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Swagelok M100 Series Manual

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Power Supply Components
SWS M100
M 1 0 0
P
S
C
O W E R
U P P L Y
O M P O N E N T S
M 1 0 0 P
S
O W E R
U P P L Y
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
©1999 Swagelok Company, all rights reserved
1
August 2001

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Summary of Contents for Swagelok M100 Series

  • Page 1 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 ©1999 Swagelok Company, all rights reserved August 2001...
  • Page 2 GROUNDED, ELECTRICAL installed according to local code and National SHOCK CAN OCCUR. Electrical Code. • The power supply must be grounded. • A dedicated electrical circuit may be desired due to current need. ©1999 Swagelok Company, all rights reserved August 2001...
  • Page 3 ** Denotes Language 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 •...
  • Page 4 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 ©1999 Swagelok Company, all rights reserved August 2001...
  • Page 5 See Figure 5. Work The four connectors on the cable are: • Fixture • Electrode (red) • Work (green) • Weld head shielding gas. Weld Head Shielding Gas Figure 5 Weld Head Assembly ©1999 Swagelok Company, all rights reserved August 2001...
  • Page 6 (+) terminal of the weld head. threaded sleeve is tight. 5. Insert the weld head shielding gas connector into the Swagelok Quick-Connect stem labeled TO WELD Note: HEAD. Ensure that the connector is firmly attached. The weld head shielding gas...
  • Page 7 • 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.
  • Page 8 Purge Fitting Ferrules or Ultra Torr®) (Swagelok Union or Reducing Union SWS Power Supply with Nylon Ferrules or Ultra-Torr® for Purge Gas Restriction SWS Fixture Block Figure 7 Typical Gas Delivery System ©1999 Swagelok Company, all rights reserved August 2001...
  • Page 9 • 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). ©1999 Swagelok Company, all rights reserved August 2001...
  • Page 10 Cylinder Internal Purge Secondary Solenoid Gas Flow Meter Bypass Plug Weld Head – Internal Purge Gas Shut-Off Valve SWS Fixture Block – Secondary Solenoid Bypass Plug Figure 8 Optional Gas Delivery System ©1999 Swagelok Company, all rights reserved August 2001...
  • Page 11 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. Rotor Figure 10 Postitioning the Weld Head to View the Rotor Rotation ©1999 Swagelok Company, all rights reserved August 2001...
  • Page 12 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 •...
  • Page 13 A remote pendant can also be used to operate the unit. It has a keypad and a display. ©1999 Swagelok Company, all rights reserved August 2001...
  • Page 14 M100 Power Supply 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.
  • Page 15 Status Indicators Weld Counter Warnings/Errors Active Key Indicators/ Prompt Line REMOTE PENDANT Submode Menu (capital letters indicate active submode) view Active Procedure TEST1 Warning/Errors Weld Counter READY Status Indicators Figure 13 Operator Display ©1999 Swagelok Company, all rights reserved August 2001...
  • Page 16 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). ©1999 Swagelok Company, all rights reserved August 2001...
  • Page 17 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). FILE WELD PROG SETUP Figure 15 Mode Keys ©1999 Swagelok Company, all rights reserved August 2001...
  • Page 18 INFO Submode – Additional information may be added to data output by operator. TEST Submode – Test of the active procedure is accomplished here. POWER SUPPLY REMOTE PENDANT view 500/049 READY Figure 16 Weld Mode Display ©1999 Swagelok Company, all rights reserved August 2001...
  • Page 19 Weld data log records are not accessed in the FILE mode; the weld data log records are located in SETUP/DATALOG. POWER SUPPLY REMOTE PENDANT Chevrons and Capital Letters Indicate Cursor Position Figure 17 File Mode Display ©1999 Swagelok Company, all rights reserved August 2001...
  • Page 20 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.” ©1999 Swagelok Company, all rights reserved August 2001...
  • Page 21 Programming privileges are obtained by entering the programmer password (if one has been set) at initial start up. POWER SUPPLY REMOTE PENDANT Figure 18 Programming Mode Display ©1999 Swagelok Company, all rights reserved August 2001...
  • Page 22 Programming privileges are obtained by entering the programmer password at initial start up (if one has been set). POWER SUPPLY REMOTE PENDANT Figure 19 Setup Mode Display ©1999 Swagelok Company, all rights reserved August 2001...
  • Page 23 Pressing again will move the cursor to the next screen of data. ©1999 Swagelok Company, all rights reserved August 2001...
  • Page 24 BACK , respectively. The PRINT and PRINT HOME HOME functions are only available when the M100 is in the WELD/WELD mode. are available in other modes. BACK ©1999 Swagelok Company, all rights reserved August 2001...
  • Page 25 (see Figure 22). Pressing will stop the: STOP STOP • Weld in progress immediately. • Rotor homing in process. Figure 22 Rotor Position ©1999 Swagelok Company, all rights reserved August 2001...
  • Page 26 SETUP/DATALOG submode. Pressing this key will move the rotor to the home position. The rotor will always move at full speed when is pressed. HOME Figure 23 Rotor Home Position ©1999 Swagelok Company, all rights reserved August 2001...
  • Page 27 Contrast Keys several times. Data Recording Printer Feed Key Press this key to advance the paper through the data recording printer. ©1999 Swagelok Company, all rights reserved August 2001...

  • Page 28: Table Of Contents

    Set heat number Set certification number or Dewar serial number Open 1 and 2 available for additional information up to 10 characters Set project name or drawing name TEST Check or demonstrate weld program ©1999 Swagelok Company, all rights reserved August 2001...
  • Page 29 Weld Counter Warnings/Errors Active Key Indicators/ Prompt Line REMOTE PENDANT Submode Menu (capital letters indicate active submode) view TEST1 Active Procedure Warnings/Errors Weld Counter READY Status Indicators Figure 25 WELD Mode Display ©1999 Swagelok Company, all rights reserved August 2001...

  • Page 30: Weld

    If tacks are part of the selected weld procedure they are executed before the level(s). As the tacks and levels are executed the data for each is highlighted. ©1999 Swagelok Company, all rights reserved August 2001...
  • Page 31 “READY” state. If error conditions occurred during the weld, the error will be displayed and will have to be pressed ENTER for confirmation. For more information on error indicators see page 32. ©1999 Swagelok Company, all rights reserved August 2001...
  • Page 32 The Information Message Box may appear in any mode or may contain actions that submode. The box may require a corrective action by the should not be taken by operator or may contain information only. the operator. ©1999 Swagelok Company, all rights reserved August 2001...
  • Page 33 ENABLED/ON is active, the PC memory card is inserted, and the write protect is on but the card is not initialized and data cannot be written to the card. To initialize card go to SETUP/UTILITY/INITIALIZE CARD. ©1999 Swagelok Company, all rights reserved August 2001...
  • Page 34 M100 rearranges files to open up additional internal memory. If the System Clean-up Information box occurs often or takes excessive time to perform, weld data logs may need to be deleted in SETUP/DATALOG/ERASE DATALOG MEMORY OR CARD. ©1999 Swagelok Company, all rights reserved August 2001...

  • Page 35: Adjust Clear Adjustments

    UP/DOWN keys. The adjusted value will be automatically constrained by the current limits. The M100 can be returned to the Ready state by pressing WELD or highlighting the WELD submode with the menu arrows. ©1999 Swagelok Company, all rights reserved August 2001...

  • Page 36: Prepurge, Postpurge

    Select PREPURGE or POSTPURGE on the selection list and change the time. The range of adjustment can be set in PROGRAM/MODIFY/PURGE LIMIT. view Figure 29 Prepurge and Postpurge Adjustment ©1999 Swagelok Company, all rights reserved August 2001...

  • Page 37: View

    Joint parameters, start parameters, tacks, and levels as well as other settings are displayed. You cannot change any information in the VIEW submode. POWER SUPPLY REMOTE PENDANT VIEW Figure 30 Review Active Weld Settings ©1999 Swagelok Company, all rights reserved August 2001...
  • Page 38 Information entered here will be displayed on the printout and in the Weld Datalog Record. POWER SUPPLY REMOTE PENDANT view Figure 31 INFO The selection is cleared when the unit is powered down. ©1999 Swagelok Company, all rights reserved August 2001...

  • Page 39: Info Select Welder Name

    The model number of the weld head is entered during creating of the procedure. This entry field is cleared on unit power down. view Figure 33 Weld Head Serial Number ©1999 Swagelok Company, all rights reserved August 2001...
  • Page 40 Figure 35 Shield Gas and Purge Gas Certification Numbers INFO – Open 1 and Open 2 These two lines are available for any additional information up to 10 characters. These entry fields will clear on unit power down. ©1999 Swagelok Company, all rights reserved August 2001...
  • Page 41 TEST submode. To use the TEST submode: Select and install a weld procedure; press . The M100 will ask START you to check that the rotor is clear to rotate; press ENTER begin the TEST. ©1999 Swagelok Company, all rights reserved August 2001...
  • Page 42 One procedure from card to memory One procedure from memory to card All procedures from card to memory All procedures from memory to card Figure 37 File Mode POWER SUPPLY REMOTE PENDANT Figure 38 File Mode Display ©1999 Swagelok Company, all rights reserved August 2001...

  • Page 43: Load Load Procedure

    S preceding the name. Arrows The arrows indicate more procedures above or below in the display. The procedures may be reached by scrolling with keys. UP/DOWN FWD/BACK Figure 39 Load a Procedure Display ©1999 Swagelok Company, all rights reserved August 2001...

  • Page 44: Print Procedure

    Press ENTER Figure 40 Print a Procedure Display Note: Card files will be listed first preceded by the letter C. System memory files will be preceded by the letter S. ©1999 Swagelok Company, all rights reserved August 2001...

  • Page 45: Print Directory

    DIRECTORY, then press ENTER Figure 41 Print the Directory Display Note: Card files will be listed first preceded by the letter C. System memory files will be preceded by the letter S. ©1999 Swagelok Company, all rights reserved August 2001...

  • Page 46: Save Store To Memory

    SAVE – STORE TO CARD This function stores the active procedure on the PC memory card. Figure 42 Store Procedure to Memory Display ©1999 Swagelok Company, all rights reserved August 2001...

  • Page 47: Delete Delete Procedure

    M100 will ask for confirmation that you want to erase the card. Using the keys to highlight your selection, UP/DOWN “yes” to proceed or “no” to cancel. ENTER Figure 43 Delete Procedure from Memory Display ©1999 Swagelok Company, all rights reserved August 2001...
  • Page 48 Select “yes” or “no” using the keys. The UP/DOWN default answer is “no.” When storing is done, press a mode key to continue. ©1999 Swagelok Company, all rights reserved August 2001...
  • Page 49 Rotor speed performance tolerance Designate required fields CREATE Procedure Auto entry Figure 45 Program Mode Manual entry Load and edit POWER SUPPLY REMOTE PENDANT Number of Levels Number of Tacks Figure 46 Program Mode Display ©1999 Swagelok Company, all rights reserved August 2001...
  • Page 50 4 tacks at a time. The M100 allows up to 10 tacks/procedure. If more then 4 tacks are present, they can be displayed by using the keys that will scroll FWD/BACK a tack at a time. ©1999 Swagelok Company, all rights reserved August 2001...
  • Page 51 ENTER name it will be overwritten without a warning message. If you enter a new name, both files will be saved. To delete one of the files, go to FILE/DELETE. ©1999 Swagelok Company, all rights reserved August 2001...
  • Page 52 The new tack will be added immediately before the selected tack. The new tack will be a copy of the selected tack. You must go to EDIT ITEM to modify the values. ©1999 Swagelok Company, all rights reserved August 2001...
  • Page 53 If you wish to adjust the tolerance for the acceptable rotor speed performance, this setting allows selection of a new tolerance. It can be set to any value between 0.0 and 9.9%. The default value is +/- 2.5%. ©1999 Swagelok Company, all rights reserved August 2001...
  • Page 54 • TB-ATW (side 1 Tube Butt Weld to side 2 Auto Tube Weld) Figure 51 Creating an Auto Entry Procedure The side 2 ATW defaults to a normal cuff thickness. However, if desired, you may adjust thickness setting. ©1999 Swagelok Company, all rights reserved August 2001...
  • Page 55 M100 presents a list for you to select tacks, levels, or both for the unit to calculate. 10. Select tacks – M100 prompts for the number of tacks desired. Figure 53 Number of Passes List ©1999 Swagelok Company, all rights reserved August 2001...
  • Page 56 13. Name Procedure – If you chose to save, you will be prompted to enter the procedure name. 14. Screen Revert to PROGRAM/CREATE – The M100 defaults back to the auto entry screen ready to program another weld procedure. ©1999 Swagelok Company, all rights reserved August 2001...
  • Page 57 EDIT ITEM so you can make changes. The default name will be untitled to remind you a new name is needed. You cannot overwrite an existing procedure from this function. ©1999 Swagelok Company, all rights reserved August 2001...
  • Page 58 Change programmer password Change security UTILITY Reset weld counter Set date and time Initialize card Clear application Executor Version F. Panel Version Loader Lo Version Loader Hi Version Figure 56 Setup Mode Display ©1999 Swagelok Company, all rights reserved August 2001...
  • Page 59 This function allows you to specify a preferred format for printed output from three choices. The choices are: long, short, and medium and each provides more or less information. See Figure 58 through Figure 60. Figure 57 Print Format ©1999 Swagelok Company, all rights reserved August 2001...
  • Page 60 M100 Power Supply Weld Data Record Examples The Short printout shown in Figure 58 contains only the header information, description, outputs, and performance confirmation. Figure 58 Short Printout ©1999 Swagelok Company, all rights reserved August 2001...
  • Page 61 M100 Power Supply The Medium printout shown in Figure 59 contains the output information most commonly requested. This printout gives header information, description, inputs, outputs, and performance confirmation. Figure 59 Medium Printout ©1999 Swagelok Company, all rights reserved August 2001...
  • Page 62 M100 Power Supply The Long printout shown in Figure 60 contains all information on inputs and outputs. This printout lists the entire weld procedure as well as the results. Figure 60 Long Printout ©1999 Swagelok Company, all rights reserved August 2001...
  • Page 63 DATALOG – ERASE DATALOG MEM Erases all datalog records from memory. DATALOG – ERASE DATALOG CARD Erases all datalog records from PC memory card. ©1999 Swagelok Company, all rights reserved August 2001...
  • Page 64 Metric and English measurement systems. Select inches, millimeters, or inches for OD and inches or millimeters for wall thickness. The dimensional units displayed are defaulted from the last auto-generated program. Figure 63 Dimensional Units ©1999 Swagelok Company, all rights reserved August 2001...
  • Page 65 The voltage will default to 4 volts. The value may have to be adjusted up when using a weld head extension cable. Refer to Weld Errors on page 32. ©1999 Swagelok Company, all rights reserved August 2001...
  • Page 66 Owner password and If no programmer password is Programmer password can override. used, all users will have programmer priveleges with full File mode activities. Note: The M100 must be turned off to activate security. ©1999 Swagelok Company, all rights reserved August 2001...
  • Page 67 Application Unlimited PROGRAM SET-UP FILE PROGRAM *WELD Limited SECURITY FILE * If a Program password is not entered the security will allow the user to access all Programmer functions Figure 65 Password ©1999 Swagelok Company, all rights reserved August 2001...
  • Page 68 All data will be cleared If the PC memory card data or formatting becomes corrupt, from the PC memory card when the PC memory card the card can be cleared and initialized. is initialized. ©1999 Swagelok Company, all rights reserved August 2001...
  • Page 69 F. Panel software, often called the application software, controls the user’s communication with the M100 Power Supply. UTILITY – LOADER LO VER: XXX UTILITY – LOADER HI VER: XXX Loader software controls the loading of F. Panel software. ©1999 Swagelok Company, all rights reserved August 2001...
  • Page 70 Impulse width also affects weld penetration. The control allows fine-tuning of the weld penetration level. Pulse rate is typically set so that each weld spot overlaps the previous one by at least 70 %. ©1999 Swagelok Company, all rights reserved August 2001...
  • Page 71 Refer to Table 5. 4. Press again to close the shield gas solenoid valve. PURGE ©1999 Swagelok Company, all rights reserved August 2001...
  • Page 72 25 mm 0.5 to 1.2 mb Note: These weld tables are for use on butt welds only. If Weld Head Purge Rates exceed Swagelok recommendations, be cautious of arc wander. For best results, use constant weld head purge between welding cycles.
  • Page 73 See the Troubleshooting section • Loading for possible causes and • Prepurge corrective actions. • Arc Start • Tacks • Rotor DLY (delay) • Ramp • Levels (time remaining) • Downslope (time remaining) • Postpurge. ©1999 Swagelok Company, all rights reserved August 2001...
  • Page 74 10. Connect the weld head to the fixture block. 11. Program the welder. 12. Press and complete the weld. START 13. Remove the weld head from the tube fixture block. ©1999 Swagelok Company, all rights reserved August 2001...
  • Page 75 1. Turn the latch counter-clockwise to release the printer body from the case. Remove the printer body from the case by pulling it forward. See Figure 70. Latch Figure 70 Opening the Data Recording Printer Drawer ©1999 Swagelok Company, all rights reserved August 2001...
  • Page 76 Figure 71 Lift the Printer Head 3. Press the ends of the spindle and lift to remove the paper roll spindle pin and used paper spindle. Figure 72 Press the Ends of the Spindle and Lift ©1999 Swagelok Company, all rights reserved August 2001...
  • Page 77 Insert the spindle through the paper roll. Press both ends of the spindle and insert into the slots. Release ends and check spindle seating. Figure 74 Advancing the Paper ©1999 Swagelok Company, all rights reserved August 2001...
  • Page 78 6. Turn the latch clockwise to secure the data recording feed mechanism, do not pull printer to the case. it back in the direction of the paper roll. Feed the paper with the Advance Paper Button. ©1999 Swagelok Company, all rights reserved August 2001...
  • Page 79 (See SETUP/DATALOG/PRINT COUPON on page 59.) • Select SETUP/DATALOG/PRINT ALL COUPONS. This function is printed on the data recording printer. (See SETUP/DATALOG/PRINT ALL COUPONS on page 59.) ©1999 Swagelok Company, all rights reserved August 2001...
  • Page 80 Maintenance The SWS data recording printer is designed to require a minimum of maintenance and service. Contact your Swagelok representative for any electrical or mechanical repairs that must be performed. Clearing Paper Jams In the event of a paper jam do not force paper into the unit or try to pry the paper out of the unit.
  • Page 81 6. Reload the paper after the jam has been cleared. 7. Slide the data recording printer back into the power supply and tighten the latch. Front Panel Slot Figure 78 Clearing a Paper Jam ©1999 Swagelok Company, all rights reserved August 2001...
  • Page 82 M100 Power Supply Optional Equipment The optional equipment available for your Swagelok Welding System (SWS) is listed below. Contact your Swagelok representative for additional information on any listed option. Optional Equipment Includes: • SWS Remote Pendant • remote pendant extension cables •...
  • Page 83 Allow the shielding gas to flow for at least 60 seconds to clear the gas lines of oxygen. Press PURGE again to stop the gas flow. PURGE Figure 81 Pushbutton Locations ©1999 Swagelok Company, all rights reserved August 2001...
  • Page 84 Visual, mechanical, and other testing must also be done to verify the weld integrity. As with any connection, proper leak testing should be performed once the weld is completed. ©1999 Swagelok Company, all rights reserved August 2001...
  • Page 85 M100 Power Supply Swagelok neither sells nor recommends a specific type or brand of recording equipment. However, when selecting data recording equipment remember that the frequency response (sampling rate) of the equipment will determine how accurately a data printout will reflect the actual welding process.
  • Page 86 M100 Power Supply PC Memory Card 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.
  • Page 87 M100 Printer Port Pin Outputs Pin No. Signal Name from SWS M100 Transmit Receive Printer Port Clear to Send (CTS) Signal Ground +15 V (dc) Data Transmit Ready (DTR) Ground Figure 83 PC Interface Cable ©1999 Swagelok Company, all rights reserved August 2001...
  • Page 88 A blank worksheet is included on page 106 for you to use when creating your own weld procedure guidelines. The steps in the worksheet show you how to develop the speed, current, and timing for the SWS. ©1999 Swagelok Company, all rights reserved August 2001...
  • Page 89 Worksheet Entry: 13 SCFH Argon 11. Record the purge gas pressure from the ID purge pressure. Refer to Table 5 Purge Rate and Pressure Tables on Page 72. Worksheet Entry: 1.2 iwc ©1999 Swagelok Company, all rights reserved August 2001...
  • Page 90 1,66 to 1,78 1,79 to 1,90 1,91 to 2,03 2,04 to 2,16 2,17 to 2,29 1 1/4 2,30 to 2,41 1 1/2 2,42 to 2,77 1 3/4 2,78 to 4,0 2 – 4 ©1999 Swagelok Company, all rights reserved August 2001...
  • Page 91 40 % of the ATW cuff thickness to the fitting wall thickness. ATW Cuff Thickness Fitting Wall Thickness Figure 84 ATW Fitting wall Thickness The new ATW wall is then used in Table 10 for the “A” factor. ©1999 Swagelok Company, all rights reserved August 2001...
  • Page 92 2,04 to 2,16 0.36 0.086 to 0.090 2,17 to 2,29 0.39 0.091 to 0.095 2,30 to 2,41 0.40 0.096 to 0.109 2,42 to 2,77 0.43 0.110 to 0.154 2,78 to 4,0 0.45 ©1999 Swagelok Company, all rights reserved August 2001...
  • Page 93 Next, calculate the weld overlap time using the following formula: (Wall Thickness x 2) ÷ Travel Speed In seconds = Weld Overlap Time For example: (0.049 x 2) ÷ (5.5 ÷ 60) = .098 ÷ .0917 = 1.1 seconds ©1999 Swagelok Company, all rights reserved August 2001...
  • Page 94 7.b on page 93. Worksheet entry: 1.1 9. Record a Prepurge Time of 20 seconds. Use a continuous purge when using the micro weld head by pressing the PURGE pushbutton. Worksheet entry: 20 ©1999 Swagelok Company, all rights reserved August 2001...
  • Page 95 2,30 to 2,41 0.096 to 0.109 2,42 to 2,77 0.110 to 0.154 2,78 to 4,0 For example, a wall thickness of 0.049 in. has a “C” factor of 30. Worksheet entry: 30 ©1999 Swagelok Company, all rights reserved August 2001...
  • Page 96 68.6 – 3.4 = 65.2 Amps Worksheet entry: 65.2 For level 3: 65.2 – 3.4 = 61.8 Amps Worksheet entry: 61.8 For level 4: 61.8 – 3.4 = 58.4 Amps Worksheet entry: 58.4 ©1999 Swagelok Company, all rights reserved August 2001...
  • Page 97 Average rpm x Circumference = Average Travel Speed For example, using the average rpm from step 2. and the circumference from step 3.3: 2.45 x 1.5708 = 3.84846 = 3.8 IPM ©1999 Swagelok Company, all rights reserved August 2001...
  • Page 98 Total Weld Time Number of Levels = Weld Time per Level ÷ For example, using the weld time from step 4 and 4 levels: 26.1÷ 4 = 6.525 = 6.5 seconds per level ©1999 Swagelok Company, all rights reserved August 2001...
  • Page 99 Arc Gap = 0.010 in. (0,25 mm) Socket OD Electrode Offset 0.010 to 0.020 in. 1/16 in. (1,5 mm) (0,2 to 0,5 mm)) Minimum Pull Back Figure 85 Socket Weld Arc Gap ©1999 Swagelok Company, all rights reserved August 2001...
  • Page 100 • All tacks should be consumed completely by the weld. (Decrease tack size or the number of tacks.) • Tacks should not break during the welding. (Increase tack size or the number of tacks.) ©1999 Swagelok Company, all rights reserved August 2001...
  • Page 101 Level 2 Downslope Ramp Ramp Time Time Level 4 Level 3 Start Level 2 Level 1 Level 3 Weld Time Weld Time Weld Time Rotor Delay Time Figure 86 Ramp Between Levels ©1999 Swagelok Company, all rights reserved August 2001...
  • Page 102 ID bead width. Ramp Time Level 1 Downslope Start Current 5 Amps Level 3 Level 1 Level 2 Level 4 Weld Time Weld Time Weld Time Weld Time Rotor Delay .1 Sec Figure 87 ©1999 Swagelok Company, all rights reserved August 2001...
  • Page 103 Level 1 Level 2 Level 3 Level 4 Level 5 No Rotor Movement Weld Time Weld Time Weld Time Weld Time Rotor Delay .1 Sec Level for Initial Penetration Welding Levels Figure 88 ©1999 Swagelok Company, all rights reserved August 2001...
  • Page 104 = Arc Start 35 Amps (68.6 x .30) + [20.6 x (1 – 0.30)] = 20.58 + [20.6 x 0.70] = 20.58 + 14.42 = 35.00 **Impulse Width is determined in step 13. ©1999 Swagelok Company, all rights reserved August 2001...
  • Page 105 Impulse Amps Level 6 – Level F=actor = Impulse Amps for Level 7 __ - ____ = Impulse amps for level 8 Impulse Amps Level 7 – Level Factor = Impulse Amps for Level 8 __ - ____ = ©1999 Swagelok Company, all rights reserved August 2001...
  • Page 106 (Imp. Level 1 x % Imp. Width**) + [Maint. x (1 - % Imp. Width)] = Arc Start (_____ x _____) + [_____ x (1- ____)] = _____ + [_____ x _____] = _____ + _____ = _____ ** Impulse Width is determined in step 13. ©1999 Swagelok Company, all rights reserved August 2001...
  • Page 107 Impulse Amps Level 6 – Level F=actor = Impulse Amps for Level 7 __ - ____ = Impulse amps for level 8 Impulse Amps Level 7 – Level Factor = Impulse Amps for Level 8 __ - ____ = ©1999 Swagelok Company, all rights reserved August 2001...
  • Page 108 (Imp. Level 1 x % Imp. Width**) + [Maint. x (1 – % Imp. Width)] = Arc Start (_____ x _____) + [_____ x (1- ____)] = _____ + [_____ x _____] = _____ + _____ = _____ ** Impulse Width is determined in step 13. ©1999 Swagelok Company, all rights reserved August 2001...
  • Page 109 Impulse Amps Level 6 – Level F=actor = Impulse Amps for Level 7 __ - ____ = Impulse amps for level 8 Impulse Amps Level 7 – Level Factor = Impulse Amps for Level 8 __ - ____ = ©1999 Swagelok Company, all rights reserved August 2001...
  • Page 110 (Imp. Level 1 x % Imp. Width**) + [Maint. x (1 - % Imp. Width)] = Arc Start (_____ x _____) + [_____ x (1- ____)] = _____ + [_____ x _____] = _____ + _____ = _____ ** Impulse Width is determined in step 13. ©1999 Swagelok Company, all rights reserved August 2001...
  • Page 111 Impulse Amps Level 2 – Level Factor = Impulse Amps for Level 3 ______ - _____ = _____ Impulse amps for level 4 Impulse Amps Level 3 – Level Factor = Impulse Amps for Level 4 _____ - ______ = ______ ©1999 Swagelok Company, all rights reserved August 2001...
  • Page 112 Figure 89 Acceptable Identifying Typical Weld Discontinuities Weld Figure 90 shows typical weld discontinuities. TYPICAL WELD DISCONTINUITIES Concavity Incomplete Penetration Partial Penetration Angular Misalignment Convexity Meander Axial Misalignment Figure 90 Typical Weld Discontinuities ©1999 Swagelok Company, all rights reserved August 2001...
  • Page 113 Arc Gap 0.035 in. Convexity ID Weld Bead Width Avg. Current Display (Amperes) Figure 91 Reference Weld Illustration The following examples show how changes in various parameters can affect the weld shape. ©1999 Swagelok Company, all rights reserved August 2001...
  • Page 114 Raising the Impulse current raises the average current. This Figure 93 Improper Weld Example increases the heat input per unit of electrode travel resulting in No. 2 increased inside diameter convexity and weld bead width. Reference Illustration of Proper Weld ©1999 Swagelok Company, all rights reserved August 2001...
  • Page 115 Raising the Maintenance current raises the average current. This increases the heat input per unit of electrode travel resulting in increased inside diameter convexity and weld bead width. Reference Illustration of Proper Weld ©1999 Swagelok Company, all rights reserved August 2001...
  • Page 116 Lengthening the Impulse Width raises the average current. This increases the heat input per unit of electrode travel resulting in increased inside diameter convexity and weld bead width. Reference Illustration of Proper Weld ©1999 Swagelok Company, all rights reserved August 2001...
  • Page 117 2 (26) No. 8 Lowering the Rotor Speed increases the heat input per unit of electrode travel resulting in increased inside diameter convexity and weld bead width. Reference Illustration of Proper Weld ©1999 Swagelok Company, all rights reserved August 2001...
  • Page 118 Raising the pulse rate increases weld-spot overlap. Figure 102 Pulse Rate Weld At times, the welding parameters (as described on Example No. 2 page 104) must be adjusted to create an acceptable weld. ©1999 Swagelok Company, all rights reserved August 2001...
  • Page 119 To inspect the fuse: 1. Turn off the power supply. See Figure 103. 2. Unplug the power cord. Figure 103 Power Supply Circuit Breaker in the OFF Position ©1999 Swagelok Company, all rights reserved August 2001...
  • Page 120 Table 26 Duty Cycle Model 100% SWS-M100-1 100 Amps 75 Amps 45 Amps 9 Volts 9 Volts 9 Volts SWS-M100-2 100 Amps 75 Amps 45 Amps 13 Volts 9 Volts 9 Volts ©1999 Swagelok Company, all rights reserved August 2001...
  • Page 121 230 V (ac) #12 AWG #10 AWG (2,5 mm) (4,0 mm) Some power loss will occur, depending on the length of the extension cord. See table to determine the minimum wire size to use. ©1999 Swagelok Company, all rights reserved August 2001...
  • Page 122 M100 Power Supply ©1999 Swagelok Company, all rights reserved August 2001...

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