Swagelok Weld Head Series 20 ユーザーマニュアル

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ユーザーマニュアル
www.swagelok.com
Series 20
Weld Head
User’s Manual
English. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Japanese . . . . . . . . . . . . . . . . . . . . . . . . . 45
ii Series 20 Weld Head User’s Manual
www.swagelok.com
Weld Head
Users Manual
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2 Series 20 Weld Head User’s Manual
Contents
Weld Head. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Fixture Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Unpacking the Weld Head Components . . . . . . . . . . . . . . 4
Installing the Weld Head. . . . . . . . . . . . . . . . . . . . . . . 5
Installing the Electrode in the Weld Head . . . . . . . . . . . . . 6
Electrode Geometry . . . . . . . . . . . . . . . . . . . . . . . . . 7
Calculating Arc Gap Gage Settings . . . . . . . . . . . . . . . . 8
Setting the Arc Gap . . . . . . . . . . . . . . . . . . . . . . . . . 9
Setting the Arc Gap Gage . . . . . . . . . . . . . . . . . . . . . . 9
Inserting the Electrode into a Rotor . . . . . . . . . . . . . . . . 11
Setting the Arc Gap . . . . . . . . . . . . . . . . . . . . . . . . . 12
Preparing the Work . . . . . . . . . . . . . . . . . . . . . . . . . 13
Fixturing the Work . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Parts Drawings . . . . . . . . . . . . . . . . . . . . . . . . . . . .29
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Series 20 Weld Head User’s Manual 3
Weld Head
The Series 20 SWS weld head delivers consistent, precise welds for
outside tubing diameters from 1/2 to 2 in. and 12 to 52 mm and pipe
diameters ranging from 1/4 to 1 1/4 in. and 10.2 to 48.3 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.
A spring-loaded, oating brush continuously contacts approximately
one-third of the circumference of the rotor. This conguration ensures
consistent, uniform electrical conductance to the rotor and electrode.
Fixture Block
The Series 20 SWS xture block accurately aligns and holds tubing,
ttings, and valve bodies. The modular design allows you to select
different side plates and create the conguration needed for the job.
The xture block is separate from the weld head, allowing work pieces
to be easily aligned and xtured before welding. Using multiple xture
blocks can increase productivity.
Each xture block is designed to accommodate a range of work
piece sizes. A Universal Collet Insert (UCI) ts into the xture block to
match the diameter of the work piece. The collet design rmly holds
tubing and ttings that vary ±0.005in. (0,13mm) from nominal outside
diameter. Collets are also available for thin wall pipe. The collets
exchange quickly, making thexture block very adaptable to changing
work requirements.
Figure 1 Series 20 Weld Head
Figure 2 Series 20 Fixture Block
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4 Series 20 Weld Head User’s Manual
Unpacking the Weld Head Components
The following weld head components are packaged in a foam-lined
shipping container:
• weldhead
• arcgapgage
• electrodepackage
• toolpackage
Perform the following steps when your Swagelok Series 20 Weld Head
arrives:
1. Inspect the container for damage.
2. Remove the components from the container.
3. Check the items for any damage.
4. Verify that the weld head serial number matches the serial number
on the shipping container.
5. Record the model and serial numbers, and the delivery dates on
the Registration Information page of your power supply user’s
manual.
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Series 20 Weld Head User’s Manual 5
Installing the Weld Head
The weld head has four connectors that plug into the power supply.
The four connectors on the cable are:
• weldhead
• electrode(red)
• work(green)
• weldheadshieldinggas
Connect the four connectors to the side panel of the power supply by
performing the following steps (see Figure 4):
1. Locate the weld head.
2. Align the notch on the one-quarter turn connector with the small
tab in the mating socket on the side panel labeled WELD HEAD.
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 side
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 side 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 rmly attached. This connection provides shielding
gas to the weld head through a mass ow controller (MFC) in the
power supply.
Figure 4 Weld Head Connectors
Caution!
Ensure that the weld head
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).
Figure 3 Weld Head
Weld Head Electrode
Work
Weld Head
Shielding Gas
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6 Series 20 Weld Head User’s Manual
Installing the Electrode in the Weld 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 model
and the outside diameter of the work piece being welded.
To select the correct electrode use the Electrode Selection Table.
Table 1 Electrode Selection Table
Electrode
Ordering Noumber
Component
OD Pipe
Electrode Length
L
Electrode
Diameter
D
CWS-C.062-1.630-P
1/2 in.
3/4 in.
12 mm
18 mm
22 mm
1/4
1/2
3/8
1.630 in.
(41,40 mm)
0.062 in.
(1,57 mm)
CWS-C.062-1.380-P
1 in.
1 1/4 in.
23 mm
25 mm
28 mm
35 mm
3/4
1
1.380 in.
(35,05 mm)
0.062 in.
(1, 57 mm)
CWS-C.062-1.105-P 1 1/2 in.
35 mm
1.105 in.
(28,07 mm)
0.062 in.
(1,57 mm)
CWS-C.062-.855-P
1 3/4 in.
2 in.
35 mm
40 mm
52 mm
1 1/4
1 1/2
0.855 in.
(21,72 mm)
0.062 in.
(1,57 mm)
Figure 5 Electrode Dimensions
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Series 20 Weld Head User’s Manual 7
Electrode Geometry
This illustration shows the electrode shape Swagelok suggests.
Properly ground electrodes provide consistent, repeatable welds.
Pre-ground electrodes are available from your Swagelok
representative. See your parts list for ordering information.
The electrode part numbers are assigned as follows:
CWS X.### - #.### - P
The ceriated electrode material type is a mixture of 98 % tungsten
and 2 % cerium and is commonly referred to as “2% ceriated.” This
electrode type has demonstrated improved arc starting performance
over the 2 % thoriated type, particularly when using puried shielding
gas.
Figure 6 Tungsten Electrode
Material Designator
C = Ceriated
Package
Designator
Electrode
Diameter
Electrode
Length
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8 Series 20 Weld Head User’s Manual
Figure 7 Arc Gap Gage Setting Formula
Calculating Arc Gap Gage Settings
To determine the arc gap gage setting for a specic arc gap, use the
formula below.
Where
A = largest OD on the weld end of the tubing or fitting (welding diameter).
B = Arc gap gage diameter
C = desired arc gap
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.
1.000 in. + 3.118 + 0.025 in. = 2.084 in.
2 2
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
25,00 mm + 79,20 + 0,50 mm = 52,60 mm
2 2
A B C
Arc Gap
Gauge
Setting
A + B + C =
2 2
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Series 20 Weld Head User’s Manual 9
Figure 8 Setting the Arc Gap Gage
Setting the Arc Gap
The proper arc gap setting facilitates control of the weld and improves
consistency. The following steps cover how to set the arc gap.
The arc gap is set by using the arc gap gage provided with the weld
head. The gage is adjusted for the desired arc gap and then installed
in the rotor. 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 8(A). The M200 will
calculate the arc gap gage setting automatically when using the
Auto Create feature.
2. Refer to the tables on page 10 for your nominal OD. Find the
“actual” outside diameter nearest to your measurement.
3. Adjust the arc gap gage to match the setting from the tables on
page 10. See Figure 8(B).
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10 Series 20 Weld Head User’s Manual
Table 2 SWS-20H Arc Gap Gage Dia. 3.118 in.
Nominal
OD
in.
Actual
OD
in.
Setting
for
0.030in.
Arc Gap
in.
Setting
for
0.040in.
Arc Gap
in.
Setting
for
0.050in.
Arc Gap
in.
Setting
for
0.060in.
Arc Gap
in.
Setting
for
0.070in.
Arc Gap
in.
Setting
for
0,5mm
Arc Gap
mm
Setting
for
0,64mm
Arc Gap
mm
Setting
for
0,76mm
Arc Gap
mm
Setting
for
1,02mm
Arc Gap
mm
Setting
for
1,14mm
Arc Gap
mm
1/2 .500 1.839 1.849 1.859 1.869 1.879 46,45 46,59 46,97 46,97 47,09
3/4 .750 1.964 1.974 1.984 1.994 2.004 49,63 49,77 49,89 50,15 50,27
1 1.000 2.089 2.099 2.109 2.119 2.129 52,80 52,94 53,06 53,32 53,44
1 1/4 1.250 2.214 2.224 2.234 2.244 2.254 55,98 56,12 56,24 56,50 56,62
1 1/2 1.500 2.339 2.349 2.359 2.369 2.379 59,15 59,29 59,41 59,67 59,79
2 2.000 2.589 2.599 2.609 2.619 2.629 65,50 65,64 65,76 66,02 66,14
Table 3 SWS-20H Arc Gap Gage Dia. 79,20 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
1,02 mm
Arc Gap
mm
Setting for
1,14 mm
Arc Gap
mm
12 12,00 46,12 46,26 46,38 46,64 46,76
18 18,00 49,12 49,26 49,38 49,64 49,76
22 22,00 51,12 51,26 51,38 51,64 51,76
23 23,00 51,62 51,76 51,38 51,64 51,76
25 25,00 52,62 52,76 52,88 53,14 53,26
28 28,00 54,12 54,26 54,38 54,64 54,76
35 35,00 57,62 57,76 57,88 58,14 58,26
52 52,00 66,12 66,26 66,38 66,64 66,76
Table 4 SWS-20H Pipe Arc Gap Gage Settings (standard)
Pipe Size
in.
Actual OD
in.
Setting for
0.030 in.
Arc Gap
Setting for
0.040 in.
Arc Gap
Setting for
0.050 in.
Arc Gap
Setting for
0.060 in.
Arc Gap
Setting for
0.070 in.
Arc Gap
1/4 0.54 1.859 1.869 1.879 1.889 1.899
3/8 0.675 1.927 1.937 1.947 1.957 1.967
1/2 0.84 2.009 2.019 2.029 2.039 2.049
3/4 1.05 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 1.66 2.419 2.429 2.439 2.449 2.459
1 1/2 1.9 2.539 2.549 2.559 2.569 2.579
Table 5 SWS-20H Pipe Arc Gap Gage Settings (metric)
Pipe Size
mm
Actual OD
mm
Setting for
0,76 mm.
Arc Gap
Setting for
1,02 mm.
Arc Gap
Setting for
1,27 mm.
Arc Gap
Setting for
1,52 mm.
Arc Gap
Setting for
1,78 mm.
Arc Gap
10,2 10,2 45,46 45,72 45,97 46,22 46,48
13,5 13,5 47,11 47,37 47,62 47,87 48,13
17,2 17,2 48,96 49,22 49,47 49,72 49,98
18,9 18,9 49,81 50,07 50,32 50,57 50,83
21,3 21,3 51,01 51,27 51,52 51,77 52,03
26,9 26,9 53,81 54,07 54,32 54,57 54,83
33,7 33,7 57,21 57,47 57,72 57,97 58,23
42,4 42,4 61,56 61,82 62,07 62,32 62,58
48,3 48,3 64,51 64,77 65,02 65,27 65,53
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Series 20 Weld Head User’s Manual 11
Inserting the Electrode into a Rotor
1. Without the xture block attached, press ELECTRODE CHANGE
on the operator panel. The electrode will move to the position
shown in Figure 9.
2. Loosen the two electrode clamping screws. If you are replacing the
electrode, remove the electrode.
3. Insert the new electrode, with the sharp tip pointing out. Tighten
the electrode clamping screws slightly to hold it in place
temporarily.
4. Set the proper arc gap with the arc gap gage.
Caution!
Do not jog or move the rotor unless
the electrode is clamped in place.
Figure 9 Electrode Installation
WARNING!
DO NOT PRESS START WHILE
TOUCHING THE ELECTRODE.
Caution!
The rotor will move when
ELECTRODE CHANGE is pressed.
The rotor is a potential pinch point.
Electrode Clamping Screws
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12 Series 20 Weld Head Users Manual
Setting the Arc Gap
1. Use JOG or ELECTRODE CHANGE 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 10(A).
3. Tilt the weld head upward. Loosen the electrode screw allowing
the electrode to drop onto the gage surface. See Figure 10(B).
4. Tighten the electrode clamping screws just enough to secure the
electrode. Remove the arc gap gage.
5. Press HOME or ELECTRODE CHANGE to return the rotor to the
home position.
Figure 10 Setting the Arc Gap
Caution!
Do not jog or move the rotor unless
the electrode is clamped in place.
Caution!
The rotor will move when
ELECTRODE CHANGE is pressed.
The rotor is a potential pinch point.
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Series 20 Weld Head User’s Manual 13
Preparing the Work
It is important to prepare the tube pieces properly before welding.
Refer to Figure 11.
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:
• Tubeendsmustbesquare.
• Tubeendsmustnothaveawallthicknessvariationexceeding±
15 % of nominal.
• Tubeendsmustbeburr-free.
• Tubeendsmustbefreeofanyrust,grease,oil,paint,orother
surface contaminates.
Figure 11 Tube Preparation
Square Corners No Gaps
Method Result
Burrs Burrs in Flow Path
Burrs
End Rolled by Cutter
Blade and Roller
Irregular Tube
Diameter
Face Perpendicular
to Axis
Smooth Transition at
Wall Faces
Reduced Flow Area
Gap
Hacksaw Cut
Tube Cutter
Tube Facing Tool
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14 Series 20 Weld Head User’s Manual
Fixturing the Work
Select or congure the appropriate xture block. Select the collets to
match the work outside diameter.
Selecting the Fixture Block and Collets
1. Select the xture block that accepts the outside diameter of the
tube to be welded. Refer to Table 6.
Table 6 Fixture Blocks
Model OD Capacity
Minimum Weld
Extension Length
SWS-20TFB-A 1/2 to 2 in.
(12 to 52 mm)
1.45 in.
(36,83 mm)
SWS-20FSP1L or
SWS-20FSP1R
1/2 to 2 in.
(12 to 52 mm)
0.80 in.
(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 Capacity Comments
CWS-20UCI-X 1/2 in. to 2 in.
(12 mm to 48.3 mm) Tubing / tube fittings
CWS-20UCI-XP 1/4 to 1 1/2
Pipe
Add J suffix for JIS pipe
(-XPJ)
Add MMP suffix for metric
pipe (-XMMP)
SWS-20UCI-XTN 1/2 in. to 2 in.
(12 mm to 52 mm)
Tubular weld fitting 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 identies the collet size in 1/16ths or metric (MM sufx)
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Series 20 Weld Head User’s Manual 15
Figure 12 Opening the Fixture Block
Installing the Collets in a Tube Fixture Block
1. Release both levers and open the tube xture block. See Figure
12.
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16 Series 20 Weld Head User’s Manual
2. Install the collet halves in both the top and bottom side plates and
tighten the collet screws. Make sure the collet shoulder is ush
against the xture side plate. See Figure 13.
Figure 13 Installing Collets
Fixture Side
Plate
Collet Shoulder
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Series 20 Weld Head User’s Manual 17
Aligning the Work Pieces in the Tube Fixture
Block
1. Place the centering gage in one side of the tube xture 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 14.
2. Butt one work piece against the centering gage. See Figure15(A).
3. Lock down the top side plate. See Figure 15(B).
4. Remove the centering gage.
Figure 14 Place the Centering Gage
Figure 15 Placing First Work Piece in the Fixture Block
Note:
When welding a Swagelok ATW fitting to
tubing, butt the tubing against the centering
gage first.
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18 Series 20 Weld Head Users Manual
5. Butt the second work piece against the rst work piece, and lock
down the top side plate. See Figure 16.
6. Inspect 360° around the weld joint for t and alignment. If the
alignment is not correct proceed to the next section.
Adjusting the Tube-to-Tube Fixture Block
In order to maintain precise alignment of the work pieces in the xture
block, the side plates must be periodically aligned.
To align the xture block, follow these steps:
1. Turn the xture block over and locate the directional arrows on the
plenum. The arrows point to the appropriate side plate. See Figure
17.
2. Loosen the two alignment knobs just enough to loosen the side
plate from the plenum. See Figure 17.
3. Turn the xture block upright and release both levers and open
both sides of the xture block.
4. Place a straight length of tubing (minimum length 1.50 in [38,1 mm])
in the collets such that it rests across both side plates.
5. Close and lock the side plate that is not adjustable. See Figure 18.
6. Lock down the top of the loosened side plate.
7. Tighten the alignment knobs. Take care to tighten the knobs evenly
to prevent the side plate from slipping.
8. Open the side plates and remove the tubing.
Figure 16 Placing Second Work Piece
Figure 18 Placing the Tubing
Figure 17 Loosening the Side Plate
Plenum
Directional
Arrows
Alignment
Knobs
Side Plate
Levers
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Swagelok Weld Head Series 20 ユーザーマニュアル

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