Swagelok 8HPH Series User manual

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English. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
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User’s Manual
Series 8HPH
Weld Head

ii Series 8HPH Weld Head User’s Manual

www.swagelok.com
Weld Head
User’s Manual
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2Series 8HPH Weld Head User’s Manual
Contents
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Unpacking the Weld Head Components . . . . . . . . . . . . . . 4
Optional Mounting of the Series 8HPH Weld Head . . . . . . . . 5
Installing the Weld Head
Connection the Extension Cable to the Weld Head . . . . . 6
Connection the Weld Head Extension Cable
to the Power Supply . . . . . . . . . . . . . . . . . . . . . . . 7
Electrode Selection and Installation
Inspecting the Electrode . . . . . . . . . . . . . . . . . . . . .9
Calculating Electrode Length . . . . . . . . . . . . . . . . . .9
Installing or Replacing the Electrode . . . . . . . . . . . . . 11
Operation
Preparing the Work . . . . . . . . . . . . . . . . . . . . . . . 14
Fixturing the Work Pieces . . . . . . . . . . . . . . . . . . . 15
Performing a Weld. . . . . . . . . . . . . . . . . . . . . . . .18
Changing the Side Plates . . . . . . . . . . . . . . . . . . . .20
Performing Daily Maintenance
Daily Fixture Maintenance . . . . . . . . . . . . . . . . . . . 25
Daily Weld Head Maintenance . . . . . . . . . . . . . . . . . 25
Performing Periodic Maintenance . . . . . . . . . . . . . . . . .26
Cleaning and Inspection . . . . . . . . . . . . . . . . . . . . 26
Ceramic Insert Replacement. . . . . . . . . . . . . . . . . .35
Arc Shield Replacement . . . . . . . . . . . . . . . . . . . . 36
Work Support Systems
Right/Left Work Support Instructions. . . . . . . . . . . . .37
Parts Drawings . . . . . . . . . . . . . . . . . . . . . . . . . . . .39
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Series 8HPH Weld Head User’s Manual 3
Description
Swagelok®series 8HPH (high performance) weld heads deliver
consistent, precise welds for outside diameters from 1/8 to 1/2 in. and
3 to 12 mm. Designed for the rigors of the production environment
and for cleanroom compliance, the series 8HPH is encased in a metal
shroud. It is capable of performing up to four times as many welds as
the traditional micro weld head in the same amount of time. The series
8HPH also provides the benet of enhanced operator comfort, as the
actuator handles allow the operator to xture work pieces without
touching the xture plates.
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. The electrode is positioned in the eight o’clock position to
facilitate visual joint alignment.
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.
This manual presents information that is specic to the high
performance weld head. The weld head xtures do not use separate
collets but rather have separate side plates with integral collet
features.
Formal training on the operation, fixture plate installation, and
maintenance is recommended.
Figure 1 Series 8HPH Weld Head
Nut Locked/Closed
Locked
Open
Tool
Change
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4Series 8HPH 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
• electrodepackage
• centeringgauge
• series8HPHtoolpackage
• extensioncable
• user’smanual
The series 8HPH weld head has size-specic side plates, and the
order number species which set will be installed upon receipt. Other
side plate sizes are optional accessories. The side plate size ordered
will determine the electrode package that is delivered with the weld
head.
Perform the following steps when your Swagelok series 8HPH 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 date on the
M200: Registration Information form.
Figure 2 Shipping Container
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Series 8HPH Weld Head User’s Manual 5
Figure 3 Series 8HPH Mounting
Dimensions Guide
Optional Mounting of the Series 8HPH Weld Head
The series 8HPH weld head comes with predrilled holes for optional
bench-top mounting.
1. Determine the mounting orientation of the weld head on the
workbench.
2. Use the integral mounting holes on the bottom of the unit to secure
the unit to the workbench.
3. Drill holes in workbench using the dimension guide in Figure 3.
4. Align holes on bottom of weld head unit to holes in workbench.
5. Insert four 1/4 in. × 20 machine screws of appropriate length (not
included) through the workbench into the weld head unit. See
Figure 4.
 Caution!
Do not drill into the weld
head. The mounting holes
on the unit are a specific
depth to prevent damage
to internal parts.
Figure 4 Optional Mounting of the
Weld Head to the Bench
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6Series 8HPH Weld Head User’s Manual
Installing the Weld Head
Connecting the Extension Cable to the Weld Head
The four connectors on the cable are:
• threaded multi-pin connector
• electrode (red)
• work (green)
• weld head shielding gas
1. Align the notch on the threaded multi-pin connector of the weld
head cable with the small tab in the mating socket of the extension
cable. Insert the threaded connector and screw on the weld head
cable by turning clockwise until it is tight.
2. Align the arrow on the female socket of the weld head electrode
cable (red) with the arrow on the male connector (red) of the
extension cable. With the arrows aligned, insert and fully seat the
red male connector of the extension cable into the red female
socket of the weld head cable. Twist the connector one-quarter
turn clockwise to lock into place.
3. Align the arrow on the male connector of the weld head work
cable (green) with the arrow on the female socket (green) of the
extension cable. With the arrows aligned, insert and fully seat the
green male connector of the weld head cable into the green female
socket of the extension cable. Twist the connector one-quarter
turn clockwise to lock into place.
4. Insert the male shielding gas connector of the weld head cable into
the female Swagelok quick-connect body of the extension cable.
Align bodies and stems when coupling or uncoupling.
Figure 5 Connecting the Weld Head
to the Extension Cable
 Caution!
Do not rotate quick-connects while
coupled. Do not insert foreign
object into uncoupled bodies or
stems.
Figure 6 Connecting the Weld Head to the
Extension Cable
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Series 8HPH Weld Head User’s Manual 7
Connecting the Weld Head Extension Cable to
the Power Supply
The weld head extension cable has four connectors that plug into the
power supply. See Figure 7.
1. Attach the threaded multi-pin connector of the extension cable to
the mating socket on the rear panel of the power supply labeled
FIXTURE. Turn the connector sleeve clockwise by hand until it is
tight. This connection provides the control signals to drive the weld
head.
2. Insert and fully seat the red connector of the extension cable
into the socket on the rear panel of the power supply labeled
ELECTRODE. Twist the connector one-quarter turn clockwise to
lock into place. This connection is the negative (-) terminal of the
weld head.
3. Insert and fully seat the green connector of the extension cable
into the socket on the rear panel of the power supply labeled
WORK. Twist the connector one-quarter turn clockwise to lock into
place. This connection is the positive (+) terminal of the weld head.
4. Insert the shielding gas connector stem into the Swagelok quick-
connect body labeled TO WELD HEAD
5. Turn the power ON. See Figure 8.
 Caution!
Ensure that the threaded
multi-pin connector is
fully seated in the mating
socket and the threaded
sleeve is tight.
 Caution!
Ensure the connector
is firmly attached. This
connection provides
shielding gas to the weld
head through a solenoid
valve in the power supply.
Figure 8 Turning the Power
Supply ON
Figure 7 Connecting the Weld Head
Extension Cable to the Power
Supply
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8Series 8HPH Weld Head User’s Manual
6. Press HOME to return the rotor to the home position.
See Figure 9.
7. Check that the rotor returns to the appropriate home positions.
See Figure 10.
8. If the rotor does not return to the home position, see the Fixture
Disassembly procedure in Performing Periodic Maintenance.
Caution!
The weld head should not
be started in any rotor
position except home. Arc
start in any other location
may cause weld head
damage.
Figure 9 Power Supply Operator Panel
Figure 10 Home Position of Rotor
Incorrect Correct
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Series 8HPH Weld Head User’s Manual 9
Electrode Selection and Installation
Inspecting the Electrode
This illustration shows the electrode shape Swagelok recommends.
Properly ground electrodes provide consistent, repeatable welds.
Pre-ground electrodes are available from your authorized Swagelok
representative. See Table 1 and Table 2 for ordering information. Tip
diameters listed in the tables are for argon only. Other shielding gases
may require different tip diameters.
The electrode ordering numbers are assigned as follows:
SWS – X.040 – #.### – .### 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.
Calculating Electrode Length
Electrode length depends on the desired arc gap and outside
diameter of the work piece being welded. The series 8HPH comes
with electrodes machined to specic arc gaps. Certain electrodes will
automatically be selected for inclusion with the series 8HPH when it is
ordered, based on the diameter of the tubing being welded.
Electrode Length = 0.615 - [(Component OD) / 2] - Arc Gap
Example: For a 0.500 in. component with a 0.035 in. arc gap:
0.615 - (0.500/2) – 0.035 = 0.330 in.
This value is inserted into the Swagelok electrode ordering number as
follows: SWS-C.040-.330-.###-P
See your authorized Swagelok representative if custom arc gaps or tip
diameters are desired, which are not listed in Table 1 or Table 2.
Figure 11 Tungsten Electrode
Material
Designator
C = Ceraited
T = Thoriated
Electrode
Diameter,
in.
Electrode
Length,
in.
Tip
Diameter,
in. Place
Designator  Caution!
Only ceriated tungsten should
be used in the weld head. The
use of other types of tungsten
may cause weld head damage.
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10 Series 8HPH Weld Head User’s Manual
Table 1 Series 8HPH Electrode Selection (Fractional)
Component OD
in.
Arc Gap
in.
Electrode
Length
in.
Electrode Ordering
Number
1/8
0.020 0.533 SWS-C.040-.533-.012-P
0.025 0.528 SWS-C.040-.528-.012-P
0.030 0.523 SWS-C.040-.523-.012-P
0.035 0.518 SWS-C.040-.518-.012-P
1/4
0.025 0.465 SWS-C.040-.465-.012-P
0.030 0.460 SWS-C.040-.460-.012-P
0.035 0.455 SWS-C.040-.455-.012-P
0.040 0.450 SWS-C.040-.450-.012-P
3/8
0.025 0.403 SWS-C.040-.403-.012-P
0.030 0.398 SWS-C.040-.398-.012-P
0.035 0.393 SWS-C.040-.393-.012-P
0.040 0.388 SWS-C.040-.388-.012-P
1/2
0.030 0.335 SWS-C.040-.335-.012-P
0.035 0.330 SWS-C.040-.330-.012-P
0.040 0.325 SWS-C.040-.325-.012-P
0.045 0.320 SWS-C.040-.320-.012-P
Table 2 Series 8HPH Electrode Selection (Metric)
Component OD
mm
Arc Gap
mm
Electrode
Length
mm
Electrode Ordering
Number
3
0.51 13.61 SWS-C.040-.536-.012-P
0.64 13.49 SWS-C.040-.531-.012-P
0.76 13.36 SWS-C.040-.526-.012-P
0.89 13.23 SWS-C.040-.521-.012-P
6
0.64 11.99 SWS-C.040-.472-.012-P
0.76 11.86 SWS-C.040-.467-.012-P
0.89 11.73 SWS-C.040-.462-.012-P
1.02 11.61 SWS-C.040-.457-.012-P
8
0.64 11.00 SWS-C.040-.433-.012-P
0.76 10.87 SWS-C.040-.428-.012-P
0.89 10.74 SWS-C.040-.423-.012-P
1.02 10.62 SWS-C.040-.418-.012-P
10
0.76 9.86 SWS-C.040-.388-.012-P
0.89 9.73 SWS-C.040-.383-.012-P
1.02 9.60 SWS-C.040-.378-.012-P
1.14 9.47 SWS-C.040-.373-.012-P
12 0.76 8.86 SWS-C.040-.349-.012-P
0.89 8.74 SWS-C.040-.344-.012-P
1.02 8.61 SWS-C.040-.339-.012-P
1.14 8.48 SWS-C.040-.334-.012-P
Note: The electrodes listed
in Table 1 and Table 2 are for
argon shielding gas only.
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Series 8HPH Weld Head User’s Manual 11
Installing or Replacing the Electrode
The series 8HPH weld head tool package includes:
• a miniature hex drive
• wire brushes
• tweezers
• a hex wrench set
Use these tools for installing a new size of electrode, or for replacing
the electrode when it shows signs of deterioration.
Reducing the jog speed may be helpful for correct positioning of the
rotor.
1. To reduce jog speed, press SETUP on the operator panel.
2. Select CONFIG from the setup options.
3. Select a jog speed of 50 % or less.
4. Open the side plates by pushing each actuator handle back to
the open position. See Figure 13
Caution!
Do not press JOG or move the
rotor unless the electrode is
clamped in place.
Figure 12 Pressing SETUP on the
Operator Panel
Figure 13 Pushing Actuator Handles
to the Open Position
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12 Series 8HPH Weld Head User’s Manual
Figure 14 JOG on the
Operator Panel
5. With the weld head in the open position, press JOG on the
operator panel (see Figure 14) until the tungsten electrode is in
the position shown in Figure 15.
Figure 15 Jogging the Rotor until the
Electrode is Accessible
Electrode
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Series 8HPH Weld Head User’s Manual 13
6. Loosen the electrode set screw with the hex drive.
See Figure 16.
7. Remove and discard the old electrode.
8. Install a new electrode using the 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 is pointing out. See
Figure 16.
9. Tighten the set screw sufciently to prevent the electrode from
falling out of the rotor.
10. Press HOME to return the rotor to the home position as shown in
Figure 17.
 Caution!
Hold on to the electrode with
tweezers so that the electrode
does not fall into the weld head
gear assembly.
Caution!
Do not overtighten the set
screw, as it could damage
the electrode, screw, or
rotor threads.
Note: Replace the electrode set screw if
any sign of stripping is observed.
Figure 16 Loosening the Electrode
Set Screw
Figure 17 Home Position of Rotor
Incorrect Correct
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14 Series 8HPH Weld Head User’s Manual
Operation
Preparing the Work
It is important to prepare the components properly before welding.
See Figure 18. Components must be square and burr-free to ensure
repeatable, high-quality autogenous fusion welds.
Follow these steps to achieve square and burr-free tubing:
1. Cut the tubing to length with a hacksaw or tube cutter.
2. Face the tube ends with a lathe or a portable facing tool.
3. Deburr the ends, making sure that both the inside and outside
diameters are square and burr-free.
4. 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 18 Preparing the Tube
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
Square corners No Gap
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Series 8HPH Weld Head User’s Manual 15
Fixturing the Work Pieces
It is very important that the work pieces are aligned so that the
electrode is in the seam of the joint, and that the ends are butted
squarely. If the work pieces are out of alignment, you may experience
angular or axial misalignment weld defects. See Figure 19 and
Figure 20.
Visual Alignment
To secure a work piece into the xture, the user actuates
the right movable clamp with the left handle. The left movable clamp is
actuated in a similar fashion. See Figure 21. This method of operation
allows the user to operate the xture with one hand while holding and
aligning the work piece with the other.
1. Insert the rst work piece into either side of the xture and visually
align the end of the work piece with the electrode tip.
2. Clamp the work piece by placing the handle in the not locked/
closed position.
3. Insert the other work piece and butt it up to the clamped work
piece. Clamp the second work piece.
4. Place both handles in the locked/closed position.
Figure 19 Angular Misalignment
Figure 21 Aligning the Electrode with the
Tube End and Clamping the
First Work Piece
Figure 20 Axial Misalignment
Left Handle
Right Handle
Electrode
Tube
Movable Side Plate
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16 Series 8HPH Weld Head User’s Manual
Alignment Using the Centering Gauge
The centering gauge is supplied attached to the weld head and must
be adjusted before use. The following steps refer to the left movable
clamp.
Note: The centering gauge can be set for use with either the left or
right movable clamp.
Note: In order to use the centering gauge in the right movable
clamp, the gauge must first be adjusted to work with the right
movable clamp. The centering gauge adjustment procedure is the
same for both the left and right movable clamps.
1. Loosen the locking screw, using the supplied hex key.
See Figure 22.
2. Clamp the centering gauge around the circular surface shown in
Figure 23, using the left movable clamp. See Figure 24.
Figure 22 Loosening the Locking Screw
Figure 23 Surface to be Clamped
Figure 24 Centering Gauge Clamped
into Position
Locking Screw
Surface to be clamped
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Series 8HPH Weld Head User’s Manual 17
3. Ensure that the centering gauge is pushed against the side plate.
4. Adjust the centering gauge so that the right edge is centered on the
electrode. See Figure 25.
5. Tighten the centering gauge locking screw.
6. Insert the work piece into the other side of the xture and butt it
squarely against the end of the centering gauge. See Figure 26.
7. Clamp the work piece into place. See Figure 27.
8. Remove the centering gauge and insert the other work piece to
be welded, butting it up against the rst work piece. Clamp the
second work piece in place.
Note: At the start of every shift, or whenever the electrode is changed,
ensure the centering gauge is re-centered.
Figure 25 Adjusting the Centering Gauge
Figure 26 Inserting the Work Piece
Figure 27 Clamping the Work Piece
Locking Screw
Electrode
Right Edge of
Centering Gauge
Locking Screw
Centering Gauge
Work Piece
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18 Series 8HPH Weld Head User’s Manual
Caution!
Do not use tack programs or
programs that include tacks with the
series 8HPH weld head.
Caution!
Do not use step programs with the
series 8HPH weld head.
Performing a Weld
Operate the weld head using the following parameters:
Series 8HPH
Shield gas flow rate
std ft3/hr (std L/min)
10 to 15➀
(4.7 to 7.1)
Prepurge and Postpurge
minimum time in seconds Continuous
Start Power U-low, Low, Norm➁
Maximum Recommended
Average Amps 40 amps
➀Set flow to higher rates when welding at high current rates.
➁M100-1 Power Supplies with serial numbers before 2802; D100-1 Power Supplies with
serial numbers before 1425; D100-2 Power Supplies with serial numbers before 3267;
or M100-2 Power Supplies with serial numbers before 3464 and ac arc start should
use Low or U-low arc starts. All D-100-1A and D-75 units should use Low or U-low arc
starts. Power supplies with dc arc starts should use Normal for wall thickness above
0.030 in.
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