2 133Sept. 2017 Sept. 2017

Standard Orbital Welding EquipmentStandard Orbital Welding EquipmentTHE ART OF WELDING THE ART OF WELDING

2017 Polysoude

Original edition: Polysoude S.A.S. Nantes France.

The photos, diagrams and drawings are given to promote understanding and are therefore not contractual.

All copyrights reserved. This catalogue 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]

Notes

Sept. 2017

Standard Orbital Welding EquipmentTHE ART OF WELDING

3

Table of contentsProcesses .............................................................................................................. 7

GTAW / TIG orbital welding process ......................................................................................7

Orbital welding equipment ..................................................................................... 9Power sources ......................................................................................................................9

PS 164-2 .............................................................................................................................11P4-2.....................................................................................................................................13P6 CW/HW ..........................................................................................................................17PC TIG CW/HW ..................................................................................................................21Switch box ...........................................................................................................................26

Welding heads range ..........................................................................................................27

Closed chamber welding heads..........................................................................................28UHP .....................................................................................................................................29MW ......................................................................................................................................33

Open welding heads ...........................................................................................................44MU IV CW ..........................................................................................................................45MU IV AVC/OSC CW .........................................................................................................49MU IV AVC/OSC HW ..........................................................................................................57

Carriage-type welding heads ..............................................................................................60Polycar 30 CW ....................................................................................................................61POLYCAR 60-2 CW/HW .....................................................................................................65POLYCAR MP HW ..............................................................................................................69

Tube-to-tubesheet welding heads ......................................................................................72TS 34-2 ...............................................................................................................................73TS 8/75-2 ............................................................................................................................79

External wire feeders ..........................................................................................................96POLYFIL ..............................................................................................................................97

Other equipment ................................................................................................ 101Tandem electrode grinding machines ...............................................................................101

Portable electrode grinding machine ................................................................................101

Plug purge kit for orbital welding.......................................................................................101

Sharpened electrodes.......................................................................................................101

Spare parts .......................................................................................................................102

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Related services ................................................................................................ 103Spare parts for UHP 1500-2 ..............................................................................................103Spare parts for MW 40-3 ...................................................................................................105TCIs and protection discs for MW 40-3 .............................................................................105TCIs and protection discs for former MW 1250, UHP 1500 & 1500-2, K 1500 .................108TCIs and protection discs for former MW 2500.................................................................110TCIs and protection discs for former MW 4500.................................................................112TCIs and gas cups for K 375 - K 875 - K 1500 .................................................................113TCIs and gas cups for K 2500...........................................................................................116MU IV open - "P" type gas lens .........................................................................................118MU IV open - "N" type gas lens .........................................................................................119MU IV open - "GM" type gas lens .....................................................................................120TS 25 clamping units ........................................................................................................121TS 2000 tube-to-tubesheet configuration ..........................................................................123TS 2000 and TS 8/75 tube-to-tubesheet - "N" type gas lens .............................................125TS 2000 – 2 balls centring mandrels.................................................................................125TS 2000 – Centring mandrel .............................................................................................126WP27 torch .......................................................................................................................127Adaptation kit for former power sources ...........................................................................128

Administrative, packing and logistics costs ....................................................... 129Order processing & administrative fees ...........................................................................129Additional costs .................................................................................................................129Specific loading costs for trucks, containers & oversized cargo .......................................129Packing costs ....................................................................................................................130

Sales conditions ................................................................................................ 131

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Icons & legends

TIG Cold Wire technology

TIG Hot Wire technology

TIG technology without wire

Sept. 2017


7

A L

T

E

Processes

GTAW / TIG orbital welding process

Main advantages of TIG with or without wire CW/HW compared to other processes: all position use, excellent surface quality, clean without spatters... Zero defects. Generally, orbital welding technique covers two main fi elds of application:

• Tube-to-tube / pipe-to-pipe joining.• Tube-to-tubesheet welding.

Electrode 1 1 1

Wire / CW HW - DC or AC

Arc type Single arc Single arc Single arc

Deposition rate / 0.15 to 0.5 kg/h 1 kg/h

or

Whenever high quality results are required, orbital welding is the fi rst choice for the joining of tubes. The welding torch - in most cases, the TIG welding (Tungsten Inert Gas) process is used - travels around the tubes to be joined, guided by a mechanical system. The name orbital welding comes from the circular movement of the welding tool around the workpiece.

Recommended tube end preparation for orbital TIG welding

Wall thickness(mm)

Angle(°)

Collar(mm)

A T L

3 ≤ E ≤ 6 30° 1

26 ≤ E ≤ 10 30° or 20°1,5

10 ≤ E ≤ 15 20°

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9

Orbital welding equipment

PS 164-2 P4 P6 PC

Process

Basic - Full Function, portable, “All Inclusive” power source

Advanced - Intelligent, portable 4-axis power source

Advanced - Intelligent, 6-axis Cold and Hot Wire power source

Unique - High power, multi-purpose, multi-axis, multi-process power source

Motion controls:

Torch rotation

Wire feeding

AVC

OSC

Multi-axes

Input Power 1

phase

220/230 V

1

phase

110/115/200/230 V

3

phase

400/415 V

3

phase

380/400/415 V

Power sources

Sept. 2017


10

1

Technical data PS 164-2

Input Power - Voltage (± 10%) 1

phaseSingle phase + Earth 220/230 V

Input Power - Frequency 50 or 60 Hz

Type of current source Inverter

Open circuit voltage (rated values) (*) 60 V

Power 5.5 KVA

Insulation class F

Protection class IP 23

Welding current

Standard (steps of 1 A) Range 160 A: 4 to 160 A - constant or pulsed

High precision (steps of 1/10 A) Range 50 A: 4 to 50 A - constant or pulsed

Welding current precision ± 1% when I > 100 A and ± 1 A when I ≤ 100 A

Duty cycle100% 100 A

60% 160 A

Motion controls Torch rotation: constant or pulsed Wire feeding: constant or pulsed / automatic wire retract

Power source cooling Forced ventilation

Torch cooling unit with fl ow detection Integrated

Display/recording (non-volatile) of real values during welding

Arc voltage, welding current, electrode position in angular degrees, rotation and wire speed

Weld procedure data storage and transfer Memo chip card

Temporary "user" memory 16 programmes

Welding procedure library (non-volatile) 60 programmes

Dimensions LxWxH 660 x 320 x 425 mm

Weight 30 kg (with cooling water)

Standards EN 60974-1/EN 60974-10

(*) The real value U(*) The real value U00 of each power source is indicated on the power source rating plate of each power source is indicated on the power source rating plate

Power sources

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► PS 164-2

1 PS 164-2 – 50 Hz 2017640099

PS 164-2 – 60 Hz 2017640097

PS 164-2 delivered withRemote control with 9 m cable Torch cooling unit with fl ow detection Torch rotation control Wire feeder control Torch gas control with safety valve and fl ow detection Integrated printer for programmed and real parameters Integrated memo-card reader & 1 memo-card (16 programmes) 9 m earth cable

Options

15 m extension cable for any kind of welding heads (current, water, gas, rotation, wire, remote control) (1) 75501200

15 m extension cable (current, water, gas, rotation for closed chamber welding heads without wire nor remote control) (1) 0018343000

Kit second gas (back purge gas) 17000002

Gas kit for UHP, MW and TS 34-2 (integrated in the power source, this device enables to keep a low gas fl ow when the welding head is not welding to improve the gas protection during welding (2) 17640006

Accessories

Memo-card 16 programs (minimum order quantity: 10 cards) 00629119

Gas hose (Argon) - Length: 4 m 0025009102

Pressure regulator and fl ow meter Argon "France" (3) max. 16 L/min. 75501002

Pressure regulator and fl ow meter Argon "Export" (4) max. 16 L/min. 71701418

Pressure regulator and fl ow meter Argon "France" (3) max. 30 L/min. 100074295

Pressure regulator and fl ow meter Argon/Hydrogen 71701421

Modifi cation kit cooling circuit connector to adapt a former welding head (MU III, TS) 15545405

Modifi cation kit gas connector to adapt a former welding head (MU III, TS) 15545406

Manual water-cooled torch (8 m) with quick release couplings and accessory box 75500532

Trolley 9000629265

Switch box "power source/two welding heads" (without AVC/OSC) 0024480001

Consumables

Ribbon for printer (Minimum order quantity: 3 ribbons) 00590064

Paper roll for printer (Minimum order quantity: 10 rolls) 00590066(1) Possibility to connect only one 15 m extension cable(2) With this option, it is not possible to integrate the second gas

option

(3) for Spain, France, Portugal, Czech Republic, Tunisia.(4) for Germany, Austria, Denmark, Finland, Netherlands, Poland,

Sweden, Switzerland. Others countries: local purchase

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1

Technical data P4-2

Input Power - Voltage (± 10%)1

phaseSingle phase + Earth - 100 V/115 V/200 V/230 V

Input Power - Frequency 50 / 60 Hz


Open circuit voltage (rated values) (*) 94 V

Power 5.5 KVA

Insulation class H

Protection class IP 23 (closed touchscreen)

Welding current

Standard (steps of 1 A)

3 to 170 A - constant or pulsed (input power 220/230 V)3 to 130 A - constant or pulsed (input power 110/115 V)

High precision (steps of 1/10 A) 3 to 50 A - constant or pulsed


Duty cycle

100%110 A (input power 220/230 V)100 A (input power 110/115 V)

40% 130 A (input power 110/115 V)

25% 170 A (input power 220/230 V)

Motion controls Torch rotation: constant or pulsed Wire feeding: constant or pulsed / automatic wire retract


Torch cooling unit with fl ow detection Integrated

Display/recording Arc voltage, welding current, electrode position in angular degrees, rotation and wire speed

Weld procedure data storage and transfer USB memory stick

Welding procedure library 200 programmes max.

Real time data acquisition Internal PC memory

Dimensions LxWxH 630 x 320 x 500 mm

Weight 35 kg (with cooling water, touchscreen and printer)

Standards EN 60974- 1/ EN 60974-10


Power sources

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► P4-2

P4-2 - Version with printer 0025049201

1 P4-2 - Version with touchscreen and printer 0025049203

P4-2 - Version with touchscreen, printer, remote control, wire feeder control and earth cable 0025049205

P4-2 delivered with 0025049201 0025049203 0025049205

Cooling circuit with fl ow detection Torch gas control with safety valve and fl ow detection Real time welding data acquisition USB-stick (saving, loading and archiving) P4 Software package (for laptop or touchscreen) Manual torch adapter (Item no. 0023000901) Printer Touchscreen Remote control Torch rotation control Wire feeder control Earth cable (9 m)

Options

"Full Function" – remote control box P4/P6 – 4 axes 0026149101

Earth cable 64599801

Kit second gas (back purge gas) 0025049110

Gas kit for UHP, MW, TS 25 and TS 34-2 (integrated in the power source, this device enables to keep a low gas fl ow when the welding head is not welding to improve the gas protection during welding (1)

0025049114

Rotation motor control kit for tachy welding heads from AMI, Orbitalum and others. 0025049115

Connection cable bundle including software confi guration for AMI welding heads series 8 or 9 (must be used with 0025049115) 11330537

Connection cable bundle including software confi guration with integrated rotation motor control for Swagelok welding heads series 5 11330536

Connection cable bundle including software confi guration for Orbitalum welding heads series 38S, 76S & 115S (must be used with 0025049115) 0023003100

15 m extension cable for any kind of welding heads (current, water, gas, rotation, wire, remote control) (2) 0018344500

15 m extension cable (current, water, gas, rotation) for closed chamber welding heads (2) 0018343000

10 m extension cable (current, water, gas, rotation) for MW closed chamber welding heads (Imax 125A) (2) (3) 0018346300

15 m extension cable (current, water, gas, rotation, remote control) for closed chamber welding heads (2) 0018344600

(1) With this option, it is not possible to integrate the second gas option(2) Possibility to connect only one extension cable(3) manual torch with "one wire" detection

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14

2

3

5

4

6

Power sources

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15

Accessories

GUI programming software for P4/P4-2 on USB stick 0025049001

2

Laptop – Windows® & keyboard (AZERTY) in French 00623666

Laptop – Windows® & keyboard (QWERTY) in English 1 00000741

Laptop – Windows® & keyboard (QWERTZ) in German 100002173


3

Pressure regulator and fl ow meter Argon "France" (4) max. 16 L/min 75501002

Pressure regulator and fl ow meter Argon "Export" (5) max. 16 L/min 71701418

Pressure regulator and fl ow meter Argon "France" (4) max. 30 L/min 100074295

Pressure regulator and fl ow meter Argon/Hydrogen 71701421

Modifi cation kit cooling circuit connector to adapt a former welding head (MU III, TS …) 15545405

Modifi cation kit gas connector to adapt a former welding head (MU III, TS …) 15545406

Manual water-cooled torch (8 m) with quick release couplings and accessory box 75500532

4 Oxygen indicator - PRO2 Plus type 0025009101

5 Trolley 9000629265

6 Switch box "power source/two welding heads" (without AVC/OSC) 0024480001

Consumables

Consumable paper roll for printer (Minimum order quantity: 10 rolls – unit price) 9000590068

(4) for Spain, France, Portugal, Czech Republic, Tunisia(5) for Germany, Austria, Denmark, Finland, Netherlands, Poland, Sweden, Switzerland

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16

1 2

Technical data P6 CW - 4/6 axes P6 HW - 6 axes

Input Power - Voltage (± 10%)3

phase

Three-phase + Earth - 400/415 VOption: multi-voltage kit - 200 to 480 V

Three-phase + Earth - 400/415 V

Input Power - Frequency 50 / 60 Hz 50 / 60 Hz


Open circuit voltage (rated value)(*) 100 V 78 V

Power 14.5 kVA 23 kVA

Insulation class F

Protection class IP 23S (closed touchscreen)

Welding current 5 to 300 A - constant or pulsed 5 to 550 A - constant or pulsed


Duty cycle100% 240 A 420 A

60% ≥ 300 A 520

Duty cycle of wire heating source 100% 140 A

Motion controls Torch rotation: constant or pulsed Wire feeding: constant or pulsed / automatic wire retractAVC – Arc Voltage Control / OSC – Torch Oscillation (only for 6 axes)

Additional function Axis for data acquisition (option)


Torch cooling unit with fl ow detection Integrated External

Display/recording (non-volatile) of real values during welding

Arc voltage, welding current, electrode position in angular degrees, rotation and wire speed

Weld procedure data storage and transfer USB memory stick

Dimensions LxWxH630 x 470 x 790 mm 630 x 470 x 1110 mm (with multi-voltage kit)

1060 x 530 x 1145 mm

Weight 90 kg (without options) 170 kg (with trolley, without options)

Standards EN 60974- 1/ EN 60974-10


Power sources

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17

1 P6 CW - 4 axes – Version with touchscreen, printer and remote control 0025059103

P6 CW - 6 axes – Version with touchscreen, printer, remote control, AVC and OSC 0025059105

2 P6 HW - 6 axes – Version with touchscreen, printer, remote control, AVC and OSC 0025069105

P6 CW/HW delivered with P6 CW - 4 axes P6 CW - 6 axes P6 HW - 6 axes

Torch rotation control Wire feeder control Arc voltage control (AVC) Oscillation control (OSC) On-board printer Touchscreen USB stick - saving, loading and archiving Manual torch adapter Torch cooling unit with fl ow detection (2)

9 m earth cable Remote control 6 axes Integrated 140 A. source (100 %) for wire heating Kit for one extra gas control with fl ow safety valve Third gas - opening/closing of the video fi lter Trolley

Options P6 CW P6 HW

Multi voltage kit, three-phase, 50/60 Hz – 200 to 480 V ± 10% 0025059113 N/A

Kit for one extra gas control with fl ow safety valve 0025059110 /

Kit for continuous gas fl ow 0025059112 /

Second cooling unit circuit 0025059115 /

Rotation motor control kit for tachy welding heads : AMI, Orbitalum and others. 0025049115 /

Connection cable bundle for AMI welding heads series 8 or 9 (must be used with 0025049115) 11330537 /

Connection cable bundle with integrated rotation motor control for Swagelok welding heads series 5 11330536

Connection cable bundle for Orbitalum welding heads series 38S, 76S & 115S (must be used with 0025049115) 0023003100 /

15 m extension cable without AVC nor OSC for MU IV and TS welding heads (1) 0018344600 /

15 m extension cable with AVC and OSC for MU IV CW POLYCAR 60-2 CW welding heads (1) 0018345300 /

15 m extension cable with AVC and OSC for MU IV and POLYCAR 60-2 HW welding heads (1) / 0018345900

15 m extension cable with AVC, OSC and remote control for the POLYCAR MP / 0018346000

Axis for data acquisition (2) 0025059141 0025069130

(1) Only one extension cable (as well as the remote control extension cable) can be connected. For longer or specifi c cables, please contact us.(2) Equipment assembled in workshop only (Polysoude Nantes)

► P6 CW/HW

Sept. 2017


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Accessories P6 CW P6 HW

GUI programming software for P6 CW or HW on USB stick 0025059001 0025069001

Gas hose (Argon) - Length: 4 m 0025009102 0025009102

Trolley with double bottle holder 0020421001 /

Water cooled manual torch (8 m) with quick couplings and accessories box 75500532 /

Oxygen indicator - PRO2 Plus type 0025009101 0025009101

Modifi cation kit cooling circuit connector to adapt a former welding head (MU III, TP, TS, POLYCAR CW) 15545405 /

Modifi cation kit gas connector to adapt a former welding head (MU III, TP, TS, POLYCAR CW) 15545406 /

Y-Adaptor with 37 pins AVC/OSC for P6 (enables to connect cross slides with two connectors or Polycar MP) 11330902 11330902

3 DAQbox (Data acquisition system) - Acquisition module, software on USB stick, measurement cable, USB cable (3). See next page 0033249101 0033249101

4

Laptop for DAQbox– Windows® & keyboard (AZERTY) in French 00623666 00623666

Laptop for DAQbox– Windows® & keyboard (QWERTY) in English 100000741 100000741

Laptop for DAQbox– Windows® & keyboard (QWERTZ) in German 100002173 100002173

Accessories: pressure regulator P6 CW P6 HW

Pressure regulator and fl ow meter Argon "France" (4) max. 16 L/min 75501002 75501002

Pressure regulator and fl ow meter Argon "Export" (5) max. 16 L/min 71701418 71701418

Pressure regulator and fl ow meter Argon "France" (4) max. 30 L/min 100074295 100074295

Pressure regulator and fl ow meter Argon/Hydrogen 71701421 71701421

Accessories: cooling unit P6 CW P6 HW

External water cooling unit RFC30 - single phase 230 V AC, 50 Hz (6) / 14750001

External water cooling unit RFC30 - single phase 230 V AC, 60 Hz (6) / 14750008

Temperature option set (-10°C) for external cooling unit RFC30 / 9000629356

Water fl ow control kit requested when using MU, TS and MW welding heads (7) / 0030050001

Consumables P6 CW P6 HW

Paper roll for printer (Minimum order quantity: 10 rolls – unit price) 9000590068 9000590068

(3) Axis for data acquisition required (not delivered with the data acquisition system). See on page 17.(4) For Spain, France, Portugal, Czech Republic, Tunisia(5) For Germany, Austria, Denmark, Finland, Netherlands, Poland, Sweden, Switzerland(6) Compulsory cooling unit to be ordered for P6 HW(7) The water fl ow control kit is compulsory when the P6 HW is used with MU, TS ou MW welding heads to protect the welding head bundle.

Pressure is limited to 3 bars

Power sources

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Data acquisition system

Laptop Rear connector panel of the power source

USB cable

Power source measurement cable17666003

Acquisition module0033240301

USB stick0033249501

3

4

Possibility to connect a printer if needed

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Technical data

PC 3

00 T

R CW

TIG

PC 3

50 A

C/DC

CW

TIG

PC 6

00-3

CW

TIG

PC 6

00-3

HW

TIG

Input power - Voltage (±10%)3

phase200/380/415/-440/500 V 380/400/415 V

Input power - Frequency 50 or 60 Hz

Open circuit voltage (rated value)(*) 70 V 78 V

Power 14 kVA 16 kVA 28 kVA

Type of current source Transistor Inverter

Insulation class F

Protection class IP 21

Welding current 3 to 300 A 5 to 350 A 5 to 550 A


Duty cycle (¤)100 % 240 A 300 A 420 A

60 % 300 A 350 A 540 A

Duty cycle of wire heating source 100% 160 A

Motion controls

Torch rotation: constant or pulsed Wire feeding: constant or pulsed / automatic wire retractAVC – Arc Voltage ControlOSC – Torch or electrode oscillation

Additional function Axis for data acquisition (option)


Torch cooling unit Integrated External and integrated(¤) External

Display/recording (non-volatile) of real values during welding Optional

Weld procedure data storage and transfer Via USB memory stick

Dimensions LxWxH - Power source 1367 x 750 x 1640 mm

Dimensions LxWxH - Tetrix Source 1100 x 455 x 950 mm

Weight 330 kg Source: 144 kgControl unit: 250 kg 330 kg

Standards EN 60974- 1/ EN 60974-10

(¤) For the PC 600-3 CW, the duty cycles when using the integrated cooling circuit are 270 A/100 % - 350 A/60 % (*) The real value U(*) The real value U00 of each power source is indicated on the power source rating plate of each power source is indicated on the power source rating plate

Power sources

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21

► PC TIG CW/HW

1 PC 300 TR CW TIG - orbital power source - 50 Hz (1) 75501146

2 PC 350 AC/DC CW TIG - orbital power source - 50 Hz (1) 18279003

3 PC 600-3 CW TIG - orbital power source - 50 Hz (1) 0024990005

4 PC 600-3 HW TIG - orbital power source - 50 Hz (1) (2) 0024990009

PC delivered withPC

300

TR

CW T

IG

PC 3

50 A

C/DC

CW

TIG

PC 6

00-3

CW

TIG

PC 6

00-3

HW

TIG

Remote control pendant extended model - 13781000 Integrated torch cooling unit with fl ow security 50 Hz

External cooling circuit Axis card for wire heating control Multi-axis card for external device control

Wire axis Rotation axis with electronic brake TETRIX AC/DC power source Voltmeter/Ammeter Integrated 160 A, AC/DC source (100 %) for wire heating

Earth cable (9 m) (9 m) (15 m) (15 m)Torch gas control with fl ow meter and safety valve Gas kit (with manually adjustable fl ow meter and security)

When ordering a PC power source, please specify its item number and, if required: - The language of the laptop - AVC axis (including "Y" connector) - Oscillation axis - External cooling unit for PC 600-3 HW. See "Accessories: cooling unit" table to order it on page 24 - The frequency of the power supply (1)

(1) 60 Hz power sources are fi tted with a special pump. See "Cooling options" table on page 23.(2) When using MW, MU or TS welding heads together with a PC 600-3 HW, a fl ow control kit (item no. 0030050001) for the external cooling

unit must be ordered to protect the welding head bundle. Pressure is limited to 3 bars. See Accessories: cooling unit" table on page 24

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22

Axis card options

AVC function axis (with electronic brake control) (4) 17580001

Oscillation function axis (with electronic brake control) (4) 17590001

1

3-4

2 Multi-axis card (control of 2 external axes without drive panel) (4) 75501000

Measurement card 8 channels (4) for recorder and data acquisition system (front side) 75500884

Cable options

15 m extension cable without AVC/OSC functions (5) 75500969

15 m extension cable with AVC/OSC functions for MU IV, TS, POLYCAR 60-2 CW (5), with remote control 0018341900

Extension mass cable 15 m with arc voltage cable return 120 mm² + 50 mm² (for TIG Hot Wire) 0018342300

15 m extension cable with AVC / OSC functions for POLYCAR MP TIG Cold Wire (70 mm²) (5), with remote control 0018342000

15 m extension cable with AVC / OSC functions for POLYCAR MP TIG Hot Wire (120 mm² + 50 mm²) (5), with remote control 0018342100

15 m extension cable with AVC/OSC function for MU IV without remote control and mass cable 18340101

Gas options

U

0-20 L/min 0-50 L/min 0-20 L/min 0-40 L/min

Programmable mass fl ow meter Manually adjustable fl ow meter & security

Kit for torch gas 19435200 19435500

Kit for Bigas (2nd torch gas) 19436200 19436500 75500880

or Kit for one extra gas (4) 19437200 19437500

Kit for trailing gas (extra gas) 75500888

Kit for backing gas (extra gas) 75500889 75500890

Kit for 2nd gas 75500891 75500892

(4) A limited number of options can be installed on standard power sources; 6 axes are available in addition to the sequencer, power supply and current axis cards.

(5) Only one extension cable (as well as the remote control extension cable) can be connected. For longer or specifi c cables, please contact us.(6) The kit for one extra gas can only be ordered in the case of an existing kit for torch gas with programmable fl ow meter. The PC Power

sources are delivered in standard version with a torch gas control, with manually adjustable fl owmeter.

Power sources

Sept. 2017


23

U

1 2External cooling circuit

Internal cooling unit

PC 600-3 CWRear side

PC 600-3 CW Front side

Cooling options

PC 3

00 T

R CW

TIG

PC 3

50 A

C/DC

CW

TIG

PC 6

00-3

CW

TIG

PC 6

00-3

HW

TIG

2nd internal cooling circuit with fl ow security and 2nd water pump 75500879 / /

2nd external cooling circuit with fl ow security / / 0014175107

Kit to replace the external coolant circuit with a 2nd internal cooling unit with fl ow security (7)

/ / 0024999909

Water pump 230V/60Hz for internal cooling circuit 00629074

(7) PC 600-3 CW power sources, factory standard, are equipped with both an external cooling circuit on the fi rst circuit 1 and the internal cooling unit item no. 0024999903 on the second circuit 2 ; See picture below

Other options

POWin software on USB stick. Languages: French, English, German. Consult us for other languages 0017769001

Split connector for the connection to the PC power source of a head with a single connector (37 pins) including AVC (19 pins) and OSC (17 pins) (included in AVC axis 1758 0001) 11330901

PC Software kit and serial link for PC Tetrix AC/DC confi guration 9000629229

Sept. 2017


24

Accessories: pressure regulator

Pressure regulator Argon "France" (12) Max. 10 bars 75501003

Pressure regulator Argon "Export" (13) Max. 10 bars 71700927

Pressure regulator Argon/Hydrogen 71700917

Argon gas tube for fl ow meter 0-40 L/min 00600530


Accessories: double earth cable

Double earth cable (PC 300 CW) - Length: 4 m 0018684500

Double earth cable (PC 600-3 HW) - Length: 4 m 0018683100

(8) NOTE: In After Sales service, before ordering a laptop with POWIN, contact our Service Department to check the compatibility with the EPROM version of the power source.

(9) Axis for data acquisition required (not delivered with the data acquisition system).(10) Working limits ambient temperature: from +5°C to +50°C(11) The water fl ow control kit (item no. 0030050001) is compulsory when the PC 600-3 HW is used with MU, TS ou MW welding heads to

protect the welding head bundle. Pressure is limited to 3 bars(12) For Spain, France, Portugal, Czech Republic, Tunisia(13) For Germany, Austria, Denmark, Finland, Netherlands, Poland, Sweden, Switzerland

Power sources

Accessories: Laptop & data acquisition

Laptop Windows® & Keyboard in English (with POWin software) (8) 0000623706

Laptop Windows® & Keyboard in French (with POWin software) (8) 0000623705

Laptop Windows® & Keyboard in German (with POWin software) (8) 0000623707

3 DAQbox (Data acquisition system) - Acquisition module, software on USB stick, measurement cable, USB cable (9) 0033249101

4

Laptop for DAQbox– Windows® & keyboard (AZERTY) in French 00623666

Laptop for DAQbox– Windows® & keyboard (QWERTY) in English 100000741

Laptop for DAQbox– Windows® & keyboard (QWERTZ) in German 100002173

Accessories: cooling unit

External water cooling unit RFC30 - single phase 230 V AC, 50 Hz (10) 14750001

External water cooling unit RFC30 - three-phase 230 V AC, 60 Hz (10) 14750008

Temperature option set (-10°C) for external cooling unit RFC30 9000629356

Water fl ow control kit requested when using MU, TS and MW welding heads (11) (PC 600-3) 0030050001

Modifi cation kit cooling circuit connector to adapt a former welding head (MU III, TP, TS, POLYCAR CW) 15545405

Modifi cation kit gas connector to adapt a former welding head (MU III, TP, TS, POLYCAR CW) 15545406

Sept. 2017


25

Data acquisition system

LaptopItem no. 0062366 - FR

Item no. 100000741 - ENItem no. 100002173 -DE

USB cable included with acquisition module

Power source measurement cable17666003

Acquisition module0033240301

USB stick0033249501

Possibility to connect a printer if needed

Y-adaptor cable12955005

Front connector panel of the power source

4

3

Measurement axis card Item no. 75500884

Connector for HW recording on multi-axis card

Sept. 2017


26

1

► Switch box

This equipment can only be used with Polysoude PS 164-2 & P4 power sources and welding heads below.The control pendant of the power source is directly connected to the switch box (for PS 164-2) or to the power source itself (for P4/P4-2).

1 Switch box power source to use two welding heads 0024480001

The switch box can be used with manual torches and:

Mode of use 1When the fi rst welding head is welding, the second one can be moved using the control buttons on the welding head

PS 164-2 P4 / P4-2MW (1)

TS 34 & TS 34-2 (1)

TS 8/75 & TS 8/75-2 (1)

Mode of use 2When the fi rst welding head is welding, the second one cannot be moved using the control buttons on the welding head

PS 164-2 P4 / P4-2 (1)

MU (without wire feeder) (1)

TS 25 (1)

TS 2000 (without wire feeder) (1)

Mode of use 3Only one welding head can use a wire feeder, because the wire feeder is connected directly onto the power source.

PS 164-2 P4 / P4-2Polyfi l-3 Polyfi l compact On-board wire feeder

(1) Without automatic switch of programs between the two welding heads

Sept. 2017


27

Equipment for orbital welding applications

Welding heads range

Closed chamber welding heads

Open welding heads

Carriage-type welding heads

Tube-to-tubesheet

welding heads

UHP - MW MU IV POLYCAR TS

Process

Precision welding in high purity industries

With or without fi ller wire, AVC and OSC

The most versatile torch carrier

The result of 60 years of continuous improvement

Diameter range(*): 1.6 mm to 168.3 mm 8 mm to 275 mm From 32 mm 8 mm to 75 mm

Equipped with:

Wire feeder / With or without(*) With or without(*)

AVC / With or without(*)

OSC / With or without(*) /(*) according to the welding head model

Sept. 2017


28

1 2

A

C

F

D

G

B

H

J

E

A

F

D

G

B

H

J

E


Sept. 2017


29

► UHP

1 UHP 250-2 (handle + drive module) – for tube O.D. 1.6 to 6.35 mm (1/16" to 1/4") 0018319801

2 UHP 500-2 (handle + drive module) – for tube O.D. 3 to 12.7 mm (1/8" to 1/2") 0018319901

UHP-2 delivered withContainer for safety packing and transport 5.5 m hose cable Tools (Cassettes)(1) Consumable & tool box

Note: we strongly recommend that you order a complete welding head (handle, drive module and clamping cassette) per model

Technical data UHP 250-2 UHP 500-2

Welding process

Compatible with power sources PS 164-2 - P4 - P6 CW - PC CW

O.D. tube range 1.60 to 6.35 mm 3.00 to 12.70 mm

Duty cycle100% 18 A 32 A

60% 50 A 50 A

Torch cooling system air-cooled

Welding speed rangefor O.D. min. 18 to 287 mm/min 12.5 to 191 mm/min

for O.D. max. 70 to 1142 mm/min 52 to 812 mm/min

Weight 3.6 kg 3.8 kg

UHP dimensions in mm

UHP 250-2 UHP 500-2A 27.8 25.4

B 11.9 12

C 5.6 5.7

D 31.6 51.3

E 16.5 25.7

F 22.3 23

G 257 261

H 23 23

I 44.5 44.5

(1) To order compulsory clamping cassettes according to the diameters of the tubes (UHP 250-2 and 500-2), see table on page 31

Sept. 2017


30

6

3 4

5


Sept. 2017


31

Accessories

3 Clamping cassette for one tube O.D. UHP 250-2 - see table below 00183108xx

4 Clamping cassette for one tube O.D. UHP 500-2 - see table below 00183109xx

5 Shunt for water circuit (1) 0014905100

Options (individual components)

6Module UHP 250-2 0018310201

Module UHP 500-2 0018310301

When ordering an UHP-2 welding head, please specify its item number and, if required: - the clamping cassettes corresponding to the tube diameters - the shunt of the water circuit (4).

(1) For PS 164 (up to serial no. 0389159) and P4/P6 (up to software version 2.4.9.) power sources, a water shunt must be ordered to close the torch cooling circuit.

Cassettes for UHP-2 welding heads

Tube - O.D. (mm)

UHP 250-2 cassette

3.00 0018310891

3.17 0018310897

4.00 0018310892

4.76 0018310896

5.00 0018310893

6.00 0018310895

6.35 (1/4") 0018310894

Tube - O.D (mm)

UHP 500-2 cassette

3.00 0018310990

3.17 0018310995

4.00 0018310989

4.76 0018310996

6.00 0018310993

6.35 0018310997

8.00 0018310991

9.52 (3/8") 0018310998

10.00 0018310994

12.00 0018310992

12.70 (1/2") 0018310999

Sept. 2017


32

A

B

D

E

O.D.

CC

MW 34 1T MW 34 2TMW 65-3 2TMW 115-3 2TMW 170 2T

Single clamp 1T Double clamp 2T

1 2

3 4


Sept. 2017


33

► MW

1 MW 34 - For tube O.D. 6 to 34 mm (2T) 0032330001

MW 34 - For tube O.D. 6 to 34 mm (1T) (1) 0032330002

2 MW 65-3 - For tube O.D. 6 to 65 mm 0017279804



MW delivered withProtective case with foam interior Cables and 5.5 m long hoses Tools

Technical data MW 34 MW 65-3 MW 115-3 MW 170-2

Welding process

Compatible with power sources PS 164-2 - P4 - P6 CW - PC CW

O.D. tube range 6 to 170 mm

Duty cycle100% 60 A 60 A 60 A 110 A

60% 60 A 120 A 120 A 120 A

Torch cooling system water-cooled water-cooled water-cooled water-cooled

Outside diameter range 6 to 34 mm 6 to 65 mm 12 to 115 mm 80 to 170 mm

Welding speed rangefor O.D. min. 8 to 179 mm/min 8 to 167 mm/min 9 to 198 mm/min 20 to 448 mm/min

for O.D. max. 46 to 1017 mm/min 49 to 1086 mm/min 41 to 911 mm/min 43 to 953 mm/min

Weight 6 kg 7 kg 9 kg 18 kg

MW dimensions in mm

MW 34 1T MW 34 2T MW 65-3 2T MW 115-3 2T MW 170-2 2T

A 95 95 126 200 290

B 350 350 458 547 580

C 31.25 33.7 38 46 63

D 16.9 16.9 19 23 31.5

E 50 50 63 100 145

(1) this welding head cannot be modifi ed in 2T-version

Sept. 2017


34

6

10

8

5

1 set of TCIs

7

9

1 set of protection disc


Sept. 2017


35

Note: to complete the welding head, 2 sets of TCIs (1) per O.D. are required (one per clamp)

Accessories: TCIs and protection discs

5 Set of TCIs for MW 34, MW 1250, UHP 1500 - reference according to O.D.(2) (4) 0299xxxx

6

Set of TCIs for MW 65-3 - reference according to O.D.(2) 001727x8xx



7 Flange kit for protection disc (MW 34) including 1 set of protection discs (3) 0032330301

8

Support for protection disc (MW 65-3) 0017271701



9 Set of protection discs (MW 34) (3) 003233x3xx

10

Set of protection discs (MW 65-3) (3) 00172717xx



(1) TCI = Tube clamp insert(2) To fi nd the reference according to the tube O.D., see tables " TCIs for MW xx welding heads" from page 38(3) 1 set per O.D – please consult us and specify the tube O.D. and its bend radius

Sept. 2017


36

12

910

A

CB

9

7

6

Example of welding set for the welding of bends

8

1 set of TCIs

1 support for protection disc

1 set of protectiondiscs

1 offset electrode holder

11


Sept. 2017


37

Standard confi guration equipped with the bend kit

Welding head type

Item no. of offset electrode

holder

Min. to max. bending

radius (mm)A (mm) B (mm) C (mm) Offset

(mm)

Electrode diameter

(mm)

MW 34 1T 0017271401 6.35 to 19.05 14.10 16 31.25 5 1.6

MW 34 2T 0017271401 6.35 to 25.40 14.10 16 33.7 5 1.6

MW 65-3

0017741401 12 to 42.40 8.10 22

38

11 1.6

0016624801 12 to 42.40 8.10 22 11 2.4

0017271401 12 to 60.30 14.10 16 5 1.6

MW 115-3

0017741401 25 to 101.60 12.10 23

46

11 1.6

0016624801 25 to 101.60 12.10 23 11 2.4

0017271401 25 to 114.30 18.10 17 5 1.6

MW 170-20017841401 76.20 to 168.30 27.60 22.90

635 2.4

0016624801 76.20 to 152.40 21.60 28.90 11 2.4

Accessories: electrode holders

9 Offset electrode holder - 11 mm (electrode Ø 1.6 mm) only with protection discs - for the welding of bends with MW 40-3, MW 65-3 and MW 115-3 0017741401

10 Offset electrode holder - 5 mm (electrode Ø 1.6 mm) MW 34, MW 40-3, MW 65-3 and MW 115-3 0017271401

11 Offset electrode holder - 11 mm (electrode Ø 2.4 mm) MW 40-3, MW 65-3, MW 115-3 & MW 170-2 0016624801

12 Offset electrode holder - 5 mm (electrode Ø 2.4 mm) MW 170-2 0017841401

Accessories: Adapter for former TCIs

Adapter (4) for the use of 1 set of former TCIs with a MW 40-3 welding head -concerns former MW 1250/HD 1500/UHP 1500/UHP 1500-2 (max. O.D. 33.7 mm) 0017741101

Adapter (4) for the use of 1 set of former TCIs with a MW 65-3 welding head - concerns former MW 2500 (max. O.D. 63.5 mm) 0017271101

Adapter (4) for the use of 1 set of former TCIs with a MW 115-3 welding head - concerns former MW 4500 (max. O.D. 114.3 mm) 0017810901

(4) Delivered with fastening screws

WARNING: 2 sets of adapters are required for each welding head.

Consumables: electrode

Sharpened electrodes, cut to suitable length (delivered in a set of 50 identical pieces) Exxx

Sept. 2017


38

Tube - O.D. (mm)

TCIs for MW 34

6.0 02990051

6.35 (1/4") 02990052

7.0 02990112

7.9 02990487

8.0 02990053

9.25 02990522

9.52 (3/8") 02990006

9.9 02990341

10.0 02990054

10.2 02991196

10.3 02990552

10.5 02990516

11.5 02990581

11.9 02990340

12.0 02990055

12.2 02990476

12.5 02990113

12.7 (1/2") 02990023

13.0 02990501

13.5 02990056

13.7 02990553

13.8 02999715

14.0 02990057

14.3 02990387

14.8 02990608

14.9 02990550

15.0 02990116

15.5 02990647

15.9 02990058

Tube - O.D. (mm)

TCIs for MW 34

16.0 02990103

17.0 02991167

17.1 02990554

17.2 02990059

17.3 02990294

17.5 02990524

17.6 02990406

17.72 02991197

17.9 02990405

18.0 02990060

18.9 02990489

19.0 02990370

19.05 02990007

19.5 02990536

20.0 02990099

20.9 02990490

21.0 02990502

21.3 02990061

21.7 02990335

21.875 02990680

22.0 02990114

22.22 02990343

23.0 02990062

23.2 02990542

24.0 02990140

24.689 02990298

25.0 02990008

25.4 02990024

26.0 02990415

Tube - O.D. (mm)

TCIs for MW 34

26.5 02991166

26.7 02990171

26.9 02990063

27.2 02990301

28.0 02990064

28.2 02990491

28.3 02990523

29.0 02990247

30.0 02990252

30.8 02990492

31.75 02990104

31.9 02990551

32.0 02990271

33.1 02990681

33.3 02990115

33.4 02990065

33.7 02990066

34.0 02990135


TCIs for MW 34 welding heads

Sept. 2017


39

TCIs for MW 65-3 welding heads

Tube - O.D. (mm)

TCIs for MW 65-3

6.00 0017270816

6.35 (1/4") 0017270871

7.00 0017272805

8.00 0017270817

9.53 0017270879

10.00 0017270854

10.20 0017272813

10.50 0017272806

11.00 0017272814

11.80 0017270840

12.00 0017270818

12.32 0017272820

12.70 0017270810

13.00 0017270865

13.50 0017270819

13.72 0017272812

13.80 0017270862

14.00 0017270877

15.00 0017270820

15.80 0017272823

15.87 (5/8") 0017270829

15.88 0017270860

16.00 0017270848

17.00 0017272809

17.20 0017270864

17.30 0017270863

18.00 0017270821

18.80 0017270841

19.00 0017270866

19.05 0017270826

Tube - O.D. (mm)

TCIs for MW 65-3

19.50 0017270895

20.00 0017270876

20.28 0017272821

21.00 0017272815

21.30 0017270822

21.60 0017272825

21.70 0017270855

22.00 0017270835

22.22 (7/8") 0017270830

22.80 0017270842

22.90 0017272826

23.00 0017270849

23.50 0017270887

23.75 0017272819

24.00 0017272811

25.00 0017270812

25.35 0017272818

25.40 0017270809

25.50 0017270888

26.30 0017270882

26.67 0017270872

26.90 0017270827

27.20 0017270856

28.00 0017270838

28.58 (1" 1/8) 0017270831

28.80 0017270843

29.00 0017270850

29.60 0017272816

30.00 0017270868

30.80 0017270861

Tube - O.D. (mm)

TCIs for MW 65-3

31.00 0017272807

31.60 0017272817

31.75 (1" 1/4) 0017270832

31.80 0017270880

32.00 0017270894

32.50 0017270891

33.40 0017270873

33.70 0017270823

34.00 0017270836

34.30 0017270892

34.80 0017270844

34.92 (1" 3/8) 0017270833

35.00 0017270824

36.00 0017270881

36.30 0017272832

37.00 0017270884

37.60 0017272810

38.00 0017270847

38.10 0017270811

40.00 0017270837

40.80 0017270845

41.00 0017270853

41.30 0017270893

42.00 0017270870

42.16 0017270874

42.40 0017270814

42.70 0017270857

43.00 0017270890

44.00 0017272808

44.45 (1" 3/4) 0017270834

Sept. 2017


40

Tube - O.D. (mm)

TCIs for MW 65-3

45.00 0017270878

46.00 0017272831

47.00 0017270889

48.00 0017270869

48.30 0017270815

48.60 0017270858

50.00 0017270867

50.50 0017272829

50.80 0017270808

51.00 0017270813

52.00 0017270825

52.80 0017270846

53.00 0017270851

54.00 0017270852

56.00 0017270883

57.00 0017270886

57.15 (2" 1/4) 0017270828

58.60 0017272830

60.00 0017270896

Tube - O.D. (mm)

TCIs for MW 65-3

60.30 0017270807

60.50 0017270859

63.00 0017270875

63.40 0017272828

63.50 0017270806

64.00 0017270885

65.00 0017270839

For protection discs, please consult us with the O.D. tube and the bent radius


Sept. 2017


41


Tube - O.D. (mm)

TCIs for MW 115-3

21.30 0017810894

21.40 0017812801

21.70 0017810863

22.00 0017810859

23.00 0017812806

24.00 0017810864

24.60 0017812810

25.00 0017810833

25.40 0017810808

26.67 0017810881

26.90 0017810834

27.00 0017810887

27.20 0017810858

28.00 0017810832

28.58 0017810817

29.00 0017810835

30.00 0017810884

31.75 0017810818

32.00 0017810856

33.00 0017810865

33.40 0017810882

33.50 0017810889

33.70 0017810836

34.00 0017810857

34.93 0017810819

35.00 0017810837

38.00 0017810829

38.10 0017810805

40.00 0017810831

Tube - O.D. (mm)

TCIs for MW 115-3

41.00 0017810815

42.00 0017810890

42.20 0017810883

42.30 0017810872

42.40 0017810838

42.70 0017810850

43.00 0017812808

44.45 0017810820

45.00 0017810875

46.20 0017810873

48.30 0017810839

48.60 0017810851

50.00 0017810866

50.80 0017810806

51.00 0017810830

52.00 0017810811

53.00 0017810816

54.00 0017810841

54.80 0017812815

56.00 0017810876

57.00 0017810877

57.15 0017810821

58.00 0017810886

60.00 0017810871

60.20 0017810891

60.30 0017810825

60.50 0017810852

63.00 0017810847

63.50 0017810812

Tube - O.D. (mm)

TCIs for MW 115-3

64.30 0017810893

65.20 0017812812

67.10 0017810861

68.00 0017812816

69.00 0017812805

69.80 0017810826

69.85 0017810822

70.00 0017810813

71.00 0017810878

72.00 0017812809

73.00 0017810888

73.40 0017810860

76.00 0017810848

76.10 0017810842

76.20 0017810807

76.30 0017810853

77.70 0017812817

80.00 0017810874

82.00 0017810870

82.50 0017810843

83.00 0017810880

84.00 0017810885

84.80 0017810827

85.00 0017810814

88.90 0017810823

89.00 0017810892

89.10 0017810854

90.00 0017810879

91.00 0017812818

Sept. 2017


42

Tube - O.D. (mm)

TCIs for MW 115-3

99.50 0017812811

100.00 0017810867

101.10 0017812807

101.30 0017812803

101.40 0017810849

101.60 0017810809

102.00 0017812802

103.00 0017812804

Tube - O.D. (mm)

TCIs for MW 115-3

103.80 0017810828

104.00 0017810810

105.00 0017812819

108.00 0017810845

114.00 0017810862

114.20 0017810855

114.30 0017810824



Sept. 2017


43


Tube - O.D. (mm)

TCIs for 170-2

80.00 0017840718

83.00 0017840723

85.00 0017840705

88.90 0017840708

92.00 0017840715

99.00 0017840716

100.00 0017840714

101.60 0017840720

103.00 0017840724

104.00 0017840707

114.30 0017840703

120.00 0017840728

129.00 0017840706

Tube - O.D. (mm)

TCIs for 170-2

130.94 0017840717

133.30 0017840727

139.70 0017840710

139.80 0017840712

141.00 0017840704

141.30 0017840704

150.00 0017840726

152.20 0017840725

152.40 0017840721

153.00 0017840722

154.00 0017840711

165.20 0017840713

168.30 0017840798


Sept. 2017


44

6

1 2 3

54

Open welding heads

P Version: welding heads with chuck clamping

C Version: welding heads with water-cooled clamp shells

Sept. 2017


45

► MU IV CW

P Version: welding heads with chuck clamping adjustable for the entire O.D. range

1 MU IV 8/38 CW P (8 - 38 mm O.D.) (1) 15639807

2 MU IV 14/38 CW P with reduced torch plate (14 - 38 mm O.D.) 0040051200

3 MU IV 19/80 CW P (19 - 80 mm O.D.) (1) 15579807

4 MU IV 25/115 CW P (25 - 115 mm O.D.) (1) 17139807

MU IV 25/128 CW P (25 - 128 mm O.D.) 15679807

5 MU IV 76/195 CW P (76 - 195 mm O.D.) (1) 15469803

MU IV 114/275 CW P (114 - 275 mm O.D.) 16029803

C Version: welding heads with water-cooled shell clamping, one shell per O.D (2)

The shells must be ordered separately

6 MU IV 14/38 CW C (14 - 38 mm O.D.) 15639805

MU IV 14/38 CW C with reduced torch plate (14 - 38 mm O.D.) 0040051201

MU IV 30/58 CW C with reduced torch plate (30 - 58 mm O.D.) 0040047901

MU IV 30/80 CW C (30 - 80 mm O.D.) 15579805

MU IV 50/115 CW C (50 - 115 mm O.D.) 17139805

MU IV 50/128 CW C (50 - 128 mm O.D.) 15679805

MU IV 76/195 CW C (76 - 195 mm O.D.) 15469805

MU IV 114/275 CW C (114 - 275 mm O.D.) 16029805

Centring shell - compulsory accessory for MU IV 38 & 128 - 1 per O.D. See on page 53

Centring pads- compulsory accessory for MU IV 195 & 275 - 2 per O.D. See on page 53

MU IV CW delivered with P version C versionContainer for safety packing and transport 9 m hose cable Water-cooled and tiltable torch without wire accessories Consumable & tool box Wire accessories (3) option option

(1) Standard MU IV welding heads with short delivery time(2) 2nd water cooling circuit on the power source is required(3) To order the wire accessory, specify the model of the wire feeder which is used: POLYFIL B, POLYFIL-2 , POLYFIL-3 or POLYFIL Compact.

See the "Options" table on page 53

Sept. 2017


46

>A/2D

B

E

C

A

D

E

>A/2A

Open welding heads

ODmin./ODmax.Ø A(mm)

B(mm)

C(mm)

D(mm)

E(mm)

MU IV 8/38 CW P 126 16 5 96 72

MU IV 14/38 CW P - reduced 96 12 5 96 72

MU IV 19/80 CW P 172 16 5 97 103

MU IV 25/115 CW P 215 16 5 101 148

MU IV 25/128 CW P 240 16 5 99 173

MU IV 76/195 CW P 410 30.5 14 158.5 208

MU IV 114/275 CW P 500 30.5 14 172.5 276

MU IV CW P-clamping dimensions

Sept. 2017


47

Technical data MU IV CW

Welding process

Compatible with power sources PS 164-2 - P4-2 - P6 - PC



60% 250 A

Torch cooling system Water-cooled

Slip clutch mechanism (1) Only from MU IV 195 onwards

Welding speed rangefor O.D. min.

(mm/min)for O.D. max.

(mm/min)MU IV 8/38 CW 8 to 192 30 to 675

MU IV 14/38 CW 14 to 290 36 to 787

MU IV 14/38 CW - reduced 14 to 290 36 to 787

MU IV 30/58 CW - reduced 20 to 432 41 to 922

MU IV 19/80 CW 10 to 214 41 to 901

MU IV 25/115 CW 10 to 207 44 to 953

MU IV 25/128 CW 8 to 175 41 to 899

MU IV 76/195 CW 15 to 319 38 to 819

MU IV 114/275 CW 16 to 332 37 to 803

MU IV CW C-clamping dimensions

ODmin./ODmax.Double clamping

system optionØ A(mm)

B(mm)

C(mm)

D(mm)

E(mm)

MU IV 14/38 CW C 126 16 5 79 72

MU IV 14/38 CW C - reduced 96 12 5 79 74

MU IV 30/58 CW C - reduced 155 12 5 88 93

MU IV 30/80 CW C 172 16 5 88 103

MU IV 50/115 CW C 215 16 5 92 148

MU IV 50/128 CW C 240 16 5 108 173

MU IV 76/195 CW C N/A 410 30.5 14 178 208

MU IV 114/275 CW C N/A 500 30.5 14 178.5 276

(1) These welding heads are equipped with a slip clutch mechanism on the drive rotation which allows to wind the hose very quickly

Sept. 2017


48

6

1 2 3

54

7

Open welding heads



Sept. 2017


49

► MU IV AVC/OSC CW P Version: welding heads with chuck clamping adjustable for the entire O.D. range

1 MU IV 8/38 AVC/OSC CW P (8 - 38 mm O.D.) (1) 15639808

MU IV 19/80 AVC/OSC CW P (19 - 80 mm O.D.) (1) 15579808


MU IV 42/128 AVC/OSC CW P (42 - 128 mm O.D.) 15679808

MU IV 42/128 AVC/OSC CW P (42 - 128 mm O.D.) with integrated wire feeder (2) 15679809


4 MU IV 76/195 AVC/OSC CW P (76 - 195 mm O.D.) (1) with integrated wire feeder (2) 15469809

5 MU IV 114/275 AVC/OSC CW P (114 - 275 mm O.D.) 16029804

MU IV 114/275 AVC/OSC CW P (114 - 275 mm O.D.) with integrated wire feeder (2) 16029809

C Version: welding heads with water-cooled shell clamping, one shell per O.D (3)

6 MU IV 14/38 AVC/OSC CW C (14 - 38 mm O.D.) 15639806

MU IV 14/38 AVC/OSC CW C with reduced torch plate support (14 - 38 mm O.D.) 0040047902



MU IV 30/80 AVC/OSC CW C (30 - 80 mm O.D.) 15579806


7 MU IV 50/128 AVC/OSC CW C (50 - 128 mm O.D.) 15679806



Centring shell - compulsory accessory for MU IV 38 & 128 - 1 per O.D. See on page 53


MU IV AVC/OSC CW delivered with P version C versionContainer for safety packing and transport 9 m hose cable Water-cooled and tiltable torch without wire accessories Consumable & tool box Wire accessories for 0.8 mm wire diameter

(1) Standard MU IV welding heads with short delivery time(2) Integrated wire feeder item no. 11879803(3) 2nd water cooling circuit on the power source is required

Sept. 2017


50

>A/2D

B

E

COSC

A

D

E

>A/2A

DCAVC

CAVC

Open welding heads


B(mm)

Amplitude D(mm)

E(mm)CAVC

(mm)COSC (mm)

MU IV 8/38 AVC/OSC CW P 142 23 20 20 140 72

MU IV 19/80 AVC/OSC CW P 200 16 20 20 126 103

MU IV 42/115 AVC/OSC CW P 235 16 20 20 129 148

MU IV 42/128 AVC/OSC CW P 340 16 20 30 124 173

MU IV 76/195 AVC/OSC CW P 410 16 20 30 155 208

MU IV 114/275 AVC/OSC CW P 530 16 20 30 169 276

MU IV AVC/OSC CW P-clamping dimensions

Sept. 2017


51

Technical data MU IV AVC/OSC CW

Welding process

Compatible with power sources P6 - PC



60% 250 A

Torch cooling system Water-cooled

Slip clutch mechanism (1) Only from MU IV 195 onwards

Welding speed range (2) for O.D. min. (mm/min)

for O.D. max. (mm/min)

MU IV 8/38 AVC/OSC CW 8 to 192 30 to 675





MU IV 25/115 AVC/OSC CW (3) 10 to 207 44 to 953




MU IV AVC/OSC CW C-clamping dimensions

ODmin./ODmax.

Double clamping system

option (4)

Ø A(mm)

B(mm)

Amplitude D(mm)

E(mm)CAVC

(mm)COSC (mm)

MU IV 14/38 AVC/OSC CW C 142 23 20 20 120 72

MU IV 14/38 AVC/OSC CW C - reduced 132 35.5 20 20 120 74



MU IV 30/80 AVC/OSC CW C 200 16 20 20 116 103

MU IV 50/115 AVC/OSC CW C N/A 235 16 20 20 118 148

MU IV 50/128 AVC/OSC CW C 340 16 20 30 133 173



(1) These welding heads are equipped with a slip clutch mechanism on the drive rotation which allows to wind the hose very quickly(2) Speed ranges are identical for welding heads with standard or reduced plate(3) 25 mm is the smallest value of diameter that can be welded (4) Recommended option

Sept. 2017


52

1 2

3 4

5 6

7

8

Open welding heads

Sept. 2017


53

Accessories

1

Adapter for Ø 8-14 mm for welding head MU IV 8/38 P (1) 15630605




2

Centring shell for MU IV 14/38 C (2) 156303xx








3

Centring pads for MU IV 76/195 C (1) 00154603xx



4

Balancer (for MU IV 28 - MU IV 80) 75501287



Spare parts box (tools & consumables) for MU IV 28 to MU IV 80 100001720

Spare parts box (tools & consumables) for MU IV 115 to MU IV 275 100001721



Options

5 Integrated wire feeder (MU IV 128/195/275) with wire accessories (X/Y adjustment and wire sheath) for wire Ø 0.8 mm. 11879803

6 Angle gearbox for welding heads MU IV 38 to MU IV 128 75500229

7 Angle gearbox for welding heads with slip clutch MU IV 195 to MU IV 275 15640600

8Wire accessory length 2.2m Ø 0.8 for MU IV 28 to MU IV 104 15649807

Wire accessory length 3.2m Ø 0.8 for MU IV 115 to MU IV 275 15649808

(1) 2 adapters or centring pads per clamping system(2) One centring shell per tube O.D.

Sept. 2017


54

1

2

3

Open welding heads

P-type gas lens

N-type gas lens

GM-type gas lens

Sept. 2017


55

MU IV CW welding heads

MU IV Range (mm)

With adapter(mm)

Without adapter

(mm)Gas lens Gas nozzle

length (mm)Ø Range

(mm)

38 8-388-14 P 12 8-14

14-38 P 12 14-38

80 19-80

19-30 N or GM 26 19-30

P 16 19-30

30-80 N or GM 26 30-51

P 16 30-54

P 12 30-80

115 25-115

25-50 N or GM 26 25-50

P 16 25-50

50-115 N or GM 26 50-95

P 16 50-115

128 25-128

25-70 GM 36 25-70

N or GM 26 42-70

70-128 GM 36 70-88

N or GM 26 70-128

P 16 70-128

195 76-195 / / N or GM 26 76-195

275 114-275 / / N or GM 26 114-275

MU IV CW AVC/OSC welding heads

MU IV Range (mm)

With adapter(mm)

Without adapter

(mm)Gas lens Gas nozzle

length (mm)Ø Range

(mm)

38 8-38 8-14 P 16 8-14

14-38 P 16 14-38

80 19-80

19-30 N or GM 26 19-30

30-80 N or GM 26 30-50

P 16 30-80

115 42-115

42-50 N or GM 26 42-50

50-115 N or GM 26 50-102

P 16 50-115

128 42-128

42-70 GM 26 42-70

N or GM 26 63-70

70-128 GM 26 70-108

N or GM 26 70-128

195 76-195 / / N or GM 26 76-195

275 114-275 / / N or GM 26 114-275

MU IV open welding heads - gas lens confi gurations

Sept. 2017


56THE ART OF WELDING

1 2

3 4

5

Open welding heads



Sept. 2017


57June 2017

Standard orbital equipmentTHE ART OF WELDING

► MU IV AVC/OSC HW

P Version: welding heads with chuck clamping adjustable 1 MU IV 76/195 AVC/OSC HW P (1) 0023580005

2 MU IV 76/195 AVC/OSC HW P with integrated wire feeder 0023580003

C Version: welding heads with water-cooled shell clamping 3 MU IV 30/60 AVC/OSC HW C with integrated wire feeder 0040051701

4 MU IV 76/195 AVC/OSC HW C with integrated wire feeder 0023580004

5 MU IV 89/219 AVC/OSC HW C (1) 0040052201

Centring shell - compulsory accessory for MU IV 30/60 - 1 per O.D. See on page 59


MU IV HW delivered with P version C versionContainer for safety packing and transport 9 m hose cable Water-cooled torch with wire accessories Consumable & tool box

Technical data MU IV 30/60 AVC/OSC C HW

MU IV 76/195 AVC/OSC HW

MU IV 89/219 AVC/OSC C HW

Welding process

Compatible with power sources P6 and PC P6 and PC P6 and PC

Duty cycle100% 190 A 250 A 190 A

60% 250 A 300 A 250 A

Torch cooling system Water-cooled Water-cooled Water-cooled

Outside diameter range 30 to 60 mm 76 to 195 mm 89 to 219 mm

Electrode diameter 2.4 mm 3.2 mm 3.2 mm

(1) can only be used with an external wire feeder POLYFIL-3 HW and its wire sheath item no. 0023581620 (see on page 97)

Sept. 2017


58

BCOSC

D

D

E

A

CAVC

D

E

A

AD

Open welding heads

Sept. 2017


59

MU IV AVC/OSC HW P-clamping dimensions


B(mm)

Amplitude D(mm)

E(mm)CAVC

(mm)COSC (mm)

MU IV 76/195 AVC/OSC P HW 560 26.5 20 20 205 201

MU IV 76/195 AVC/OSC P HW with integrated wire feeder 560 26.5 20 20 205 201

MU IV AVC/OSC HW C-clamping dimensions


B(mm)

Amplitude D(mm)

E(mm)CAVC

(mm)COSC (mm)

MU IV 30/60 AVC/OSC C HW with integrated wire feeder

280 26.5 20 30 160 /

MU IV 76/195 AVC/OSC C HW with integrated wire feeder 560 26.5 20 20 225 208

MU IV 89/219 AVC/OSC C HW 496 26.5 20 20 241.5 276

Accessories

Balancer (for MU IV 195 - MU IV 245) (1) 75501288


Centring pads for MU IV 195 HW C – 2 pads per welding head 00154603xx

(1) This balancer can be used with all MU IV AVC/OSC HW welding heads on this page



Options

Angle gearbox for welding heads with slip clutch MU IV 195 (1) 15640600

Electrode kit Ø 4.0 version (with gas lens support, gas lens and chuck) 0029851201

Wire sheath for POLYFIL-3 HW 0023581620

Sept. 2017


60

1 2

E

A B

DC

FGPolycar 30 dimensions in mm

Polycar 30 CWA 60

B 32

C 60

D 168

E 34

F 185

G 200


Ø 70Ø 50

Sept. 2017


61

► Polycar 30 CW

1 POLYCAR 30 AVC/OSC LP CW, TIG with Ø 50 mm spool (radial clearance 60 mm) (1) 0023680001

2 POLYCAR 30 AVC/OSC CW, TIG with Ø 70 mm spool (radial clearance 75 mm) 0023680002

The POLYCAR 30 CW welding head is especially design for orbital welding of tubes with an O.D. from 32 to 168 mm (1.3" to 6.6") for minimum radial clearance conditions.

Polycar 30 CW delivered withCompact shipping case for safety packing and transport AVC/OSC slides Wire accessories On board wire feeder Cable bundles and hoses 15m Consumable & tool box Kit for daily operation

Technical data Polycar 30 CW

Welding process

Compatible with power sources P6 - PC


60% 200 A

O.D. tube range 32 to 168mm (2)

Torch type Special TIG torch with large gas lens

Torch cooling Closed loop water cooling

Maximum AVC/OSC travel speed 500 mm/min

AVC/OSC slide stroke 10 mm

AVC/OSC slide motorisation Stepper motor

Wire feeder On board

Maximum wire feeding speed 2000 mm/min

Compatible spool Ø50 mm - 0.5 kg (LP version) or Ø70 mm - 1.5 kg

Axis wire adjustment X/Y axis wire adjustment ± 2.5 mm - 0.1" and angular adjustment

Recommended wire-Ø 0.8 mm

Bundle cable length 15m

Weight (without cable nor bundle) 3 kg

(1) Only for aluminium application(2) For bigger O.D. tube, please consult us.

Sept. 2017


62

2 3

1

R


Radial Clearance

On calibrated tubes - O.D ± 0.2mmO.D (mm) 32 42 50 70 108 114 168

R with spool Ø 50 60

R with spool Ø 100 113 112 111.5 109.5 108.5 108 106

On tubes according to EN 10216-2O.D (mm) 33.7 42.4 48.3 60.3 73 88.9 101.6 114.3 141.3 168.2

R with spool Ø 70 75

R with spool Ø 100 124 122 120 119 119 118 118 117 116 116

(1) Important: aluminium application only.(2) The 0.5 kg wire spool can be used with aluminium wire ONLY.

Ø 100

Ø 70

Sept. 2017


63

Accessories: Guide rings for calibrated tubes – O.D. ±0.2 mm

1

Guide ring (Stainless steel 304L) O.D. 32 mm (1.3") 0023682900


Guide ring (Stainless steel 304L) O.D. 50 mm (2") 0023682800






Other diameters between 32 to 168 mm On request

Accessories: Guide rings for standard O.D. tubes - Seamless steel tubes (1)

1

Guide ring (Stainless steel 304L) O.D. 33.7 mm (1.33") 0023684020






Guide ring (Stainless steel 304L) O.D. 101.6 mm (4") 0023684050




Consumables

Pressure roll Ø 0.8 0023680453

Pressure roll Ø 1.0 (2) 0023680454

Pressure roll Ø 1.2 (2) 0023680455

Sharpened electrodes cut to suitable length (delivered in a set of 50 identical pieces) Exxx

The standard version of the wire feeder includes 2 pressure rolls for 0.8 mm wire

Options

2 Wire spool holder support 1.5 kg (Ø 100 mm) including: casing holder 4", casing 4" and swivel 0023680801

3 Steel tube welding kit including: spool holder 70 mm, long nozzle 36 mm, wire accessory for Ø 0.8 wire and spool Ø 70 mm (empty) 0023681901

(1) Standard O.D. tubes according to EN 10216-2 - Seamless steel tubes(2) Only for aluminium application

Sept. 2017


64

1

2


Sept. 2017


65

► POLYCAR 60-2 CW/HW

1 POLYCAR 60-2 CW 0019500001

1 + 2 POLYCAR 60-2 HW 0019500002

POLYCAR 60-2 delivered with CW HWCompact shipping case for safety packing and transport AVC/OSC slides Wire accessories On-board wire feeder Cable bundles and hoses 12m Consumable & tool box

Technical data 60-2 CW 60-2 HW

Welding process

Compatible with power sources P6 - PC P6 HW - PC HW

Diameter range ≥ 168 mm

Duty cycle100% 250

60% 300

Torch type TIG torch


Torch tilting ±15°

Maximum AVC travel speed 500 mm/min

AVC slide stroke 60 mm

AVC slide motorisation Stepper motor

Maximum OSC travel speed 1000 mm/min

OSC slide stroke 60 mm

OSC slide motorisation Stepper motor

Wire feeder On-board

Maximum wire feeding speed 2068 mm/min 7929 mm/min

Compatible spool 200 mm / 5 kg 200 mm / 5 kg

Axis wire adjustment X/Y axis wire adjustment ± 2.5 mm - 0.1" and angular adjustment

Recommended wire-Ø 0.8 mm – 1.0 mm – 1.2 mm


Weight (without spool nor bundle) 9 kg

Sept. 2017


66

1 3

D

G

B EC

A

F

2


Polycar 60-2 dimensions in mm

Polycar 60-2 CW/HW

A 167 min (190*) (*) dimensions with offset

B 146.5

C 405 ±35

D 27

E 120

F ± 15°

G 618

Sept. 2017


67

Accessories: Guide rings (1)

1

Nickel-plated steel guide ring with spacers (stainless steel) O.D. 168 mm (6") 12672101

















Nickel-plated straight track, length 2.5 m 12671501

Other dimensions On request

Extension feet in stainless steel On request

Important: Please consult us to choose the guide ring and indicate tube O.D.

Accessories: torche (1)

2 V2 torch kit for POLYCAR 60-2 (for welding up to 75 mm wall thickness) in addition to WP27 torch for fi nal layer 0021140001



Options

3 Cartridge torch 0019500501

(1) Compatible with Polycar 60 welding heads

Sept. 2017


68

1


Sept. 2017


69

1 POLYCAR MP TIG HW with WP27 torch 0024750001

The POLYCAR MP TIG HW welding head equipped with the WP27 torch is designed for orbital welding of tubes & pipes with wall tickness up to 35 mm (1)

Polycar MP HW delivered withCompact shipping case for safety packing and transport AVC/OSC slides with electronic brake & limit switches Adjustable slide for torch height Tiltable torch -20°/0° 2-axes wire adjustment Cables and hoses bundles length 15 m Integrated wire feeder Consumable & tool box

Technical data Polycar MP HW

Welding process

Compatible with power sources P6 HW - PC 600-3 HW

Diameter range ≥ 168 mm/6"


60% 450 A

Torch type WP27 TIG torch


Maximum AVC/OSC travel speed 2500 mm/min

AVC/OSC slide stroke 69 mm

AVC/OSC slide motorisation Stepper motor

Slide for torch height Manual adjustment - stoke 180 mm

Wire feeder On-board HW

Maximum wire feeding speed 7929 mm/min

Compatible spool Ø200 mm - 5 kg

Axis wire adjustment X/Y axis wire adjustment

Recommended wire-Ø 0.8 mm – 1.0 mm – 1.2 mm


Weight (without cable) 16 kg

(1) For wall thicknesses >35 mm, see accessories on page 71

► POLYCAR MP HW

Sept. 2017


70

A

B

D

C

EFG

1

42 3

H


Sept. 2017


71

Polycar MP HW dimensions in mmPolycar MP HW

A 182 E 40

B 550 F 236 ±35

C 550 ±35 G 120

D 270 H 348 ±35

Accessories: Stainless Steel Guide Ring with feet (mm/in)

1

Stainless steel guide ring with feet - O.D. 168 mm (6") 0021730601

















Other dimensions On request

Accessories: torches & cable

2 V2 torch kit for the POLYCAR MP TIG (for welding up to 75 mm wall thickness) 0020511301

3Narrow groove torch kit - NG 100 - 150 mm for the POLYCAR MP On request

Narrow groove torch kit for wall thicknesses >150 mm for double POLYCAR MP On request

4 120 mm²/70 mm² adaptation kit for current or earth cable for POLYCAR MP use (1) 0023001800



(1) Must be ordered to adapt the 70 mm² current (or earth) cable of the power source with the 120 mm² current (or earth) cable of the welding head

Sept. 2017


72

Tube-to-tubesheet welding heads

1

Sept. 2017


73

► TS 34-2

1 TS 34-2 for tube I.D. 10 to O.D. 33.7 mm without centring chuck unit 0020470005

TS 34-2 delivered withContainer for safety packing and transport 9 m hose cable Manual clamping assembly unit Spare parts box (tools) Kit shielding gas chambers with 3 front rings Clamping units from 10 to 14 mm Clamping units from 14 to 19 mm Clamping units from 19 to 25 mm Clamping units from 25 to 33.7 mm

When ordering a TS 34-2 welding head: - Please specify the range of tube I.D. to be welded - For each I.D., order a clamping unit (Item no. 00204740xx) and specify the I.D.

Technical data TS 34-2

Welding process,

Compatible with power sources PS 164-2 - P4-2 - P6 series - PC series

Duty cycle 100% 120 A

Collector cooling Closed water circuit

Min. tube I.D. 10 mm

Max. tube O.D. 33.7 mm – other dimensions on request

Tube joint design

Flush Standard

Recessed 1 mm max.

Protruding 0.5 mm max.

Internal bore welding Option

Positioning / Centering Expansion mandrel

Purge gas chamber Standard

Weight 3.8 kg (without cable)

Cable length 9 m

Sept. 2017


74

Centring unit

Clamping unit

B

A C

D

E

2

1 34


Sept. 2017


75

TS 34- 2 dimensions in mm

TS 34-2A 305

B 233

C 70

D 35

E 220

Accessories

1 Centring unit (centring chuck, introduction nose) (I.D. 10 to 33.7 mm). I.D. to be specifi ed on order. 00204740xx

2

Clamping unit (without centring unit) - tubes I.D. 10 to 14 mm 0020472201



Clamping unit (without centring unit) - tubes I.D. 25 to O.D. 33.7 mm 0020472501

Balancer type K22/5 3.8 kg 75501234

Additional fee for chromium of the centring chuck On demand

3 Pneumatic clamping unit 0020472001

4 Torch TS 34-2 with Ø 2.4 gas lens, assembled 0020470411



Sept. 2017


76

Tube I.D. (mm) Centring unit

10.00 0020474001

10.40 0020474002

10.60 0020474033

11.60 0020474059

11.80 0020474043

12.00 0020474052

13.00 0020474009

13.20 0020474039

13.40 0020474068

13.60 0020474020

13.90 0020474058

14.00 0020474008

15.00 0020474029

16.00 0020474017

16.05 0020474013

16.50 0020474070

16.65 0020474040

16.90 0020474041

17.00 0020474030

17.60 0020474073

17.75 0020474051

18.05 0020474021

18.20 0020474074

18.40 0020474023

18.60 0020474056

19.00 0020474057


19.85 0020474045

20.00 0020474018

20.40 0020474003

20.60 0020474069

21.00 0020474006

21.75 0020474063

21.85 0020474060

22.00 0020474022

22.20 0020474044

23.00 0020474004

23.60 0020474048

24.00 0020474024

24.20 0020474064

24.50 0020474025

25.00 0020474053

25.60 0020474027

26.00 0020474019

26.60 0020474028

27.00 0020474049

27.20 0020474055

27.40 0020474010

27.60 0020474054

29.75 0020474016

30.30 0020474037

30.60 0020474038

31.75 0020474015


TS 34-2 centring units

Sept. 2017


77

Expanded tubesWhen tubes are expanded by press fi t, the O.D. of the centring chuck may be larger than the original tube I.D. When ordering the clamping unit, please specify the depth of expansion and the diameter of the tube I.D. where it has been expanded.


11.00/11.25 0020474072

14.25/14.50 0020474050

14.40/14.80 0020474007

15.50/15.75 0020474026

15.70/15.40 0020474032

16.90/16.60 0020474061

17.00/17.30 0020474031

17.60/17.85 0020474042

18.00/18.30 0020474014

21.60/21.90 0020474062

22.60/23.00 0020474035

23.00/23.40 0020474034

23.60/24.00 0020474071

24.13/24.30 0020474065

24.80/24.40 0020474036

27.00/26.60 0020474012

27.40/27.00 0020474011

29.90/30.20 0020474067

30.30/30.60 0020474066

31.40/31.00 0020474005

31.70/30.60 0020474046

32.00/31.00 0020474047

Sept. 2017


78

65

2

3

1

4


Sept. 2017


79

(1) For pneumatic centring and clamping system: mandrel (1 per I.D.) to be ordered separately(2) For the welding heads without pneumatic centring and clamping system, please add centring shaft Ø 6.5 mm or Ø 8.0 mm and the centring

mandrel corresponding to the application (1 mandrel per I.D.)(3) For centring or expanding mandrel with 8 ≤ I.D. < 10.5 mm and 60 < I.D. ≤ 75 mm: on request(4) Water-cooled locating pin sub-assembly & expanding mandrel not delivered with the TS 8/75-2. See table "Accessories: low protruding

tools" on page 85

► TS 8/75-2

TS 8/75-2 with pneumatic centring and clamping system (1)

Tube 15 mm ≤ I.D. ≤ 40 mm

1 TS 8/75-2 – motorised adjustment distance electrode/tubesheet (AVC) to use with an existing external wire feeder POLYFIL Compact or POLYFIL-3 CW 0032230007

2 TS 8/75-2 – motorised adjustment distance electrode/tubesheet (AVC) with on-board "rotating" wire feeder, Spool Ø 100 mm 0032230004

TS 8/75-2 with centring system for 2 balls centring mandrel (2)

Tubes 10 mm ≤ I.D. ≤ 60 mm(3)

3 TS 8/75-2 – manual adjustment distance electrode/tubesheet for use with an external wire feeder POLYFIL Compact or POLYFIL-3 0032230012

4 TS 8/75-2 – motorised adjustment distance electrode/tubesheet (AVC) with on-board "rotating" wire feeder, Spool Ø 100 mm 0032230011

5 TS 8/75-2 – motorised adjustment distance electrode/tubesheet (AVC) or use with an external wire feeder POLYFIL Compact or POLYFIL-3 0032230010

TS 8/75-2 with pneumatic clamping system & low protruding tooling(3

Tubes 13.5 mm ≤ I.D. ≤ 40 mm(3)

6 TS 8/75-2 – motorised adjustment distance electrode/tubesheet (AVC) with on-board "rotating" wire feeder, Spool Ø 100 mm (4) 0032230009

TS 8/75-2 delivered with 1 3 5 2 4 6

Compact shipping case for safety packing and transport Wire accessories for external wire feeder /

On-board wire feeder / Cable bundles and hoses 9m Consumable & tool box

Sept. 2017


80

6 1

2

3

8

74

9

5


Sept. 2017


81

AB G

C

D

E

H

F

I

J

Description of the TS 8/75-2

1 Stationary wire feeder

2 Rotating wire feeder

3 External wire feeder kit

4 Torches

5 Pneumatic centring & clamping system with expanding mandrel

6 Low protruding tooling

7 Centring shaft Ø 8 mm with 2 ball-centring mandrel with housing

8Centring shaft Ø 6.5 mm with 2 ball-centring mandrel or monobloc centring mandrel with housing

9 Additional gas housing

TS 8/75-2 dimensions in mm

TS 8/75-2A 205

B218 Centring shaft with centring mandrel

244 Pneumatic centring / clamping mandrel

C 148

D 161

E 202

F 583

G 223

H 20

I 139

J 66

Sept. 2017


82

78

10

9

1 2 3

4 5 6

delivered with the TS 8/75-2 welding head

Application Torch angle

1 Recess welding -15°

2 Recess welding -5°

3 Flush welding 0°

4 Flush welding +5°

5 Protrusion welding +15°

6 Protrusion welding +30°

Air-cooled torches are fi tted with a slide, a torch, a gas lens assembly and a wire adjuster.


Sept. 2017


83

Accessories: Equipped air-cooled torches for TS 8/75 and TS 8/75-2 welding heads

1 Torch with slide -15°, air cooled, equipped with its wire guide 0023411735

2 Torch with slide -5°, air cooled, equipped with its wire guide 0023411730

3 Torch with slide 0°, air cooled, equipped with its wire guide 0023411710

4 Torch with slide +5°, air cooled, equipped with its wire guide 0023411715



For “extreme” working conditions (preheated workpieces or for use in confi ned spaces), water-cooled torches are available on request in order to increase the performance of the system.



Accessories: for pneumatic centring and clamping system — tubes 15 mm ≤ I.D. ≤ 75mm

7

Expanding mandrel for tube 10.5 mm ≤ I.D. ≤ 15 mm On request

Expanding mandrel for tube 15 mm ≤ I.D. ≤ 22 mm 00234116x1



Expanding mandrel for tube 40 mm ≤ I.D. ≤ 75 mm On request

Accessories: for centring system with 2 balls centring mandrel — tubes 15 mm ≤ I.D. ≤ 75 mm

8 Housing for simple centring system with 2 balls centring mandrel (1) 0023411506

9 Centring shaft Ø 8 mm 0023411521

10

Centring mandrel for tube 15 mm ≤ I.D. ≤ 30 mm (2) 3842xxx2

Centring mandrel for tube 30 mm ≤ I.D. ≤ 60 mm (2) 3842xxx3

Centring mandrel for tube 60 mm ≤ I.D. ≤ 75 mm (2) On request

To modify or replace the pneumatic centring and clamping system by a 2-ball centring mandrel, you must order

- a centring shaft Ø 6.5 mm or Ø 8.0 mm - the centring mandrel corresponding to the application (1 mandrel per I.D.) - the housing 8

- the cap M5 item no. 01501101.

(1) You must also order cap M5 item no. 01501101(2) One centring mandrel per I.D.

Sept. 2017


84

14

15

17

16

11

13

12


Sept. 2017


85

Accessories: for centring system with 2 balls centring mandrel — tubes 8 mm ≤ I.D. ≤ 15 mm

11 Centring shaft Ø 6.5 mm 0023411524

12 Housing for simple centring system with 2 balls centring mandrel (1) 0023411506

13Centring mandrel for tube 8 mm ≤ I.D. ≤ 10.5 mm (2) On request

Centring mandrel for tube 10.5 mm ≤ I.D. ≤ 15 mm (2) 3842xxx1

Note: The centring mandrels of the TS 8/75-2, TS 8/75 and TS 2000 are identical and have the same reference numbers

Accessories

Centring shaft with "monobloc" centring mandrel for tube ≤ 10.5 mm On request

Additional gas housing - can be used for fl ush tube welding with torches 0° & 5° (3) 0032231201

Balancer 75500353


Spare part box TS 8/75 and TS 8/75-2 (tools and consumables) 0023410098

Adaptor for use of the TS 8/75 and TS 8/75-2 welding heads with PS 406-2 or PC power source 0023000902

Accessories: for low protruding tooling (dedicated for 3 - 4 mm tube protruding)

14

Water-cooled locating pin sub-assembly - for I.D. 13.50 mm (tube O.D. 19.05 x 2.77) 0032231604








Water-cooled locating pin sub-assembly - for other dimensions On request

15 Tilted AVC kit - including equipped water-colled 10° torch and wire guide 0032231501

16 Adjustable pneumatic self-clamping system (without centring mandrel) 0032234001

17

Expanding mandrel for tube 10.2 mm ≤ I.D. ≤ 15 mm (4) 00168816x1

Expanding mandrel for tube 15 mm ≤ I.D. ≤ 22 mm (4) 00168816x2



(1) You must also order cap M5 item no. 01501101(2) One centring mandrel per I.D.(3) Can only be used if the adjustable self-clamping system or the backing plate with the adjustable legs are removed (4) Concerning the expanding mandrel dimensions, see the "TS 8/75 & TS 8/75-2 welding heads – Expanding mandrels for..." table

on page 94

Sept. 2017


86

21

5

1

2

6

3

4


Sept. 2017


87

SD

TS 8/75-2 - double plate welding equipment

Description of the double plate welding equipment1 TS 8/75-2 – dedicated for welding lance 4 Centring ring

2 Double plate welding lance 5 Centring mandrel kit

3 Support 6 Adaptation lance set (1)

(1) The adaptation lance set must be ordered to assembly a welding lance on a TS 8/75 or TS 8/75-2.

A complete double plate welding lance must include at least:

- 1 double plate welding lance 2

- 1 support 3 , fi tted for the right SD (see table "Support length" on page 89) - 1 centring ring 4 , fi tted for the fi rst tubesheet I.D. - 1 centring mandrel kit 5 , fi tted for the tube I.D. to be welded - 1 adaptation lance set 6 (1)

1 TS 8/75-2 – dedicated for welding lance, motorised adjustment distance electrode/tubesheet (AVC) with on-board "rotating" wire feeder for spool Ø 100 mm 0032230014

SD = Distance between the same sides of the sheets (plates) in mm

Accessories: Double plate welding lance

2

Double plate welding lance for I.D. 25.4 mm - SD 50-300 (2) to be used with TS 2000 0023230701

Double plate welding lance for I.D. 25.4 mm - SD 170-475 (1) to be used with TS 8/75-2 0023230702

Double plate welding lance for I.D. 31.75 mm - SD 170-475 (1) to be used with TS 8/75-2 0023230703

Sept. 2017


88

4

5

6

3

Sept. 2017


89

Tube I.D. (mm)

Centring mandrel kit 5

19 0023231578

19.2 0023231580

19.6 0023231589

19.9 0023231593

20 0023231597

20.4 0023231592

20.6 0023231588

Tube I.D. (mm)


21 0023231595

21.2 0023231503

22.1 0023231599

22.4 0023231584

23.6 0023231596

24.3 0023231579

26.1 0023231598

Tube I.D. (mm)


26.3 0023231587

26.8 0023231586

27.5 0023231504

28.1 0023231594

28.5 0023231577

30.7 0023231583

33 0023231585

Support length (mm) 3

125 175 225 275 325 375Welding lance I.D. (mm) SDmin. SDmax. SDmin. SDmax. SDmin. SDmax. SDmin. SDmax. SDmin. SDmax. SDmin. SDmax.

For TS 2000 25.4 295 350 245 300 195 250 145 200 95 150 45 100

For TS 8/75-2 25.4 or 31.75 425 480 375 430 325 380 275 330 225 280 175 230

SD = Distance between the same sides of the sheets in mm

Accessories: Tooling for double plate welding lance

3

Support length 125 mm 0013262640






4 Centring ring 00232321xx

5 Centring mandrel kit (Chuck & introduction nose) 00232315xx

6 Adaptation lance set - to assembly a double plate welding lance with a TS 8/75-2 0032231801

Tube I.D. (mm)

Centring ring4

28 0023232112

32.8 0023232111

33 0023232105

Tube I.D. (mm)

Centring ring4

35.76 0023232108

35.8 0023232107

39.4 0023232106

Tube I.D. (mm)

Centring ring4

39.16 0023232110

45.51 0023232109

Other I.D. On request

Sept. 2017


90

15

TS 8/75 & TS 8/75-2 welding heads – 2 balls centring mandrels for centring shaft 6.5mm

Tube I.D. mm

Centring mandrel for

centring shaft Ø 6.5 mm

10.00 100002940

10.20 38420201

10.40 38420234

10.70 38420235

11.00 38420213

11.40 100001531

11.60 38420218

11.80 38420219

12.00 38420205

12.10 38420223

12.20 38420220

12.40 38420212

12.50 38420242

12.60 38420216

12.70 38420217

13.00 38420214

13.20 38420225

13.40 38420227

13.50 38420208

13.60 38420207

13.90 38420241

14.00 38420209

14.10 38420215

14.20 38420224

14.22 38420237

14.40 38420210

14.45 38420239

14.50 38420206

14.80 100000585

14.83 100002696

Tube I.D. mm



15.00 38420211

15.75 38420226

16.00 38420232

For expanded tubes

Expanded tubes (mm)



11.00/11.35 38420240

11.60/11.30 38420236

11.70/14.20 38420224

12.40/12.90 38420238

12.50/12.80 38420231

13.65/13.85 38420230

13.80/14.30 38420221

14.00/14.20 100001238

14.00/14.30 100000848

14.25/14.45 38420229

15.75/15.95 38420228

16.62/17.17 38420222


Sept. 2017


91

12

Tube I.D. mm


centring shaft Ø 8 mm

14.20 38420220

14.50 38420122

14.70 38421275

14.80 100002688

14.90 38421214

15.00 38420121

15.25 38420126

15.40 38420108

15.70 38421215

15.75 100001628

15.80 38420136

16.00 38420123

16.25 38420134

16.40 38421240

16.50 38420124

16.65 38420110

16.80 100001088

16.83 100001591

17.00 38420125

17.27 100001592

17.50 38420118

17.60 38421213

17.80 38420177

Tube I.D. mm



18.00 38420127

18.30 38421254

18.40 38420159

18.50 38420128

18.65 38420111

19.00 38420129

19.40 38420138

19.50 38420130

19.60 38421212

19.80 38420195

19.86 38420154

20.00 38420131

20.10 38421216

20.30 38421245

20.40 38420114

20.50 38420132

20.60 38420161

20.80 38421260

20.90 38421267

21.10 38420185

21.18 100001818

21.20 100002689

21.30 100002546

21.40 38421225

21.50 38421252

21.60 38420116

21.70 38420160

22.00 38420135

22.10 38420112

22.20 38421273

Tube I.D. mm



22.30 38420143

22.50 38420115

22.90 38420196

23.00 100002135

23.20 38421270

23.50 38421280

23.60 38420113

23.80 38421258

24.00 38420139

24.60 38421269

24.80 100000586

24.90 38421276

25.00 38420141

25.40 38421238

25.50 38420142

25.90 38420173

26.00 38420144

26.20 38420158

26.40 38421255

26.70 38421256

27.00 38420149

27.40 38420182

27.50 38421279

27.80 38421233

28.00 38420147

28.50 38420148

29.00 38420117

29.70 38421253

30.00 38420150

30.50 38420179

TS 8/75 & TS 8/75-2 welding heads – 2 balls centring mandrels for centring shaft 8mm

Sept. 2017


92

Tube I.D. mm



30.70 38420188

30.80 38421268

31.00 38421230

31.30 100000584

31.70 38420190

32.00 38420162

32.60 38420109

32.80 100000587

33.00 38420119

33.30 38421257

33.70 38420189

33.90 38421217

34.00 38420192

34.85 100001395

35.00 38420199

35.10 38420186

35.20 38421263

35.50 38420167

35.60 100002136

36.00 38421244

36.50 38421232

36.80 38420187

37.00 38420165

37.25 38420166

37.60 38420194

38.90 38420180

39.20 38421277

39.30 38420146

39.65 38420156

40.00 38420169

Tube I.D. mm



40.10 38421239

40.30 38420168

40.40 38420175

40.50 38420184

41.00 38420176

41.70 38420178

42.50 38420197

43.10 100001320

43.25 3420181

44.50 38420173

45.00 38420107

45.30 38421264

45.60 38421241

45.90 38421234

46.00 38421266

47.50 38421271

48.30 38420157

48.50 38420174

49.00 38420155

49.80 38421262

50.00 38420151

51.00 38421249

51.20 38421265

52.00 38420163

52.30 38421242

53.10 38420153

53.90 38421243

56.50 38421250

57.00 100002691

58.00 38420193

Tube I.D. mm



59.50 38420164

62.40 38421251

67.50 38421272

68.00 100001891

70.00 38420198

For expanded tubes

Expanded tubes (mm)



14.00/13.30 100000848

14.40/14.09 38421259

15.79/16.25 100001594

15.90/15.50 38420170

18.80/18.50 38420137

19.86/20.06 38421236

22.10/22.30 38421237

23.40/23.10 38420140

24.10/23.60 38420146

26.20/26.40 38421235

31.00/31.20 38421231

31.00/31.40 38421278

35.60/35.80 100001151

40.00/40.60 38421274

47.50/47.80 38421261

51.00/52.50 38421246

56.50/58.00 38421247

62.40/63.90 38421248


Sept. 2017


93

7

Tube I.D. mm Expanding mandrel

14.75 to 15.00 0023411688

15.50 to 15.75 0023411698

16.50 to 16.75 0023411687

16.75 to 17.00 0023411696

17.25 to 17.50 0023411675

21.25 to 21.50 0023411656

21.50 to 21.75 0023411673

21.75 to 22.00 0023411674

32.50 to 32.75 0023411672

15.25 to 15.50 0023411662

15.75 to 16.00 0023411694

16.00 to 16.25 0023411652

17.75 to 18.00 0023411668

18.35 to 18.60 0023411695

18.75 to 19.00 0023411684

19.00 to 19.25 0023411671

19.25 to 19.50 0023411676

19.50 to 19.75 0023411655

19.75 to 20.00 0023411699

20.25 to 20.50 0023411645

20.31 to 20.56 0023411689

20.75 to 21.00 0023411692

21.00 to 21.25 0023411686

22.00 to 22.25 0023411697

22.25 to 22.50 0023411665

22.75 to 23.00 0023411667

23.25 to 23.50 0023411653

23.50 to 23.75 0023411663

23.75 to 24.00 0023411682

24.75 to 25.00 0023411669


25.50 to 25.75 0023411643

25.75 to 26.00 0023411680

26.00 to 26.25 0023411670

26.50 to 26.75 0023411644

26.75 to 27.00 0023411681

27.25 to 27.50 0023411693

27.75 to 28.00 0023411666

28.25 to 28.50 0023411657

29.00 to 29.50 0023411646

29.50 to 29.75 0023411648

30.25 to 30.50 0023411683

30.50 to 30.75 0023411664

31.50 to 31.75 0023411685

31.75 to 32.00 0023411691

32.75 to 33.00 0023411679

33.65 to 33.90 0023411690

34.00 to 34.25 0023411647

34.55 to 34.80 0023411677

34.75 to 35.00 0023411661

35.75 to 36.00 0023411649

36.50 to 36.75 0023411659

36.75 to 37.00 0023411650

37.75 to 38.00 0023411651

38.75 to 39.00 0023411678

39.25 to 39.50 0023411660

39.75 to 40.00 0023411607

40.25 to 40.50 0023411658

48.50 to 48.75 0023411654

19.75 to 20.00 0023411699

TS 8/75 & TS 8/75-2 welding heads – Expanding mandrels for pneumatic centring & clamping

Sept. 2017


94

19

TS 8/75 & TS 8/75-2 welding heads – Expanding mandrels for low protruding tooling clamp


10,20 0016881607

10,40 0016881647

10,60 0016881685

10,70 0016881648

11,00 0016881614

11,40 0016881615

11,65 0016881636

11,80 0016881616

12,00 0016881617

12,25 0016881690

12,35 0016881679

12,80 0016881695

13,00 0016881620

13,10 0016881684

13,20 0016881680

13,45 0016881677

13,51 0016881654

13,70 0016881646

14,00 0016881621

14,10 0016881632

14,40 0016881626

14,70 0016881627

14,83 0016881612

15,20 0016881691

15,30 0016881658

15,40 0016881623

15,55 0016881672

15,75 0016881611

16,00 0016881625

16,40 0016881669


16,60 0016881637

16,80 0016881670

16,90 0016881655

17,00 0016881633

17,30 0016881631

17,50 0016881674

19,00 0016881693

19,60 0016881649

19,80 0016881624

19,90 0016881656

20,00 0016881629

20,15 0016881613

20,30 0016881605

20,40 0016881622

20,58 0016881644

21,00 0016881638

21,18 0016881606

21,40 0016881650

22,00 0016881639

22,10 0016881610

22,50 0016881675

22,90 0016881635

23,00 0016881652

23,60 0016881663

24,00 0016881682

24,40 0016881681

25,40 0016881608

26,00 0016881660

26,20 0016881661

26,60 0016881683


Sept. 2017


95


27,00 0016881630

27,53 0016881659

27,80 0016881668

28,45 0016881642

30,58 0016881678

31,20 0016881657

31,50 0016881688

32,50 0016881665

33,70 0016881609

33,90 0016881673

34,40 0016881687

34,50 0016881686

34,80 0016881628

35,60 0016881664

36,00 0016881643

37,00 0016881689

40,00 0016881618

Sept. 2017


96

1

2

External wire feeders

Sept. 2017


97

► POLYFIL

1POLYFIL-3 CW 2023500001

POLYFIL-3 HW 2030500202

2 POLYFIL Compact CW 0024390001

POLYFIL-3 delivered with CW HW Compact CW

Motor for wire feeder Cable bundle - 9m hose cable Pressure roll Ø 0.8 mm

Technical dataPOLYFIL-3 CW (1) POLYFIL-3 HW POLYFIL-3 Compact

CW (2)

Welding process

Compatible with power sources All Polysoude powers sources All Polysoude powers sources (except P6 HW)

Compatible with wire spool - diameter and weight 300mm / 15kg and 200mm / 5kg 100 mm/1.5 kg

Wire diameter 0.6 mm - 0.8 mm - 0.9 mm - 1.0 mm - 1.2 mm - 1.6 mm(other diameters on request)

Wire feed speedMin. 150 mm/min 150 mm/min 94 mm/min

Max. 2552 mm/min 8000 mm/min 2068 mm/min

Dimensions (LxWxH) 620 x 450 x 300 mm 320 x 305 x 165 mm

Weight 16 kg (without wire spool) 7 kg (without wire spool)

Cable length 9 m

(1) To use the POLYFIL-3 CW, the power source must be equipped with the following minimum software version: PSxx4: Eprom L633 Version 6.7 minimum PSxx6: Eprom L644 Version 1.A minimum PC/ K1476 Version V and card 0021700703

(2) This wire feeder can be used in horizontal and vertical position.

Sept. 2017


98

1

2

3

4

56

External wire feeders

Sept. 2017


99

Accessories: POLYFIL-3 CW, HW & POLYFIL Compact CW

1

Wire sheath for MU Ø 0.6 mm – 2.20m length 44419817








Wire sheath for TS 2000 Ø 0.8 mm – 2.20m length 0016881901



Wire sheath for TS 8/75 Ø 0.8 mm – 2.20m length 0023411903

Consumables: POLYFIL-3 CW & HW (1)

2

Short nozzle for wire Ø 0.8 mm 25610560




3

Pressure roll for POLYFIL-3 Ø 0.6 mm/0.9 mm (price per roll, 2 rolls needed for each Ø) 2023500206



(1) Compatibility of the wire liner with wire feeder and welding heads:All POLYFIL wire sheathes (MU and TS) can be used with the POLYFIL-2 or POLYFIL-3 wire feeder and with POLYFIL-B or POLYFIL Compact by using an adapter, which is delivered with the wire liner. The wire sheath MU can be used with the whole range MU IV and MU III.

Consumables: POLYFIL-3 Compact CW (1)

4

Drive roller for POLYFIL Compact - Ø 0.6 mm 11000149






5 Pressure roller for POLYFIL Compact 10731212

6 Straightening roller for POLYFIL Compact 10731217

(1) The wire sheathes type POLYFIL for MU are compatible with this wire feeder. An adapter, sent in standard version together with the wire feeder, will be used. Recommended wire: Ø 0.8 mm

Sept. 2017


100

θφ

Average values for electrode grinding:

Current intensity (A)

Electrode diameter (mm) Grinding angle θ° Flat section φ

(mm)10 - 110 1.6 15° 0.1 to 0.2

40 - 190 2.0 15 - 30° 0.1 to 0.3

60 - 210 2.4 30° 0.1 to 0.4

125 - 290 3.2 30° 0.2 to 0.5

250 - 400 4 30° 0.3 to 1

Sept. 2017


101

Tandem electrode grinding machines

Tandem electrode grinding machine (WIG-SPITZ)Tungsten electrode grinding and cutting machine with emergency brake 75500877

Table support with extractor 100000212

Accessories

Support guide for short electrodes (520.619) Ø 1.6 mm 75573664

Support guide for short electrodes (520.619) Ø 2.4 mm 75573672

Spare parts

Diamond cutting wheel 75500967

Grinding wheel grain 120 75500966

Portable electrode grinding machine

Portable grinding machine ESG PLUS - 230 V - 50 or 60 Hz 790052485

Spare parts

Diamond grinding wheel (Fine grain) 790052487

Electrode holder (with clamping sleeve 1 - 3.2 mm)) 790052457

Clamping sleeve 1 - 3.2 mm 790052481

Plug purge kit for orbital welding

Purge plug kit for orbital welding 100077871

Sharpened electrodes

Sharpened cut-to-length electrodes (delivered in a set of 50 identical pieces) Exxx

Information to be specifi ed for ordering: - Welding head type - Tube diameter - Electrode diameter - Grinding angle if different from 30°

Other equipment

Sept. 2017


102

3 4

21

Spare parts

Sept. 2017


103

Related services

Accessories

1 Set of standard TCIs UHP 1500-2 - item according to O.D. - see table below (1) 0299xxxx

2 Holder for electrode offset Ø 1.6 mm (UHP 1500-2) (offset 2.5 mm) 0018311801

Options (individual components)

3 Module UHP 1500-2 0018311501

4 Clamping system UHP 1500-2 (without TCIs) (2) 0018311601

(1) 2 sets of TCIs (Tube Insert Clamping) per O.D. are required(2) Former modules and clamping systems of UHP 1500 cannot be used with the UHP 1500-2.

► Spare parts for UHP 1500-2

TCIs for UHP 1500-2 welding heads

Tube - O.D. (mm)

TCIs for UHP 1500-2

5.9 02990488

6.0 02990051

6.35 (1/4") 02990052

7.0 02990112

7.9 02990487

8.0 02990053

9.25 02990522

9.52 (3/8") 02990006

9.9 02990341

10.0 02990054

10.2 02991196

10.3 02990552

10.5 02990516

11.5 02990581

11.9 02990340

12.0 02990055

12.2 02990476

Tube - O.D. (mm)

TCIs for UHP 1500-2

12.5 02990113

12.7 (1/2") 02990023

13.0 02990501

13.5 02990056

13.7 02990553

13.8 02999715

14.0 02990057

14.3 02990387

14.8 02990608

14.9 02990550

15.0 02990116

15.5 02990647

15.9 02990058

16.0 02990103

17.0 02991167

17.1 02990554

17.2 02990059

Sept. 2017


104

Tube - O.D. (mm)

TCIs for UHP 1500-2

17.3 02990294

17.5 02990524

17.6 02990406

17.72 02991197

17.9 02990405

18.0 02990060

18.9 02990489

19.0 02990370

19.05 02990007

19.5 02990536

20.0 02990099

20.9 02990490

21.0 02990502

21.3 02990061

21.7 02990335

21.875 02990680

22.0 02990114

22.22 02990343

23.0 02990062

23.2 02990542

24.0 02990140

24.689 02990298

25.0 02990008

25.4 02990024

26.0 02990415

26.5 02991166

26.7 02990171

26.9 02990063

27.2 02990301

28.0 02990064

28.2 02990491

Tube - O.D. (mm)

TCIs for UHP 1500-2

28.3 02990523

29.0 02990247

30.0 02990252

30.8 02990492

31.75 02990104

31.9 02990551

32.0 02990271

33.1 02990681

33.3 02990115

33.4 02990065

33.7 02990066

34.0 02990135

35.0 02990067

38.0 02990339

38.1 (1 1/2") 02990009

40 02990286

Former TCIs of UHP 1500 can be used with the UHP 1500-2, K 1500 et MW 1250.

Related services - Spare parts

Sept. 2017


105

► Spare parts for MW 40-3

Accessories: TCIs and protection discs




Adapter (3) for the use of 1 set of former TCIs with a MW 40-3 welding head -concerns former MW 1250/HD 1500/UHP 1500/UHP 1500-2 (max. O.D. 33.7 mm) 0017741101

(1) TCI = Tube clamp insert (2) 1 set per O.D – please consult us and specify the tube O.D. and its bend radius(3) Delivered with fastening screws

Standard confi guration equipped with the bend kit

Welding head type

Item no. of offset electrode

holder

Min. to max. bending

radius (mm)A (mm) B (mm) C (mm) Offset

(mm)

Electrode diameter

(mm)

MW 40-3

0017741401 6.35 to 19.05 8.10 22

38

11 1.6

0016624801 6.35 to 19.05 8.10 22 11 2.4

0017271401 6.35 to 33.70 14.10 16 5 1.6

► TCIs and protection discs for MW 40-3

Tube - O.D.(mm)

TCIs for MW 40-3

Protection disc

R = 1.5 D4.77 0017740884

5.00 0017740871

6.00 0017740820 0017741786

6.35 0017740811

7.00 0017740872

7.50 0017740859 0017741768

7.80 0017742815

7.94 0017740848

7.95 0017742811

8.00 0017740821 0017741745

8.60 0017742825

Tube - O.D.(mm)

TCIs for MW 40-3

Protection disc

R = 1.5 D9.00 0017740873

9.10 0017740892

9.25 0017740842

9.35 0017740827

9.50 0017741767

9.52 (3/8") 0017740812

9.53 0017741792

10.00 0017740828 0017741787

10.20 0017740844

10.29/10.30 0017740885

11.00 0017740874

Sept. 2017


106


Tube - O.D.(mm)

TCIs for MW 40-3

Protection disc

R = 1.5 D11.11 (7/16") 0017740849

11.50 0017740860 0017741766

11.70 0017742813

12.00 0017740819 0017741788

12.20 0017740852

12.30 0017740896

12.60 0017740861

12.70 0017740805 0017741791

12.80 0017742821

13.00 0017740858

13.10 0017742817

13.50 0017740829 0017741797

13.70 0017740882

13.80 0017740870

14.00 0017740810 0017741760

14.28 (9/16") 0017740850

15.00 0017740853

15.20 0017740869

15.70 0017742819

15.87 (5/8") 0017740813

16.00 0017740822

16.50 0017742820

16.80 0017742816

17.00 0017740855

17.10 0017740830

17.15 0017740886

17.20 0017740843 0017741796

17.30 0017740888

17.46 0017740851

17.50 0017742804

Tube - O.D.(mm)

TCIs for MW 40-3

Protection disc

R = 1.5 D18.00 0017740831 0017741763

18.20 0017740854

18.50 0017740894

19.00 0017740846

19.05 0017740806 0017741790

19.30 0017740893

19.50 0017742818

20.00 0017740823

20.60 0017740895

21.00 0017740875

21.20 0017742810

21.30 0017740832 0017741795

21.34 0017740887

21.60 0017742814

21.70 0017740818

21.80 0017740891

22.00 0017740833 0017741762

22.20 0017742812

22.22 (7/8") 0017740814

23.00 0017740834

24.00 0017740835

24.50 0017740889

25.00 0017740824 0017741798

25.20 0017742807

25.35 0017742802

25.40 0017740807 0017741789

25.70 0017742806

26.70 0017740867

26.90 0017740825 0017741794

26.97 0017742801

Sept. 2017


107

Tube - O.D.(mm)

TCIs for MW 40-3

Protection disc

R = 1.5 D27.00 0017740876

27.20 0017740856

28.00 0017740836 0017741761

28.58 (1 1/8") 0017740815

29.00 0017740845

29.70 0017742808

30.00 0017740837

30.20 0017742805

31.00 0017740877

31.75 (1 1/4") 0017740816

31.88 0017742803

32.00 0017740838

32.50 0017740881

33.00 0017740878

33.40 0017740868

33.70 0017740839 0017741793

34.00 0017740857

34.60 0017742823

34.93 (1 13/8") 0017740817

35.00 0017740840

35.60 0017742824

36.00 0017740883

37.00 0017740879

38.00 0017740841

38.10 0017740808

38.50 0017740847

38.90 0017742809

39.00 0017740880

40.00 0017740809

Protection discs appendix for MW 40-3 welding heads – R ≠ 1.5 D

Tube - O.D. (mm) R

MW 40-3 Protection

disc6.35 R = 9.53 0017741747

8.00 R = 12 0017741748

9.53 R = 14.29 0017741756

12.00 R = 18 0017741755

13.72 R = 20.58 0017741754

15.00 R = 25 0017741742

17.20 R = 20 0017741771

17.20 R = 28 0017741770

18.00 R = 27 0017741753

19.00 R = 28.5 0017741752

20.00 R = 30 0017741741

21.30 R = 19.05 0017741751

21.30 R = 25.5 0017741775

21.30 R = 28 0017741774

21.30 R = 30 0017741769

21.30 R = 30.5 0017741773

24.00 R = 36 0017741750

26.7 R = 28.58 0017741749

26.9 R = 28.5 0017741772

27.00 R = 40.5 0017741746

28.00 R = 49 0017741765

32.00 R = 3.5D 0017741764

Sept. 2017


108

Tube - O.D. (mm) TCI Protection disc

5.90 02990488

6.00 02990051 02991039

6.35 (1/4") 02990052 02991185

7.00 02990112 02991147

7.90 02990487

8.00 02990053 02991148

9.00 02991149

9.25 02990522

9.52 (3/8") 02990006 02991186

9.90 02990341

10.00 02990054 02991150

10.20 02991196

10.30 02990552

10.50 02990516

11.00 02991151

11.50 02990581

11.90 02990340

12.00 02990055 02991152

12.20 02990476

12.50 02990113

12.70 (1/2") 02990023

13.00 02990501 02991153

13.50 02990056 02991071

13.70 02990553


13.75 02991070

13.80 02999715

14.00 02990057

14.30 (9/16") 02990387

14.80 02990608

14.90 02990550

15.00 02990116

15.50 02990647

15.90 02990058

16.00 02990103

17.00 02991167

17.10 02990554

17.20 02990059

17.30 02990294

17.50 02990524

17.60 02990406

17.72 02991197

17.90 02990405

18.00 02990060 02991154

18.90 02990489

19.00 02990370

19.05 02990007 02990600

19.50 02990536

20.00 02990099

► TCIs and protection discs for former MW 1250, UHP 1500 & 1500-2, K 1500


Accessories: TCIs for MW 1250, UHP 1500, UHP 1500-2 & K 1500

Set of TCIs for MW 34, MW 1250, UHP 1500 - reference according to O.D (1) 0299xxxx

(1) 2 sets of TCIs (1) per O.D. are required (one per clamp)

Sept. 2017


109


20.90 02990490

21.00 02990502

21.30 02990061

21.70 02990335

21.88 02990680

22.00 02990114

22.22 02990343

23.00 02990062

23.20 02990542

24.00 02990140

24.69 02990298

25.00 02990008 02991040

25.4 (1") 02990024 02991019

26.00 02990415

26.50 02991166

26.70 02990171

26.90 02990063

27.20 02990301

28.00 02990064 02991155

28.20 02990491

28.30 02990523

29.00 02990247

30.00 02990252

30.80 02990492

31.75 02990104

31.90 02990551

32.00 02990271 02991156

33.10 02990681

33.30 02990115

33.40 02990065

33.70 02990066


34.00 02990135

35.00 02990067

38.00 02990339

38.10 (1 1/2) 02990009

40.00 02990286

Sept. 2017


110

► TCIs and protection discs for former MW 2500

Tube - O.D. (mm) Standard TCI Widened TCI

9.52 (3/8") 02990100

10.00 02990284

11.90 02990342

12.00 02990068

12.70 02990069 02991111

13.00 02990408

13.50 02990283

13.70 02990121

13.80 02990450

14.00 02990070

15.00 02990315

15.88 02990282

16.00 02990243

17.00 02991104

17.20 02990071

17.30 02990288

18.00 02990072 02991058

19.00 02990234

19.05 02990073 02991002

19.50 02990173

20.00 02990102

21.00 02990623

21.30 02990074 02991004

21.70 02990209


22.00 02990134 02991048

23.00 02990075

24.00 02990070

25.00 02990010

25.20 02990565

25.4 (1") 02990076 02991006

26.60 02990344 02991078

26.70 02990174

26.90 02990077 02991125

27.20 02990210 02991131

28.00 02990078 02991050

29.00 02990079 02991142

30.00 02990299

31.60 02990644

31.75 02990101

32.00 02990316

33.40 02990080 02991080

33.50 02990317

33.70 02990002 02991105

34.00 02990230 02991060

35.00 02990081

37.90 02990572

38.00 02991026

38.1 (1 1/2") 02990011 02991008


Accessories: TCIs for MW 2500

Set of TCIs for MW 2500 (1) - reference according to O.D 02990xxx


Sept. 2017


111


40.00 02990082 02991052

41.00 02990083

42.00 02990084 02991126

42.10 02990345 02991082

42.40 02990085 02991010

42.60 02990511

42.70 02990224

42.80 02990287

44.50 02990086

44.95 02990635

45.00 02990560

48.20 02990346 02991084

48.30 02990087 02991012

48.60 02990225

50.00 02990232


50.70 02990584

50.80 02990012 02991046

51.00 02991025 02991138

52.00 02990143 02991054

53.00 02990024 02991143

54.00 02990088

56.00 02990559

57.15 02990636

60.00 02990508

60.30 02990001 02991086

60.50 02990226

63.00 02990122

63.20 02990573

63.50 02990013 02991109

64.00 02990486

Sept. 2017


112

► TCIs and protection discs for former MW 4500

Tube O.D. (mm)

Standard TCI

Widened TCI

Protection disc

21.30 02990423

25.00 02990626

25.4 (1) 02990163 02991168

26.90 02990424

28.00 02990535

29.00 02990270

30.00 02990371

31.75 02990304

32.00 02990604

33.40 02990162

33.70 02990334

34.00 02990354

37.00 02990314

38.1 (1 1/2") 02990111 02991020

40.00 02990331

40.05 02990547

41.00 02990394

42.00 02990372

42.40 02990107

45.00 02990605

46.05 02990548

48.30 02990117

50.00 02990469 02990474

50.80 02990110 02991169

Tube O.D. (mm)

Standard TCI

Widened TCI

Protection disc

51.00 02990582

52.00 02990355 02991096 02991100

53.00 02990233

54.00 02990373

57.00 02990606

63.00 02990161

63.50 02990093 02991113 02991114

68.00 02991164

70.00 02990228 02991097 02991101

75.00 02991098 02991102

76.00 02990583

76.10 02990204

76.20 02990015 02991115 02991116

84.00 02990507

85.00 02990229 02991106 02991107

85.80 02990426

88.90 02990016

89.00 02990607

101.60 02990160 02991117 02991118

103.00 02991165

104.00 02990014 02991099 02991103

112.00 02990624

114.30 0299 0106


Accessories: TCIs for MW 4500

Standard TCIs for MW 4500 (1) - reference according to O.D 029900xx


Sept. 2017


113

Tube - O.D. (mm)

K 375 K 875 K 1500 (*)Standard

TCI Gas Cup Standard TCI Gas Cup Standard

TCI Gas Cup

2.90 02990589 02990594

3.17 02990285

3.20 02990026

3.90 02990590 02990595

4.00 02990639 02990638 02990653 02990413

4.76 (3/16") 02990430 02990431 02990388

4.78 02990027

5.90 02990488

6.00 02990535 02990432 02990278 02990028 02990051 02990622

6.35 (1/4") 02990020 02990017 02990094 02990376 02990052 02990479

7.00 02990112

7.11 02990646

7.90 02990487

7.92 02990029

7.94 (5/16") 02990389

8.00 02990598 02990596 02990021 02990030 02990053

9.25 02990522

9.50 02990540

9.52 (3/8") 02990141 02990108 02990022 02990118 02990006 02990478

9.90 02990341

10.00 02990599 02990597 02990291 02990292 02990054

10.20 02991196

10.30 02990552

10.50 02990516

10.60 02990463

10.70 02990411

10.90 02990614

11.00 02990031

11.10 (7/16") 02990390

► TCIs and gas cups for K 375 - K 875 - K 1500

Sept. 2017


114

Tube - O.D. (mm)

K 375 K 875 K 1500 (*)Standard


TCI Gas Cup

11.50 02990581

11.90 02990340

12.00 02990089 02990090 02990055

12.20 02990412 02990476

12.50 02990113

12.70 (1/2") 02990095 02990410 02990023 02990295

13.00 02990501 02990512

13.50 02990025 02990056

13.70 02990553

13.80 02990416 02999715

14.00 02990098 02990454 02990057 02990593

14.20 02990268

14.28 (9/16") 02990289 02990290

14.30 02990387

14.80 02990608

14.90 02990550

15.00 02990377 02990116 02990513

15.50 02990647

15.88 (5/8") 02990097 02990035

15.90 02990058

16.00 02990453 02990436 02990103 02990036

17.00 02991167

17.10 02990554

17.20 02990059

17.30 02990303 02990294 02990293

17.50 02990524

17.60 02990406

17.72 02991197

17.90 02990405

18.00 02990318 02990319 02990060

18.90 02990489

19.00 02990370 02990514


Sept. 2017


115

Tube - O.D. (mm)

K 375 K 875 K 1500 (*)Standard


TCI Gas Cup

19.05 (3/4") 02990041 02990395 02990007 02990019

19.50 02990536

20.00 02990655 02990032 02990099 02990640

20.90 02990490

21.00 02990502 02990515

21.30 02990091 002990092 02990061

21.60 02991195

21.70 02990333 02990335 02990375

21.88 02990680

22.00 02990114 02990105

22.22 02990142 02990033 02990343

23.00 02990062

23.20 02990542

23.60 02990497

24.00 02990140

24.69 02990298

25.00 02990034 02990008

25.40 (1") 02990024 02990305

26.00 02990415

26.50 02991166

26.70 02990171

26.90 02990063

27.20 02990301

28.00 02990064 02990645

28.20 02990491

28.30 02990523

29.00 02990247

30.00 02990252

30.80 02990492

31.75 02990104 02990037

31.90 02990551

32.00 02990271

Sept. 2017


116

Tube - O.D. (mm)

K 375 K 875 K 1500 (*)Standard


TCI Gas Cup

33.10 02990681

33.30 02990115

33.40 02990065

33.70 02990066 02990096

34.00 02990135

35.00 02990067

38.00 02990339

38.10 (1 1/2") 02990009 02990038

40.50 02990286

(*) also compatible with UHP 1500, UHP 1500-2 and MW 1250

► TCIs and gas cups for K 2500

Tube - O.D. (mm) Standard TCI Gas Cup

9.52 02990100

10.00 02990284

11.90 02990342

12.00 02990068

12.70 02990069 02990434

13.00 02990408

13.50 02990283

13.70 02990121

13.80 02990450

14.00 02990070

15.00 02990315

15.88 02990282


16.00 02990243 02990244

17.20 02990071

17.30 02990288 02990427

18.00 02990072 02990245

19.00 02990234

19.05 02990073 02990363

19.50 02990173

20.00 02990102

21.00 02990623

21.30 02990074

21.70 02990209 02990332

22.00 02990134


Sept. 2017


117


23.00 02990075

24.00 02990470

25.00 02990010 02990246

25.20 02990565

25.40 02990076 02990364

26.60 02990344

26.70 02990174 02990378

26.90 02990077

27.20 02990210 02990227

28.00 02990078

29.00 02990079

30.00 02990299

31.60 02990644

31.75 02990101 02990612

32.00 02990316

33.40 02990080 02990379

33.50 02990317

33.70 02990002 02990627

34.00 02990230 02990136

35.00 02990081

37.90 02990572

38.00 02990026

38.10 02990011 02990365

40.00 02990082

41.00 02990083 02990613

42.00 02990084

42.10 02990345

42.40 02990085 02990626

42.60 02990511

42.70 02990224

42.80 02990287

44.50 02990086

44.95 02990635 02990633


45.00 02990560 02990563

48.20 02990346

48.30 02990087 02990380

48.60 02990225

50.00 02990232 02990562

50.70 02990584

50.80 02990012 02990169

51.00 02990025 02990571

51.17 02990632

52.00 02990143

53.00 02990024

54.00 02990088

56.00 02990559 02990564

57.15 02990636 02990634

60.00 02990508

60.30 02990001 02990381

60.50 02990226 02990302

61.00 02990570

63.00 02990122 02990561

63.20 02990573

63.50 02990013 02990018

64.00 02990486

Sept. 2017


118

2

3

4

1

5

6

► MU IV open - "P" type gas lens

1 Electrode chuck

Ø 1.6 29810135

Ø 2.0 29810108

Ø 2.4 29810143

Ø 3.0 29810145

2 Seal Ø 24 29810146

3 Electrode

Ø 1.6 62410016

Ø 2.0 62410020

Ø 2.4 62410024

Ø 3.0 62410030

4 Gas lens

Ø 1.6 29810140

Ø 2.0 29810101

Ø 2.4 29810142

Ø 3.0 29810130

5 Ceramic nozzle

Ø 9 – L 12 29810170

Ø 9 – L 16 29810175

Ø 9 – L 19 29810177

Ø 11 – L 8 29810150

Ø 11 – L 10 29810155

Ø 11 – L 12 29810180

Ø 11 – L 16 29810181

Ø 11 – L 19 29810182

6 Ignition deviceL 90 29830200

L 150 29830100

Sept. 2017


119

2

3

4

1

5

6

► MU IV open - "N" type gas lens

1 Electrode chuck

Ø 1.6 29820145

Ø 2.0 29820150

Ø 2.4 29820170

Ø 3.0 29820155

2 Seal 62325105

3 Electrode

Ø 1.6 62410016

Ø 2.0 62410020

Ø 2.4 62410024

Ø 3.0 62410030

4 Gas lens

Ø 1.6 29820120

Ø 2.0 29820101

Ø 2.4 29820160

Ø 3.0 62310130

5 Ceramic nozzleØ 9 62300115

Ø 11 62300117


L 150 29830100

Sept. 2017


120

2

3

4

1

5

6

7

► MU IV open - "GM" type gas lens

1 Electrode chuck

Ø 2.4 29820170

Ø 3.0 29820155

Ø 3.2 29840406

2 Seal Tefl on 29840112

Silicone 29840113

3 Large washer 01216201

4 gas lens

Ø 2.4 29840301

Ø 3.0 29840101

Ø 3.2 29840401

5 Electrode

Ø 2.4 62410024

Ø 3.0 62410030

Ø 3.2 62410032

6 Ceramic nozzle

Ø 13 – L 26 29840116

Ø 16 – L 26 29840107

Ø 19 – L 26 29840108

Ø 19 – L 32 29840115

Ø 13 – L 36 29840117

Ø 16 – L 36 29840118

Ø 19 – L 36 29840119

7 Ignition device

L 90 14070300

L 250 14070100

L 120 0014070201

L 300 0014070401


Sept. 2017


121

► TS 25 clamping units

Tube I.D. 7 to 9.99 mm

Clamping unit (Special

version)7.00 15219710

7.70 15219712

8.00 15219709

9.40 15219767

9.60 15219711



Clamping unit

10.00 15219719

10.40 15219762

10.90 15219713

11.40 15219717

12.00 15219725

13.00 15219744

14.00 15219714

14.60 15219757

14.83 15219706

15.00 15219745

15.75 15219707

16.25 15219751

16.65 15219741

16.90 15219766

17.30 15219729

17.65 15219718

18.00 15219737

18.25 15219740

18.65 15219701

19.00 15219747

19.40 15219722


Clamping unit

20.00 15219726

20.40 15219763

20.80 15219750

21.00 15219746

21.18 15219702

21.45 15219733

21.60 15219765

21.90 15219734

22.10 15219703

22.60 15219748

23.00 15219704

23.80 15219764

24.20 15219727

24.40 15219728

24.50 15219755

24.90 15219756

Expanded tubes

Tube I.D. (mm)Clamping

unit 11.50/11.20 15219752

13.50 /13.60 15219743

14.40/14.10 15219749

14.45/14.75 15219759

15.10/15.20 15219742

16.57/17.25 15219715

16.65/17.25 15219708

17.50/17.24 15219724

17.60/18.00 15219758

18.00/18.30 15219753

18.00/18.60 15219754

21.00/21.50 15219732

21.10/21.40 15219761

21.60/21.80 15219735

22.00/22.20 15219736

22.00/22.30 15219730

22.10/22.90 15219716

23.00/23.40 15219739

23.60/24.00 15219705

23.90/23.60 15219723

23.90/24.30 15219760

27.00/27.30 15219731

Sept. 2017


122

-15°

2

3

4

1

SlidePosition A

TorchCentring shaft

AdjustmentCR

Position B


Sept. 2017


123

► TS 2000 tube-to-tubesheet confi guration

2 mm recessed tubes

O.D. (mm)

Diameters of centring mandrels No. torch No. slide

Support pin position (CR min.)

Slide type

19 - 500016881316 (Ø 6.5 mm for

tube I.D. < 15 mm)

0016881315 (Ø 8 mm for

tube I.D > 15 mm)

0016881310 (-15°) 38414064

A (140 mm)

1

41 - 60 0016881310 (-15°) 38414065 2

41 - 60 38414083 (-15°) 38414064 1

Flushed tubes

OD. (mm)



Slide type

12 - 38

0016881316 (Ø 6.5 mm for

tube I.D. < 15 mm)

0016881315 (Ø 8 mm for

tube I.D > 15 mm)

75500289 (0°) 38414064

A (140 mm)

1

30 - 60 75500289 (0°) 38414065 2

12 - 38 38414086 (5°) 38414064 1

30 - 60 38414086 (5°) 38414065 2

12 - 38 75500288 (15°) 38414064 1

30 - 60 75500288 (15°) 38414065 2

Protruding tubes

OD. (mm)



Slide type

Pro

tudi

ng <

5 m

m 19x2 - 34

0016881316 (Ø 6.5 mm for

tube I.D. < 15 mm)

0016881315 (Ø 8 mm for

tube I.D. > 15 mm)

75500288 (15°) 38414064

A (143 mm)

1

30 - 50 75500288 (15°) 38414065 2

19x2 - 34 75500287 (30°) 38414064 1

30 - 50 75500287 (30°) 38414065 2

Pro

tudi

ng <

13 m

m 12 - 34 75500288 (15°) 0016881305

B (153 mm)

3

30 - 50 75500288 (15°) 0016881317 4

12 – 34 75500287 (30°) 0016881305 3

30 - 50 75500287 (30°) 0016881317 4

- Minimum I.D.: 10.2 mm (standard) and 6.5 mm (special) - The values are given for a "N" gas lens with an electrode stick-out of 9 mm for recessed tubes, 7 mm

for fl ush tubes, 10 mm for low protuding tubes (5 mm) and 13 mm for high protruding tubes (< 13 mm).

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124

TS 2000 tube-to-tubesheet confi guration welding heads

No. torch No. slideElectrode gyration

diameters (mm)

min. distance between

tubes

Axial positions electrode tip/

tubesheet

Min Max Min Max

0016881310 (-15°)38414064 16.5 50 - -4 11

38414065 38.5 60 -

38414083 (-15°) 38414064 38.5 60 - -4 11

75500289 (0°)38414064 11 44 - -3 12

38414065 30 60 -

38414086 (5°)38414064 11 44 - -3 12

38414065 30 60 -

75500288 (15°) Flushed

38414064 11 44 - -3 12

38414065 30 60 -

75500288 (15°) Protuding

38414064 (5 mm) 19 44 6.5 -3 12

38414065 (5 mm) 30 57 6.5

0016881305 (13 mm) 12 42 15 -9 6

0016881317 (13 mm) 30 55 15

75500287 (30°) Protuding

38414064 (5 mm) 19 42 6.5 -2.5 11.5

38414065 (5 mm) 30 55 6.5

0016881305 (13 mm) 12 39 22 -8 7

0016881317 (13 mm) 30 53 22

- Minimum I.D. 10.2 mm (standard) / 6.5 mm (special) - The values are given for a "N" gas lens with an electrode stick-out of 9 mm for recessed tubes, 7 mm

for fl ush tubes, 10 mm for low protuding tubes (5 mm) and 13 mm for high protruding tubes (< 13 mm). - In case of preparations requiring an adjustment of the diameter close to the max. rotating diameter

of the electrode, you must turn the tool before you start the welding cycle in order to move the torch away from the supporting feet (striking risk)

- The minimum distance between tubes is given for protruding tubes without preparation. For distances between tubes with preparation, the width of this preparation has to be added to the value mentioned in the table.

- Dimensions are given for information only, and allow to evaluate the required space.

Recommendations: For protruding tubes, the torch angle depends on the thickness of the tube and the gap between tubes. The smaller the gap between the tubes, the smaller the angle of the torch (for similar protruding tubes) in order to avoid any interference during welding between the torch and wire, and adjacent tubes.

For thin wall pipes (1.6 mm – 2 mm), preference will be given to a 15° angle rather than to a 30° angle in order to reduce the risk of BURN THROUGH inside the tube. For fl ush tubes, it is better to use a 0° angle or 5° angle. The tables include standard values. Adjustments are possible for borderline cases.


Sept. 2017


125

2

3

4

1

5

6

7

► TS 2000 and TS 8/75 tube-to-tubesheet - "N" type gas lens

1 Adapter Ø 2.4 11410127

2 Electrode chuck

Ø 1.6 29820145

Ø 2.0 29820150

Ø 2.4 29820170

Ø 3.0 29820155

3 Electrode

Ø 1.6 62410016

Ø 2.0 62410020

Ø 2.4 62410024

Ø 3.0 62410030

4 Seal 62325105

5 Gas lens

Ø 1.6 29820120

Ø 2.0 29820101

Ø 2.4 29820160

Ø 3.0 62310130

6 Ceramic nozzleØ 9 62300115

Ø 11 62300117


L 250 29830400

► TS 2000 – 2 balls centring mandrels

See paragraph "TS 8/75 & TS 8/75-2 welding heads – 2 balls centring mandrels"

Sept. 2017


126

Tube I.D. (mm)

Centring mandrel

10.00 16881619

10.20 16881607

10.40 16881647

10.70 16881648

11.00 16881614

11.40 16881615

11.65 16881636

11.80 16881616

12.00 16881617

13.00 16881620

13.51 16881654

13.70 16881646

14.00 16881621

14.10 16881632

14.40 16881626

14.70 16881627

14.83 16881612

15.30 16881658

15.40 16881623

15.75 16881611

16.00 16881625

16.60 16881637

16.90 16881655

17.00 16881633

17.30 16881631

19.60 16881649

19.80 16881624

19.90 16881656

Tube I.D. (mm)

Centring mandrel

20.00 16881629

20.15 16881613

20.30 16881605

20.40 16881622

20.58 16881644

21.00 16881638

21.18 16881606

21.40 16881650

22.00 16881639

22.10 16881610

22.90 16881635

23.00 16881652

25.40 16881608

27.00 16881630

27.53 16881659

28.45 16881642

31.20 16881657

33.70 16881609

34.80 16881628

36.00 16881643

40.00 16881618

40.10 16881645

40.40 16881653

45.00 16881634

46.00 16881651

Expandable tube (mm)

Centring mandrel

39.7/40.0 1688 1640

40.1/40.4 1688 1641

► TS 2000 – Centring mandrel


Sept. 2017


127

Description Item no.0 Torch (AVC) 1m with connectors 0017480601

1 Torch body, length 230 mm WP27A 1881001

1 Torch body, length 510 mm WP27B 100006858

2 Protection muff 27-12 9018251315

3 Sleeve "A" 27-10A 100009900

3 Sleeve "B" Ref 27-10B 100001298

4 Toothed rail for model "B" 24 teeth 100018241

5 Toothed rail for model "B" 32 teeth 100018243

6 Screw 6-32 3/16" 100018245

7 Electrode holder Ø1.0 - 57N45 01882001







8 Seal 27-2-4 100001300

10 Brass screw Ref 27-10 x 3 100009903

11 Support of clamp "A" R.27-13A 9018251308

11 Support of clamp "B" R.27-13B 100001299

Description Item no.12 Seal 27.13.2 01882027

13 Seal 27.13.3 01882028

14 Seal 181W89 9018251322

15 Gas lense Ø1.6 mm - 49 V23 01882011

15 Gas lense Ø2.4 mm - 49 V24 01882012

15 Gas lense Ø3.2 mm - 49 V25 01882013

15 Gas lense Ø4.0 mm - 49 V26 01882014

15 Gas lense Ø4.8 mm - 49 V27 01882015

15 Gas lense Ø6.4 mm - 49V28 100006860

16 Tefl on seal - 57N56 01882029

17 Nozzle Ø10.0 mm - 57N75 100006861

17 Nozzle Ø12.5 mm - 57N74 01882021

17 Nozzle Ø16.0 mm - 53N88 01882022

17 Nozzle Ø19.0 mm - 53N87 01882023

17 Nozzle Ø24.0 mm - 53N89 100009911

17 Nozzle Ø15.5 mm/lg 83 mm - 53N88XL 100006263

17 Nozzle Ø19.0 mm/lg 83 mm - 53N87XL 100015273

17 Special extra long nozzle (min. 10 pcs) 100011996

18 Adaptor for metallic nozzle - 57N76 9018840806

► WP27 torch

Sept. 2017


128

Description Item no.19 Metallic nozzle no.10 Ø16 - 57N78 100015667

19 Metallic nozzle N° 12 Ø 19 - 57 N 77 9018840807

23 Gas hose 1m/Thread 5/8" 100018484

23 Gas hose 1m/Thread M12 100018486

24 Water/current hose 1m/thread. 5/8" 100001516

Description Item no.24 Water/current hose 1m/thread. M14 100016672

25 Water hose 1m/Thread. 5/8" 100018488

25 Water hose 1m/Thread M14" 100018491

26 Cable bundle water/gas/current1m - 5/8" 100018493

Ignition device lg. 250 14070100

► Adaptation kit for former power sources

This kits are designed to adapt former power sources with self-opturing new generation welding heads.

Adaptation kit for former power sources

Adaptation kit – water connector 15545401

Adaptation kit – gas connector 15545402


Sept. 2017


129

Administrative, packing and logistics costs

► Order processing & administrative fees

Flat rate for logistics coordination & documentation for France, E.U. countries, Switzerland, Norway 100062304

Flat rate for logistics coordination & documentation for Algeria, Azerbaijan , Libya, Russia, Ukraine, Belorussia 100062307

Flat rate for logistics coordination & documentation for Japan, Canada, US, China 100062308

Flat rate for logistics coordination & documentation for Korea, Taiwan, Singapore, Malaysia, Vietnam, Morocco, Tunisia, Turkey 100062309

Flat rate for logistics coordination & documentation for South America (except Brazil), Argentina, Chile, Mexico, Venezuela 100062310

Flat rate for logistics coordination & documentation for South America, Pakistan, Indonesia, the Philippines, Africa ( except South Africa, Morocco, Tunisia ) 100062312

Flat rate for logistics coordination & documentation for The Middle East (Saudi Arabia, Egypt, UAE, Qatar, Oman, Kuwait, Jordania, Israel, Iran, etc.) 100062313

Flat rate for logistics coordination & documentation for India 100062314

Flat rate for logistics coordination & documentation for Other countries Contact us

► Additional costs

Additional costs for letter of credit treatment for standard equipment 100062317

Additional costs for certifi cates on documents 100062318

Additional costs for certifi cates of conformity - VERITAS type 100083958

Loading cost for partial loading - over 5 standard equipment 100062319

Loading cost for full truck with standard packages 100062327

Loading cost for full container 20 ft Dry or Open Top 100062329

Loading cost for full container 40 ft Dry or Open Top 100062332

Additional charges for loading oversized cargo or Open Top container with heavy or bridge crane 100062334

Additional charges for wedging/lashing any package over 3 tons on truck or container 100062337

► Specifi c loading costs for trucks, containers & oversized cargo

Sept. 2017


130

Packing cost for PS 164-2 power source 100063021

Packing cost for P4 power source 100063022

Packing cost for P6 CW power source 100084837

Packing cost for P6 HW power source 100084838

Packing cost for P6 HW power source with trolley 100084839

Packing cost for PC power source (except AC/DC and MIG MAG) 100063024

Packing cost for PC AC/DC or MIG MAG power source) 100063025

Packing cost for Polyfi l-3 wire feeder 100063026

Packing cost for Polyfi l Compact wire feeder 100084842

Packing cost for switch box 100084840

Packing cost for RFC 30 type cooling unit 100063028

Administrative, packing and logistics costs

► Packing costs

Sept. 2017


131

Sales conditions

PricesOur prices are quoted

• In euros (€)• Per unit• Ex-works Nantes (EXW Nantes INCOTERMS ICC 2010)• Administrative, packing and logistics costs not included• Excluding French VAT

WarrantyTwelve months from delivery date, against all construction defects (for second hand equipment, six months from delivery date). The warranty is limited to the exchange of parts acknowledged as defective. Extract from Polysoude general sales conditions:

• Application of warranty termsVendor guarantees that all goods sold will be free from malfunctioning resulting from defects in material, workmanship or design for a period of twelve (12) months from delivery and where the product is used for the intended purpose. Warranty is void where malfunctioning results from unauthorised servicing to the product by the purchaser, normal wear and tear, carelessness or lack of maintenance, caused by a third party or force majeure occurrence.

• Performance of warrantyUnder the warranty, the vendor shall replace free of charge any components acknowledged as defective by its technical department. The warranty shall not include labour and costs resulting from the following operations: disassembly, reassembly, shipping to site,etc. Replacement of components shall not be construed as an extension of warranty period.

Repairs, commissioning and trainingThese services will be invoiced as per lump-sum prices stipulated in the valid price list.

Technical documentationAt the date of delivery, one free copy on USB stick is supplied to you. Additional copies will be supplied at additional costs.

Minimum amount of invoiceFor each order (for example spare parts) with a net total amount inferior to 150 € (exclusive of packing and transportation costs), we will invoice an additional fee of 30 € to cover the administrative costs for such small orders.

Payment termsWithin the limits of agreed total running: 30 days net after shipment

Reserve of ownershipPolysoude retains the title of the goods until paid for in full. This close also applies if payment is subject to security or bank warranty.

AnymodificationofsalestermsandconditionsmustinallcasesbeconfirmedbyPolysoude.

Sept. 2017


132

Notes

2 133Sept. 2017 Sept. 2017

Standard Orbital Welding EquipmentStandard Orbital Welding EquipmentTHE ART OF WELDING THE ART OF WELDING

2017 Polysoude

Original edition: Polysoude S.A.S. Nantes France.

The photos, diagrams and drawings are given to promote understanding and are therefore not contractual.

All copyrights reserved. This catalogue 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]

Notes

2017Standard Orbital

Welding Equipment

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www.polysoude.com • e-mail : [email protected] ART OF WELDING

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