Swagelok 40 series User manual

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Series 40
Weld Head
User’s Manual

ii Series 40 Weld Head User’s Manual

www.swagelok.com
Weld Head
User’s Manual
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2Series 40 Weld Head User’s Manual
Contents
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
Unpacking the Weld Head Components . . . . . . . . . . . . . . .6
Installing the Weld Head. . . . . . . . . . . . . . . . . . . . . . . .7
Selecting the Electrode . . . . . . . . . . . . . . . . . . . . . . . .8
Installing the Electrode . . . . . . . . . . . . . . . . . . . . . . . 10
Preparing the Work . . . . . . . . . . . . . . . . . . . . . . . . . 11
Operating the Weld Head . . . . . . . . . . . . . . . . . . . . . . 12
Performing Daily Maintenance . . . . . . . . . . . . . . . . . . . 14
Performing Periodic Maintenance . . . . . . . . . . . . . . . . . 15
Weld Head Cleaning and Inspection . . . . . . . . . . . . . . . . 16
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Parts Drawings . . . . . . . . . . . . . . . . . . . . . . . . . . . .21
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Series 40 Weld Head User’s Manual 3
Description
Swagelok series 40 welding system components deliver consistent,
precise welds for outside tube diameters ranging from 1 1/2 to 4 in.
and 38.1 to 114.3 mm and pipe diameters ranging from 1 ¼ to 4 in. and
42.2 to 114.3 mm.
A dc motor in the weld head drives a rotor, which revolves 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 maintains contact with approximately
two-thirds of the circumference of the rotor. This conguration ensures
consistent, uniform electrical conductance to the rotor and electrode. Figure 1 Series 40 Weld Head
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4Series 40 Weld Head User’s Manual
Unpacking the Weld Head Components
The weld head assembly and tool package are packaged in a foam-
lined shipping container. Perform the following steps when your
Swagelok series 40 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 40 Weld Head User’s Manual 5
Installing the Weld Head
The weld head assembly has four connectors that plug into the power
supply. See Figure 2.
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 3.
1. Locate the weld head cable assembly.
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 in the power
supply.
Figure 2 Weld Head Assembly
Figure 3 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).
Weld Head Electrode
Work
Weld Head
Shielding
Gas
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6Series 40 Weld Head User’s Manual
Selecting the Electrode
Electrode length depends on the desired arc gap and outside diameter
of the work piece being welded. To select the correct electrode use
the Tungsten Electrode Length Calculation. Once you have the correct
length calculated either select an electrode from stock using the
Electrode Selection Table or place a special order.
Tungsten Electrode Length Calculation
To determine the tungsten electrode length for a specic arc gap, use the formula below:
(Rotor OD ÷ 2) − (Tube OD ÷ 2) − Arc Gap = Electrode Length
Figure 4 Electrode Length Calculation Parameters
Example No. 1: (1.5 in. to 1.5 in. tube butt weld)
Rotor OD A = 6.850 in.
Tube outside diameter B = 1.500 in.
Desired arc gap C = 0.060 in.
(6.850 ÷ 2) − (1.500 ÷ 2) − 0.060 in. = 2.615 in.
Example No. 2: (38,1 mm to 38,1 mm tube butt weld)
Rotor OD A = 173,99 mm
Tube outside diameter B = 38,10 mm
Desired arc gap C = 1,52 mm
(173,99 ÷ 2) − (38,10 ÷ 2) − 1,52 mm = 66,425 mm
A
Rotor OD
B
Tube
OD
C
Arc Gap
Electrode
Length
Rotor OD = 6.850 in. (173,99 mm)
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Series 40 Weld Head User’s Manual 7
Table 1 Electrode Selection for 0.060 in. Arc Gap
Electrode
Ordering Number
Component
OD
Electrode
Length
L
Electrode
Diameter
D
SWS-C.094-2.615-P 1.5 in. 2.615 in.
(66,40 mm)
0.094 in.
(2,39 mm)
SWS-C.094-2.365-P 2.0 in. 2.365 in.
(60,07 mm)
0.094 in.
(2,39 mm)
SW S- C. 0 94 -2 .115 - P 2.5 in. 2.115 in.
(53,72 mm)
0.094 in.
(2,39 mm)
SWS- C.094-1.865-P 3.0 in. 1.865 in.
(47,37 mm)
0.094 in.
(2,39 mm)
SWS- C.094-1.615-P 3.5 in. 1.615 in
(41,02 mm)
0.094 in.
(2,39 mm)
SWS- C.094-1.365-P 4.0 in. 1.365 in.
(34,67 mm)
0.094 in.
(2,39 mm)
SW S- C. 09 4 -1.10 5 - P 4.5 in. 1.105 in.
(28,07 mm)
0.094 in.
(2,39 mm)
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 the Orbital Welding System, Series 40, catalog, MS-02-140, for
ordering information.
The electrode ordering numbers are assigned as follows:
SWS – 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.
Note:
Auto generated programs are exact lengths.
You may substitute another length that is
within 0.005 in.
Figure 5 Tungsten Electrode
Material Designator
C= Ceriated
Package
Designator
Electrode
Diameter
Electrode
Length
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8Series 40 Weld Head User’s Manual
Installing the Electrode
1. With the weld head in the open position, press JOG or
ELECTRODE CHANGE on the operator panel until the tungsten
electrode is in the position shown in Figure 6.
2. Loosen the electrode set screw. Remove the electrode if you are
replacing it.
3. Insert the new electrode until it is ush with the outside edge of the
rotor.
4. Tighten the electrode set screw to secure the electrode.
5. Press HOME or ELECTRODE CHANGE on the operator front
panel to return rotor to the home position.
Figure 6 Electrode Installation
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.
Electrode
Electrode
Set Screw
Outside Edge
of Rotor
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