Polysoude MU IV 104 User Manual Download

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THE ART OF WELDING

MU IV

User manual PN-0706056

Open Welding Head

TIG – with or without filler wire , AVC , OSC

Summary of Contents for MU IV 104

Page 1: ...THE ART OF WELDING MU IV User manual PN 0706056 Open Welding Head TIG with or without filler wire AVC OSC...

Page 2: ...andards and equipment compatibility Ind 4 Update Tools box and MU IV wiring plug AVC OSC wiring Ind 5 Update Sparepart box Ind 6 Update Ind 7 Update Recommended lubricant brands Ind 8 Update on page 3...

Page 3: ...4 Installation 26 4 1 Handling 26 4 2 Installation on site 26 4 3 Handling 26 4 4 Bundle 27 5 Use 28 5 1 Precautions 28 5 2 The electrode 29 5 3 Wire sheaths 33 5 4 Ignition ring 35 5 5 Built in feede...

Page 4: ...THE ART OF WELDING MU IV 4 80 PN 0706056 Ind 8...

Page 5: ...not working on the equipment must remain well clear when it is in use Meaning of the symbols 1 2 Risk of electric shocks Risk of severe injuries caused by moving parts Risk of fume or gas inhalation R...

Page 6: ...ely The power supply must be properly earthed Use a separate cable if the workpiece must be earthed Appropriate connectors must be used Pay attention to the off load voltage that is limited to 80 V ef...

Page 7: ...m between the welding equipment and any greasy inflammable or dusty substance Use protective curtains to protect staff working nearby Risk of explosion These risks related to the use and handling of...

Page 8: ...THE ART OF WELDING MU IV 8 80 PN 0706056 Ind 8...

Page 9: ...lustrated parts lists MU IV 80 welding head PN 0706050 Illustrated parts lists MU IV 104 welding head PN 0706051 Illustrated parts lists MU IV 115 welding head PN 0706052 Illustrated parts lists MU IV...

Page 10: ...THE ART OF WELDING MU IV 10 80 PN 0706056 Ind 8...

Page 11: ...e MU IV welding head range is used to weld tubes with an exterior diameter of between 8 mm and 275 mm It includes 10 head sizes with different welding capacities as shown in the following table and di...

Page 12: ...an be reheated up to 150 C Max inter pass temperature of 200 C Description of the equipment 3 4 This range of open welding heads is flexible and adaptable Two welding plates Simple plate the torch is...

Page 13: ...ed shell clamps Chuck clamps Shell clamps Tube outlet Tube outlet Tube outlet for clutch Tube outlet for clutch Clutch Drive Plate AVC OSC plate Torch Gas lens Wire ad justment Wire sheath Wire sheath...

Page 14: ...led the motor output Fig 3 2 2 Drive mechanism Fig 3 2 3 Clamping device Clamps Fig 3 2 4a Shell Fig 3 2 4b Weld plate Fig 3 2 5 Weld plate with AVC OSC Fig 3 2 6 A built in wire feeder from MU 128 AV...

Page 15: ...PN 0706056 Ind 8 15 80 THE ART OF WELDING MU IV 4a 4b 7 8...

Page 16: ...the motor in forms the Polysoude welding generator of the actual position of the torch and is used to control the weld ing sequence control of the sector starts and stops This encoder is also used to...

Page 17: ...let parallel to the tube An angle output perpendicular to the tube For MU IV 195 to 275 A clutch An outlet parallel to the tube for the clutch An angle output for the clutch perpendicular to the tube...

Page 18: ...clamp and unclamp The shell clamp The shell clamp is made up of a spring clip type mechanism that controls a clamping arm Fig 3 5 3 fitted with an adjusting screw Fig 3 5 4 according to the diameter...

Page 19: ...on plates MU IV 195 to 245 AVC OSC plate Fig 3 6 3 4 Heads equipped with an AVC OSC plate can only be used with generators with the corresponding functions The AVC OSC plate is fitted with two motor...

Page 20: ...n the welding head 2 2 m for MU IV 28 to 104 3 2m for MU IV 115 to 295 Gas lenses Three types of gas lens according to the diameter of the tubes to be welded GM type Fig 3 8 1 P type Fig 3 8 2 N type...

Page 21: ...rage I A Wireless MU IV 250 to 100 190 to 100 MU IV with wire filler Amps 250 to 100 190 to 100 MU IV AVC OSC Amps 250 to 100 190 to 100 Ambient noise In welding mode as per the directive 2006 42 EC d...

Page 22: ...80 PN 0706056 Ind 8 Equipment compatibility 3 7 The MU IV welding heads are compatible with all the generators in the Polysoude range provided that the duty cycles heads and generators and options th...

Page 23: ...5 14 174 5 254 MU IV 114 275 P 500 30 5 14 172 5 276 O D related shell clamping MU IV 14 28 C 8 to 28 116 16 5 79 70 MU IV 14 38 C 8 to 38 126 16 5 79 72 MU IV 30 64 C 19 to 64 155 16 5 88 93 MU IV 3...

Page 24: ...U IV 25 128 P 340 16 20 30 134 173 MU IV 76 195 P 410 16 20 30 165 208 MU IV 101 245 P 500 16 20 30 179 254 MU IV 114 275 P 530 16 20 30 179 276 O D related shell clamping MU IV 14 38 C 8 to 38 142 23...

Page 25: ...PN 0706056 Ind 8 25 80 THE ART OF WELDING MU IV A Ca A 2 B C Cb D E...

Page 26: ...c to the ma chine Please keep the original packaging and use it whenever transporting the machine in order to avoid any damage When the machine is not in use and is removed from its support it must be...

Page 27: ...f electromagnetic interference is detected the user of the arc weld ing material is responsible for correcting the situation with the manufacturer s assistance extract from the standard EN 60974 10 20...

Page 28: ...of the torch or the slides The operators must be informed to this effect When welding large parts whose shape is similar to a confined space or tank the operator must check that the oxygen level be t...

Page 29: ...f the electrode is crucial for the ignition arc to be checked regularly The length of the electrode must be adapted to the type of gas lens used and the thickness of the tube Each electrode can withst...

Page 30: ...128 N 26 42 108 GM 36 25 88 195 N 26 76 195 GM 26 76 195 245 N 26 101 245 GM 26 101 245 275 N 26 114 275 GM 26 114 275 MU IV AVC BL Model Gas lens Length of the nozzles Min Maxi 38 P 16 14 38 64 P 19...

Page 31: ...ip of the electrode on the side of the slits in the chuck Install the chuck electrode assembly in the gas lens Fig 5 5 3 Screw the gas lens with its washer Fig 5 5 3 pay attention to the direction of...

Page 32: ...rew to reduce the distance between the electrode and the part MU IV 195 245 and 275 welding heads without servo control The adjustment is made using the knurled but ton Fig 5 7 1 The sensor fitted wit...

Page 33: ...ozzles are available depending on the diameter of the wire 0 6 0 8 1 0 1 2 mm A small nozzle option is available for 0 9 wire Two Teflon liners are available according to the diameter of the wire 2 4...

Page 34: ...he bath and the nozzle outlet It is advisable to use wires with a diameter of 0 8 mm or 0 9 Note if the diameter of the wire is changed remember to change the corresponding accessories wire contact no...

Page 35: ...be adapted to each welding application The adjustment system comprises A vertical runner used to control the altitude De f using a screw Fig 5 10 1 A transverse runner used to adjust the wire in the s...

Page 36: ...the driving rollers rotating Fig 5 12 View F The wire speed is important do not place your hand in front of the wire Direct the wire so that it may not reach you Actuate the wire at a low speed The wi...

Page 37: ...PN 0706056 Ind 8 37 80 THE ART OF WELDING MU IV A B C D E F G H 3 4 2 1 5 Fig 5 12 Placing the wire...

Page 38: ...straightening rollers on the side Fig 5 13 View C Replace the wire Adjust with the adjusting screws of the rollers until the wire comes out straight If the wire unwinds on the same side as the two gu...

Page 39: ...ust be free Bring the clamp into contact with the tube using one of the adjusting knobs Fig 5 14 2 Open the clamp with the lever direction B Tighten the clamp by turning the adjusting knob by a 1 6 tu...

Page 40: ...p using the control lever direction A Fig 5 15 2 In this position the tube must be free Adjust the screw Fig 5 15 3 until it is in contact with the tube Open the clamp direction B Tighten the locking...

Page 41: ...ng head correctly Wind the multi duct and the wire sheath on the reels provided on the welding plate before start ing the automatic welding cycle They must always unwind during the welding cycle The w...

Page 42: ...t adjusted No impulses Faulty impulse emitter Control electronic fault Rotation under 360 Programming error Drive damaged Drive pin broken Wire No wire Wire switch in wrong position Polyfil not engage...

Page 43: ...re indicative of leaks and therefore deterioration of the internal housing Check the connections and end pieces are tight Looking for abnormal noises Frequency Operation Every 3 months Every 3 months...

Page 44: ...power switch locked Clean all the teeth with solvent with a brush Remove all traces of lubricant or other debris Check the condition of the pinion it should not be oxidised and its surface treatment...

Page 45: ...generating screw nut assemblies of both slides by means of a soft paint brush Lubricate both sides of the screws with a hard paint brush Put some lubricant on the joints and adjusting screws with a sm...

Page 46: ...not rest on it and that it does not have any foreign bodies or sharp edges likely to tear the notches of a notched belt for example Check that the sides of the groove base are worn in the same way De...

Page 47: ...r MU IV 28 to 80 Ref 100001720 For MU IV 104 to 275 Ref 100001721 Consumables 6 4 1 Order code Designation MU IV 28 to MU IV 80 MU IV 104 to MU IV 275 29810143 Short chuck 2 4 X X 29820170 Chuck 2 4 X...

Page 48: ...8 80 PN 0706056 Ind 8 Tools 6 4 2 Order code Designation MU IV 28 MU IV 80 MU IV 104 MU IV 275 100003625 BTR wrench assembly Ref 82H X X 62209801 Box tools 240x195x42 X X 62811004 Screwdriver 4x75 X X...

Page 49: ...e factory adjustments Certain parts cannot be delivered separate ly they must be included with the pre adjusted subassembly ready for mounting Risk of electric shocks for the following opera tions the...

Page 50: ...Clean cloth Hex head key set Consumables Spare parts Frequency Replacement criteria In the event of ingress of foreign bodies Preconditions Disconnect the equipment from the power supply Procedure Com...

Page 51: ...PN 0706056 Ind 8 51 80 THE ART OF WELDING MU IV...

Page 52: ...t the outlet of the reducer gear If the 2 mm hole is oval or if the shaft shows signs of scratches or impacts then install a new reducer gear Check the insulating gear support 3 If it is split or brok...

Page 53: ...PN 0706056 Ind 8 53 80 THE ART OF WELDING MU IV 2 5 3 4 1 6...

Page 54: ...ntly extract the motor 4 by pushing the power cable through the packing gland Loosen the screws in the pillars 5 supporting the sensor Unsolder the five wires Remove the sensor 6 Solder the three wire...

Page 55: ...PN 0706056 Ind 8 55 80 THE ART OF WELDING MU IV 2 1 6 6 5 3 4...

Page 56: ...two stop screws of the hose connectors 1 Unscrew the fastening screw 2 of the cover 3 Remove the cover plate Wire feeder pressure roller Unscrew the roller axle 4 Remove the pressure roller 6 and the...

Page 57: ...PN 0706056 Ind 8 57 80 THE ART OF WELDING MU IV 1 2 4 6 5 8 7 9 10 11 12 3...

Page 58: ...ining the inlet nozzle 5 Remove the inlet nozzle 4 and the worn Teflon sheath 2 Remove the worn Teflon sheath from the inlet nozzle Unscrew the small outlet nozzle 1 Cut a length of Teflon sheath that...

Page 59: ...PN 0706056 Ind 8 59 80 THE ART OF WELDING MU IV 1 2 3 4 5...

Page 60: ...Loosen the pressure screw retaining the braid 2 Stretch the braid 1 and the multi duct Cleanly cut the braid leaving about 20 mm protruding Installation For greater ease of installation slide the mult...

Page 61: ...PN 0706056 Ind 8 61 80 THE ART OF WELDING MU IV 6 5 4 1 2...

Page 62: ...the multi duct then push back the silicon sheath 4 and the Nomex sheath 6 at the same time Loosen the pressure screw retaining the braid 4 then remove the piece of braid 1 remaining in the torch Cut t...

Page 63: ...PN 0706056 Ind 8 63 80 THE ART OF WELDING MU IV 1 3 2 5mm env 6 5 4...

Page 64: ...al equipment Consumables Spare parts Silicone tube Plug 00563302 Grounding braid Frequency Replacement criteria Wiring repair Preconditions Non live equipment Procedure Insert the AVC OSC wires 1 in t...

Page 65: ...t tab and nut hole Insert the induction coil tab in the hole while hot Wait a few seconds for the assembly to cool down Solder a 5 cm wire onto the induction coil 8 Insert the wire into a heat shrinka...

Page 66: ...ing screw of the induction coil 14 Leave the other lug 15 free ready to be connec ted to the harness Assemble a grounding braid with two lugs one with a diameter of 3 mm and the other with a diameter...

Page 67: ...PN 0706056 Ind 8 67 80 THE ART OF WELDING MU IV...

Page 68: ...BTR wrenches Crimping and cutting pliers Welding tool for electric equipment Consumables Spare parts Frequency Replacement criteria Repairing the wiring Preconditions Non live equipment Procedure Stri...

Page 69: ...uency Replacement criteria Repairing the wiring Preconditions Non live equipment Procedure Strip the 4x0 5 3x2x0 22 cable on the generator side Place a rubber ring in the sleeve Insert the rotation wi...

Page 70: ...Capteur opto Opto sensor Capot moteur Motor cover Rotation Rotation X Y 0 V 15 V Z imp Moteur Motor G E D 00563103 00563130 10503302 PR F C A B 1 4x0 5 3x2x0 22 00551134 L 9m PR A PR C PR F PR B PR G...

Page 71: ...PN 0706056 Ind 8 71 80 THE ART OF WELDING MU IV MU IVWelding head wiring piece of wiring diagram 11334101...

Page 72: ...THE ART OF WELDING MU IV 72 80 PN 0706056 Ind 8...

Page 73: ...e 2002 96 EC some of the electric and electronic components installed in the equipment must be recycled At the end of its life expectancy the material must be handed over to approved recycling compani...

Page 74: ...THE ART OF WELDING MU IV 74 80 PN 0706056 Ind 8...

Page 75: ...designation taken from Power source Type Serial number Welding head Type Serial number Wire feeder Type Serial number Other to be specified Serial number REASON FOR RETURN Return of loan equipment Re...

Page 76: ...THE ART OF WELDING MU IV 76 80 PN 0706056 Ind 8...

Page 77: ...y 20 Fig 4 1 Slinging 27 Fig 5 1 Electrode grinding 29 Fig 5 2 GM Type gas lens 30 Fig 5 3 N Type gas lens 30 Fig 5 4 P Type gas lens 30 Fig 5 5 Gas lens assembly 31 Fig 5 6 Adjustment of the distance...

Page 78: ...THE ART OF WELDING MU IV 78 80 PN 0706056 Ind 8...

Page 79: ...refore not contrac tual All rights reserved No total or partial reproduction of this work will be made in any form or by any means whatsoever be it electronic or mechanical including photocopying reco...

Page 80: ...39 02 93 79 90 94 info polysoude it JAPAN GMT CO Ltd KAWASAKI 81 0 44 222 6751 gmt e gmt co jp GMT CO Ltd OSAKA 81 0 789 35 6751 gmt kansai e gmt co jp JORDAN POLYSOUDE UK 44 0 1942 820 935 info polys...

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