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Polysoude PS 254 Operating, Programming And Maintenance Manual

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OPERATING,
PROGRAMMING AND
MAINTENANCE MANUAL
POWER SOURCE PS 254

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Summary of Contents for Polysoude PS 254

  • Page 1 OPERATING, PROGRAMMING AND MAINTENANCE MANUAL POWER SOURCE PS 254...
  • Page 2 Consequently in this case the liability of Polysoude is released; the purchaser or the third party has to take the engagements of a builder and to satisfy all applicable legal requirements.

  • Page 3: Table Of Contents

    The open welding heads....................6 1.3. The tube to tubesheet welding heads..................6 1.3.1. The closed chamber weld heads..................7 1.4. Technical specifications of the power source PS 254............8 1.4.1. Design features ......................8 1.4.2. The remote control pendant................... 9 1.4.3.
  • Page 4 MU open welding heads with filler wire ................ 79 5.1.3. TS/TP welding heads for welding of tubes to tubesheet ..........80 5.2. Error codes ........................81 CONFIGURATION OF THE DIPS FOR PS 254................82 SUMMARY SPARE PARTS ......................85 MAN. PS 254 EN – Ind. 2...

  • Page 5: Introduction

    1. INTRODUCTION 1.1. The PS power sources The power source PS 254 belongs to a versatile new family of universal and easy to use orbital TIG power sources. Special features are: PS 204 Portable 200 A, single phase input power source.

  • Page 6: The Orbital Welding Heads

    Integrated wire feeder. Possibility to adapt equipment for Wire feeder with four roll linear drive distance controlled or mechanised system to minimise wire deformation and welding processes. surface distortion. External wire feeder. MAN. PS 254 EN – Ind. 2...

  • Page 7: The Closed Chamber Weld Heads

    K to answer the demand of a very reliable shielding gas protection. MW, when high production rates are required. High duty cycle due to water cooling. Adaption kits welding accessories (elbows, flanges, valves, connections, etc.) available. MAN. PS 254 EN – Ind. 2...

  • Page 8: Technical Specifications Of The Power Source Ps 254

    1.4. Technical specifications of the power source PS 254 1.4.1. Design features The PS 254 was designed especially for automatic TIG (GTAW) welding. It works with H type enclosed welding heads and it is compatible with all standard Polysoude MU III...

  • Page 9: The Remote Control Pendant

    Modifications to be made during a cycle • The shielding gas to be tested • The manual start of the cooling pump • The stopping of a cycle in the case of an emergency. MAN. PS 254 EN – Ind. 2...

  • Page 10: Technical Characteristics

    Specific functions As an option : possibility of controlling welding heads with tachometer feedback Size L x W x H (mm) 890 x 500 x 890 Weight 100 kg Standard EN 60974-1/EN 50199 MAN. PS 254 EN – Ind. 2...

  • Page 11: Safety Precautions

    The working environment for the welding machines must be free of combustible material and solvents. 1.5.4. Ergonomics The PS 254 should never be used for the purpose of defrosting. Identification 1.5.8. Protection against burns Identification by means of colours, especially...

  • Page 12: Failure Elimination

    Avoid the penetration of liquids to electric devices. In the area around welding machines, solvants and combustible liquids are not allowed. Watches, jewelry and bracelets may not be worn during interventions on electric devices. MAN. PS 254 EN – Ind. 2...

  • Page 13: Installation

    2. INSTALLATION 2.1. Preparation of the PS 254 The PS 254 is delivered in a transport protection case. You will find: • A gas connection (two other ones in case • The remote control pendant BP 1436 or of an optional second gas) (3).

  • Page 14: Installation

    2.2.2. Installation For safe work the PS 254 has to be placed horizontally, on a firm surface. In this case a shaft system ensures the stability of the machines.
  • Page 15 400 V only. connections and nominal voltage (Un). In the case of a PS 254 fitted out with the multivoltage kit, the input power jumpers must be set correctly before it is switched on. The...

  • Page 16: Connection With Gas Supply

    Connection of the electrode current cable Connect the current cable on the "-" terminal with the quick connector, locking it by a short rotation to the right. MAN. PS 254 EN – Ind. 2...

  • Page 17: Connection Of An Air Cooled Closed Chamber Welding Head

    Connection of the electrode current cable Connect the current cable on the "-" terminal with the quick connector, locking it by a short rotation to the right. This cable is not indicated. MAN. PS 254 EN – Ind. 2...

  • Page 18: Connection Of A Liquid Cooled Closed Chamber Welding Head

    Connection of the torch shielding gas Connection is made with a quick disconnect fitting situated at the connection panel of the " PS 254 (symbol Fig. 2.9 : Connection of a wire feed unit MAN. PS 254 EN – Ind. 2...

  • Page 19: Connection Of A Manual Torch With Double Command

    Fig. 2.11 : Connection of a liquid cooled " power source (symbol closed chamber welding head with tachometry Gas coupling Torch command connection Electrode connection Workpiece connection Water outlet Water return Fig. 2.10 : Connection of a manual torch MAN. PS 254 EN – Ind. 2...

  • Page 20: Controls

    (option). FA 1 FA 2 FA 3 FA 5 FA 4 FA 6 FA 7 FA 8 FA 9 FA 12 FA 10 FA 11 FA 13 Fig. 2.12 : Front panel MAN. PS 254 EN – Ind. 2...

  • Page 21: Synopsis

    SY 9 SY 12 SY 13 SY 15 SY 20 SY 22 SY 16 SY 18 SY 25 SY 27 SY 28 SY 23 SY 17 SY 19 SY 21 Fig. 2.14 : Synopsis MAN. PS 254 EN – Ind. 2...

  • Page 22: The Remote Control Pendant

    During weld cycle: Decrease wire BT 15 BT 16 speed. BT 15 Push button to start the cooling pump "Test cooling circuit". BT 16 Push button "Gas test". Fig. 2.15 : The remote control pendant MAN. PS 254 EN – Ind. 2...

  • Page 23: Operation Of The Ps 254

    PS 254 in order to make If the switch is in the "Manual" position, the the power source work. function of the wire retract button BT 9 remains If a problem should occur, please refer to as stated above.

  • Page 24: Programmation Surface

    The creation and modification of programs in corresponding memo card. the memory of a PS 254 is only possible if the key operated switch «Modification authorised Making a program or not» is in the position «Modification There are two different ways to make a authorised»...

  • Page 25: Modifying The Program Name

    Saving, loading a program Saving a program. Loading a program. Press once 3.3.10 Printing a program. 3.3.11 Programmable parameters Press and hold for at least 2 seconds Indicator not illuminated Indicator flashing Indicator illuminated MAN. PS 254 EN – Ind. 2...
  • Page 26 2 5 4 P A R I S P A R I S N A R I S N A N T E N A N T E S P A R I S MAN. PS 254 EN – Ind. 2...
  • Page 27 R 3 0 = A 0 0 1 0 1 - N A N T E S S 0 1 2 . 7 x 0 . 8 - 0 R 3 0 = B 0 0 1 & MAN. PS 254 EN – Ind. 2...

  • Page 28: Programming And Modifying The Welding Parameters

    3.3.4. Programming and modifying the welding parameters 3.3.4.1. Configuration N A N T E S MAN. PS 254 EN – Ind. 2...
  • Page 29 T 1 0 = 0 1 0 N A N T E S T 1 0 = 1 2 0 N A N T E S T 1 0 = 1 1 9 MAN. PS 254 EN – Ind. 2...
  • Page 30 T 1 1 = 0 0 5 0 1 - N A N T E S T 1 1 = 0 0 5 0 1 - N A N T E S T 1 1 = 0 0 5 MAN. PS 254 EN – Ind. 2...
  • Page 31 0 1 - N A N T E S T 2 1 = 0 3 . 0 0 1 - N A N T E S T 2 1 = 0 2 . 0 MAN. PS 254 EN – Ind. 2...
  • Page 32 0 1 - N A N T E S I 2 3 = 0 4 5 0 1 - N A N T E S T 2 3 = 0 1 0 0 MAN. PS 254 EN – Ind. 2...
  • Page 33 N 2 0 = 0 3 6 5 0 1 - N A N T E S T 2 5 = 0 5 N A N T E S T 2 5 = 1 0 MAN. PS 254 EN – Ind. 2...
  • Page 34 R 3 0 D 0 3 4 ^ ^ ^ R 3 0 = D 0 3 4 R 3 0 = D 0 3 4 R 3 0 = D 0 3 4 MAN. PS 254 EN – Ind. 2...
  • Page 35 0 1 - N A N T E S V 3 2 0 7 0 % 0 1 - N A N T E S V 3 2 3 6 0 % MAN. PS 254 EN – Ind. 2...
  • Page 36 MU IV 64 A040 MU IV 80 A051 MU IV 104 A062 MU IV 115 A069 MU IV 128 A082 MU IV 195 A137 MU IV 245 101.6 A200 MU IV 275 A197 MAN. PS 254 EN – Ind. 2...
  • Page 37 Positioners Polyturn Weld head Minimum Maximum Reference Number of Factor C type diameter diameter number impulses per (VP=C*VL/D) (mm) (mm) (R30) revolution Polyturn 11 A017 Polyturn 50 A038 Polyturn 175 1000 A132 MAN. PS 254 EN – Ind. 2...
  • Page 38 D073 C MW170 C103 C MW1250 33.4 C017 MW2500 63.5 C047 MW4500 114.3 A119 UHP 250 6.35 D006 UHP 500 12.7 D009 UHP 1500 38.1 D023 * a : previous n : new MAN. PS 254 EN – Ind. 2...
  • Page 39 1 1/2 G018 MW 1250 1 5/16 G018 MW 2500 2 1/2 F037 MW 4500 4 1/2 F073 UHP 250 A 1/16 G006 UHP 500 A G009 UHP 1500 A 1 1/2 G018 MAN. PS 254 EN – Ind. 2...
  • Page 40 (VP=C*VL/D) (mm) (mm) (R30) revolution A014 TS 25 (H014, J014) A044 TS 73 (H044, J014) A044 TS – TP 60 (H044, J014) A032 TS 2000 (H032, J032) C021 MAN. PS 254 EN – Ind. 2...
  • Page 41 , Downslope counterclockwise. , End of cycle Push the sector key SY 15 again and repeat adjustments, if necessary, until the rotation stops exactly after one revolution. MAN. PS 254 EN – Ind. 2...
  • Page 42 ‰ 0 1 - N A N T E S V 4 2 4 0 0 ‰ 0 1 - N A N T E S V 4 2 4 0 0 ‰ MAN. PS 254 EN – Ind. 2...
  • Page 43 2 . 0 0 1 - N A N T E S T 4 1 2 . 5 0 1 - N A N T E S T 4 1 2 . 5 MAN. PS 254 EN – Ind. 2...

  • Page 44: Programming Of Sectors

    V 3 2 = 2 0 0 ‰ 0 1 - N A N T E S N = 0 1 0 0 V 3 2 = 2 0 0 ‰ V 3 2 = 2 0 0 ‰ MAN. PS 254 EN – Ind. 2...
  • Page 45 0 1 - N A N T E S N = 0 1 5 0 V 3 2 = 2 0 0 ‰ V 3 2 = 1 8 0 ‰ V 3 2 = 1 8 0 ‰ MAN. PS 254 EN – Ind. 2...
  • Page 46 0 1 - N A N T E S N = 0 1 3 0 V 3 2 = 2 0 0 ‰ V 3 2 = 1 8 0 ‰ V 3 2 = 1 8 0 ‰ MAN. PS 254 EN – Ind. 2...

  • Page 47: Deleting A Program From The Source Memory

    To select the program to be deleted, enter the program number with the remote control pendant. P A R I S P A R I S P O L Y S O U D E 2 5 4 MAN. PS 254 EN – Ind. 2...

  • Page 48: Entering The Time And Date

    0 8 - 0 4 - 9 6 N A N T E S 2 5 4 0 - > 1 2 H 1 0 : 3 1 : 2 0 p m 2 5 - 9 6 MAN. PS 254 EN – Ind. 2...

  • Page 49: Saving, Loading A Program

    If, during the transfer, a fault is detected, the manual. A brief summary is given below. operation is stopped and an error code is shown on the display of the PS 254. Refer to 2 possibilities : Appendix 3 and Chapter 8.5 for the error codes and corrections to be made.

  • Page 50: Printing A Program

    Validate by pressing the button . The parameter concerned is displayed during 5 corresponding indicator will illuminate. seconds on the front face of the PS 254. • Wait for the indicator to extinguish before Wire feeder rotation speed : removing the memo card.

  • Page 51: Programmable Parameters

    The units used. In each column, the by a flashing light on the remote control abbreviations stand for: pendant. An error code will also appear on the display of the PS 254. Appendix 5.2 gives the Amperage. error codes, their...
  • Page 52 Rotation speed (high) then 0 Rotation speed (base) then 0 Wire Delay for wire start V42 Wire feed speed (high) then 0 Wire feed speed (base) then 0 Wire stop 9999 Delay for wire retract MAN. PS 254 EN – Ind. 2...

  • Page 53: Execution Of A Weld Program

    Fig. 3.7 : "Start cycle" button is stored in the memory of the PS 254. If !75! is displayed on the screen, the right range of current is not selected. Modification of a weld cycle Parameter values can be modified during the 3.4.3.

  • Page 54: End Of Welding Cycle

    >>>> ! OK ! <<<< Fig. 3.11 : Printer switch 3.4.6. Manual weld cycle stop Manual weld cycle stop with downslope The manual downslope button BT 6 on the remote control pendant starts the programmed MAN. PS 254 EN – Ind. 2...
  • Page 55 Fig. 3.14 : Emergency stop button Using a manual welding torch You should introduce a short program with both a high and a low current when welding with a manual torch as described in paragraph 2.3.6. MAN. PS 254 EN – Ind. 2...

  • Page 56: Servicing, Maintenance And Troubleshooting

    21700634 synoptic card are pre-adjusted in the factory. In case of a standard exchange of these cards, no further adjustments are necessary. However, further adjustments are necessary in case of replacement of the 21700690 card or the source. MAN. PS 254 EN – Ind. 2...
  • Page 57 F ig. 4.1 : Inverter switch S3/2 for shunt circuit security system of monitoring welding current in « CLOSED » position for adjustments (sequencer card) Fig 4.2 : Inverter switch S1/4 in « CLOSED » position (21700634 synoptic card) MAN. PS 254 EN – Ind. 2...

  • Page 58: Adjustment Of The Inverter Unit

    Repeat operations D and E until the Introduce program without set-up is correct. pulsation with a current of 160 A. Fig. 4.3 : Potentiometers and test points for the regulation of the current reference on the 21700633 sequencer card MAN. PS 254 EN – Ind. 2...
  • Page 59 Start another cycle with a current of 10 A. The value read must be 10 mV. If not, use the potentiometer P4 to adjust Fig. 4.4 :Potentiometers for the regulation of the current (interface card 2170069) MAN. PS 254 EN – Ind. 2...
  • Page 60 200 A. The value read must be 4 V. If not, adjust it with the potentiometer T3. Fig. 4.4: Potentiometer for adjusting the current voltage measurement MAN. PS 254 EN – Ind. 2...
  • Page 61 These adjustments are made on the 21700634 synoptic card. contrast adjustment made with potentiometer brightness adjustment with potentiometer T2. Fig. 4.5 : Adjusting the contrast and brightness of the display (synoptic card 21700634) MAN. PS 254 EN – Ind. 2...

  • Page 62: Adjusting The Rotation Speed Of Welding Heads With Tachometry (Optional)

    Repeat operations I and J until the of 110 Hz. set-up is correct. Repeat operations D and E until the set-up is correct. Fig. 4.6 : Potentiometers to adjust the speed of welding heads with tachometry MAN. PS 254 EN – Ind. 2...

  • Page 63: Coolant

    The paper advances by pushing the printer switch Fig. 4.9 : Change of ribbon cartridge SY 29 downwards. Insert the paper into the slot of the cover before closing it. MAN. PS 254 EN – Ind. 2...

  • Page 64: Maintenance And Troubleshooting

    Two fuses RF1 and RF2 are situated on when switching the relay card WK-3 A2 and another one is machine after you change a located on the +12V/ +5V power supply fuse. card. Fig. 4.14: Location of the fuses MAN. PS 254 EN – Ind. 2...

  • Page 65: Trouble Shooting

    - Reload the programs from the memory of the power source - Card 217 00 633 has been replaced - Reload the programs - RAM memory on card 217 00 633 defect - Replace RAM memory MAN. PS 254 EN – Ind. 2...
  • Page 66 Any rotation movement - shear pin broken - replace shear pin (see operation (welding head) or wire manual of the welding head or feeding, any error message wire feeder for details) appears MAN. PS 254 EN – Ind. 2...
  • Page 67 - Lack of insulation between welding head and wire guide support. - Check and correct - Card 217 00 633 defect. - Replace - Inverter unit defect (card TRDC2). - Call After Sales Service MAN. PS 254 EN – Ind. 2...
  • Page 68 - Bad cable connection between the power source and the motor. - Can be checked only by a qualified specialist. - Card 217 00 633 defect. - Change. - Transformer T1 defect. - Can be checked only by a qualified specialist. MAN. PS 254 EN – Ind. 2...
  • Page 69 - - Use only programs made for a power source. power source PS 254. - The position of the switch S3/1 or S3/4 on the card 217 00 633 is - Set switches to the ""OPEN"" wrong. position. MAN. PS 254 EN – Ind. 2...

  • Page 70: Spare Parts ( See "Summary Spare Parts" Pages 84/85)

    Red remote control pendant button 00549065 Black remote control pendant button 00549066 Emergency stop button 00542070 Red cover for emergency stop button 00542071 Coding wheel 00543016 Interconnection card 21700627 Coque caoutchouc pour télécommande 17375299 34,35 MAN. PS 254 EN – Ind. 2...

  • Page 71: Circuit Description

    4.2.4. Circuit description Remark The following information refers to the wiring scheme of the PS 254 (Ref. 1700 xx xx) and the remote control pendant (Ref. 1436 xx xx or The power switch 1737 xx xx) as well as to the sequencer card The power switch consists of a self holding (Ref.
  • Page 72 Fig. 4.18 : Wiring scheme of PS 254 MAN. PS 254 EN – Ind. 2...
  • Page 73 Rotation motor control, based on the principle (Pulse Width • Power supplies. Modulation). • Wire motor control, identical to the control of the rotation motor. Fig. 4.19 : Sequencer card MAN. PS 254 EN – Ind. 2...
  • Page 74 The procedure for their adjustment is given in paragraph 9.2.6. The memo cards used with the PS 254 are compatible with the databus I²C. The presence of a signal "Memo card engaged", resulting from a contact in the connector, authorises all other connections, including the 5 V power supply.
  • Page 75 Fig. 4.20 : Synoptic card MAN. PS 254 EN – Ind. 2...
  • Page 76 The «In cycle» indicator is a light emitting BT 14 diode LED. BT 5 BT 15 BT 12 BT 9 BT 6 BT 10 BT 13 BT 8 BT 4 (1) BT 4 (2) BT 4 (4) BT 4 (8) MAN. PS 254 EN – Ind. 2...

  • Page 77: Appendix

    "flush" and "protruding" tubes. Warning multipass welding necessary, parameter values for the passes are given in the tables without repeating diameter thickness of the tubes. Fig. 5.2 : Weld preparation Fig. 5.1 : Weld set-up MAN. PS 254 EN – Ind. 2...

  • Page 78: Closed Chamber Welding Heads Or Mu Heads Without Filler Wire

    PS 254 orkpiece welding program degree heads Stainless Stainless 6.35 Stainless Stainless 9.52 1.65 Stainless 1.55 Stainless 10.5 Stainless 0.35 Stainless Stainless 12.7 Stainless 15.8 Stainless Stainless 2.25 Stainless 17.2 Stainless 1.25 Stainless Stainless MAN. PS 254 EN – Ind. 2...
  • Page 79 PS 254 workpiece welding program degrés heads Stainless Stainless 26.9 Stainless Stainless 40.5 Stainless 48.7 Stainless Stainless Stainless 63.5 Stainless 63.5 Stainless 88.9 Stainless 88.9 Stainless 88.9 Stainless 114.3 Stainless MAN. PS 254 EN – Ind. 2...

  • Page 80: Mu Open Welding Heads With Filler Wire

    V 37.5° 0.2 60.3 Mild steel mm nose 12 H J 30° 10H30 1 mm nose 88.9 Mild steel 1.5 mm land 10H30 V 37.5° 0.2 114.3 Mild steel mm nose 12 H MAN. PS 254 EN – Ind. 2...

  • Page 81: Ts/Tp Welding Heads For Welding Of Tubes To Tubesheet

    Stainless Flushing 15° 30° 26.7 Stainless Protruding 15° 30° Mild 30° 30° Flushing steel 30° 30° Mild Protruding steel 30° 30° Mild 0° 30° Flushing steel 15° 30° Mild Protruding steel 15° 30° MAN. PS 254 EN – Ind. 2...

  • Page 83: Configuration Of The Dips For Ps 254

    1 2 3 4 With Convention 1 2 3 4 Without Closed Extension 1 2 3 4 cable With 1 2 3 4 Open Analog Voltage and 1 2 3 4 current display Digital MAN. PS 254 FR – Ind. 3...
  • Page 84 ! Return for revision ! Return for calibration ! Return for repair please specify the type of the error : ! systematically ! occasionally Description of breakdown : ! Other (please specify) : MAN. PS 254 EN – Ind. 2...
  • Page 85 Date : Signature: MAN. PS 254 EN – Ind. 2...

  • Page 86: Summary Spare Parts

    00542071 Red cap for emergency stop 00542070 Emergency stop button (without red cap) 00549067 Remote pendant button grey 00549066 Remote pendant button black 00549065 Remote pendant button red 00542006 Switch remote pendant 2 positions MAN. PS 254 EN – Ind. 2...
  • Page 87 PARTN° DESIGNATION 00543016 Digit coding wheel 00563085 Plug remote control pendant 00320042 Supply unit + 12 V 00544031 Relay 12 VDC 41410144 Transformer 00590065 Printer paper 00590064 Ribbon MAN. PS 254 EN – Ind. 2...

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