Head Components The following weld head components are packaged in a foam lined shipping container e weld head e arc gap gage e electrode package e tool package Inspect the container for damage Remove the components from the container Check the items for any damage a TS Verify that the weld head serial number matches the serial number on the shipping container 5 Record the model and serial numbers and the delivery dates on page 7 of the Regulatory Module 2 2001 2004 Swagelok Company all rights reserved April 2004 Series 20 Weld Head Installing the Weld Head The weld head has four connectors that plug into the power supply See Figure 3 The four connectors on the cable are e fixture e electrode red e work green e weld head shielding gas Connect the four connectors to the rear panel of the power supply by performing the following steps see Figure 4 1 Locate the weld
18. ll rights reserved 37 April 2004 Series 20 Weld Head Figure 41 SWS 20FSP1R Special Purpose Side Plate 38 2001 2004 Swagelok Company all rights reserved April 2004 Series 20 Weld Head Table 14 SWS 20FSP1R Special Purpose Side Plate Parts List Reference Description a Minimum No Order Quantity i VA 2 NA NA i 5 i i 7 i i i ri NA 2 NA NA For part ordering information contact your Swagelok representative 2001 2004 Swagelok Company all rights reserved 39 April 2004 Series 20 Weld Head 7 X Wa Figure 42 SWS 20FSP1L Special Purpose Side Plate 40 2001 2004 Swagelok Company all rights reserved April 2004 Series 20 Weld Head Table 15 SWS 20FSP1L Special Purpose Side Plate Parts List Reference Description Part No Minimum No Order Quantity N A 2 N A 3 N A N A 7 NA 10 10 7 i 5 o 10 10 i 10 2 N A E i 14 E NA For part ordering information contact your Swagelok representative 2001 2004 Swagelok Company all rights reserved 41 April 2004 Series 20 Weld Head 42 2001 2004 Swagelok Company all rights reserved April 2004 Swagelok TM Swagelok Company 2001 2004 Swagelok Company Printed in U S A PPI April 2004 R2 SWS MANUAL 20HC E
19. nents are not damaged Housing Locking 7 Remove the rotor from the motor half of the weld head Ring Half housing See Figure 27 8 Carefully lift the power block subassembly out of the motor half of the weld head housing See Figure 28 Weld Head Housing Motor Half ae Figure 26 Removing the Locking Ring Half of the Weld Head Housing ec Figure 27 Removing the Rotor Weld Head Housing Locking Ring Half See a Figure 28 Removing the Power Block Subassembly 24 2001 2004 Swagelok Company all rights reserved April 2004 Series 20 Weld Head 9 Examine the brush See Figure 29 Inspect and clean the brush using the following steps a Check the brush for excessive wear b Verify that the brush has a groove Replace the brush if the groove is not present Refer to the Parts Drawings at the end of this manual for part ordering information c Remove any oxidation from the brush with a fine grit abrasive pad 10 Blow any loose material from the power block assembly with clean low pressure air 11 Verify that the two power strap screws are tight See Figure 30 12 Verify that the work plate screw is tight and free from excessive oxidation See Figure 31 Clean the work plate with a fine grit abrasive pad if necessary 13 Inspect the gears for wear and replace if damaged Refer to the Parts Dr
20. ries 20 Weld Head Mating the Weld Head to the Fixture Block 1 Rotate the locking lever on the weld head counter clockwise until it stops See Figure 18 2 Insert the weld head into the fixture block See Figure 19 A 3 Rotate the locking lever clockwise to secure the weld head See Figure 19 B Operating the Weld Head Operate the weld head using the following parameters Shield Gas Flow Rate std ft hr 20 to 400 std L min 9 4 to 18 8 Prepurge and Postpurge 302 Minimum Time in Seconds Start Power Normal Maximum Recommended o Average Amps 70 Amps at 50 Duty Cycle Set flow to higher rates when welding at high currents Flow should be continuous for cooling when welding at high currents Figure 19 Mating the Weld Head to the Fixture Block 2001 2004 Swagelok Company all rights reserved April 2004 Series 20 Weld Head Maintenance i i Note To ensure your Swagelok Welding System SWS equipment jp you experience problems while is always 1n proper working order you must perform performing the procedures in this periodic maintenance on the system components section refer to the Troubleshooting manual or contact your This section describes the procedures necessary for Swagelok representative maintaining the fixture blocks and weld heads For detailed part drawings and information refer to the Parts Drawings section at the end of this manual Perform fixture block main
21. tenance daily and after every 40 hours of welding time Depending on usage and wear maintenance may be performed before the 40 hour interval 2001 2004 Swagelok Company all rights reserved 19 April 2004 Series 20 Weld Head Fixture Block Daily Maintenance At the start of each work day l Inspect the fixture block for cleanliness wear and damage See Figure 20 Remove dirt carbon and vapor deposits from the fixture block with a clean soft cloth A solvent such as alcohol or acetone can be used Remove heavier deposits with a fine grit abrasive pad At the end of each workday clean and store the fixture block in a dry place Fixture Block Periodic Maintenance Every 500 700 welds l PA 3 20 Inspect and clean the collets See Figure 20 A Check for scratches and dents Remove dirt and oxides from all surfaces of the collet with a soft stainless steel wire brush Remove any oxides from the non anodized mating surfaces of the side plates with a fine grit abrasive pad See Figure 20 B Remove any dirt and oxides from the inside surfaces of the side plates with a clean soft cloth See Figure 20 C Remove heavier deposits with a fine grit abrasive pad Check the lever cam and latch for smooth operation See Figure 21 a Remove lever cam by removing the set screw from the latch and pulling the lever cam from the fixture block b Clean the lever cam and lightly lubricate if necessary c R
22. tting for Setting for Setting for 0 030 in 0 040 in 0 050 in 0 060 in 0 070 in Pipe Size in Actual OD in Arc Gap Arc Gap Arc Gap Arc Gap Arc Gap i 895 a 967 1 2 2 009 2 019 2 029 2 039 2 049 3 4 2 114 2 124 2 134 2 144 2 154 1 1 315 2 247 2 257 2 267 2 277 2 287 1 1 4 2 419 2 429 2 439 2 449 2 459 1 1 2 2 539 2 549 2 559 2 569 2 579 Table SWS 20H C Pipe Arc Gap Gage Settings metric 5 Setting for Setting for Setting for Setting for Setting for 0 76 mm 1 02 mm 1 27 mm 1 52 mm 1 78 mm Pipe Size mm Actual OD mm Arc Gap Arc Gap Arc Gap Arc Gap Arc Gap 10 2 45 46 45 72 45 97 46 22 46 48 13 5 47 11 1 937 1 947 1 957 1 967 17 2 48 96 49 22 49 47 49 72 49 98 18 9 50 83 21 3 52 03 26 9 54 83 33 7 58 23 42 4 62 58 18 3 65 53 8 2001 2004 Swagelok Company all rights reserved April 2004 Series 20 Weld Head Inserting the Electrode into a Rotor 1 Without the fixture block attached press WELD on the operator panel 2 Use JOG to position the rotor as shown in Figure 8 Loosen the two electrode clamping screws If you are replacing the electrode remove the electrode 4 Insert the new electrode with the sharp tip pointing out Tighten the electrode clamping screws slightly to hold it in place temporarily 5 Set the proper arc gap with the arc gap gage Electrode Clamping Screws Figure 8 Electrode Installation WARNING DO NOT PRESS START WHILE TOUCHING THE ELECTRODE
23. www swagelok com SERIES 20 WELD HEAD gt a sn 1 f h er LJ FFFFFEFFFFFFF HELE UL LL FREE REGRET TT CER EEE EE EH FEER USER S MANUAL WEU TICA ernearen A 1 FIXture BIOCK siccsidnnsanushusainnsinastavesseeteneteiudanantaudionnns 1 Unpacking the Weld Head Components 2 Installing the Weld Head cccccceceeeeeeeeeees 3 Installing the Electrode in the Weld Head 4 Calculating Arc Gap Gage Settings 6 Setting the Arc GAD wraiarcinassnranarssersannenreinnncnretnas 7 Fixturing the WoMK ccccccecceeeeeseeeseeeeeeaeeees 12 Maintenance sinus saccunsesernnsnredteesaereaseceetieveca toate 19 Parts Drawings c2x 6cdciedincdeietcadcheimadesedecieietien 29 OWAN The Swagelok Limited Lifetime Warranty Swagelok hereby warrants to the purchaser of this Product that the non electrical components of the Product shall be free from defects in material and workmanship for the life of the Product All electrical components installed in or on the Product are warranted to be free from defects in material and workmanship for twelve months from the date of purchase The purchaser s remedies shall be limited to replacement and installation of any parts that fail through a defect in material or workmanship MANUFACTURER SPECIFICALLY DISAVOWS ANY OTHER REPRESENTATION EXPRESS OR IMPLIED WARRANTY OR LIABILITY RELATING TO THE CONDITION OF USE OF THE PRODUCT AND IN NO E
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