Swagelok M100 Series User manual

SWS M100 Power Supply Components
©1999 Swagelok Company, all rights reserved 1
August 2001
M100
POWER SUPPLY COMPONENTS
The power supply features microcontroller electronics and
closed-loop circuitry to precisely control output current.
The software is accessible using the M100 operator display
and keypad or the remote keypad. The data recording
printer prints program information as well as welded
outputs. The PC card may be used to store weld data and
transfer data to a PC for QA/QC records.
Figure 1 Power Supply
The power supply uses screen-prompted software for weld
parameter control. See Figure 2. The appropriate settings
are generally defined by the work pieces to be welded and
are refined using test welds. The correct settings used for a
specific job are developed into a weld procedure guideline.
The guideline is used to maintain repeatability and quality
control for subsequent jobs of the same type.
Figure 2 Power Supply Operator
Display and Keypad
M100 POWER SUPPLY

M100 Power Supply
2 ©1999 Swagelok Company, all rights reserved
August 2001
Installation
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 Weld Head
Electrode Package Yes Weld Head
Arc Gap Gage Yes Weld Head
Flat Blade Screw Driver Yes Weld Head
Centering Gage Yes Fixture Block
Quick-Connect Stem Yes Power Supply
Secondary Solenoid Bypass Plug Yes Power Supply
Dial/Digital Calipers or Micrometer No -
Purge Connector(s) No -
Shielding/Purge Gas Lines ①No -
Shielding/Purge gas Source②No -
Pressure Regulator No -
Internal Purge Gas Flow Meter No -
Shielding Gas Flow Meter No -
Internal Pressure Gage No -
①All lines used for shielding/purge gas should be the low moisture
absorption type.
②A compressed gas bottle or liquid Dewar source can be used. Argon
is the gas most frequently used.
Note:
The Series 40 weld head does not
include an arc gap gage, centering
gage, or electrode package.
Electrical Requirements
Table 1 Power Supply Electrical Requirements
Power Supply
Model
Voltage
Requirement
Service Current
SWS-M100-1 115 V*(ac) 20 A
SWS-M100-2 230 V (ac) 15 A
* If the input voltage is 100 V or less, the output power capabilities
may be reduced.
Follow the electrical system guidelines below for power
supply installation.
• All wiring and related components must be
installed according to local code and National
Electrical Code.
• The power supply must be grounded.
• A dedicated electrical circuit may be desired due
to current need.
WARNING!
THE POWER SUPPLY MUST
BE GROUNDED. IF IT IS NOT
GROUNDED, ELECTRICAL
SHOCK CAN OCCUR.

M100 Power Supply
©1999 Swagelok Company, all rights reserved 3
August 2001
Using an Extension Cord
If it is necessary to use an extension cord, follow the
guidelines below.
• Use only extension cords that meet the
specifications indicated in Table 29.
• Extension cords longer than 100 ft (30m) are
not recommended.
Caution!
The voltage drop in an
extension cord 100 ft long
may affect the output
performance of the SWS.
Unpacking the Power Supply
The SWS power supply is packaged in a plastic shipping
container. The power supply part number and serial
number are located on a label on the outside of
the container.
Table 2 Shipping Container Contents
Part Description Part No. Qty.
Welder Power Supply SWS-M100-* 1
Power Cord CWS-CORD-* 1
1/4 in. Male Quick-Connect SS-QC4-S-400 1
Secondary Solenoid Bypass
Plug
- 1
Swagelok Welding System
User’s Manual
SWS-MANUAL-M100-** 1
PC Memory Card SWS-PCCARD-1MB 1
PC Interface Cable SWS-PC-CABLE 1
* Denotes Model
** Denotes Language
Note:
Keep the shipping container for
storing and/or shipping.
Remove the contents of the shipping container by
performing the following steps:
1. Remove the following items:
• Swagelok Welding System User’s Manual
• Swagelok Quick-Connect stem
• Secondary solenoid bypass plug
• Power Cord
• PC Memory card
• PC interface cable
2. Remove the power supply by lifting it by the handle.
Place the power supply on a stable cart, platform,
or table.

M100 Power Supply
4 ©1999 Swagelok Company, all rights reserved
August 2001
3. Check the power supply and accessories for damage.
Check that a roll of thermal printing paper is installed
in the data-recording printer.
4. Check that the serial number on the rear panel of the
power supply matches the serial number on the
shipping container label.
5. Record the model number, serial number, and the
delivery date on the Registration Information page in
the Regulatory Module.
Installing the Power Supply
To get the maximum performance and reliability from
your SWS, it must be set up and installed properly.
To install the power supply, follow these steps:
1. Position the power supply so that the front and rear
panel controls are easily accessible.
2. Locate the power cord. Insert the cord into the
polarized receptacle on the rear of the power supply.
See Figure 3.
3. Tighten the connector lock at the base of the
receptacle to secure the cord in the receptacle.
4. Ensure that the power cord reaches an electrical outlet.
Do not connect the power cord to the outlet at
this time.
Figure 3 Insert the Power Cord Here

M100 Power Supply
©1999 Swagelok Company, all rights reserved 5
August 2001
5. Turn off the power supply circuit breaker on the rear
panel of the unit. See Figure 4.
Figure 4 Turn Off Circuit Breaker
Installing the Weld Head
The weld head assembly has four connectors that plug
into the power supply. See Figure 5.
The four connectors on the cable are:
• Fixture
• Electrode (red)
• Work (green)
• Weld head shielding gas.
Figure 5 Weld Head Assembly
Fixture Electrode
Work
Weld Head
Shielding Gas

M100 Power Supply
6 ©1999 Swagelok Company, all rights reserved
August 2001
Connect the four connectors to the rear panel of the power
supply by performing the following steps (see Figure 6):
1. Locate the weld head assembly.
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.
Figure 6 Weld Head Connectors
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).

M100 Power Supply
©1999 Swagelok Company, all rights reserved 7
August 2001
Installing the Gas Delivery
System
The gas delivery system provides shielding gas to the
weld head to reduce oxidation or contamination of the
weld puddle, tungsten electrode, and
Heat Affected Zone (HAZ).
There are two types of gas delivery systems commonly
used. For a typical gas delivery system, refer to the
installation procedure beginning on this page.
For a gas delivery system using a secondary shielding gas
solenoid valve, see Optional Gas Delivery System
beginning on page 9.
Typical Shielding/Purge Gas Delivery
System
Figure 7 shows a typical system. Be sure to adhere to the
following precautions:
• Ensure that the gas storage container(s) are
secured before using them.
• Ensure all connections are tight and do not leak.
• Use only a Swagelok single-ended shut-off
Quick-Connect stem on the shield/purge line for
the shielding gas connector.
• Adjust the low-pressure regulator gage to reduce
the gas storage container source pressure to 25 to
50 psig (1,9 to 3,5 bar).
When complete, continue to the Preliminary Check
procedure beginning on page 11.

M100 Power Supply
8 ©1999 Swagelok Company, all rights reserved
August 2001
Figure 7 Typical Gas Delivery System
Flow Meter for
Internal Purge Gas
(Range 0 to 30 Ft3/h)
(Range 0 to 1.02 m3/h)
2-sta
g
e Re
g
ulato
r
Internal Purge Gas
Shut-Off Valve
Low Pressure Gage
(0 to150 psig)
(0 to 10.3 Bar)
Flow Meter for Shielding
Gas (Range 0 to 50 ft3/lh)
(Range 0 to 1.70 m3/h)
High Pressure Gage
(0 to 3000 psig)
(0 to 206.8 Bar)
Supply Manifold
Shielding Gas
Supply Inlet
SWS Power Supply
Purge Fitting
(Swagelok Union or Reducing Union
with Nylon Ferrules or Ultra-Torr® for
Purge Gas Restriction
Tubing to be Welded
Inert
Gas Cylinder
SWS Fixture Block
Purge Fitting
(Swagelok Union or
Reducing Union with Nylon
Ferrules or Ultra Torr®)

M100 Power Supply
©1999 Swagelok Company, all rights reserved 9
August 2001
Optional Gas Delivery System
The optional gas delivery system is generally used in Ultra
High Purity (UHP) gas sytems where quick connects are not
permitted. This type of system uses an external 12 V (dc)
secondary solenoid valve instead of using the solenoid valve
located inside the power supply. If necessary, the secondary
solenoid valve may be the high purity type.
A secondary solenoid bypass plug is inserted in the EXT
GAS CONTROL connector on the rear panel to disable the
solenoid inside the power supply and provide +12V to
control the secondary solenoid.
For the gas delivery system using a secondary shielding gas
solenoid valve, locate the:
• Secondary solenoid bypass plug
• Secondary shielding gas solenoid valve
• 1/4-turn internal purge gas shut-off valve.
Referring to Figure 8, install the optional gas delivery
system. Be sure to adhere to the following precautions:
• Ensure that the gas storage container(s) are secured
before using them.
• Ensure all connections are tight and do not leak.
• Observe correct polarity on the secondary solenoid
bypass plug.
• Adjust the low pressure regulator gage to reduce the
gas storage container source pressure to 25 to 50 psig
(1,9 to 3,5 bar).
Caution!
Do not insert the secondary
solenoid bypass plug into the
connector unless you are
using a secondary solenoid.
Inserting the plug disables
the power supply solenoid.

M100 Power Supply
10 ©1999 Swagelok Company, all rights reserved
August 2001
Figure 8 Optional Gas Delivery System
Inert Gas
Cylinder
Internal Purge
Gas Flow Meter
Weld Head
Internal Purge Gas
Shut-Off Valve
Secondary Solenoid
Bypass Plug
Secondary
Shielding Gas
Solenoid Valve
SWS Power Supply
SWS Fixture Block
2-stage Regulator
Shielding Gas
Flow Meter
Secondary Solenoid
Bypass Plug
Supply
Manifold
+
+
–
–

M100 Power Supply
©1999 Swagelok Company, all rights reserved 11
August 2001
Preliminary Check
Before placing the SWS into operation, you should make
some preliminary checks to verify the power supply is
operating correctly.
To check the system, follow these steps:
1. Connect the power supply power cord to an appropriate
electrical outlet.
2. Turn on the power supply circuit breaker.
3. At this point, an owner password, which can be up to 11
characters in length, is requested. You must enter a
password to continue.
• The programmer or the welding user does not need
the owner password. Discrete passwords are available
for these users.
• The owner of the welding system should consider the
owner password a “master key” and protect it as such.
Figure 9 Password Requested
4. Position the weld head so that the rotor can be easily
seen. See Figure 10. Do not have the fixture block
attached to the weld head.
Figure 10 Postitioning the Weld Head
to View the Rotor Rotation
Roto
r

M100 Power Supply
12 ©1999 Swagelok Company, all rights reserved
August 2001
5. Press WELD, then JOG on the operator keypad to return the
rotor to its home position.
6. Turn off the power supply.
7. If problems occur, refer to the Troubleshooting manual
for a list of possible causes and corrective actions.
Figure 11 Checking the Rotor Rotation
Operation
This section describes the basic operation of the Swagelok
Welding System (SWS). This section covers:
• Front panel controls
• M100 modes of operation and functions
• Entering the weld parameters
• Setting the shield gas flow
• Starting and completing the weld
• Using the data recording printer
• Using the PC memory card
The welding process described in this section uses a weld
procedure guideline for tubing with a 1/2 in. OD and
0.049 in. wall thickness. A weld procedure guideline is a list
of weld parameter settings for a particular job. Keep in mind
that the weld parameters listed in this section are for
demonstration purposes and may not produce an optimum
weld. Weld Parameter Development describes how to
optimize welding parameters.

M100 Power Supply
©1999 Swagelok Company, all rights reserved 13
August 2001
Front Panel Controls
Figure 12 Front Panel Controls
The operator interface on the front panel of the
power supply includes a keypad and the operator
display. The keypad provides a means of entering
information needed to operate the M100. The
operator display allows you to monitor the
welding process and to perform programming and
file operations.
A remote pendant can also be used to operate the
unit. It has a keypad and a display.
Operator Remote
Display
Operator Remote
Ke
yp
ad
Operato
r
Dis
p
la
y
Operator Keypad
Data Recording Printe
r
PC Memory Card Slot
Remote Plug
POWER SUPPLY
REMOTE PENDANT

M100 Power Supply
14 ©1999 Swagelok Company, all rights reserved
August 2001
A Swagelok PC memory card is a flash memory device
designed for use with the M100. No other memory card
may be used in its place.
The PC memory card has a Write Protect Switch. When the switch
is on, the card will read only. The M100 will prompt you if the
switch is on and you attempt to write or delete.
The PC memory card has three (3) basic functions:
1. Weld procedures may be stored outside the internal memory of
the unit on the PC memory card. The procedures may be re-
installed into the internal memory of any M100 or used
directly from the card.
2. Weld data logs may be stored on the PC memory card as they
are made or downloaded from the internal memory to the card
for transfer to a PC.
3. Front Panel application software may be loaded into the M100
using the PC memory card.

M100 Power Supply
©1999 Swagelok Company, all rights reserved 15
August 2001
Operator Display
WLD view
adj
TEST1
W:
READY 000
tst
inf
Figure 13 Operator Display
Tube or
Pipe OD
Wall
Thickness Material Number
of Levels
Number
of Tacks
Mode
Step, Invalid,
or ATW
Procedure
Submode Menu
Active Procedure
Generated
Description
Active
Parameters
Status Indicators
Warnings/Errors
Active Key Indicators
/
Prompt Line
Weld Counte
r
REMOTE PENDAN
T
Submode Menu
(capital letters indicate
active submode)
Active Procedure
Warning/Errors
Status Indicators
Weld Counte
r
POWER SUPPLY

M100 Power Supply
16 ©1999 Swagelok Company, all rights reserved
August 2001
The operator display shows information about the current
mode of operation. It also displays indicators, warnings,
pop-up menus, and prompts when appropriate. The remote
pendant displays a limited range of information.
In each mode, a series of submodes are displayed across the
top of the screen. When a submode that has several functions
is selected, those functions are listed in a pop-up menu below
the heading.
In the WELD and PROG modes, the second line on the
display shows the name of the active procedure and the
current mode of operation. Below the name of the active
procedure is a brief description of the procedure. On the next
line, the welders and programmers names are listed. The first
page of parameters for the active procedure is also displayed.
In all modes, the M100 will display brief directions on how
to make selections or continue a function in the bottom line
of the display (Prompt Line).

M100 Power Supply
©1999 Swagelok Company, all rights reserved 17
August 2001
Operator Keypad
The operator keypad has four types of keys:
• Mode keys
• Navigation and selection keys
• Weld function keys
• Alphanumeric keys
Figure 14 Operator Keypad
MODE KEYS
The four mode keys are located in the top row of the
keypad. These keys are “hot,” meaning you can press
them at any time, except when a weld is being executed,
to change the operation mode.
Whenever a mode key is pressed, the available series
of submodes are displayed with the left most submode
and the first active parameter of the submode
highlighted (selected).
SETUP
PROG
FILE
WELD
Figure 15 Mode Keys
POWER SUPPLY REMOTE PENDANT

M100 Power Supply
18 ©1999 Swagelok Company, all rights reserved
August 2001
WELD
Accesses the WELD mode.
In the WELD mode, you can execute a weld
using the active procedure, make minor
adjustments (ADJUST) to the procedure, or
review the parameters of the procedure using
the VIEW submode. In the WELD mode, the
weld function keys are active. Pressing
START, for example, would start a weld using
the active weld procedure.
Though minor modifications to the active
procedure are possible, most parameters must
be set in the PROG (programming) mode.
INFO Submode – Additional information may
be added to data output by operator.
TEST Submode – Test of the active procedure
is accomplished here.
Figure 16 Weld Mode Display
WLD view
adj
500/049 SS 316 04
READY 000
tst
inf
REMOTE PENDANT
POWER SUPPL
Y

M100 Power Supply
©1999 Swagelok Company, all rights reserved 19
August 2001
FILE
Accesses the FILE mode.
In FILE mode, a saved weld procedure can be
selected from memory, the active procedure
can be saved, or stored procedures can be
deleted or copied. Procedure files can be saved
in either the internal memory or the PC
memory card. Weld data log records are not
accessed in the FILE mode; the weld data log
records are located in SETUP/DATALOG.
Figure 17 File Mode Display
POWER SUPPLY
REMOTE PENDANT
Chevrons and Capital Letters
Indicate Cursor Position

M100 Power Supply
20 ©1999 Swagelok Company, all rights reserved
August 2001
File access can be limited by installing a
programmer password.
FILE Mode – Limited Access: When a
programmer password has been set, the user has
limited access to the LOAD PROCEDURE
functions. The procedure is read only which means
no changes can be made. The user may also access
PRINT COUPON and PRINT DIRECTORY. If
any other function is requested, the unit will ask for
the programmer password. The user cannot save
weld changes, delete weld procedures, or transfer
data to the PC memory card for weld procedures.
FILE Mode – Unlimited Access: When a
programmer password has not been set, or it was
entered at initial start up, the user has access to all
the functions described later in this section under
“File Mode.”