Swagelok 5 Series User manual

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User’s Manual
Weld Head

ii Series 5 Weld Head User’s Manual

www.swagelok.com
Weld Head
User’s Manual

4Series 5 Weld Head User’s Manual
Contents
Weld Head. . . . . . . . . . . . . . . . . . . . . . . . . . . .5
Fixture Block . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Unpacking the Weld Head Components . . . . . . . . . . . 6
Installing the Weld Head . . . . . . . . . . . . . . . . . . . .7
Installing the Electrode in the Weld Head . . . . . . . . . . 8
Calculating Arc Gap Gage Settings. . . . . . . . . . . . . 10
Setting the Arc Gap . . . . . . . . . . . . . . . . . . . . . 11
Fixturing the Work . . . . . . . . . . . . . . . . . . . . . . 16
Installing the Collets in a Tube Fixture Block . . . . . . . 17
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . 26
Parts Drawings . . . . . . . . . . . . . . . . . . . . . . . . 35

Series 5 Weld Head User’s Manual 5
Weld Head
The Series 5 Swagelok Welding System (SWS) weld head
delivers consistent, precise welds for outside diameters from
1/8 to 5/8 in. and 3 to 17.3 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 5 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. The collets
exchange quickly, making the xture block very adaptable to
changing work requirements.
Figure 1 Series 5 Weld head
Figure 2 Series 5 Fixture Block

6Series 5 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 5 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.

Series 5 Weld Head User’s Manual 7
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.
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).
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 3 Weld Head
Weld Head Electrode
Work
Weld Head
Shielding Gas

8Series 5 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. The M200 will generate the appropriate
electrode when using the Auto Create feature.
Electrode
Part No.
Component
OD
Electrode
Length (L)
in. (mm)
Electrode
Diameter (D)
in. (mm)
CWS-C.040.705-P
1/8 in.
3/16 in.
3 mm
1/4 in.
0.705
(17,90)
0.040
(1,02)
CWS-C.040-.605-P
5/16 in.
6 mm
8 mm
0.605
(15,37)
0.040
(1,02)
CWS-C.040-.555-P
3/8 in.
1/2 in.
10 mm
12 mm
0.555
(14,10)
0.040
(1,02)
CWS-C.040-.450-P 5/8 in.
15 mm
0.450
(11,43)
0.040
(1,02)
CWS-C.040-.405-P 16 mm
17.3 mm
0.405
(10,29)
0.040
(1,02)
Table 1 Electrode Selection Table
Figure 5 Electrode Dimensions
D
L

Series 5 Weld Head User’s Manual 9
Figure 6 Tungsten Electrode
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.
Material Designator
C= Ceriated
Package
Designator
Electrode
Diameter
Electrode
Diameter

10 Series 5 Weld Head User’s Manual
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 tting
(welding diameter).
B = Arc gap gage diameter
C = desired arc gap
Example No. 1: (Series 5 Weld Head)
1/4 to 1/4 in. tube butt weld—
Largest outside diameter A = 0.253 in.
Arc gap gage diameter B = 1.244 in.
Desired arc gap C = 0.028 in.
0.253 in. + 1.244 + 0.028 in. = 0.777 in.
2 2
Example No. 2: (Series 5 Weld Head)
6 to 6 mm tube butt weld—
Largest outside diameter A = 6,081 mm
Arc gap gage diameter B = 31,60 mm
Desired arc gap C = 0,71 mm
6,081 mm + 31,60 mm + 0,71 mm = 19,551 mm
2 2
Figure 7 Arc Gap Gage Setting Formula
A B C
Arc Gap
Gauge
Setting
A+ B+ C =
2 2

Series 5 Weld Head User’s Manual 11
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 aperture. 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 when using the
Auto Create feature.
2. Refer to the tables on page 12 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 8. See Figure 12 (B).

12 Series 5 Weld Head User’s Manual
Nominal
OD
in.
Actual
OD
in.
Setting
for
0.025 in.
Arc Gap
in.
Setting
for
0.030 in.
Arc Gap
in.
Setting
for
0.035 in.
Arc Gap
in.
Setting
for
0.040 in.
Arc Gap
in.
Setting
for
0.045 in.
Arc Gap
in.
Setting
for
0.050 in.
Arc Gap
in.
Setting
for
0,51 mm
Arc Gap
mm
Setting
for
0,64 mm
Arc Gap
mm
Setting
for
0,89 mm
Arc Gap
mm
Setting
for
1,02 mm
Arc Gap
mm
1/8 0.125 0.710 0.715 0.720 0.725 0.730 0.735 17,91 18,04 18,29 18,42
1/4 0.250 0.772 0.777 0.782 0.787 0.792 0.797 19,48 19,61 19,86 19,99
3/8 0.375 0.835 0.840 0.845 0.850 0.855 0.860 21,08 21,21 21,46 21,59
1/2 0.500 0.897 0.902 0.907 0.912 0.917 0.922 22,66 22,79 23,04 23,17
5/8 0.625 0.960 0.965 0.970 0.975 0.980 0.985 24,25 24,38 24,63 24,76
Table 2 SWS-5H Arc Gap Gage Dia. 1.244 in.
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
3 3,00 17,80 17,94 18,06 18,19 18,32
6 6,00 19,30 19,44 19,56 19,69 19,82
8 8,00 20,30 20,44 20,56 20,69 20,82
10 10,00 21,30 21,44 21,56 21,69 21,82
12 12,00 22,30 22,44 22,56 22,69 22,82
Table 3 SWS-5H Arc Gap Gage Dia. 31,60 mm
ATW
Size
Cuff
OD
Setting for
0.035 in. (0,89 mm)
Arc Gap
1/4 in. 0.29 in. 0.801 in.
3/8 in. 0.41 in. 0.863 in.
1/2 in. 0.55 in. 0.931 in.
6 mm 7 mm 20,19 mm
8 mm 9 mm 21,20 mm
10 mm 11 mm 22,20 mm
12 mm 13,2 mm 23,32 mm
Table 4 SWS-5H ATW Arc Gap Gage Dia. 1.244 in. (31,60 mm)

Series 5 Weld Head User’s Manual 13
Inserting the Electrode into a Rotor
1. Without the xture block attached, press ELECTRODE
CHANGE on the power supply. 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.
Figure 9 Electrode Installation
•WARNING!
Do not press START while touching
the electrode.
Caution!
Do not jog or move the rotor unless
the electrode is clamped in place.
Electrode
Clamping Screws
Caution!
The rotor will move when
ELECTRODE CHANGE is pressed.
The rotor is a potential pinch point.

14 Series 5 Weld Head User’s Manual
Setting the Arc Gap
1. Use JOG or ELECTRODE CHANGE to position the rotor.
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 JOG,
ELECTRODE CHANGE, or HOME
is pressed. The rotor is a potential
pinch point.

Series 5 Weld Head User’s Manual 15
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 contaminants.
Figure 11 Tube Preparation
Method Results
Hack Saw Cut
Tube Cutter
Tube Facing Tool
Burrs Burrs in
Flow Path
End Rolled by Cutter,
Blade and Roller
Face Perpendicular
to Axis
Irregular Tube
Diameter
Smooth Transition at
Wall Faces
Gap
No Gaps
0.003 in (0.08 mm) across tube or
0.006 in. (0.15 mm) at one end
Reduced Flow Area
Burrs
Square Corners

16 Series 5 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.
Table 5 —Fixture Block
Extension length is the minimum amount of the tube needed to create a
weld in the center of the fixture block.
2. Select the proper collets for the diameter of the parts being
welded.
Table 6 —Collets
Model OD Capacity Minimum Weld Extension Length
CWS-5TFB 1/8 to 5/8 in.,
3 to 17.3 mm 3/4 in., 19 mm
CWS-5FSP1 1/4 in.
Used when welding VCR®or VCO®fittings with
captured male or female nuts with extension
lengths of less than 3/4 in., 19 mm
SWS-5FSP1-EX 1/2 in.
Used when welding VCR fittings with captured
male nuts with overall fitting length less than 1.79
in., 45.5 mm or with captured female nuts with
overall fitting length less than 1.12 in., 28.4 mm
CWS-5FSP2 1/8 to 1/2 in.,
6 to 12 mm
Used to hold Micro-Fit®fittings with an extension
length of 1/4 in., 6 mm
SWS-5FSP3L 1/8 to 1/2 in.,
3 to 12 mm
Used to hold certain valves with an extension
length of 1/2 in., 12 mm
SWS-5FSP3R
SWS-5FSP4L 1/4 to 3/8 in.,
6 to 9 mm
Used to hold Swagelok valves BN, DL, DS, HD,
DA, and DP with an extension length of 1/4 in., 6
mm
SWS-5FSP4V
Model OD Capacity Comments
CWS-5UCI-X➀1/8 to 5/8 in.,
3 to 17.3 mm
Tubing
Add “mm” suffix for metric sizes.
CWS-5UFCI-.95 n/a Fixture collets to hold adapter inserts for
CWS-5FSP1 side plate
CWS-5UFCI-X➀1/8 to 5/8 in.,
3 to 16 mm Tube collet for 5FSP1 and 5FSP2
SWS-5UFCI-EX-.95 n/a
Fixture collets to hold adapter inserts used
for 1/4 in. and smaller VCR or VCO fittings for
SWS-5FSP1-EX side plate
CWS-5MWCI-04 1/8 and 1/4 in.,
6 mm
Used to hold certain valves with an extension
length of 1/2 in., 12 mm
CWS-5MWCI-06 3/8 in.,
8 and 10 mm For Micro-Fit fittings
CWS-5MWCI-08 1/2 in., 12 mm For Micro-Fit fittings
SWS-5F3UCI-X➀1/8 to 1/2 in.,
6, 8, and 10 mm For valves
➀Where Xidentifies the collet size in 1/16ths or metric (mm suffix)

Series 5 Weld Head User’s Manual 17
Figure 12 Opening the Fixture Block
Figure 13 Installing Collets
Installing the Collets in a Tube Fixture
Block
1. Release both levers and open the tube xture block. See
Figure 12.
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(B).
Fixture
Side Plate
Collet
Shoulder

18 Series 5 Weld Head User’s Manual
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.
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 Place First Work Piece in the Fixture Block
Note:
When welding a Swagelok ATW fitting to
tubing, butt the tubing against the centering
gage first.

Series 5 Weld Head User’s Manual 19
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
alignment is not correct proceed to the next section.
Adjusting the Fixture Block
The modular design of the Series 5 Fixture block allows you to
assemble the block to meet a variety of welding requirements.
In order to maintain precise alignment of the work pieces in the
xture block, the side plates must be periodically aligned.
This section covers:
• Tube-to-tube
• Micro-Fit tting-to-tube
• Micro-Fit tting-to-Micro-Fit tting
Tube-to-Tube Fixture Block
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. Using the provided 3/32 in. hex wrench, unscrew the four
cap screws in the appropriate side plate just enough to
loosen it from the plenum. See Figure 17 to locate the
appropriate side plate.
3. Turn the xture block upright and release both levers and
open both sides of the xture block.
Figure 16 Placing Second Work Piece
Figure 17 Loosening the Side Plate
Plenum
Directional
arrows
Cap screws
Side plate

20 Series 5 Weld Head User’s Manual
Plenum
Directional
arrows
Cap screws
Side plate
1. 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.
2. Close and lock the side plate that is not adjustable. See
Figure 18.
3. Lock down the top of the loosened side plate.
4. Tighten the four cap screws in the loosened side plate. Take
care to tighten the screws evenly to prevent the side plate
from slipping.
5. Open the side plates and remove the tubing.
Micro-Fit Fitting-to-Tube Fixture Block
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 19.
2. Using the provided 3/32 in. hex wrench, unscrew the four
cap screws in the appropriate side plate just enough to
loosen it from the plenum. See Figure 19 to locate the
appropriate side plate.
3. Turn the xture block upright and release the lever and open
the top of the tube side plate.
4. Choose and install a collet that holds tubing that matches
the outside diameter of the Micro-Fit tting.
Figure 18 Placing the Tubing
Figure 19 Loosening the Side Plate
CWS-5FSP2