Manual torch, AS20 DD

Technical Manual PN-1218178

 Manual torch, AS20 DD

Product Manual torch, AS20 DD

Reference 75500532
Manual PN-1218178
Author SBR

Document revision history

Rev. 0 Original version 01/2018

If this technical manual is to be printed, both sides of the page must be used to improve understanding
and readability.

Users of the equipment must receive a copy of this manual.

2-26 PN-1218178 Rev.0

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Contents

1. Safety instructions ............................................................................................ 4

1. 1. Hazards associated with arc welding .................................................................... 4
1. 2. Meaning of the symbols ...................................................................................... 4
1. 3. Recommendations ............................................................................................. 6
2. General information .........................................................................................10
2. 1. Applicable directives ........................................................................................ 10
2. 2. Classification of the machine ............................................................................. 10
2. 3. Environment and conditions of use..................................................................... 10
2. 4. Technical data ................................................................................................. 11
3. Installation .....................................................................................................12
3. 1. Handling ........................................................................................................ 12
3. 2. Installing the bundle ........................................................................................ 12
4. Use ................................................................................................................13
4. 1. Precautions for use .......................................................................................... 13
4. 2. Electrodes ...................................................................................................... 14
4. 3. Mounting the V2 assembly ................................................................................ 16
4. 4. Changing the electrode ................................................................................... 17
5. Maintenance and troubleshooting .......................................................................18
5. 1. Non-programmable parameters ......................................................................... 18
5. 2. Routine maintenance operations ........................................................................ 18
5. 3. Maintenance recommendation ........................................................................... 19
5. 4. Consumables .................................................................................................. 20
1. 1. Consommables................................................................................................ 20
6. End of service life – Recycling the machine ..........................................................22

PN-1218178 Rev.0 3-26

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1. Safety instructions
Warning: Protect yourself and others from injury − Read and follow these precautions.

1. 1. Hazards associated with arc welding

The symbols reproduced below are used throughout this Technical Manual in order to draw your
attention to and identify the potential hazards. When you see one of these symbols, refer to the safety
instructions in the ‘Recommendations’ section below.
This equipment must only be installed, used, maintained and repaired by qualified persons.
While it is in use, anyone not working with the equipment must be kept well away.

1. 2. Meaning of the symbols

Risk of serious injury caused

Risk of electric shocks
by moving parts

Risk of inhaling fumes or

Risk of explosion
gases

Risk of burns to the eyes or Risk of exposure to magnetic

the skin due to heat radiation fields

Warning: hot surfaces – Risk

Danger caused by noise
of burns

Risk of burns to the eyes or

Risk of excessive heat or fire
the skin due to flying sparks

Hardhats must be worn Safety glasses must be worn

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Protective footwear must be

Fall hazard
worn

Read the instructions

Refer to the
Le pictogramme Information
recommendations below in
signale une information
importante order to take the necessary
precautions to avoid all
hazards

Le pictogramme Avertissement
Le pictogramme Danger signale
signale un danger pour la
un danger pour le matériel
sécurité de l'opérateur

Danger rayonnement laser.

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1. 3. Recommendations

Risk of electric shocks Risk of inhaling fumes or

gases

The electrical components include the electrode,

the welding circuit, the input circuit and the internal Welding generates fumes and gases which are
circuits, the welding wire and the metal parts in hazardous to health. Do not inhale the fumes.
contact with it, the wire feeder and the housing for Origin of the fumes and gases: base metal, filler
the welding wire feed rollers. The slightest contact metal, coating (flux) with welding by coated electrode,
with these parts may cause an electric shock or even shielding gas, solvents and materials covering the
electrocution when the machine is switched on. metal to be welded.
Factors increasing the risk of electric shock: Moisture
in the immediate area, working on an electrically- To prevent risks:
conductive surface, inadequate earthing, poor • Use respiratory protection such as reusable
maintenance of the equipment and unsafe working respirators, powered or supplied air respirators,
methods. or disposable respirators.
• Avoid chlorinated solvents.
To prevent risks: • Ensure that the components are completely dry
• Avoid any contact with live wire spools. before welding.
• In the case of water-cooled torches, inspect the • Do not work alone!
torch at regular intervals in order to identify • Trap the fumes and gases at source.
any leaks; take care to prevent condensation. • Remove paint, oil or any other surface coat-
• Do not coil the cables around your body. ing.
• Before replacing the electrode, ensure that it is
no longer live.
• Switch off the machine before carrying out any
maintenance or repair operations or while it is
not in use. Risk of burns to the eyes or
• Wear safety gloves, clothing, aprons and boots the skin due to heat radiation
which are dry and free from holes.
• Insulate the component and the earth by
means of mats or other means of providing
sufficient insulation if the welder is required to Radiation from arc welding is liable to cause burns to
work on metal surfaces or structures. the eyes and the skin.
• This machine must be installed and earthed in
accordance with its User Manual and with na- Identification of risks: exposure to the radiation
tional, local and municipal codes of practice. emitted by the arc, generating intense visible and
• The return cable must be attached correctly invisible rays (ultraviolet and infrared), reflection of
(clean contact surface, cable securely fastened, the rays while welding metals such as aluminium and
as close as possible to the area to be welded). stainless steel, stray flashes, sparks and pin-holes
• Do not use damaged, worn or bare (uninsulat- created by the tip of a tungsten electrode.
ed) cables which are of insufficient size or not
properly assembled. If this is the case, they To prevent risks:
must be replaced immediately. • Wear gloves or leather gauntlets to protect
• The welding station must be correctly your hands and lower arms.
earthed. • Wear an apron or gaiters to protect your legs
• If the workpiece to be welded has to be from the knee to the forefoot.
earthed, use a separate cable. • Wear a mask (headband-type, hand-held or
• Use the appropriate connectors. electronic mask) or goggles fitted with a suit-
able filter.
Note the no-load voltage, which is limited to 80 V • Use safety shields to protect nearby workers.
r.m.s. for alternating current or 113 V for direct • Tie a scarf around your neck and button the
current (the voltage required to ignite the arc). The neck of protective clothing.
maximum value for plasma cutting power sources is
500 V.

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Warning: hot surfaces – Risk

Risk of explosion
of burns

Do not touch welded or flame-cut components with These risks are associated with the use and handling
bare hands. If such components have to be handled, of gas cylinders and flying sparks.
use the appropriate tools and/or wear thick, insulated
welders’ gloves to prevent any burns. • Do not use damaged cylinders.
Allow the components to cool before handling them • Store the cylinders in a well-ventilated area
or welding them. and restrict access to authorised personnel
only.
• Never exceed 55°C when storing or using cyl-
inders.
• Clearly identify empty cylinders to distinguish
Risk of burns to the eyes or them from full ones.
• Protect the cylinders from extremes of tem-
the skin due to flying sparks
perature (ice, sunlight, sparks, etc.).
• Check the connectors and hoses at regular
intervals.
• Wear gloves or leather gauntlets to protect • Use protective shields.
your hands and lower arms.
• Wear an apron or gaiters to protect your legs
from the knee to the forefoot.
• Wear a mask (headband-type, hand-held or
electronic mask) or goggles fitted with a suit- Risk of serious injury caused
able filter. by moving parts
• Use safety shields to protect nearby workers.
• Wear garments with long cotton or woollen
sleeves, preferably free from any traces of oil
• Keep hands away from fans and any moving
or grease. Do not wear clothing made from
parts.
synthetic fabrics.
• Keep all protective devices closed or in the
• Tie a scarf around your neck and button the
‘safety’ position.
neck of protective clothing.
• Wear welders’ safety boots.

Risk of exposure to magnetic

fields

Risk of excessive heat or fire

The distance between the welding circuit and the
brain is of fundamental importance.
• Never coil the cables around your body and
• Maintain the equipment at the electrical work-
certainly not around your shoulders.
station in good operating condition, particularly
• Advise your immediate superior if you are
the cables carrying the feed and return cur-
wearing a heart pacemaker. The interfer-
rent.
ence generated by the circuit requires special
• Maintain a minimum distance of 6 metres be-
protective measures, which must be applied in
tween the welding equipment and any greasy,
consultation with the company doctor.
inflammable or dust-laden materials.
• Use safety shields to protect nearby workers.

The operator must ensure

that no-one is exposed to the
hazardous area.

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The Information pictogram The Warning pictogram

indicates important information. indicates an operator safety
hazard.

If the information provided is performed incorrectly, Improper execution of a procedure or manoeuvre may
equipment malfunction or a poor quality result may result in serious injury or death. The operator must halt
occur. operations until the indications are fully understood
The operator must halt operations until the indications and applied.
are fully understood and applied.

The Hazard pictogram indicates

a hazard for the equipment Danger caused by noise.

Equipment damage may result if the procedure or Hearing protection is mandatory beyond this area.
the manoeuvre is performed incorrectly. The operator
must halt operations until the indications are fully
understood and applied.

Danger laser rayonnement

Never look directly into the beam. Never direct the

light beam towards third parties. serious eye injury
risk.
Never disconnect an optical fiber when it is on. The
light beam would not be directed into the groove and
can damage the eyes of operators.

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PN-1218178 Rev.0 9-26

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2. General information

2. 1. Applicable directives

2006/42/EC "Machinery" Directive

2014/30/UE Electromagnetic compatibility

2014/35/UE Electrical equipment designed for use within certain voltage limits

2. 2. Classification of the machine

The machine complies with the requirements of directives 2006/42/UE “Machinery”, 2014/30/UE “Electrical
equipment designed for use within certain voltage limits” and 2014/35/UE “Electromagnetic compatibility”.

2. 3. Environment and conditions of use

This equipment is designed for use in workshops, in a non-explosive atmosphere.

When operating the machine, the following conditions must be observed:

 Ambient air temperature: +10 to +40 °C.

 Relative humidity:
• Up to 50% at 40°C.
• Up to 80% at 20°C.

The ambient air shall not contain abnormal quantities of dust, acids, gas or corrosive substances. Fumes due to
welding are considered to be normal.

Examples of abnormal conditions of use:

 Abnormal corrosive smoke.
 Vapour.
 Excessive oil vapour.
 Shaking and vibration.

Ensure that air can enter and leave when using the equipment.

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2. 4. Technical data

Welding process

Bundle
Type Fast-on connections

Length (mm) 1000

Duty cycles
I peak max DC (A) 225 at 60%

I peak max AC (A) 200 at 60%

Fixed wire angle (°) 25

Electrodes
Diameters (mm) 1.6 - 2.4

Cooling
Water + Glycol 1

PN-1218178 Rev.0 11-26

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3. Installation

3. 1. Handling

This equipment must be unpacked and handled with care. If a

component has been damaged in transit, state this on the shipping
note and immediately notify the carrier.

Comply with the

symbols shown on the
case.

The machine is delivered in a packing case with protection, etc. This packaging is specific to the machine. The
original packaging must be kept for use each time the machine is transported in order to prevent damage.

When the machine is not used and removed from its support, it should be stored on a suitable support away
from any impacts (or in its packaging).

3. 2. Installing the bundle

The user is responsible for the installation and use of the arc
welding equipment in accordance with the manufacturer’s
instructions. If electromagnetic interference is detected, it must
be the responsibility of the user of the arc welding equipment to
resolve matters, with technical assistance from the manufacturer
(extract of standard EN 60974-10 2008 – Annex A).

Before using the machine, check the bundle. Too sharp an angle
can pinch the coolant and gas hoses. Limit this angle to 90° for
optimum operation.

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4. Use

4. 1. Precautions for use

To use a welding torch or perform maintenance, operators must

wear their protective equipment (gloves, boots, etc.).

Operators should pay particular attention to the temperature of

the material in contact with the high temperature zone.

Out welding operations, the electrodes represent a danger for

the operators, risk of injury with the tips.
During handling, maintenance operations or adjustment
operations, place the electrode covers on all the torches of the
installation. Remove these covers before welding operations and
keep them accessible

When not using the torch, it must be stored in the storage rack
provided for this purpose. It is important to keep the torch stored
to avoid any damaging shocks.

PN-1218178 Rev.0 13-26

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4. 2. Electrodes

Electrodes are fragile and must be handled carefully.

In order to obtain a good weld and avoid premature wear of the electrodes, it is essential that they are perfectly
clean. Avoid contact between the filler metal and the electrode otherwise the latter will deteriorate rapidly.

The electrode supplied by Polysoude is made of tungsten alloy with additional elements such as lanthane. It
produces easier ignition and greater arc stability.

To maintain a stable and concentrated welding arc, tungsten electrodes must have a conical end. The diameter of
the electrode, its grinding angle and the diameter of the flat tip depend on the intensity of the welding current.

Electrodes used for the same application must have a constant geometry in order to guarantee repeatability of
results. This is essential when using equipment with the AVC function.

The end of the electrode must always incorporate a flat tip. The shape of the end of the electrode is a determining
factor for arc ignition (this must be checked at regular intervals).

The diameter and the shape of the tip of the electrode are dependent on the intensity of the welding current.
Grinding must be carried out along the centreline of the electrode. The use of a bench grinder ensures that the
operation is straightforward, fast and to a high standard.
The length and the diameter of the electrode must be compatible with the type of gas lens and the thickness of
the tube. Each electrode can withstand a maximum current.

Mean values for grinding the electrode.

Current intensity Grinding angle Flat tip φ

Electrode diameter (mm)
(A) θ° (mm)

1.6 10 - 110 15° 0.1 à 0.2

2.4 60 - 210 30° 0.1 à 0.4

Electrodes must always be replaced preventively in order to

reduce weld defects. For certain heavy-duty applications, the
electrode must be replaced after every weld.
The current ranges (A) are given as a guide only for DCEN (direct
current electrode negative) use under Argon. To avoid damage
to the installation, these currents must be used in conjunction
with the duty cycles for the torch shown in the technical data
table.

Correctly ground

θ
φ

Incorrectly ground

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PN-1218178 Rev.0 15-26

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4. 3. Mounting the V2 assembly

• Insert the electrode (1) into the chuck (2) with the electrode tip at the same end
as the slots in the chuck.
• Fit this assembly in the gas lens (3). The chuck and gas lens must be compatible
with the electrode diameter.
• Mount the gas lens unit on the WP27 torch (5), remembering to insert the seal
(4).
• Screw the CLS nozzle (6) onto the torch.
• Before fitting the V2 nozzle (7), make sure that the gas box O-ring is in place.
• Screw the V2 nozzle assembly (7) onto the WP27 torch.
• Connect the trailing gas supply (8) for the gas box to the bundle connection
plate.
• Connect the outward (9) and return (10) V2 nozzle coolant circuit to the bundle
connection plate.

3 1 2 4
0

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4. 4. Changing the electrode

• Unscrew the knob (1) about a quarter of a turn.

• Pull the electrode (2) downwards.
• Insert a new electrode.
• Adjust electrode stickout to the desired length (SE).
• Lock the electrode by tightening the knob.

3
1 2

PN-1218178 Rev.0 17-26

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5. Maintenance and troubleshooting

5. 1. Non-programmable parameters

Function Nature of the incident Possible causes

Earth not connected

Braid cut
No welding gas
Welding current No ignition No ignition aid
No cooling
Defective electrode
Remote control in "without arc" position

Unsuitable gas flow

Gas lens in poor condition
Gas Poor shielding
Electrode stickout too long
Gas cylinder empty

5. 2. Routine maintenance operations

Inspecting the hoses

Consumable
Frequency Operation
items and tools

Hard bristle Every 3 Machine switched off, isolating switch locked.

brush, cloth. months. Inspect the hoses:

• Clean all hoses using a brush or cloth.

• Inspect all visible circuits.
• Check that none of the hoses are too sharply curved or pinched and
check for kinks, tears or bulges.
• Check that none of the hoses are rubbing against a moving part of the
machine (safety guard, etc.)
• Check that none of the hoses are perished or worn.
• Check that there is no seepage or noise; these are symptoms of
leakage and, therefore, damage to the internal lining.
• Check that the connectors and unions are tight.

Inspecting the torches

Frequency Operation

Depending Machine switched off, isolating switch locked.

on use. • Check the general condition of the gas lens, nozzle and torch.

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5. 3. Maintenance recommendation

Polysoude recommends regular revision of the equipment by a Polysoude

technician or a Polysoude approved technician, once a year minimum or
every 2300 h* (depending nevertheless on the conditions of use).

During the guarantee period, the Polysoude contractual guarantee shall

not apply unless the equipment undergoes revision at least once a year
by a Polysoude technician
or a Polysoude approved technician.

Maintenance services:
• Polysoude equipment maintained on a regular basis by the manufacturer for optimum efficiency.
• Complete equipment overhaul and calibration.
• Advice on parts to be kept in stock/to replace.
• Guaranteed maximisation of equipment and production availability
• Tailored maintenance services.

[email protected]

Think about it every year!

* First of the 2 conditions coming to term. Calculation based on 52 weeks x 5 days/week x 9 hours/day

PN-1218178 Rev.0 19-26

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1. 4.
5. 1. Consumables
Consommables
C o n s Pièces
o consommables
m m a b l e s

Polysoude supplies original spare parts and consumables, which keep the welding equipment in
optimum condition during the whole machine life cycle and ensure efficiency in production.

Ordered
Description Technical data Order code
quantity

dia. 7.9 mm 100019271

1 Ceramic nozzle
dia. 9.9 mm 18708730

dia. 11.1 mm 18708740

3 Ceramic nozzle
dia. 12.7 mm 18708750

3 Oring Teflon 18704830

dia . 1.6 mm 70108630

4 Gas lens
dia. 2.4 mm 70108640

dia. 1.6 mm 70108170

5 Electrode chuck
dia. 2.4 mm 70108180

dia. 1.6 mm 62410016

6 Electrode
dia. 2.4 mm 62410024

Polysoude Services
To order consumables, please use the table above and send it to:

[email protected]

20-26 PN-1218178 Rev.0

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1 2 4 5 3 6

PN-1218178 Rev.0 21-26

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6. End of service life – Recycling the machine

Our machines incorporate electrical and electronic components which must be recycled 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 disposal. A number of solutions
may be deployed, including:

• Reuse
• Recycling
• Any other form of recovery (including energy recovery) of WEEE (Waste Electrical and Electronic
Equipment).

7. Equipment Return form

22-26 PN-1218178 Rev.0

THE ART OF WELDING
 RETU
URN O
OF EQU
UIPMEN
NT
PDS_FOR_032
2_Retour matérie
el_EN.docm_ Revv. : 06_Date d’app
plication : 05 janv
v 2017_ Rédacteu r : CPO

Ö Please fill out and join this sheet when re

eturning equ
uipment to POLYSOUDE
P E
Ö 1 doc p
per equipme ent

Resellerr / Person in charge :

Custome er / Person in
n charge / Te
el. :

1. EQ
QUIPMENT
T RETURN
NED :

‰ Power source Type

T : Seria
al number :

‰ Welding head Type

T : Seria
al number :

‰ Wire ffeeder Type

T : Seria
al number :

‰ Otherr (specify dessignation) :

taken from :

‰ Power source Type

T : Seria
al number :

‰ Welding head Type

T : Seria
al number :

‰ Wire fee
eder Type
T : Seria
al number :

‰ Other(to
o be specified
d) : Seria
al number :

1. RE
EASONS FOR
F RETU
URN :
‰ Return of loan equ uipment
‰ Return of demonsstration / fair equipment
‰ Return of hired eqquipment
‰ Return after excha ange
‰ Deficient delivery / incorrect orrder
‰ Return for modificcation (to be specified)
s :
‰ Return for revision
n
‰ Return for calibrattion
‰ Return for repair
(to
o be specifieed) : ‰ system
matically occu
urring error
‰ occasio
onally occurrring error
escription of breakdown :
De

‰ Otherr issue (to be

e specified) :

Date : Signatture:

PDS_FOR_032__Retour matériel__EN.docm_Rev. 06_Date Applicaation : 05 janv 20

017_ Rédacteur : CPO
C
La seule versio
on de référence
e de ce document est celle géré
ée sur «Référen ntiel Qualité_Documents de struucture »
 Manual torch, AS20 DD

24-26 PN-1218178 Rev.0

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2018 Polysoude
Original issue: Polysoude S.A. S. Nantes France.

The photos, diagrams and drawings are used as an aid to understanding and are therefore not contractual.

All copyrights reserved. This work shall not be copied, either in part or whole, in any form or by any means
whatsoever, whether electronic or mechanical, including photocopying, recording or the use of computer
medium, without the publisher’s written permission.

Printed in France.
Published by Polysoude, Nantes, France.

www.polysoude.com [email protected]

Translation of original
instructions

PN-1218178 Rev.0 25-26

THE ART OF WELDING
 POLYSOUDE : Related services
Guidance and technical support Maintenance / Repair
A welding application specialist in your area will advise you on the Maintenance and repair operations can be carried out at the
welding process and appropriate equipment for your application. Polysoude plant as well as on site by our service network.

Commissioning / Training Rental service

A complete training program will enable you to start using the Increase the flexibility of your production! A large range of equipment
equipment immediately and in the best way possible. is available for rental from our hire fleet.

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