Switching box

Part number 0024480001

 Switching box

Study 2448
Product Switching box
Reference 0024480001
Manual PN-1111145
Redactor SBR

Document revision

Rev. 0 Original issue 02/2012

Rev. 1 Addition : Net weigt and dimensions 06/2012

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

This manual must be delivered to users.

2-34 PN-1111145 Rev.1

THE ART OF WELDING
 Switching box

Contents

1. Safety instructions ............................................................................................ 5

1. 1. Hazards associated with arc welding .................................................................... 5
1. 2. Meaning of the symbols ...................................................................................... 5
1. 3. Recommendations ............................................................................................. 6
1. 4. Prevention of fire and explosion ........................................................................... 8
1. 5. Preventing release of gas and fumes .................................................................... 8
1. 6. Troubleshooting ................................................................................................. 8
2. General Information .......................................................................................... 9
2. 1. Reference documents ......................................................................................... 9
2. 2. Applicable directives .......................................................................................... 9
3. General presentation ......................................................................................... 9
3. 1. Description ...................................................................................................... 9
3. 2. Classification of the machine ............................................................................... 9
3. 3. Environment and conditions of use....................................................................... 9
3. 4. Technical Specification...................................................................................... 11
3. 5. Equipment compatibility ................................................................................... 11
4. Installation .....................................................................................................12
4. 1. Handling ........................................................................................................ 12
4. 2. Installation on site ........................................................................................... 12
4. 3. Connecting to the mains supply ......................................................................... 12
4. 4. Bundle connection ........................................................................................... 13
4. 5. Connecting the welding heads ........................................................................... 14
4. 6. Connecting the remote control .......................................................................... 14
5. Use ................................................................................................................15
5. 1. Usage precaution............................................................................................. 15
5. 2. Switching on ................................................................................................... 15
5. 3. Selecting the welding head ............................................................................... 15
5. 4. Remote Control ............................................................................................... 15
5. 5. Manually controlling the welding head ................................................................ 15
5. 6. Selecting the welding program .......................................................................... 15
5. 7. Emergency stop .............................................................................................. 15
5. 8. Description of controls and connections .............................................................. 16
6. Maintenance and troubleshooting .......................................................................18
6. 1. Routine maintenance operations ........................................................................ 18
6. 2. Repairs and servicing ....................................................................................... 19
7. Wiring diagram ................................................................................................20

8. End of service life - Recycling the equipment .......................................................27

9. Equipment Return form ....................................................................................28

PN-1111145 Rev.1 3-34

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 Switching box

Contents

1. Safety instructions ............................................................................................ 5

1. 1. Hazards associated with arc welding .................................................................... 5
1. 2. Meaning of the symbols ...................................................................................... 5
1. 3. Recommendations ............................................................................................. 6
1. 4. Prevention of fire and explosion ........................................................................... 8
1. 5. Preventing release of gas and fumes .................................................................... 8
1. 6. Troubleshooting ................................................................................................. 8
2. General Information .......................................................................................... 9
2. 1. Reference documents ......................................................................................... 9
2. 2. Applicable directives .......................................................................................... 9
3. General presentation ......................................................................................... 9
3. 1. Description ....................................................................................................... 9
3. 2. Classification of the machine ............................................................................... 9
3. 3. Environment and conditions of use....................................................................... 9
3. 4. Technical Specification...................................................................................... 11
3. 5. Equipment compatibility ................................................................................... 11
4. Installation .....................................................................................................12
4. 1. Handling ........................................................................................................ 12
4. 2. Installation on site ........................................................................................... 12
4. 3. Connecting to the power supply ......................................................................... 12
4. 4. Connecting the bundle ..................................................................................... 13
4. 5. Connecting the welding heads ........................................................................... 14
4. 6. Connecting the remote control .......................................................................... 14
5. Use ................................................................................................................15
5. 1. Usage precaution............................................................................................. 15
5. 2. Switching on ................................................................................................... 15
5. 3. Selecting the welding head ............................................................................... 15
5. 4. Remote control................................................................................................ 15
5. 5. Manually controlling the welding head ................................................................ 15
5. 6. Selecting the welding program ......................................................................... 15
5. 7. Emergency Stop .............................................................................................. 15
5. 8. Description of controls and connections .............................................................. 16
6. Maintenance and troubleshooting .......................................................................18
6. 1. Routine maintenance operations ........................................................................ 18
6. 2. Repairs and servicing ....................................................................................... 19
7. Electrical diagram ............................................................................................20

8. End of service life - Recycling the equipment .......................................................23

9. Equipment Return form ....................................................................................24

4-34 PN-1111145 Rev.1

THE ART OF WELDING
 Switching box

1. Safety instructions

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

1. 1. Hazards associated with arc welding

The symbols reproduced below are used throughout this Technical Manual in order to draw your
attention to and identify the potential hazards. When you see one of these symbols, refer to the safety
instructions in the following section ‘Recommendations’.

This equipment must only be installed, used, maintained and repaired by qualified persons.
While it is in use, anyone not working with the equipment must be kept well away.

1. 2. Meaning of the symbols

Risk of serious injury caused

Risk of electric shocks
by rotating parts

Risk of inhaling fumes or

Risk of explosion
gases

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

the skin due to heat radiation fields.

Warning: hot surfaces – Risk

Danger caused by noise
of burns

Risk of burns to the eyes or

Read the instructions
the skin due to flying sparks

Safety goggles must be

Risk of excessive heat or fire.
worn

Safety helmets must be

Safety boots must be worn
worn

Refer to the
recommendations on the
Fall hazard next page in order to take
the necessary precautions
to avoid any hazard.

PN-1111145 Rev.1 5-34

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 Switching box
1. 3. Recommendations
Risk of electric shocks
The electrical components include the electrode,
the welding circuit, the input circuit and the internal
circuits, the welding wire and the metal parts in
contact with it, the wire feeder and the housing for
the welding wire feed rollers. The slightest contact
with these parts may cause an electric shock or even
electrocution when the machine is switched on.
Factors increasing the risk of electric shock: Moisture
in the immediate area, working on an electrically-
conductive surface, inadequate earthing, poor
maintenance of the equipment, unsafe working
methods.
Preventing risks:
• Avoid any contact with the spools of wire while
they are under tension.
• In the case of water-cooled torches, inspect the
torch at regular intervals in order to identify
any leaks; take care to prevent condensation.
• Do not coil the cables around your body.
• Before replacing the electrode, ensure that it is
no longer live.
• Switch off the machine before carrying out any
maintenance or repair operations or while it is
not in use.
• Wear safety gloves, clothing, aprons and boots
which are dry and free from holes.
• Insulate the component and the earth by means
of mats or other means of providing sufficient
insulation if the welder is required to work on
metal surfaces or structures.
• This machine must be installed and earthed
in accordance with its User Manual and
with national, local and municipal codes of
practice.
• The return cable must be attached correctly
(clean contact surface, cable securely fastened,
as close as possible to the area to be welded.
• Do not use damaged, worn or bare (uninsulated)
cables which are of insufficient size or not
properly assembled. If this is the case, they
must be replaced immediately.
• The welding station must be correctly
earthed.
• If the component to be welded has to be
earthed, use a separate cable.
• Use the appropriate connectors.
Note the no-load voltage, which is limited to 80 V
r.m.s. for alternating current or 113 V for direct
current (the voltage required to strike the arc). The
maximum value for plasma cutting power sources is:
500 V.
6-34 PN-1111145 Rev.1
Risk of inhaling fumes or
gases
Welding generates fumes and gases which are
hazardous to health. Do not inhale the fumes.
Origin of the fumes and gases: Base metal, filler
metal, coating (flux) with welding by coated electrode,
shielding gas, solvents and materials covering the
metal to be welded.
In order to prevent risks:
• Use breathing apparatus, such as filtering
masks, assisted-ventilation masks, inducted
air masks and disposable masks.
• Avoid chlorinated solvents.
• Ensure that the components are completely
dry before welding.
• Do not work alone!
• Trap the fumes and gases at source.
• Remove paint, oil or any other surface
coating.
Risk of burns to the eyes or
the skin due to heat radiation
Radiation from arc welding is liable to cause burns to
the eyes and the skin.
Identifying the risks: Exposure to the radiation
emitted by the arc, generating intense visible and
invisible rays (ultraviolet and infrared), reflection of
the rays while welding metals such as aluminium and
stainless steel, arc strike, sparks, pin-holes created
by the tip of a tungsten electrode.
In order to prevent risks:
• Wear gloves or leather gauntlets to protect
your hands and lower arms.
• Wear an apron or gaiters to protect your legs,
knees and forefoot.
• Wear a mask (headband-type, hand-held
or electronic mask) or goggles fitted with a
suitable filter.
• Use safety shields to protect nearby workers.
• Tie a scarf around your neck and button the
neck of the protective clothing.
THE ART OF WELDING

Warning: hot surfaces – Risk
of burns
Do not touch welded or flame-cut components with
bare hands. If such components have to be handled,
use the appropriate tools and/or wear welders’ gloves,
thick and insulated, to prevent any burns.
Allow the components to cool before handling them
or welding them.
Risk of burns to the eyes or
the skin due to flying sparks
• Wear gloves or leather gauntlets to protect
your hands and lower arms.
• Wear an apron or gaiters to protect your legs,
knees and forefoot.
• Wear a mask (headband-type, hand-held
or electronic mask) or goggles fitted with a
suitable filter.
• Use safety shields to protect nearby workers.
• Wear garments with long cotton or woollen
sleeves, preferably free from any traces of oil
or grease. Do not wear clothing made from
synthetic fabrics.
• Tie a scarf around your neck and button the
neck of the protective clothing.
• Wear welders’ safety boots.
Risk of excessive heat or fire.
• Maintain the equipment at the electrical
workstation in good operating condition,
particularly the cables carrying the feed and
return current.
• Maintain a minimum distance of 6 metres
between the welding equipment and any
greasy, inflammable or dust-laden materials.
• Use safety shields to protect nearby workers.
PN-1111145 Rev.1
THE ART OF WELDING
Switching box
Risk of explosion
These risks are associated with the use and handling
of gas cylinders and flying sparks.
• Do not use damaged cylinders.
• Store the cylinders in a well-ventilated area and
restrict access to anyone other than authorised
personnel.
• Never exceed a temperature of 55 ºC while
storing or using the cylinders.
• Clearly identify empty cylinders to distinguish
them from full ones.
• Protect the cylinders from extremes of
temperature (ice, sunlight, sparks, etc.).
• Check the connectors and hoses at regular
intervals.
• Use protective shields.
Risk of serious injury caused
by rotating parts
• Do not place your hands near fans or any
moving parts.
• Keep all safety shields closed or in the ‘safety’
position.
Risk of exposure to magnetic
fields.
The distance between the welding circuit and the
brain is of fundamental importance.
• Never spool the cables around your body and
certainly not around your shoulders.
• Advise your immediate superior if you are
wearing a heart pacemaker. The interference
generated by the circuit requires special
protective measures, which must be applied in
consultation with the company doctor.
The operator must ensure
that no-one is exposed to the
hazardous area.
7-34
 Switching box

1. 4. Prevention of fire and explosion

Welding equipment must not be used on premises where inflammable, volatile or explosive products are present.
Under no circumstances may the power source be used for de-icing pipes.

1. 5. Preventing release of gas and fumes

It is the user’s responsibility to assess:
• inconvenience or unhealthy conditions inside his workshop and to take the necessary measures to apply
this clause.
• Protection against radiation from electric arcs.
• Safety instructions and protective arrangements must conform to NF EN 166 and NF EN 169.

1. 6. Troubleshooting
Only qualified electricians are permitted to inspect, test, tune or repair electrical or electronic equipment.
Before any work or connection of an item of test equipment to a circuit, the power shall be switched off and a
pause of 2 minutes observed. These instructions are detailed on the label on the right hand side.

Always check that the equipment is not live, even if the power supply has
been cut. A capacitor may still retain an electrical charge after the power
supply has been cut.

Never shunt or circumvent the safety devices and interlocks that are provided for the protection of personnel.

Never stand on a wet floor when working on electrical or electronic equipment. It is essential to avoid all liquid
leaks into electrical circuits.

Do not use volatile and inflammable solvents in the compartment. An electrical arc may ignite vapours or
inflammable liquids.

Remove all jewellery (rings, watches and other bracelets) when repairing and maintaining electrical equipment.
Wear insulating footwear when the situation demands.

8-34 PN-1111145 Rev.1

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2. General Information

2. 1. Reference documents

N/A

2. 2. Applicable directives

2006/42/EC Machinery Directive

2004/108/EC Electromagnetic compatibility

2006/95/EC Electrical equipment designed to be used within certain voltage limits

3. General presentation

3. 1. Description
The switching unit allows an operator to use two welding heads connected to the same welding set. While one
head is welding, the operator can fit the other in place. A control panel is located on the front panel of the
switching unit. The box allows the power source remote control (For PS 164-2 only) to be connected in order to
control the power source and the head during the welding cycle.

This document deals with the installation, usage and maintenance of Polysoude equipment. It does
not deal with components which are not supplied by Polysoude.

3. 2. Classification of the machine

The machine complies with the requirements of directives 2006/42/EC “Machinery”, 2006/95/EC “Electrical
equipment designed for use within certain voltage limits” and 2004/108/EC “Electromagnetic compatibility”.

3. 3. Environment and conditions of use

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

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

Î Ambient air temperature -10 to +40 °C.

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

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

Examples of abnormal conditions of use:

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

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

PN-1111145 Rev.1 9-34

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10-34 PN-1111145 Rev.1

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3. 4. Technical Specification

Type of power supply

Possible mains voltages (V) 230

Single phase power supply (Hz) 50/60 +/-10%

Maximum current (A) 1

3. 5. Equipment compatibility

MW MU (1) TS 25 TS34 TS34-2 TS 2000 (2)

PS 164-1 A B A A B B

PS 164-2 A B B A A B

P4 A (3) B (3) B (3) A (3) A (3) A (3)

K Manual Wire
UHP Polysoude
version torch feeder

PS 164-1 B B OK C

PS 164-2 B B OK C

P4 B (3) B (3) OK C

(1) - without AVC/OSC and wire.

(2) - without AVC and wire.
(3) - without automatic program switch between the two welding heads (a manual program switch is
required)

Methods of use:
A - When welding head 1 is welding, welding head 2 can be moved using the control buttons on the welding
head (MW and TS 34 welding heads only).

B - When welding head 1 is welding, welding head 2 cannot be moved (no control button on the welding
head).

C- Wire feed only possible with one welding head, there is no electricaly switching function for the wires.

Devices which cannot be used with this switch :

• Motors with tachometer (for example "K" welding heads/PAA version) and motors with brakes (for example
KR33 slides).
• P6, P6 HW, PS 406, PS 406-2 and PC series power sources.
• Welding heads with filler wire, AVC/OSC, Polycar type welding heads and mechanised equipment.

The use of a current exceeding 170 A is prohibited.

PN-1111145 Rev.1 11-34

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 Switching box

4. Installation

4. 1. Handling

All installation and servicing must be carried out with no voltage

present. Always use the attachments provided for the purpose
when handling the various parts of the installation. Never use parts
of the machine to provide a grip for handling. There is a risk that
the equipment will be damaged or destroyed.

The switching unit is delivered in packaging which protects it during transit: case, protective blocks, etc. This
packaging is specific to the machine. The original packaging must be kept for use each time the machine is
transported in order to prevent damage. When the equipment is not in use, it must be stored on a suitable
support and protected against impact damage, e.g. in its packaging.

4. 2. Installation on site

The complete installation must be fitted with a power supply

isolation switch that can be locked.

The installation must be mounted on and secured to a flat, horizontal floor to prevent it from toppling over and
to ensure correct operation of the mechanised installation.

Net weight 20 kg.

Dimensions lxwxh 67x22x45

4. 3. Connecting to the mains supply

Connect the mains connector from the unit to a single phase, earthed power supply with wires of cross section
1.5 mm² minimum.

12-34 PN-1111145 Rev.1

THE ART OF WELDING
 Switching box

4. 4. Bundle connection
This unit is designed to be connected to certain power sources and to be used with certain welding heads and
in certain configurations. Refer to the "equipment compatibility" section.
Connect the bundle from the unit to the welding power source.

Item Description Item Description

1 Welding current + 5 Welding gas supply

2 Max. welding current - 6 Remote control connection

3 Coolant circuit supply 7 Rotation connection

Connection for local controls for

4 Cooling system return 8
MW type welding head

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

1 4 3
2
6 7

5
8

Fig.4.1 - Switch unit bundle

PN-1111145 Rev.1 13-34
THE ART OF WELDING
 Switching box

4. 5. Connecting the welding heads

The first welding head must be fully connected to the front panel of the unit on side no. 1 (left-hand side), and
the second head to side no. 2 (right-hand side).
Î Current + and -.
Î Welding gas supply.
Î Coolant circuit feed and return.
Î Rotation connection.
Î Connection for local controls for MW type welding head.

4. 6. Connecting the remote control

Connect the remote control connector to the front panel of the switching unit.

When using the switching unit, program selection on the remote control no longer available.

Fig.4.2 - Example of remote control (power source PS 164-2)

14-34 PN-1111145 Rev.1

THE ART OF WELDING
 Switching box

5. Use

5. 1. Usage precaution

This machine must only be used by personnel who are qualified to

perform the tasks involved, in accordance with the rules governed
by the French Labour Code.

5. 2. Switching on
After connecting to the power supply and gas supply on the welding power source and completing the other
connections described above:
Î Turn on the power source (refer to the manual for your equipment).
Î Turn the power switch on the unit to ON.
Î Turn on the gas supply.

The 2 coolant circuits must be connected. If only one head is used,

install a shunt.

5. 3. Selecting the welding head

WHEN NOT WELDING, briefly pressing button (2) switches one of the heads on the power source so that it is
ready to start welding.
The lit indicator shows the number of the head set to weld with the power source.

The unit is protected against accidental switching during a welding

cycle. In this case, switching will not take place.

5. 4. Remote Control
To use the remote control, refer to the user manual for the power source.

5. 5. Manually controlling the welding head

MW type heads. The local controls for the head not switched onto the power source can be used to position the
torch onto the welding joint.

5. 6. Selecting the welding program

The operator has to select the welding program on the switching unit.
There are two mechanical counters on the front panel of the switch, one for each head.
Quickly pressing one of the buttons on the counter increments or decrements the number of the welding program.

5. 7. Emergency stop
Pressing the emergency stop on the power source immediately stops the switching unit.

PN-1111145 Rev.1 15-34

THE ART OF WELDING
 Switching box

5. 8. Description of controls and connections

Item Function

1 Main power switch ON/OFF

2 Pushbutton - Select switched head

3 Green indicator light - Lit indicates powered on

4 Yellow indicator light - Lit indicates welding cycle in progress

5 Blue indicator light 1 - Lit indicates head 1 is switched

6 Blue indicator light 2 - Lit indicates head 2 is switched

7 Connection of remote control for PS 164 power source

8 Welding current feed + head 1

9 Welding current feed - head 1
10 Welding current feed + head 2
11 Welding current feed - head 2
12 Welding gas feed head 1

13 Welding gas feed head 2

14 Local control connection head 1

15 Local control connection head 2

16 Rotation connection head 1

17 Rotation connection head 2

18 Coolant circuit feed head 1

19 Coolant circuit return head 1

20 Coolant circuit feed head 2

21 Coolant circuit return head 2

22 Mechanical counter - Increment welding program head 1

23 Mechanical counter - Increment welding program head 2

16-34 PN-1111145 Rev.1

THE ART OF WELDING
 Switching box

22 2 23

5 4 3 6

16 7 17

14 15
12 13

9 11

8 10

19 21
18 20

Fig. 5-1 - Switching unit

PN-1111145 Rev.1 17-34

THE ART OF WELDING
 Switching box

6. Maintenance and troubleshooting

6. 1. Routine maintenance operations

6. 1. 1. Preventive maintenance

Hose inspection

Consumable
Frequency Operation
items and tools

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

brush, cloth. months. Inspecting the hoses:

• Clean all the hoses using a brush or cloth.

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

Trace abnormal noises

Frequency Operation

Every 3 Machine switched on and operating.

months. Axis movement:

• Move the axis in a positive or negative direction within the physical

limits of the machine.
• Pay particular attention to any suspicious noises (creaking, abrasion,
noise caused by abnormal vibrations, etc.).
• Repeat the operation on all the axes.

Every 3 Machine switched on and operating.

months. Motors:

• No abnormal noise should be generated while the machine is in

operation: rumbling, scraping, creaking or any other unusual noise.
• Also check that no unusual noise is emanating from the motor.

Check the electronic connectors

Consumable
Frequency Operation
items and tools

Clean cloth. Every 3 Machine switched off, isolating switch locked.

months. • Check that the connections are tight.
• Check that there is no sign of overheating of the wiring between the
components.

18-34 PN-1111145 Rev.1

THE ART OF WELDING
 Switching box

Trace leaks in the circuit

Consumable
Frequency Operation
items and tools

Clean cloth. Every 3 Machine switched on and operating.

months.
Reminder: symptoms of a leak
• Noise.
• Drips.
• Seepage.
• Pools of liquid.
• Frequent and abnormal topping-up.

Every 3 Machine switched off, isolating switch locked.

months. Visually check the following sensitive items:
• All pipework accessories (connectors, tee-pieces, elbows, plugs,
valves, etc.)
• All application components.

6. 2. Repairs and servicing

The Polysoude After-Sales Service is available to help you with solving any problems with the machine and to
supply any spare parts you may require.

For repair and maintenance operations,

completely disconnect the switch from the
power source.

PN-1111145 Rev.1 19-34

THE ART OF WELDING
 L1 N

20-34
Main Switch
QM1
E1 E2
Head 1 active Head 2 active Y1 Y2 S1 S2
Switcher Gas-Security E3
Blue Blue Gas Head 1 Gas Head 2
Cycle
Yellow

E4 F1
Power
T4A
Green
Switching box

J6 - Main PCB
1 2 3 4 5 6 7 8 9
10 11 12 13 14 15 16 17 18

Transfo 230V/24V

PN-1111145 Rev.1
T1

K3

Switching relais
7. Wiring diagram

K1 K2
Courant 1 Courant 2
Title Component wiring
Author
Walter Heftbauer

File Document
C:\Polysoude\Projekte\SB2v0.001.dsn
Revision Date Sheets
1.0 1 of 1

THE ART OF WELDING

THE ART OF WELDING
Main PCB
Polysoude 747325684 001

PC Out 1
420mm Handtorch Output 1
Yellow 1
Green 2
Brown 3

PC IN 1800mm J4
Handtorch Input Handtorch Input

1 Yellow 3
J5
2
Green 1 Handtorch Output 1+2

1
2
3
4
5
6
3 Brown 2

PN-1111145 Rev.1
PC Out 2
310mm Handtorch Output 2
Yellow 1
Green 2
Brown 3

Title
Handtorch wiring
Author
Switching box

Walter Heftbauer

File Document
C:\Polysoude\Projekte\SB2v0.005.dsn
Revision Date Sheets

21-34
1.0 1 of 1
 0 1 2 3 4 5 6 7 8 9 10 11 12 13 14

22-34
K13
K11 K5 Rel_2xUM
Rel_2xUM Rel_2xUM
A J7 A

6
6
7
L`

7
7
5
3

5
5
2
L

3
1

3
3
2
WIEL_KST_3P K12

2
2
4
Rel_2xUM
K10
Platinenstecker 3polig 25.350.3353.0

4
4
Rel_2xUM
Kabelstecker 3polig 25.340.0353.0

6
7

8
1
V1

7
5

1
8
8
1
B JVR05N101K B

5
3
D15

3
2

2
4
1N4007P

4
D9

8
1
R1
Switching box

1N4007P
100R

8
1
K6
Rel_2xUM D12
C D13 C

6
J2
1N4007P

7
1N4007P

5
1 A
2 B K9 K8

3
Rel_2xUM Rel_2xUM
3 +15V

2
4 0V

4
6
6
5 IMP Rotation Head 1

7
7
6 END

5
5
J1 7 END

1
8
D 8 J6 D

3
3
A 1

2
2
MOL_8PV
B 2 1 Indicator1

4
4
+15V 3 2 Courant1
0V 4 Platinenstecker WR-MPC4 649 008 211 22 3 Gas1
IMP 5 Kabelstecker WR-MPC4 649 008 113 322 4 N01

8
1
8
1
END 6 5 N01
END 7 K7 J3 6 Cycle Indicator
8 Rel_2xUM 7 Switch wire
1 A 8 +

6
MOL_8PV 2 B D11 9 24V AC

7
E 3 +15V 10 Indicator2 E

5
Rotation Input 4 0V 11 Courant2
Rotation Head 2 1N4007P
5 IMP D14 12 Gas2

3
6 END 13 N01
Platinenstecker

2
7 END 1N4007P 14
WR-MPC4 649 008 211 22

4
8 15
16 Welding head selection
Kabelstecker MOL_8PV
17 -
WR-MPC4 649 008 113 322

1
8
18 24V AC
F1

5 FUSE_5X20 4 MOL_18PV
F D10 6 3 F
Platinenstecker WR-MPC4 649 018 211 22
1N4007P 7 2
Kabelstecker WR-MPC4 649 018 113 322

PN-1111145 Rev.1
8 1
K3 2_5A
Rel_2xUM

7
2

5
3
G G

2
1 4

4
Platinenstecker WR-MPC4 649 012 211 22
C1 C2
Kabelstecker WR-MPC4 649 012 113 322 GL1

1
8
3
J8 J9 100uF_50V 100uF_50V GBU408_F
12V 1 1 12V
E_Stop 2 2 E_Stop
K2 Stop_Cycle 3 3 Stop_Cycle
Rel_2xUM
Cycle_Indicator Cycle_Indicator
1
8

J5 4 4
H Line1 5 5 Line1 H

6
0V 1 1 Line2 6 6 Line2

7
0V 2 Line3 Line3
4

2 7 7

5
Rotate 1 Line4 Line4
2

3 J4 8 8
Rotate 2 Column1 Column1
3

4 9 9

3
Start 1 5 1 0V Column2 10 10 Column2

2
Start 2 Rotate Column3 Column3
5

6 2 11 11

4
Start Column4 Column4
7

3 12 12
MOL_6PV
6

4
MOL_12PV MOL_12PV
Platinenstecker

1
8
MOL_4PV
I WR-MPC4 649 006 211 22 K1 I
Platinenstecker WR-MPC4 649 004 211 22 Rel_2xUM
Kabelstecker Kabelstecker WR-MPC4 649 004 113 322
WR-MPC4 649 006 113 322
K4
Rel_2xUM
J10 J11

7
Line4 1 1 Line4

5
Column1 2 2 Column1 PETER ANGELE ELEKTROGERÄTEBAU
D1 D5
Column2 3 3 Column2

3
1N4148P 1N4148P DÜRERSTR.4, 72116 MÖSS-ÖSCHINGEN
Column3 4 4 Column3
J D2 D6 J

2
Column4 5 5 Column4 DEUTSCHLAND

4
1N4148P 1N4148P
MOL_5PV D3 D7 MOL_5PV Title: Polysoude_Rel_Pl1
1N4148P 1N4148P
Platinenstecker WR-MPC4 649 005 111 22 D4 D8

1
8
Kabelstecker WR-MPC4 649 005 013 322 Platinenstecker WR-MPC4 649 005 111 22
Desc.: Polysoude_Rel_Pl1
1N4148P 1N4148P
Kabelstecker WR-MPC4 649 005 013 322
Design. by: MATZE Date: 2011-04-21 Sheet 1 of 1

0 1 2 3 4 5 6 7 8 9 10 11 12 13 14

THE ART OF WELDING

 Switching box

Ultiboard-Polysoude_Rel_Pl1 - 29.11.2010 - 12:07:25

PN-1111145 Rev.1 23-34

THE ART OF WELDING
 Main PCB 425mm
J11
Polysoude 747325684 001 Coding Wheel 1

24-34
1 Coding wheel 1 Brown C

2 White 8

3 Green 4

4 Yellow 2

5 Grey 1

PT IN 1750mm J8
Remote Controll Input Remote Controll Input 340mm
J9
PT Out
J Grey 1 1 New symbol Grey J Remote Control Output

A Brown 2 2 Brown A
Switching box

I Purple 3 3 Purple I

K White 4 4 White K

G Red / Blue 5 5 Red / Blue G

M Pink 6 6 Pink M

L Black 7 7 Black L

B Blue 8 8 Blue B

C Red 9 9 Red C

D Pink / Grey 10 10 Pink / Grey D

E Green 11 11 Green E

F Yellow 12 12 Yellow F

230mm
J10
Coding Wheel 2
1 Coding wheel 2 Brown C

2 Grey 8

PN-1111145 Rev.1
3 Yellow 4

4 White 2

5 Green 1

Title
Remote Control & Coding wheel
Author
Walter Heftbauer

File Document
C:\Polysoude\Projekte\SB2v0.004.dsn
Revision Date Sheets
1.0 1 of 1

THE ART OF WELDING

THE ART OF WELDING
Main PCB
Polysoude 747325684 001
J2 360mm
PR Out 1
Rotation Output 1 Rotation Output 1

1 Red A

2 Blue B

3 Grey C

4 White F

5 Pink G

6 Yellow E

PR IN 1650mm 7 Green D
J1
Rotation Input
Rotation Input

A Red 1

B Blue 2

C Grey 3

F White 4

G Pink 5

PN-1111145 Rev.1
E Yellow 6

D Green 7 210mm
J3 PR Out 2
Rotation Output 2 Rotation Output 2

1 Red A

2 Blue B

3 Grey C

4 White F

5 Pink G

6 Yellow E

7 Green D

Title
Rotation wiring
Author
Switching box

Walter Heftbauer

File Document
C:\Polysoude\Projekte\SB2v0.002.dsn
Revision Date Sheets

25-34
1.0 1 of 1
 Switching box

26-34 PN-1111145 Rev.1

THE ART OF WELDING
 Switching box

8. End of service life - Recycling the equipment

Our machines incorporate electrical and electronic components which must be recycled in accordance with
Directive 2002/96/EC. Any item of equipment which is declared obsolete or out of service must be sent to
approved recycling companies in order to reduce the amount of ultimate waste disposal. A number of solutions
may be deployed, including:

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

PN-1111145 Rev.1 27-34

THE ART OF WELDING
 Switching box

9. Equipment Return form

28-34 PN-1111145 Rev.1

THE ART OF WELDING
 RETURN OF EQUIPMENT
(Please fill out and join this sheet when returning equipment to POLYSOUDE)

Reseller / Person in charge :

Customer / Person in charge / Tel. :

EQUIPMENT RETURNED :

‰ Power source Type : Serial number :

‰ Welding head Type : Serial number :

‰ Wire feeder Type : Serial number :

‰ Other (specify designation) :

taken from :

‰ Power source Type : Serial number :

‰ Welding head Type : Serial number :

‰ Wire feeder Type : Serial number :

‰ Other(to be specified) : Serial number :

REASON FOR RETURN :

‰ Return of loan equipment
‰ Return of demonstration / fair equipment
‰ Return of hired equipment
‰ Return after exchange
‰ Deficient delivery / incorrect order
‰ Return for modification (to be specified) :
‰ Return for revision
‰ Return for calibration

‰ Return for repair

to be specified : ‰ systematically occurring error
‰ occasionally occurring error
Description of breakdown :

‰ Other issue (to be specified) :

Date : Signature:

SAV_FOR_011_Return of equipment_REV_03
 Switching box

30-34 PN-1111145 Rev.1

THE ART OF WELDING
 Switching box

Table of illustrations

Fig.4.1 - Switch unit bundle ..........................................................................................13

Fig.4.2 - Example of remote control (power source PS 164-2) ...........................................14

Fig.5.1 - Switching unit ................................................................................................17

PN-1111145 Rev.1 31-34

THE ART OF WELDING
 Switching box

32-34 PN-1111145 Rev.1

THE ART OF WELDING
 Switching box

2012 Polysoude
Original edition: Polysoude S.A.S. Nantes France.

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

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

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

www.polysoude.com info@polysoude.com

Translation of original
instructions

PN-1111145 Rev.1 33-34

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

Commissioning / Training Rental service

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

This document is not contractual. Typographical errors & omissions excluded. - Copyright - POLYSOUDETM – 05/2012
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Polysoude S.A.S.
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