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Polysoude P6 HW, Operating, Maintenance And Programming Manual, Page: 48 / 100

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Polysoude P6 HW Operating, Maintenance And Programming Manual Download Page 48

THE ART OF WELDING

P6 HW

48-100 

PN-0110008 Rev. 12 

 

Rear connector panel

4. 4. 2. 

Item

Description

Item

Description

FA 1

On/off switch.

FA 23

Connection of a bar code reader.

FA 6

Connection of the second gas supply (op-

tion).

FA 24

Incoming external coolant feed (cold cir-

cuit)

FA 8

Connection of the torch shielding gas input

FA 25

External coolant return (hot circuit)

FA 20

Connection of auxiliary equipments.

FA 30

Connection of the video system - Harting 

connector

FA 21

Connection of the data acquisition unit.

FA 31

Connection emergency stop button (option)

FA 22

Connection for RS232 serial link (oxygen 

analyzer).

FA 32

Connection of the video gas shielding

Summary of Contents for P6 HW

Page 1: ...P6 HW Operating maintenance and programming manual Mobile power source T I G H o t W i r e A V C O S C...

Page 2: ...rd source changes and corrections of translation 06 2012 Rev 6 Addition adapter manual torch 10 2012 Rev 7 Addition Settings oxygen meter configuration IP Address updates chapters Making adjustments d...

Page 3: ...ads 16 3 2 3 The tube to tube sheet welding heads 17 3 2 4 Accessories 17 3 3 Technical data for the P6 HW 18 3 3 1 Basic design 18 3 3 2 The P6 HW version remote control 20 3 4 Technical characterist...

Page 4: ...nt of the gas flow 57 5 1 7 Switching on the coolant pump 57 5 2 Use 58 5 2 1 Safety instructions 58 5 2 2 Program selection 58 5 2 3 Simulation 58 5 2 4 Weld cycle 58 5 2 5 Stop at end of the weld cy...

Page 5: ...y qualified persons While it is in use anyone not working with the equipment must be kept well away Meaning of the symbols 1 2 Risk of electric shocks Risk of serious injury caused by rotating parts R...

Page 6: ...embled If this is the case they must be replaced immediately The welding station must be correctly earthed If the component to be welded has to be earthed use a separate cable Use the appropriate conn...

Page 7: ...distance of 6 metres be tween the welding equipment and any greasy in flammable or dust laden materials Use safety shields to protect nearby workers Risk of explosion These risks are associated with t...

Page 8: ...s of push buttons and indicator lights refer to NF X 08 003 NF EN 60073 NF EN 894 1 ISO 369 must not be modified in any circumstances inversion of the colours Indicator lights or buttons with whose co...

Page 9: ...m electric arcs Safety instructions and protective arrangements must conform to NF EN 166 and NF EN 169 Faultfinding 1 4 8 Only a qualified electrician is authorised to inspect test adjust or repair e...

Page 10: ...C Electrical equipment designed to be used within certain voltage limits Standards applied 2 2 EN 60974 1 Arc welding equipment Part 1 Welding power sources EN 60974 10 Arc welding equipment Part 10 E...

Page 11: ...for successful welding The features of the P6 HW gener ator are as follows The welding sequences are completely programmable in the operator s language The handling is simple and easy to learn becaus...

Page 12: ...THE ART OF WELDING P6 HW 12 100 PN 0110008 Rev 12 Fig 3 3 P6 HW power source P6 HW 520 A mobile power source Ideal for high current hot wire welding...

Page 13: ...OF WELDING P6 HW PN 0110008 Rev 12 13 100 Fig 3 1 P4 power source Fig 3 2 P6 power source P4 170 A mobile power source Ideal for mobile use on site P6 300 A mobile power source Ideal for prefabricati...

Page 14: ...Rev 12 P6 HW 400 415 V 10 50 60 Hz with standard couplings with torch rotation control touch screen wire feeder control printer remote control pendant 6 axes torch rotation control arc voltage contro...

Page 15: ...THE ART OF WELDING P6 HW PN 0110008 Rev 12 15 100...

Page 16: ...head Fig 3 5 to weld large diameter pipes The closed chamber welding heads 3 2 2 MW Fig 3 6 when high productivity is required High duty cycle due to water cooling Adaptor kits available for welding o...

Page 17: ...plates for applications with high duty cycles Closed head designed for flush or slightly protruding tubes TS 2000 Fig 3 8 and TS 8 75 Fig 3 9 standard head for welding tubes plates Open head designed...

Page 18: ...nt panel also supports the printer and connec tions for the USB key and the RJ45 link for connect ing a PC There is a touchscreen mounted on top of the power source for programming and monitoring of t...

Page 19: ...THE ART OF WELDING P6 HW 1 2 3 4 5 6 PN 0110008 Rev 12 19 100 Fig 3 11 Description of the P6 HW power source...

Page 20: ...settings remotely Positioning welding heads and wire feeders Starting and stopping weld cycles Starting and suspension of the hot wire cur rent Selecting WPs and programs Simulating weld programs Min...

Page 21: ...1 for Vp Vmax Vp programmed speed 2 for Vp Vmax Controlled gases Torch gas second gas optional Source cooling Forced ventilation Torch cooling By external coolant Actual value display in cycle Permane...

Page 22: ...urce accessories 9 meters of hot wire current earthing cable Fig 4 1 2a 9 meters of welding earthing cable Fig 4 1 2b with Uworkpiece measurement cable A gas hose connector 3 hose connectors if the op...

Page 23: ...P23S it can be stored outside but must not be used without protection during precipitation Connection to mains electricity 4 2 3 supply All connections must be made by a qualified technician in accord...

Page 24: ...rate of this gas is controlled by a manual adjustment valve inserted into the circuit if the gas used refer to Fig 4 4 is the same as the welding gas The valve Fig 4 4 A is adjusted manually the litre...

Page 25: ...WELDING P6 HW 1 2 P6 A P6 1 2 2 1 PN 0110008 Rev 12 25 100 Fig 4 3 Connecting the gas supply to the P6 HW Fig 4 4 Connection diagram if one gas is used Fig 4 5 Connection diagram if two different gase...

Page 26: ...THE ART OF WELDING P6 HW 26 100 PN 0110008 Rev 12 Power supply Notebook P C Printer optional Ethernet cable RJ45 Acquisition module 240 VAC Connecting the acquisition module 4 2 5...

Page 27: ...THE ART OF WELDING P6 HW PN 0110008 Rev 12 27 100 P6 HW welding power source Measure connector of power source...

Page 28: ...er The connection to a wastewater system or external cooling system is at the rear of the power source Fig 4 6 1 Water inlet Fig 4 6 2 Water return The direction in which the coolant travels must be c...

Page 29: ...h o Select IP Adress with the button BT 1 Confirm the selection with the button BT 3 N On the display of the remote control pendant appears Ip number The IP address is in the form of four numeric bloc...

Page 30: ...xis configuration to equipments Polysoude see the memo Axis Configuration Standard L op rateur doit imp rativement respecter le choix de types d axes sp cifi s par Polysoude En cas de non respect de c...

Page 31: ...g the button for one second that action be taken into account Remote control unit connection 4 3 2 The wire feed unit is connected at the front connection panel of the P6 HW by a screw connector If th...

Page 32: ...vo control of height to the arc voltage is required this voltage must be measured on the workpiece directly and as close as possible to the electrode A white wire tied to the earth cable makes it poss...

Page 33: ...THE ART OF WELDING P6 HW PN 0110008 Rev 12 33 100 Fig 4 9 Connection of an open welding head of the MU type or a tube tube sheet welding head of the type TS or TP...

Page 34: ...and oxide Connecting the voltage measurement device to the workpiece If servo control of height to the arc voltage is required this voltage must be measured on the workpiece directly and as close as...

Page 35: ...THE ART OF WELDING P6 HW PN 0110008 Rev 12 35 100 Fig 4 10 Connection of a Polycar hot wire type head...

Page 36: ...cable to the terminal on the connector panel The terminal is surrounded by a red ring Connection is made with a quick fit connector locked by turning clockwise The cable end is marked red Connection...

Page 37: ...uick fit connector locked by turning clockwise The cable end is marked red Connection of the rotation motor cable The wire feed unit is connected at the front connection panel of the P6 HW by a screw...

Page 38: ...ion of a wire feed unit Connection of a wire feed unit 4 3 7 The wire feed unit is connected at the front connection panel of the P6 HW by a screw connector symbol Make sure that the securing ring is...

Page 39: ...urn Earth current and water feed The connection of these adapters to the power source and cooling circuit is identical to those of a liquid cooled closed chamber welding head To avoid damage or poor w...

Page 40: ...tor locked by turning clockwise Connect the other end of the cable to the workpiece as close as possible to the joint to be welded in an area free from grease and oxide Connection of the trigger contr...

Page 41: ...e or change the head appropriately to enable the welding cycle to start Detection of the open head 4 3 11 position If an old type of closed head is used the power source starts to strike an arc provid...

Page 42: ...the oxygen meter on the GUI It is particularly important to refer to the oxygen meter user manual In it you will find detailed explanations of the various functions of the equipment Oxygen meter setti...

Page 43: ...thernet switch and power supply must be filed right side plate of the power source The drive connects to the power source via a cable equipped with an auxiliary connector 44 pin 0 10 V or 10 10 V sign...

Page 44: ...F WELDING P6 HW 1 44 100 PN 0110008 Rev 12 Fig 4 20 Remote control unit with emergency stop The rear connector 44 pin connector allows the drive Here the representation of the connector with the I O a...

Page 45: ...4 V max input 9 0V motor 10 Not used 0 10V signal 11 Not used 12 Not used 13 14 15 16 Way B encoder 17 0V encoder 18 24V output 19 Left stop 20 Order start cycle 21 Forward run 22 24 V max input 23 St...

Page 46: ...le FA 12 Coolant outlet connection 1 FA 13 Coolant return connection 1 FA 14 Connection of the PC interface RJ45 FA 15 Connection of the USB key FA 16 Short press a ticket is printed summarising the w...

Page 47: ...THE ART OF WELDING P6 HW FA 15 FA 2 FA 29 FA 7 FA 11 FA 10 FA 3 FA 14 FA 4 FA 5 FA 9 FA 28 FA 13 FA 19 FA 18 FA 12 FA 26 FA 27 FA 17 FA 16 PN 0110008 Rev 12 47 100 Fig 4 22 Front connector panel...

Page 48: ...Incoming external coolant feed cold cir cuit FA 8 Connection of the torch shielding gas input FA 25 External coolant return hot circuit FA 20 Connection of auxiliary equipments FA 30 Connection of the...

Page 49: ...THE ART OF WELDING P6 HW FA 1 FA 20 FA 6 FA 8 FA 21 FA 30 FA 22 FA 24 FA 25 FA 32 FA 31 FA 32 PN 0110008 Rev 12 49 100 Fig 4 23 Rear connector panel...

Page 50: ...everal seconds On the display of the remote control pendant appears I P A d r e s s T a c h o Select IP Adress with the button BT 1 Confirm the selection with the button BT 3 N Modification of the IP...

Page 51: ...BT 15 BT 14 BT 13 BT 12 V 6 V2 V1 BT 4 BT 5 BT 7 BT 9 BT 10 V 11 BT 6 BT 8 BT 11 AF 1 V4 V3 BT 23 BT 25 BT 22 BT 24 BT 21 BT 18 BT 19 V 9 V 10 BT 20 V 7 V 8 V 12 V 5 BT 28 BT 27 BT 26 PN 0110008 Rev 1...

Page 52: ...minated BT 22 Has two functions Out of cycle torch oscillation with self cen tring In cycle Decreases the oscillation in amplitude or in time according to BT 21 BT 23 Has two functions Out of cycle no...

Page 53: ...3 BT 1 BT 2 BT 16 BT 15 BT 14 BT 13 BT 12 V 6 V2 V1 BT 4 BT 5 BT 7 BT 9 BT 10 V 11 BT 6 BT 8 BT 11 AF 1 V4 V3 BT 23 BT 25 BT 22 BT 24 BT 21 BT 18 BT 19 V 9 V 10 BT 20 V 7 V 8 V 12 V 5 BT 28 BT 27 BT...

Page 54: ...C y c l e e n d O K W P 0 0 1 I N 1 7 0 x 1 5 P R G 0 3 A B C D E F G F r i 0 5 J a n 2 0 0 7 1 1 4 9 W P 0 0 1 I N 1 7 0 x 1 5 P R G 0 3 A B C D E F G S 0 5 T 0 0 1 5 s 0 1 2 4 i M a n u a l d o w n...

Page 55: ...cycle shows on the first two rows the WP and the current program on the third row the number of the current sector elapsed time and the movement pulses on the fourth row 2 stars 1Hz encircling an exc...

Page 56: ...closed chamber welding heads the cycle cannot be started unless the electrode is in the open head position The command is carried out in 3 stages for 1 second the rotation is made at low speed then fo...

Page 57: ...ouching the sides This implies that the workpiece voltage measurement wire and electrode must be connected Adjustment of the gas flow 5 1 6 The gas flow is adjusted with a flow meter installed on the...

Page 58: ...ck the flow rate settings or save gas during the simulation phases Selection of a simulation is made with BT 4 which illuminates V 1 Fig 5 5 Controls used for selecting the WP pro gram Weld cycle 5 2...

Page 59: ...rmed On this ticket are The names of the WP and program Values of current voltage rotation speed and wire feed speed measured regularly during the cycle Reason for stopping OK for normal cycle oth erw...

Page 60: ...gain changes to high current and so on The cycle is stopped either by pressing the downslope button or pressing both buttons at the same time will stop the cycle immediately Fig 5 11 Pushbutton to com...

Page 61: ...tion a sign should be marked as point of reference on the fix part of the welding head With the remote control pendant Press the button BT 6 I of the remote control pendant during several seconds On t...

Page 62: ...THE ART OF WELDING P6 HW 62 100 PN 0110008 Rev 12...

Page 63: ...THE ART OF WELDING P6 HW PN 0110008 Rev 12 63 100...

Page 64: ...THE ART OF WELDING P6 HW 64 100 PN 0110008 Rev 12...

Page 65: ...THE ART OF WELDING P6 HW PN 0110008 Rev 12 65 100...

Page 66: ...THE ART OF WELDING P6 HW 66 100 PN 0110008 Rev 12...

Page 67: ...THE ART OF WELDING P6 HW PN 0110008 Rev 12 67 100...

Page 68: ...THE ART OF WELDING P6 HW 68 100 PN 0110008 Rev 12...

Page 69: ...rinter change the roll of thermal paper either by pulling down the two tabs of the cover Fig 6 1 1 or by pressing the button Fig 6 1 4 Take out the empty roll and insert the new one so that the curve...

Page 70: ...FU4 Fig 6 3 4 with time delay 1 6 AT for transformers T2 and T3 is located on the lower left hand side of the power source Fig 6 4 Coolant filter Cooling circuit filter 6 2 2 The P6 HW generator is f...

Page 71: ...d correct or replace Remote control card 0028049100 defect Replace No display on the remote con trol or no backlighting Remote control card 0028049100 or display adapter 0028209200 de fect Replace The...

Page 72: ...gnition Immediate stop Weld current cable badly connected or cut Correct or replace Earth connection not clamped at a clean zone Move earth connection 4 3 2 or 4 3 6 Electrode contaminated or too far...

Page 73: ...Power source badly adjusted Contact Polysoude After Sales Service Current source defect Contact Polysoude After Sales Service Rotation or wire feed control Immediate stop or enforced slope down Sticky...

Page 74: ...in the welding program Insufficient sensitivity Check and correct the values of parameters in the welding pro gram Connection of Uarc measurements defective Correct or modify connections or replace c...

Page 75: ...f it had been switched off by mistake anyhow the following instructions shall be carried out to save the remai ning files Connect the USB flash drive to the appropriate USB port Appuyer sur le bouton...

Page 76: ...13 17 8 9 18 1 11 10 9 18 16 15 19 20 5 6 4 2 21 22 23 24 76 100 PN 0110008 Rev 12 Fig 6 9 Internal right hand view Fig 6 10 Internal left hand view Fig 6 11 Internal view from above In front of the p...

Page 77: ...00 LVDS screen module 13 0028279100 Welding source adaptation 14 0028229200 motor inductor interface 24 9000629245 Source 520 A 15 0028029200 Hot wire source module 16 9000629184 Printer 17 00530054 F...

Page 78: ...THE ART OF WELDING P6 HW 4 3 5 8 2 1 7 9 6 78 100 PN 0110008 Rev 12 Fig 6 12 View of P6 HW remote con trol front panel Fig 6 13 Internal view of P6 HW remote control...

Page 79: ...with emergency stop 9000563323 Remote control plug 9000563326 Crimp contact for the plug 1 9000502015 Green light 2 9000502019 Red light 3 9000542083 Green button for the remote control 4 9000542082...

Page 80: ...THE ART OF WELDING P6 HW 2 3 4 6 5 7 2 3 4 6 5 7 1 80 100 PN 0110008 Rev 12 Fig 6 14 Internal view of the touchscreen...

Page 81: ...ion 1 0026119199 Touchscreen unit 2 9000623722 Touchscreen 3 9000623724 Screen SVGA LVDS 10 4 4 9000623725 Backlight converter for the screen 5 9000623723 Touchscreen controller old 9000623790 Touchsc...

Page 82: ...rol cards 0028019100 and the LVDS screen and touchscreen control card 0028069100 are directly connected to sequencer card 1 The welding current source inter face card 0028029400 is connected via a rib...

Page 83: ...THE ART OF WELDING P6 HW PN 0110008 Rev 12 83 100 Fig 6 15 Block diagram of the P6 HW power source for gas current rotation and wire feeding...

Page 84: ...THE ART OF WELDING P6 HW 84 100 PN 0110008 Rev 12 Fig 6 16 Block diagram of the P6 HW for AVC Oscillation and hot wire...

Page 85: ...be executed with argon as shielding gas Warning some applications require several programs All programs that use filler wire have been developed with wire of 0 8 mm diameter The result and the qualit...

Page 86: ...ages Stop Rotation 4241 Control of rotation speed Stop 4273 Rotation overcurrent Rotation motor blocked Stop 4449 Start open welding head Stop Wire 4257 Control of wire speed Imposed downslope 4289 Wi...

Page 87: ...n Max Unit Increment Default Ignition current Ignition current I20 5 520 A 1 25 Prefusion ramp time Ramp time T20 0 9999 s 1 0 High current High current I22 5 0 520 0 A 0 1 10 High current time Pulse...

Page 88: ...wire speed V42 0 then d d mm min 1 d 0 then d d in min 0 1 d Wire speed low current Low wire speed V43 0 then d d mm min 1 d 0 then d d in min 0 1 d Delaying of wire feeding stop Stop wire N40 0 9999...

Page 89: ...at thermal pulsing H52 e e V 0 1 e Arc voltage background current Low voltage H53 e e V 0 1 e Time Blocage front T54 10 250 ms 1 10 Height torch retract Height H54 e e mm 1 e e e in min 0 1 e Oscilla...

Page 90: ...THE ART OF WELDING P6 HW 90 100 PN 0110008 Rev 12...

Page 91: ...in accordance with Directive 2002 96 EC Any item of equipment which is declared obsolete or out of service must be sent to approved recycling companies in order to reduce the amount of ultimate waste...

Page 92: ...THE ART OF WELDING P6 HW 92 100 PN 0110008 Rev 12...

Page 93: ...THE ART OF WELDING P6 HW PN 0110008 Rev 12 93 100...

Page 94: ...THE ART OF WELDING P6 HW 94 100 PN 0110008 Rev 12...

Page 95: ...sed 25 Fig 4 5 Connection diagram if two different gases are used 25 Fig 4 6 Connection of external coolant to the P6 HW 28 Fig 4 8 Connection of the remote control unit to the P6 HW power source 31 F...

Page 96: ...tart 58 Fig 5 8 Pushbutton for tuning during the cycle 58 Fig 5 9 Override buttons for developing programs 59 Fig 5 10 Reprint ticket for weld carried out 59 Fig 5 11 Pushbutton to command stoppage wi...

Page 97: ...t panel 78 Fig 6 13 Internal view of P6 HW remote control 78 Fig 6 15 Block diagram of the P6 HW power source for gas current rotation and wire fee ding 83 Fig 6 16 Block diagram of the P6 HW for AVC...

Page 98: ...THE ART OF WELDING P6 HW 98 100 PN 0110008 Rev 12...

Page 99: ...ding and are therefore 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 p...

Page 100: ......

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