Micro Series User Manual, (MS-13
Contents
1. A Caution Make sure the fixture latches are closed before attaching the fixture to the micro weld head The electrode can be damaged if the latches are left open during welding Caution Make sure that the purge line or a heavy work piece does not exert a side load force on the fixture This may cause an unacceptable weld damage to the micro weld head or both Latch Spring Captures Button Keepers Figure 19 Placing the Fixture on the Micro Weld Head 2008 Swagelok Company June 2008 Micro Series Operating the Weld Head Operate the weld head using the following parameters Series 4 Shield gas flow rate std ft3 hr 8 to 10 std L min 3 8 to 4 7 Prepurge and Postpurge Continuous minimum time in seconds Start Power U low Low Norm Maximum Recommended 30A Average Amps Series 8 Shield gas flow rate std ft3 hr 15 to 20 std L min 7 1 to 9 4 Prepurge and Postpurge Continuous minimum time in seconds Start Power U low Low Norm 2 Maximum Recommended 38A Average Amps Use U low start power for 0 010 in 0 25 mm wall thickness and an arc gap of 0 020 in 0 51 mm or less Use Low start power for wall thickness less than 0 030 in 0 76 mm and an arc gap of 0 025 in 0 64 mm or less Use Norm start power for wall thickness greater than 0 030 in 0 76 mm and an arc gap of 0 035 in 0 89 mm or less U low power setting only available on M100 Power Supply When wel2. Figure 41 SWS 8MRH B Rigid Weld Head 40 2008 Swagelok Company June 2008 Micro Series Table 12 SWS SMRH B Rigid Weld Head Parts List No Order Quantity 0 i 11506 i i Dowel Pin Included with 11515 N A i 2 i 2 E r r oo NI O O1 R O N ol i E i 7 0 18 Housing Gear Side Bottom 1 E 0 x 0 5 i 5 i 23 Interface Cover Gear Side 1 z 55 1 6 27 28 Interface Assembly Rigid 21242 29 0 3 3 i x 34 0 x i x 7 7 0 6 i For part ordering information contact your Swagelok representative Use Part Number 11521 for the SWS 8MRH A 2 Use Part Number 11522 for the SWS 8MRH A Use Part Number 11516 for the SWS 8MRH A 2008 Swagelok Company A June 2008 Micro Series Figure 42 SWS 8MFA XX Fixture 42 2008 Swagelok Company June 2008 Table 13 SWS SMFA XX Fixture Parts List Micro Series Reference Description Minimum No Order Quantity 1 1 8 in Moveable Side Plate Right 12504 02 1 1 1 4 in Moveable Side Plate Right 12504 04 1 1 3 8 in Moveable Side Plate Right 12504 06 1 1 1 2 in Moveable Side Plate Right 12504 08 1 1 6 mm Moveable Side Plate Right 12504 6MM 1 1 8 mm Moveable Side Plate Right 12504 8MM 1 1 10 mm Moveable Side Plate Right 12504 10MM 1 1 12 mm Moveable Side Plate Right 12504
3. Micro Series 4 Push the micro weld head onto the motor module until Caution it is firmly seated then lock the assembly together Do not force the micro weld with the two side latches See Figure 6 A and head and motor module Figure 6 B together The drive gears of the micro weld head and the motor module must be aligned for the pieces to mate correctly If you have problems mating the components rotate the micro weld head drive gear a small amount and try again See Step 1 on page 5 Figure 6 Connecting Weld Head and Motor Module 2008 Swagelok Company June 2008 Micro Series Electrode Geometry This illustration shows the electrode shape Swagelok suggests Properly ground electrodes provide consistent repeatable welds Pre ground electrodes are available from your Swagelok representative See your parts list for ordering information The electrode part numbers are assigned as follows SWS KAHE HAHA FHF 7 Electrode Package Diameter Designator Material Designator Electrode TIP Diameter C Ceriated Length T Thoriated The ceriated electrode material type is a mixture of 98 Figure 7 Tungsten Electrode 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 Installing Replacing the Electrode The micro we
4. The parts identified in this section include e SWS M MTR B Motor Module e SWS 4MRH B Rigid Weld Head e SWS 4MFH B Flexible Weld Head e SWS 4MFB XX Fixture e SWS 8MRH B Rigid Weld Head e SWS 8MFA XX Fixture 2008 Swagelok Company 31 June 2008 mem Series ss CC Be 5 d 0 1 we Li 4 A mw Co Figure 37 SWS M MTR B Motor Module 32 2008 Swagelok Company June 2008 Micro Series Table 8 SWS M MTR B Motor Module Parts List Reference Description Minimum No Order Quantity i i 2 10 i i 5 10 For part ordering information contact your Swagelok representative 2008 Swagelok Company 33 June 2008 0 9 GA H res O ep O Deg O Figure 38 SWS 4MRH B Rigid Weld Head 2008 Swagelok Company June 2008 Micro Series Table9 SWS 4MRH B Rigid Weld Head Parts List Order Quantity T i 3 i 1 i 5 i e NA 7 i 2 56 x 0 125 in modified i 10 i i 10 12 i 13 Plastic Flat Head Screw 13157 1 4 40 x 0 313 in 15 SS Socket Head Cap Screw 13112 10 4 40 x 0 250 in 4 40 x 0 250 in 7 10 18 Interface Cover Gear Side 1 19 i 20 10 21 Interface Assembly Rigid 21241 1 22 i 23 i 24 i 25 10 26 i 27 i 26 i 29 10 30 i For part ordering information contact your Swagelok representative Use Part Number 11401 A for the CWS 4MRH A 2 Use Part Number 11402 A for the CWS 4MRH A Use Part Number 10456 for the CWS 4MRH A
5. 12MM 1 2 Latch Right 12508 1 3 Split Base Adjustable 12516 1 4 Split Base Fixed 12515 1 5 Button Keeper 13300 10 6 SS Flat Head Screw 4 40 x 0 375 in 13108 10 7 Latch Left 12507 1 8 1 8 in Moveable Side Plate Left 12503 02 1 8 1 4 in Moveable Side Plate Left 12503 04 1 8 3 8 in Moveable Side Plate Left 12503 06 1 8 1 2 in Moveable Side Plate Left 12503 08 1 8 6 mm Moveable Side Plate Left 12503 6MM 1 8 8 mm Moveable Side Plate Left 12503 8MM 1 8 10 mm Moveable Side Plate Left 12503 10MM 1 8 12 mm Moveable Side Plate Left 12503 12MM 1 9 SS Flat Head Screw 00 90 x 0 188 in 13302 10 10 1 8 in Fixed Side Plate Right 12502 02 1 10 1 4 in Fixed Side Plate Right 12502 04 1 10 3 8 in Fixed Side Plate Right 12502 06 1 10 1 2 in Fixed Side Plate Right 12502 08 1 10 6 mm Fixed Side Plate Right 12502 6MM 1 10 8 mm Fixed Side Plate Right 12502 8MM 1 10 10 mm Fixed Side Plate Right 12502 10MM 1 10 12 mm Fixed Side Plate Right 12502 12MM 1 11 Arc Cover Moveable 12506 B 1 12 Arc Cover Fixed 12505 B 1 13 SS Socket Head Cap Screw 4 40 x 0 250 in 13112 10 14 1 8 in Fixed Side Plate Left 12501 02 1 14 1 4 in Fixed Side Plate Left 12501 04 1 14 3 8 in Fixed Side Plate Left 12501 06 1 14 1 2 in Fixed Side Plate Left 12501 08 1 14 6 mm Fixed Side Plate Left 12501 6MM 1 14 8 mm Fixed Side Plate Left 12501 8MM 1 14 10 mm Fixed Side Plate Left 12501 10MM 1 14 12 mm Fixed Side Plate Left 125
6. Extended internal purging assists the WHEN HANDLING cooling process 2008 Swagelok Company 21 June 2008 Micro Series Using the Optional Bench Mounting Bracket Caution The bench mounting brackets attach Series 4 and Series 8 A ER Micro Weld Heads to a workbench There are two Do not put the micro weld mounting plates on the bracket giving you a choice of denen in a vise A mounting orientations amage may result whic would void any Warranty Series 4 Bench Mount Bracket 1 Determine the mounting orientation of the bracket on the workbench See Figure 21 Secure the bracket to the workbench Make sure the latch is accessible 2 Open the latch on the side of the bracket Slide the micro weld head into the bracket from below until the raised detent on the bracket 15 aligned to the recess of the micro weld head body Fasten the latch to secure the micro weld head to the bracket Figure 21 Using the Series 4 Bench Mount Bracket 22 2008 Swagelok Company June 2008 Micro Series Series 8 Bench Mount Bracket 1 Remove one of the button head screws holding the latch bracket to the weld head See Figure 22 A Insert one of the supplied adapter screws 2 Secure the adapter screw with a 1 4 in wrench or the micro fixture tool See Figure 22 B 3 Repeat steps 1 and 2 for the remaining latch bracket screw Verify the latch bracket remains securely attached to the weld
7. alcohol or acetone EE SY AL N c Apply one end of the pre cut tape strip to the inside edge of the underside surface The tape should wrap in the direction shown in Figure 25 d Wrap the tape tightly approximately 1 1 2 turns The tape should end at the outside edge of the top surface Figure 25 Checking Replacing the Insulator Tape 24 2008 Swagelok Company June 2008 Micro Series Micro Weld Head Maintenance DISCONNECT THE WELD Perform micro weld head maintenance daily and every HEAD FROM THE POWER 1200 1500 welds Depending on usage and wear SUPPLY BEFORE maintenance may be performed before the 1200 1500 PERFORMING THE weld interval ADJUSTMENT AND MAINTENANCE PROCEDURES Daily Maintenance 1 Caution At the start of each work day Do not use lubricants inside 1 Inspect the micro weld head for cleanliness Pay close the weld head attention to the rotor area See Figure 26 2 Press HOME Check the rotor for smooth rotation If the rotation is erratic or noisy disassemble the micro weld head and clean the rotor idler gears and brush At the end of each work day 1 Remove dirt carbon and vapor deposits from the weld head with a clean soft cloth and a solvent such as alcohol See Figure 26 2 Store the micro weld head in a clean dry place Figure 26 Inspect Exposed Surfaces of the Weld Head 2008 Swagelok Company 25 June 2008 Micro Series Peri
8. housing may result 2008 Swagelok Company 9 June 2008 Micro Series 4 While holding the micro weld head as shown in Figure 9 A loosen the electrode clamping screw 5 This orientation helps to prevent the electrode from falling out during installation Install a new electrode using tweezers Insert the electrode through the ceramic insulator and into the rotor to its full insertion depth Make sure the sharp tip of the electrode 1s pointing out See Figure 9 B 6 Tighten the clamping screw sufficiently to prevent the electrode from falling out of the rotor Do not over tighten the clamping screw Note Clean the electrode before every weld for optimum performance BA Figure 9 Installing the Electrode 10 2008 Swagelok Company June 2008 Micro Series Calculating Arc Gap Gage Settings To determine the arc gap gage setting for a specific arc gap use the formula below AN A ARC GAP SETTINGS 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 10 Arc Gap Gage Setting Formula Example No 1 Series 4 Weld Head 1 8 to 1 8 in tube butt weld A 0 125 in largest outside diameter Arc gap gage diameter B 0 620 in Desired arc gap C 0 03 in 0 125in an im OO3in 0 4025 in 2 Example No 2 Series 4 Weld Head 6 to 6 mm tube butt weld A 6 00 mm largest outside diameter Arc ga
9. steps See Figure 3 Locate the motor module b 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 1s tight This connection provides the control signals to drive the motor module c 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 motor module d 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 motor module e Insert the motor module 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 2 Press HOME to return the drive coupling to the home position Figure 3 Motor Module Connectors A Caution Ensure that the fixture connector is fully seated in the mating socket and the threaded sleeve is tight Note The motor module shielding gas connector must be a single end shut off SESO Swagelok Quick Connect stem SS QC4 S 400 2008 Swagelok Company June 2008 Mi
10. the home position rs Figure 12 Setting the Arc Gap 2008 Swagelok Company June 2008 Micro Series Fixturing the Work The work pieces must be properly prepared before fixturing 1 Locate the centering gage Turn the gage so the labeled side faces the part to be installed first Insert the gage into the fixture See Figure 13 2 Open the fixture side facing the labeled side of the centering gage by rotating the latch 90 See Figure 14 The fixture opens with a scissors type action Figure 14 shows how to use the micro fixture tool on the Series 4 fixture Figure 13 Inserting Centering Gage Centering Gage Label Towards Part Opening Note Use the micro fixture tool the Fixture for Series 4 and Series 8 Figure 14 Insert First Work Piece 2008 Swagelok Company 15 June 2008 Micro Series Insert the first work piece butting the weld end against the centering gage surface Close and latch that side of the fixture Make sure that the latch is fully closed against the body of the fixture See Figure 15 Remove the centering gage Open the other side of the fixture and insert the second work piece Butt the weld ends together Close and latch that side Check the weld joint for proper fit and alignment See Figure 15 Verify that the latches are fully closed See Figure 15 Series 4 or Figure 16 Series 8 Connect the purge gas line to the work pieces Refer to the Pur
11. 0 020 in 0 025 in 0 030 in 0 035 in 0 51mm 0 64mm 0 77mm 0 89 mm Nominal Arc Gap Arc Gap Arc Gap Arc Gap Arc Gap Arc Gap Arc Gap Arc Gap OD in in in in GE mm mm mm mm 1 8 0 125 0 490 0 495 0 500 12 45 12 57 12 70 N A 3 15 98 1 17 58 Table6 SWS SMRH B Arc Gap Gage Dia 20 65 mm Ea Setting for Setting for Setting for Setting for Nominal OD Actual OD 0 51 mm Arc 0 64mm Arc 0 76mm Arc 0 89 mm Arc om mm Gap mm Gap mm Gap mm Gap mm 14 22 15 22 0 16 22 12 17 22 3 Set the arc gap gage to the value from the table using the provided 3 32 in hex wrench Measure from the bottom of the arc gap gage to the top of the adjustment screw See Figure 11 B 4 Insert the arc gap gage into the micro weld head rotor opening 2008 Swagelok Company 13 June 2008 Micro Series Hold the micro weld head so that the electrode tip is pointing down Loosen the electrode clamping screw to allow the electrode to fall against the arc gap gage See Figure 12 Tighten the electrode clamping screw to hold the electrode in place Do not over tighten Remove the arc gap gage The rotor may move due to the torque of tightening the clamping screw Use your finger to hold the rotor in place Attach it to the motor module Complete the steps in Connecting the Micro Weld Head to the Motor Module beginning on page 5 When complete proceed with step 8 Press HOME to return the rotor to
12. 01 12MM 1 15 SS Shoulder Screw 4 40 13288 10 16 Wave Washer 13291 10 17 SS 6 Washer 13290 10 18 SS Screw 6 32 x 0 240 in 13289 10 For part ordering information contact your Swagelok representative 2008 Swagelok Company June 2008 43 Micro Series 44 2008 Swagelok Company June 2008 Swagelok VCR VCO Ultra Torr Micro Fit TM Swagelok Company 2001 2004 2008 Swagelok Company Printed in U S A OM June 2008 R2 MS 13 207
13. 2008 Swagelok Company 35 June 2008 Micro Series Figure 39 SWS 4MFH B Flexible Weld Head 36 2008 Swagelok Company June 2008 Micro Series Table 10 SWS 4MFH B F lexible Weld Head Parts List Order Quantity i i NA i i 9 i 10 i 1 10 12 3 i 5 10 16 17 i E i E 0 20 10 3 22 Interface Assembly Flex 21240 23 i i NI OO R O PO 24 Drive Coupling Gear 11424 e 25 26 10 27 10 28 29 For part ordering information contact your Swagelok representative Use Part Number 11401 A for the CWS 4MFH A 2 Use Part Number 11402 A for the CWS 4MFH A O Use Part Number 10455 for the CWS 4MFH A 2008 Swagelok Company 37 June 2008 Micro Series Figure 40 SWS 4MFB XX Fixture 38 2008 Swagelok Company June 2008 Micro Series Table II SWS 4MFB XX Fixture Parts List No Order Quantity 2 10 i 1 10 5 10 10 7 10 8 i SWS AMFE MSPL 02 i 8 8 i 8 2 mm Moveable Side Plate Left 1 8 4 mm Moveable Side Plate Left 1 i 9 10 10 10 10 i 10 1 4 in Fixed Side Plate Right SWS 4MFB FSPR 04 1 10 10 i 10 4 mm Fixed Side Plate Right 1 10 11 1 16 in Fixed Side Plate Left 1 1 1 T T 11 3 mm Fixed Side Plate Left 1 T T 12 12 12 12 12 12 12 12 SWS 4MFB MSPR 6MM For part ordering information contact your Swagelok representative 2008 Swagelok Company 39 June 2008 Micro Series
14. RANTY OR LIABILITY RELATING TO THE CONDITION OR USE OF THE PRODUCT ARE SPECIFICALLY DISAVOWED AND IN NO EVENT SHALL SWAGELOK AND ITS AUTHORIZED DISTRIBUTORS BE LIABLE TO PURCHASER OR ANY THIRD PARTY FOR ANY DIRECT OR INDIRECT CONSEQUENTIAL OR INCIDENTAL DAMAGES Micro Series MICRO SERIES The micro weld heads are used to weld work pieces from 1 16 to 1 2 in 3 to 12 mm OD The Series 4 Micro Weld Head can weld work pieces from 1 16 to 1 4 in 3 to 6 mm OD and 15 available in both rigid drive and flexible drive configurations The Series 8 Micro Weld Head can weld work pieces from 1 8 to 1 2 in 5 to 12 mm OD and is available in a rigid drive configuration All micro weld heads operate with a detachable motor module See Figure 1 Series 4 Flexible Drive Series 8 Rigid Drive Motor Module Series 4 Rigid Drive Figure 1 Rigid Drive and Flexible Drive Micro Weld Heads 2008 Swagelok Company 1 June 2008 Micro Series This manual presents information that 1s specific to the micro weld heads Additional handling 1s necessary because the motor module and weld head are separate units The micro weld head fixtures do not use separate collets so fixture setup differs slightly from the Series 5 10 20 fixture block procedures The procedures unless noted are the same for all micro weld heads Most figures in this section show the Series 4 Rigid Drive Micro Weld Head Refer to the Power Sup
15. cro Series Connecting the Micro Weld Head to the Motor Module 1 Using the micro fixture tool turn the weld head drive gear on the base of the micro weld head to align the rotor opening to the weld head housing opening See Figure 4 A and Figure 4 B showing views of the rotor misaligned and in proper alignment The drive gear on the base of the micro weld head must be aligned so that it meshes with the drive pins on the motor module Micro Fixture Tool Figure 4 Rotor Manual Adjustment 2008 Swagelok Company June 2008 Micro Series 2 Locate the shielding gas port on the micro weld head A Caution and verify that the O ring is in place See Figure 5 The micro weld heads should The O ring seals the gas port A valve in the port not be started in any rotor opens the gas flow through the motor module The position except fully homed valve opens when the micro weld head 15 properly See Figure 5 Arc start in any connected to the motor module other location may cause weld head damage A Caution Step Programs should not be used with Series 4 or Series 8 Micro Weld Heads 3 Align the connecting surfaces of the micro weld head and motor module See Figure 5 Caution gt Tack programs or programs that include tacks should not be used with the micro weld heads O ring Mating Connections Figure 5 O ring and Mating Connections 6 2008 Swagelok Company June 2008
16. ding 1 2 in or 12 mm OD with a Series 8 weld head use the single pass one revolution weld procedure only Table 7 Wall Thickness and Arc Gap Material Thickness mm Arc Gap 0 010 to 0 020 0 51 0 021 to 0 030 0 64 0 031 to 0 045 0 76 0 046 to 0 055 0 89 20 A Caution The Series 8 weld head can not be used with 1 2 in ATW fittings 2008 Swagelok Company June 2008 Micro Series Considerations During Welding The approach to welding using the micro weld head 1s Hold Here similar to that used for other Swagelok weld heads Develop a weld procedure guideline as you would for any job The power supply controls and indicators work the same However the unique qualities of the micro weld head and its fixtures cause some noticeable differences during welding e The sound of the weld is slightly louder compared to other Swagelok weld heads This 15 due to the reduced size of the fixture e You may notice a clicking sound during the downslope cycle This is normal The fixture contracts slightly due to heat dissipation producing the sound e Because the fixture is small heat build up may make the device too hot to handle immediately after welding Hold the fixture in the base areas Figure 20 Cooling Plate shown in Figure 20 Use the optional aluminum WARNING cooling plate to hold the fixture and allow it to THE FIXTURE MAY BE HOT cool faster See Figure 20 AFTER WELDING IS COMPLETE USE CAUTION e
17. ectrode clamping screw then remove the electrode and ceramic insert See Figure 29 C 6 Clean the rotor with the provided stainless steel wire brush 7 Clean the ceramic insert with the provided nylon brush 8 Remove and inspect the two idler gears for damage Replace if necessary See Figure 29 D Housing Brush Side 9 Clean the two idler gears with isopropyl alcohol and a soft cloth Figure 29 Removing Series 4 Micro Weld Head Components for Cleaning 2008 Swagelok Company 27 June 2008 Micro Series 10 11 12 13 14 28 See Figure 30 Hold the micro weld head as shown Gently lift the brush from the brush side housing noted in the figure and rotate it outward a few degrees Remove the spring Clean any oxide deposits from the weld head brush with the provided stainless steel wire brush Inspect all other weld head components and clean any that are dirty Blow any loose dirt from the weld head with clean dry low pressure air Reverse steps 2 to 11 to reassemble Note Place the spring into the brush pocket with the ends bending down towards the housing See Figure 31 Note Place the rotor on the brush with the electrode screw facing up See Figure 29 Figure 30 Lifting the Weld Head Brush for Cleaning AA 42 d AN 27 Figure 31 Replacing the Spring A Caution Damage could occur if the plastic screws are overtorqued 2008 Swagelok C
18. ge Gas Delivery System section in the Power Supply manual Open the shut off valve in the purge gas line Set the flow meters according to the weld procedure guideline for both the shielding and internal purge gas The length of time for internal purge before welding depends on the internal volume and length of the work piece to be welded Refer to the Gas Flow Rate Tables in the Power Supply manual Caution When closing the fixture be sure the moving side of the fixture engages into the small groove on the stationary side of the fixture Correct Wrong Figure 15 Checking the Weld Joint and Latch Position Series 4 Fixture Correct Wrong Figure 16 Proper Latch Position Series 8 Fixture 2008 Swagelok Company June 2008 Micro Series Aligning the Work Pieces Series 4 Micro Weld Head Fixture A Open Fixture To align tubing in the Series 4 Micro Weld Head Fixture follow these steps 1 Using the micro fixture tool place the latch in the open position then open the fixture See Figure 17 A 2 Loosen the two alignment screws See Figure 17 A Loosen Screw 3 Insert the tubing See Figure 17 B 4 Close the fixture and latch and then align the tubing See Figure 17 C 5 Tighten the two alignment screws See Figure 17 C Screw Tighten By Screw Tighten Close Screw Latch Figure 17 Aligning the Tubing in the Series 4 Micro Weld Head Fi
19. head 4 Secure the bracket to the workbench 5 Position the weld head so that the exposed ends of the adapter screws slide through the hole m the bracket See Figure 22 C Figure 22 Using the Series 8 Bench Mount Bracket 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 Figure 23 Figure 23 Storing the Thumb Nuts on the Adapter Screws 2008 Swagelok Company 23 June 2008 Micro Series Fixture Block Maintenance Bets EI 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 wire brush included in the micro weld head tool package See Figure 24 2 If applicable check the fixture insulating tape for damage Replace the tape if it 1s loose or torn exposing the metal under it See Figure 25 Clean these To replace the tape SSES a Remove the damaged tape from both sides of Figure 24 Cleaning the Micro the fixture Disassembly of the SWS 8MFA Weld Head Fixtures 08 and SWS 8MFA 12MM may be necessary to assist in replacing the tape Disassemble by riere removing the screws that hold the arc covers Outside Edge S on each side of the fixture Refer to the Part Drawings section of this manual for more 3 detail Clean these 1 2 b Clean the surfaces with
20. ld head tool package includes a screwdriver tweezers and an electrode cleaning tool Use these tools for installing or replacing the electrode 1 Select the proper electrode for the job Table Series 4 Electrode Selection Electrode Electrode Diameter Electrode Part No Component OD Length L D CWS C 040 405 P 1 8 in 0 405 in 0 040 in 1 16 in 10 29 mm 1 02 mm 3mm CWS C 040 325 P 1 4 in 0 325 in 0 040 in 6mm 8 26 mm 1 02 mm Table 2 Series 8 Electrode Selection Electrode Electrode Diameter Electrode Part No Component OD Length L D CWS C 040 405 P 1 4 in 0 405 in 0 040 in 6to8mm 10 29 mm 1 02 mm CWS C 040 325 P 3 8 in 0 325 in 0 040 in 10 mm 8 26 mm 1 02 mm CWS C 040 281 P 1 2 in 0 281 in 0 040 in 12 mm 7 14 mm 1 02 mm 8 2008 Swagelok Company June 2008 Micro Series 2 Disconnect the micro weld head from the A Caution ONE nous Only ceriated tungsten 3 Manually turn the rotor drive gear shown in should be used in the micro Figure 4 until the electrode clamping screw is weld heads The use of other types of tungsten may cause exposed See Figure 8 weld head damage Note Replace the electrode when it shows signs of deterioration Electrode Clamping Screw Figure 8 Electrode Clamping Screw Location A Caution Do not rotate the rotor with the electrode clamping screw loose Damage to the micro weld head
21. odic Maintenance Clean the motor module and weld head after every 1200 1500 welds Motor Module 1 Disconnect the weld head from the motor module 2 Clean the motor module power lug sockets with the provided stainless steel brush See Figure 27 3 Carefully remove any obstructions from the purge port See Figure 27 4 Clean the two power lugs on the weld head with the provided stainless steel wire brush See Figure 28 26 A Caution Do not clamp the motor module in a vise while cleaning Power Lug Sockets 4 0 0 3 Purge Port Figure 27 Cleaning the Power Lug Sockets and the Purge Port Figure 28 Cleaning the Weld Head Power Lugs 2008 Swagelok Company June 2008 Micro Series Series 4 Micro Weld Head Disassembly and Cleaning To disassemble the Series 4 micro weld head for cleaning use the following instructions See 29 30 and 31 for part references A Housing Screws 1 Lay the micro weld head down on a clean dry surface with the model and serial numbers facing up Housing 2 Remove the five screws from the weld head housing Gea ide 7 See Figure 29 A Idler A 3 Rock the gear side body gently to loosen it from the Gears est Electrode rest of the assembly Lift and remove the housing Electrode ER 9 4 Remove the rotor by lifting it clear of the brush side ___Ceramic Insert gi vr housing See Figure 29 B 5 Loosen the el
22. ompany June 2008 Micro Series Series 8 Micro Weld Head Disassembly and Cleaning To disassemble the Series 8 micro weld head for cleaning use the following instructions See Figure 32 and Figure 33 for part references 1 Remove the two screws that secure the latch bracket and remove the bracket from the weld head See Figure 32 8 ey m 37 pw Lay the micro weld head down on a clean dry surface cy Latch Bracket with the model and serial numbers facing up ES Remove the seven screws from the weld head housing See Figure 33 A Rock the gear side housing gently to loosen it from Figure 32 Removing Series 8 Micro Weld the rest of the assembly Lift and remove the housing Head Latch Bracket Remove the rotor by lifting it clear of the brush side housing See Figure 33 B A Housing Screws Loosen the electrode clamping screw then remove the electrode and ceramic insert See Figure 33 C Clean the rotor with the provided stainless steel wire brush o Housing Clean the ceramic insert with the provided Gear Side nylon brush Ceramic Insert 9 ell Screw C Remove and inspect the four idler gears for damage Electrode 7 Replace if necessary See Figure 33 D T 10 Clean the idler gears with isopropyl alcohol and a fin Ea Gears soft cloth Figure 33 Removing Series 8 Micro Weld Head Components for Cleaning 2008 Swagelok Company 29 June 2008 Micro Se
23. p gage diameter B 15 75 mm Desired arc gap C 0 64 mm 6 00 mm RS LE O064mm 11 515 mm 2 2008 Swagelok Company 11 June 2008 Micro Series Setting the Arc Gap The micro weld head also includes an arc gap gage which is required to set the arc gap The gage fits the rotor aperture and adjusts for the desired arc gap 1 Measure the OD of the work to be welded with a caliper or micrometer and record the value See Figure 11 A 2 Locate the OD value in the following table that matches the OD of the work Find the arc gap gage setting listed for that OD and record it Figure 11 Setting Arc Gap Gage 12 2008 Swagelok Company June 2008 Micro Series Table 3 SWS 4MRH B SWS 4MFH B Arc Gap Gage Dia 0 620 in Setting Setting Setting Setting Setting Setting for for for for for for 0 020 in 0 025 in 0 030 in 0 51mm 0 64mm 0 76mm Nominal Arc Gap Arc Gap Arc Gap Arc Gap Arc Gap Arc Gap OD in in in in in mm mm mm 1716 9 44 me 0 125 0308 0398 0403 999 1012 1024 4 17 83 Table4 SWS 4MRH B SWS 4MFH B Arc Gap Gage Dia 15 75 mm Setting for Setting for Setting for Nominal OD Actual OD 0 51 mm Arc 0 64mm Arc 0 76mm Arc mm mm Gap mm Gap mm Gap mm 3 10 04 10 76 6 600 11 41 11 54 11 66 Table 5 SWS SMRH B Arc Gap Gage Dia 0 813 in Setting Setting Setting Setting Setting Setting Setting Setting for for for for for for for for
24. ply manual for information on power supply setup and weld procedure guidelines This manual includes e using the micro fixture tool e installing the motor module e connecting the micro weld head to the motor module e installing replacing the electrode e electrode geometry e calculating the arc gap gage settings e setting the arc gap e fixturing the work e connecting the micro weld head to the fixture e considerations during welding e using the optional bench mounting bracket e fixture block maintenance e micro weld head maintenance e parts drawings 2008 Swagelok Company June 2008 Micro Series Using the Micro Fixture Tool Each micro weld head includes a micro fixture tool See Figure 2 The primary purpose of the tool 15 to latch and unlatch the fixtures In addition the tool can be used for 2 the following 3 Tabs to engage the Rotor Drive Gear Wrench Opening for Bench Mount Bracket Adapter Screws e aligning the micro weld head rotor Hole e attaching the optional bench mount bracket Series 8 only The micro fixture tool has a hole that allows the tool to be Slots Used io Open and Close Fixtures secured to a key chain Figure 2 Micro Fixture Tool 2008 Swagelok Company June 2008 Micro Series Installing the Motor Module 1 To connect the motor module to the power supply connect the four connectors to the rear panel of the power supply by performing the following
25. ries 11 Replace the idler gears in the micro weld head Conect idler Gear Placement housing Verify the idler gear axles are pressed into Pressed Fully into Body Incorrect the body See Figure 34 12 Clean any oxide deposits from the exposed surface of OI the weld head brush with the provided stainless steel Saal Se wire brush si _ 13 Verify that the spring is positioned with the ends pointing up in the housing pocket and 15 completely covered by the brush See Figure 35 and 36 If necessary reposition the spring under the weld head brush Figure 34 Correct Placement of Idler 14 Inspect all other weld head components and clean any Gears in Micro Weld Head Housing that are dirty Blow any loose dirt from the weld head Caution with clean dry low pressure air A Damage could occur if the 15 Reverse steps 1 through 6 to complete reassembly gears are not seated properly or the plastic screws are overtorqued ls a ee ech Figure 35 Spring Orientation Correct Position Incorrect Position Spring Covered by Brush Spring Exposed Under Brush Figure 36 Spring Position 30 2008 Swagelok Company June 2008 Micro Series Parts Drawings This section includes exploded assembly drawings and associated parts lists These drawings are provided as a guide to identifying part names For specific part ordering information contact your Swagelok representative
26. www swagelok com MICRO SERIES i P Ai f Ap BL 0 i E A ee D 5 EEE FF i Ll gd 1 1 LA 1 BAN USER S MANUAL Using the Micro Fixture Tool 3 Installing the Motor Module 4 Connecting the Micro Weld Head to the Ville rel 1747970 0 ice te 0 a 5 Electrode Geometry 8 Installing Replacing the Elechrode 8 Calculating Arc Gap Gage Settings 11 Setting the Arc Gap 12 sen 15 Aligning the Work PieceS 17 Connecting the Micro Weld Head LO NE PDO er eee ee 19 Fixture Block Mamtenance 24 Micro Weld Head Maintenance 25 PARIS Drawing S Se 31 ONNO The Swagelok Limited Lifetime Warranty Swagelok and its authorized distributors hereby warrant to the purchaser of their Products that the non electrical components shall be free from defects in material and workmanship for the life of the Products 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 All customer specified components carry the applicable manufacturer s warranty ALL OTHER REPRESENTATIONS EXPRESS OR IMPLIED WAR
27. xture 2008 Swagelok Company 17 June 2008 Micro Series 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 then open the fixture See Figure 18 A 2 Loosen the two alignment screws See Figure 18 A 3 Insert the tubing See Figure 18 B 4 Close the fixture and latch and then align the tubing See Figure 18 C 5 Tighten the two alignment screws See Figure 18 C Insert Tube Close Fixture Tighten Screws 2 Figure 18 Aligning the Tubing in the Series 8 Micro Weld Head Fixture 18 2008 Swagelok Company June 2008 Micro Series Connecting the Micro Weld Head to the Fixture 1 Place the fixture on the micro weld head e On the Series 4 Micro Weld Head make sure the fixture 15 firmly seated Rotate the locking lever 90 to secure the fixture to the micro weld head See Figure 19 A e On the Series 8 Micro Weld Head engage the two latch springs over the button keepers on the sides of the fixture and close the latch levers See Figure 19 B The micro weld head assembly and the work are ready for welding 2 Press PURGE to begin the shielding gas flow The shielding gas should remain on at all times when using the micro weld head 3 Program the power supply and perform the weld using the parameters in Operating the Weld Head on page 20
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