Swagelok CWS-D100-1B User manual

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USER’S MANUAL
CWS-D100-1B
CWS-D100-2B
WELDING SYSTEM

The Swagelok Limited
Lifetime Warranty
Swagelok hereby warrants to the purchaser of this Product that the
non-electrical components of the Product shall be free from defects in
material and workmanship for the life of the Product. All electrical
components installed in or on the Product are warranted to be free
from defects in material and workmanship for twelve months from the
date of purchase.
The purchaser’s remedies shall be limited to replacement and installation
of any parts that fail through a defect in material or workmanship.
MANUFACTURER SPECIFICALLY DISAVOWS ANY OTHER
REPRESENTATION, EXPRESS OR IMPLIED, WARRANTY, OR
LIABILITY RELATING TO THE CONDITION OF USE OF THE
PRODUCT, AND IN NO EVENT SHALL SWAGELOK BE LIABLE TO
PURCHASER, OR ANY THIRD PARTY, FOR ANY DIRECT OR
INDIRECT CONSEQUENTIAL OR INCIDENTAL DAMAGES.

2005 Swagelok Company, all rights reserved
September 2005 TOC−1
Table of Contents
Foreword
Registration Information i. . . . . . . . . . . . . . . . . . . . . . . .
Safety Summary iii. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Statements iii. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Symbols iii. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Safe Practices and Safety Precautions vii. . . . . . . .
User Precautions ix. . . . . . . . . . . . . . . . . . . . . . . . . .
Power Supply Warning Label x. . . . . . . . . . . . . . . .
Referenced Specifications xi. . . . . . . . . . . . . . . . . . .
Section 1 Introduction SWS D100
Gas Tungsten Arc Welding 1-2. . . . . . . . . . . . . . . . . . . . . .
Principles of the GTAW Process 1-2. . . . . . . . . . . . .
GTAW Process Advantages 1-2. . . . . . . . . . . . . . . . .
Process Variables 1-3. . . . . . . . . . . . . . . . . . . . . . . . . .
System Components 1-4. . . . . . . . . . . . . . . . . . . . . . . . . . .
The SWS D100 Power Supply 1-4. . . . . . . . . . . . . . .
The Weld Head 1-5. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fixture Blocks 1-6. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Overview of SWS Operation 1-7. . . . . . . . . . . . . . . . . . . .
Specifications 1-9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Section 2 Installation
Introduction 2-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Tools and Accessory Requirements 2-2. . . . . . . . . . . . . .
Electrical Requirements 2-3. . . . . . . . . . . . . . . . . . . . . . . .
Input Voltage 2-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Using an Extension Cord 2-3. . . . . . . . . . . . . . . . . . . .
Unpacking and Inspecting System Components 2-4. . .
Unpacking the Power Supply 2-4. . . . . . . . . . . . . . . .
Unpacking the Weld Head Cable Assembly
and Related Components 2-5. . . . . . . . . . . . . . . . . . .

Table of Contents CWS−D100−B Welding System
2005 Swagelok Company, all rights reserved
September 2005
TOC−2
Installing the SWS 2-6. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installing the Power Supply 2-6. . . . . . . . . . . . . . . . . .
Installing the Weld Head 2-7. . . . . . . . . . . . . . . . . . . .
Installing the Gas Delivery System 2-9. . . . . . . . . . . . . . .
Introduction 2-9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installing the Typical Shielding/Purge Gas
Delivery System 2-10. . . . . . . . . . . . . . . . . . . . . . . . . . .
Installing the Optional Gas Delivery System 2-12. . .
Preliminary Check 2-14. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Section 3 Operation
Introduction 3-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Front Panel Controls 3-2. . . . . . . . . . . . . . . . . . . . . . . . . . .
Current Control Switches 3-3. . . . . . . . . . . . . . . . . . . .
Timing Control Switches 3-4. . . . . . . . . . . . . . . . . . . .
Pushbuttons 3-6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Status Indicator Lights 3-8. . . . . . . . . . . . . . . . . . . . . .
Digital Displays 3-9. . . . . . . . . . . . . . . . . . . . . . . . . . . .
SWS Modes of Operation 3-9. . . . . . . . . . . . . . . . . . . . . . .
Operational Mode 3-12. . . . . . . . . . . . . . . . . . . . . . . . . .
Program Mode 3-17. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Test Mode 3-22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installing the Electrode in the Series 5/10/20
Weld Head 3-26. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Selecting the Proper Electrode 3-26. . . . . . . . . . . . . . .
Inserting the Electrode into a Rotor 3-26. . . . . . . . . . .
Setting the Arc Gap 3-27. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Setting the Arc Gap Gage 3-27. . . . . . . . . . . . . . . . . . .
Setting the Arc Gap 3-27. . . . . . . . . . . . . . . . . . . . . . . .
Preparing the Work 3-28. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fixturing the Work 3-29. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Selecting the Fixture Block and Collets 3-29. . . . . . . .
Installing the Collets in a Tube Fixture Block 3-29. . .
Aligning the Work Pieces in the Tube
Fixture Block 3-30. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Connecting the Purge Gas Line 3-32. . . . . . . . . . . . . .
Connecting the Weld Head to the Fixture Block 3-33. . . .
Safety Interlock 3-33. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Mating the Weld Head to the Fixture Block 3-34. . . .

CWS−D100−B Welding System Table of Contents
2005 Swagelok Company, all rights reserved
September 2005 TOC−3
Entering the Weld Parameters 3-35. . . . . . . . . . . . . . . . . . .
Using a Weld Procedure Guideline 3-35. . . . . . . . . . .
Effects of Weld Parameters 3-36. . . . . . . . . . . . . . . . .
Setting the Shield Gas Flow 3-37. . . . . . . . . . . . . . . . . . . . .
Starting and Completing the Weld 3-37. . . . . . . . . . . . . . .
Display Indications During Welding 3-38. . . . . . . . . . .
After the Weld is Complete 3-39. . . . . . . . . . . . . . . . . .
Operation Summary 3-40. . . . . . . . . . . . . . . . . . . . . . . . . . .
Section 4 Micro Weld Heads CWS-4MRH-A,
CWS-4MFH-A, CWS-8MRH
Introduction 4-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Using the Micro Fixture Tool 4-3. . . . . . . . . . . . . . . . . . . . .
Installing the Motor Module 4-3. . . . . . . . . . . . . . . . . . . . .
Installing the Micro Weld Head 4-4. . . . . . . . . . . . . . . . . .
Installing/Replacing the Electrode 4-6. . . . . . . . . . . . . . . .
Setting the Arc Gap 4-8. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fixturing the Work 4-9. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Connecting the Micro Weld Head to the Fixture 4-11. . . .
Considerations During Welding 4-13. . . . . . . . . . . . . . . . . .
Using the Optional Bench Mounting Bracket 4-14. . . . . . .
Series 4 Bench Mount Bracket 4-14. . . . . . . . . . . . . . .
Series 8 Bench Mount Bracket 4-15. . . . . . . . . . . . . . .
Section 5 Weld Parameter Adjustment
Introduction 5-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Developing a Weld Procedure Guideline 5-1. . . . . . . . . .
Determining the Work Specifications 5-2. . . . . . . . . .
Setting the Front Panel Switches 5-3. . . . . . . . . . . . .
Example Weld Procedure Guideline Worksheet 5-9
Weld Procedure Guideline Worksheet 5-10. . . . . . . .
Evaluating the Weld 5-16. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Identifying Typical Weld Discontinuities 5-16. . . . . . .
Identifying Proper Welds 5-17. . . . . . . . . . . . . . . . . . . .
Adjusting Controls for Weld Quality 5-22. . . . . . . . . . . . . .
Section 6 Maintenance
Introduction 6-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Series 5/10/20 Fixture Blocks 6-2. . . . . . . . . . . . . . . . . . .
Daily Maintenance 6-2. . . . . . . . . . . . . . . . . . . . . . . . .
Forty-Hour Maintenance 6-2. . . . . . . . . . . . . . . . . . . .
Micro Weld Head Fixture Blocks 6-3. . . . . . . . . . . . . . . . .
Daily Maintenance 6-3. . . . . . . . . . . . . . . . . . . . . . . . .

Table of Contents CWS−D100−B Welding System
2005 Swagelok Company, all rights reserved
September 2005
TOC−4
Series 5/10/20 Weld Head 6-4. . . . . . . . . . . . . . . . . . . . . .
Daily Maintenance 6-4. . . . . . . . . . . . . . . . . . . . . . . . .
Forty-Hour Maintenance 6-4. . . . . . . . . . . . . . . . . . . .
Series 5/10/20 Weld Head Disassembly
and Cleaning 6-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Series 5/10/20 Weld Head Assembly 6-9. . . . . . . . .
Micro Weld Heads 6-10. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Daily Maintenance 6-10. . . . . . . . . . . . . . . . . . . . . . . . .
Eight-Hour Maintenance 6-11. . . . . . . . . . . . . . . . . . . .
Micro Weld Head Assembly 6-15. . . . . . . . . . . . . . . . .
Power Supply 6-15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fuse Inspection and Replacement 6-15. . . . . . . . . . .
Section 7 Troubleshooting
Introduction 7-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Swagelok Welding System (SWS) Repair Procedure 7-1
Repair/Replacement Instructions 7-2. . . . . . . . . . . . .
Appendix A Glossary
Appendix B Optional Equipment
SWS Remote Pendant B-2. . . . . . . . . . . . . . . . . . . . . . . . .
Weld Head Extension Cables B-3. . . . . . . . . . . . . . . . . . .
Data Logging/Monitoring B-4. . . . . . . . . . . . . . . . . . . . . . . .
Data Recording Printer B-6. . . . . . . . . . . . . . . . . . . . . . . . .
Introduction B-6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Unpacking and Inspection B-6. . . . . . . . . . . . . . . . . . .
Installation B-6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Operating the Printer B-9. . . . . . . . . . . . . . . . . . . . . . .
Maintenance B-15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Using a Standard RS-232 Printer B-16. . . . . . . . . . . . .
Appendix C Electrode Selection Tables
and Geometry
CWS-4MRH-A, CWS-4MFH-A
Micro Weld Heads C-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CWS-8MRH Micro Weld Head C-1. . . . . . . . . . . . . . . . . . .
CWS-5H-B Weld Head C-2. . . . . . . . . . . . . . . . . . . . . . . . .
CWS-10H-A Weld Head C-2. . . . . . . . . . . . . . . . . . . . . . . .
CWS-20H-A/B Weld Head C-3. . . . . . . . . . . . . . . . . . . . . .
Electrode Geometry C-3. . . . . . . . . . . . . . . . . . . . . . . . . . . .

CWS−D100−B Welding System Table of Contents
2005 Swagelok Company, all rights reserved
September 2005 TOC−5
Appendix D Weld Head Information
MICRO WELD HEAD −TUBE WELDING D-2. . . . . . . . .
SERIES 5 WELD HEAD −TUBE WELDING D-2. . . . . . .
SERIES 10 WELD HEAD −TUBE WELDING D-3. . . . .
SERIES 20 WELD HEAD −TUBE WELDING D-3. . . . .
SERIES 20 WELD HEAD −PIPE WELDING D-4. . . . . .
MICRO WELD HEAD −TUBE WELDING D-4. . . . . . . . .
SERIES 5 WELD HEAD −TUBE WELDING D-5. . . . . . .
SERIES 10 WELD HEAD −TUBE WELDING D-5. . . . .
SERIES 20 WELD HEAD −TUBE WELDING D-6. . . . .
Appendix E Arc Gap Gage Setting Tables
Wall Thickness and Arc Gap E-1. . . . . . . . . . . . . . . . . . . .
Weld Head Arc Gap Gage Setting Tables E-2. . . . . . . . .
Arc Gap Gage Setting Tables
for Swagelok ATW Fittings E-11. . . . . . . . . . . . . . . . . . . . . .
Arc Gap Gage Setting Formula E-12. . . . . . . . . . . . . . . . . .
Appendix F Parts Drawings
Appendix G Gas Flow Rate Tables
Purge Rate and Pressure Tables G-1. . . . . . . . . . . . . . . .
Purge Rate and Pressure Tables Continued G-2. . . . . . .
General Suggested Shielding
Gas Flow Rates (Argon) G-2. . . . . . . . . . . . . . . . . . . . . . . .
Appendix H Fixture Block Alignment
Series 5 Fixture Block H-1. . . . . . . . . . . . . . . . . . . . . .
Series 20H-B Fixture Block H-5. . . . . . . . . . . . . . . . . .
Series 8 Micro Weld Head Fixture H-6. . . . . . . . . . . .
Appendix I Weld Procedure Guidelines
Index

Table of Contents CWS−D100−B Welding System
2005 Swagelok Company, all rights reserved
September 2005
TOC−6

2005 Swagelok Company, all rights reserved
September 2005 i
Foreword
Registration Information
Your Swagelokrepresentative can provide support and
service of your Swagelok Welding System (SWS) as well
as local stock of precision fittings and valves.
Please take a moment to fill out the warranty information
form as well as the information listed below. Keep this
information available in case you need to contact your
Swagelok representative.
Power Supply:
Model Number*:
Serial Number*:
Delivery Date:
* See rating label on the rear of the unit, shown in Figure 1.
Weld Head(s):
Weld Head:
Model Number:
Serial Number:
Delivery Date:
Model Number:
Serial Number:
Delivery Date:
Model Number:
Serial Number:
Delivery Date:
Figure 1 Rating Label

Foreword CWS−D100−B Welding System
2005 Swagelok Company, all rights reserved
September 2005
ii