Polysoude PS 164-2 Owner's manual

PS 164-2
Operating, maintenance and
programming manual
PN-0908073
Power source
TIG - With or without Wire

2-92 PN-0908073 Rev. 11
PS 164-2
THE ART OF WELDING
Review of document
Rev. 0 Original document.
Rev. 1 Update following to review process.
Rev. 2 Addition of new graphic style guide FNCA 1009-012 + FNCA 1012-015 (PLE - 12/2010)
Rev. 3 Addition of information about coolant levels on page 64 (PLE - 07/2011)
Rev. 4 Addition of information about “R40 = Selection of wire feeder” on page 42 (PLE - 09/2011)
Rev. 5 Update for FNCA 1101-39 on page 18 + Shunt of coolant circuit on page 20 + FNCA 1201-013
(Remote control reference) + FNCA 1201-020 relay reference 12VDC on page 71 (PLE 02/2012)
Rev. 6 Addition Quick connector gas input 06/2012
Rev. 7 Update for FNCA 1208 026 pages 61-62 (09/2012)
Rev. 8 Update quick connector refrences FNCA 1211-071 (01/2013)
Rev. 9 Update «Servicing, maintenance and troubleshooting» 12/2014
Rev. 10 Update «Servicing, maintenance and troubleshooting» 09/2015
Rev. 11 Update : Chapters " Ulternating use of at two welding stations on the same workpiece"

PN-0908073 Rev. 11 3-92
PS 164-2
THE ART OF WELDING
Contents
1. Safety precautions ...................................................................................................... 5
1. 1. Arc welding hazards................................................................................................. 5
1. 2. Meaning of symbols ................................................................................................. 5
1. 3. Recommendations ................................................................................................... 6
1. 4. Safety precautions related to power sources ........................................................ 8
1. 4. 1. Training of the operators............................................................................ 8
1. 4. 2. Maintenance and adjustment work............................................................... 8
1. 4. 3. Ergonomics............................................................................................... 8
1. 4. 4. Protection in case of breakdown or failure of the equipment ............................ 8
1. 4. 5. Devices for the disconnection of energy sources ............................................ 8
1. 4. 6. Prevention of fire and explosions ................................................................. 8
1. 4. 7. Extraction of gas and fumes........................................................................ 8
1. 4. 8. Failure elimination..................................................................................... 8
2. General information .................................................................................................... 9
3. Introduction............................................................................................................. 10
3. 1. The PS power sources .............................................................................................10
3. 2. The orbital welding heads ........................................................................................11
3. 2. 1. The open welding heads............................................................................11
3. 2. 2. The closed chamber welding heads .............................................................11
3. 2. 3. The tube to tubesheet welding heads ..........................................................12
3. 2. 4. Accessories..............................................................................................12
3. 3. Technical specifications of the
power source PS 164-2 ........................................................................................................13
3. 3. 1. Design features........................................................................................13
3. 3. 2. The remote control pendant.......................................................................14
3. 4. Technical characteristics ..........................................................................................15
4. Installation .............................................................................................................. 16
4. 1. Preparation of the PS 164-2 .....................................................................................16
4. 2. Installation ............................................................................................................17
4. 2. 1. Handling .................................................................................................17
4. 2. 2. Installation..............................................................................................17
4. 2. 3. Input power connection.............................................................................17
4. 2. 4. Connection with gas supply........................................................................18
4. 3. Preparation for work ...............................................................................................19
4. 3. 1. Connection of the remote control pendant...................................................19
4. 3. 2. Connection of an MU welding head or a TP or TS tube/tube-plate welding head.19
4. 3. 3. Connection of an air cooled closed chamber welding head..............................20
4. 3. 4. Connection of a liquid cooled closed chamber welding head...........................20
4. 3. 5. Connection of a wire feed unit....................................................................21
4. 3. 6. Connection of a manual torch with double command .....................................21
4. 4. Controls ................................................................................................................22
4. 4. 1. Front panel..............................................................................................22
4. 4. 2. Back panel ..............................................................................................22
4. 4. 3. Synopsis .................................................................................................23
4. 4. 4. The remote control pendant.......................................................................24

4-92 PN-0908073 Rev. 11
PS 164-2
THE ART OF WELDING
5. Operation of the PS 164-2 ......................................................................................... 25
5. 1. Fundamental procedures ........................................................................................25
5. 1. 1. Switching on............................................................................................25
5. 1. 2. Positioning the welding head on the workpiece .............................................25
5. 1. 3. Wire setting.............................................................................................25
5. 1. 4. Adjustment of the gas flow ........................................................................25
5. 1. 5. Manual cooling system start.......................................................................26
5. 2. Programmation surface ...........................................................................................26
5. 3. Programming .........................................................................................................27
5. 3. 1. Entering the program name .......................................................................28
5. 3. 2. Modifying the program name .....................................................................28
5. 3. 3. Choice of a built-in program.......................................................................29
5. 3. 4. Programming and modifying the welding parameters.....................................30
5. 3. 5. Programming of sectors.............................................................................44
5. 3. 6. Deleting a program from the source memory ...............................................47
5. 3. 7. Entering the time and date ........................................................................48
5. 3. 8. Entering / modifiying the company name.....................................................49
5. 3. 9. Saving, loading a program.........................................................................49
5. 3. 10. Printing a program....................................................................................51
5. 3. 11. Functioning modes ...................................................................................51
5. 3. 12. Programmable parameters.........................................................................52
5. 4. Execution of a weld program ....................................................................................54
5. 4. 1. Safety precautions....................................................................................54
5. 4. 2. Choosing the program to be executed .........................................................54
5. 4. 3. Simulation...............................................................................................54
5. 4. 4. Weld cycle...............................................................................................54
5. 4. 5. End of welding cycle .................................................................................55
5. 4. 6. Manual weld cycle stop..............................................................................56
5. 5. lternating use of at two welding stations on the same workpiece...................................56
6. Servicing, maintenance and troubleshooting................................................................. 57
6. 1. Adjustments ..........................................................................................................57
6. 2. Coolant .................................................................................................................58
6. 3. Printer ..................................................................................................................58
6. 3. 1. Loading paper to the printer.......................................................................58
6. 3. 2. Change of ribbon......................................................................................58
6. 4. Replacing fuses ......................................................................................................59
6. 5. Filter of the cooling circuit........................................................................................59
6. 5. 1. Trouble shooting ......................................................................................60
6. 5. 2. Spare parts .............................................................................................65
6. 5. 3. Circuit description.....................................................................................68
7. Appendix ................................................................................................................. 76
7. 1. Built-in programs ...................................................................................................76
7. 1. 1. Closed chamber welding heads or MU heads without filler wire .......................77
7. 1. 2. MU open welding heads with filler wire ........................................................78
7. 1. 3. TS/TP welding heads for welding of
tubes to tubesheet....................................................................................79
7. 2. Error codes............................................................................................................80
7. 3. Factory settings of DIPS ..........................................................................................81
8. End of life, recycling the machine................................................................................ 83
9. Equipment Return form ............................................................................................. 85

PN-0908073 Rev. 11 5-92
PS 164-2
THE ART OF WELDING
1. Safety precautions
Note: Protect yourself and others from injury - read and follow these instructions
1. 1. Arc welding hazards
The following symbols are used in the text to draw your attention and to identify risks and dangers.
When you see a symbol, consult the safety rules in the Recommendations chapter hereafter.
Installation, utilisation, maintenance and repair work on a power source is admitted only for qualified staff.
When using the equipment, keep away everybody who is not working with the installation.
1. 2. Meaning of symbols
Risk of electric shocks Risk of severe injuries
caused by moving parts
Risk of fume or gas inhalation Risk of explosion
Risk of eye or skin burn cau-
sed by radiation
Risk caused by magnetic
fields
Warning: hot parts – Risk of
burn Danger caused by noise
Risk of eye or skin burn
caused by flying sparks Read the instructions
Risk of overheating, fire Eye protection mandatory
Foot protection mandatory Helmet mandatory
Fall risk.
Consult the following recommendations
and take necessary action to avoid dan-
gerous situations.

6-92 PN-0908073 Rev. 11
PS 164-2
THE ART OF WELDING
1. 3. Recommendations
Risk of electric shocks
Live parts include the electrode, the weld circuit, the
supply circuit and the internal circuits, the filler wire
and metal parts in contact with it, the wire feeder
unit and the wire feeding mechanism. Any contact
with these parts can cause an electric shock if the
installation is connected to the mains supply.
Circumstances increasing the risk of electric shocks:
humid environment, work on a conducting surface,
poor earth connection, installation in bad condition,
unsafe work conditions.
To prevent risks:
• Avoid any contact with energised wire spools.
• Inspect water cooled torches regularly to detect
leakage, pay attention to condensation phenom-
ena.
• Do not wind the cables around your body.
• Make sure that the electrode is not energised
when changing it.
• Before any maintenance, repair or pause, discon-
nect the equipment from the mains supply.
• Wear gloves, clothes, aprons and safety shoes
that are dry and without holes.
• Carpets or other insulating materials must be
used if the welder has to work on metallic sur-
faces or structures.
• The equipment must be installed and earthed as
specified in the operating manual.
• The current return cable must be fixed correctly
(clean surface, solid clamping as close as possible
to the weld area).
• Cables that are damaged, worn or unsheathed,
the wrong size must or wrongly assembled must
not be used otherwise immediately.
• The power source must be properly earthed.
• Use a separate cable if the workpiece must be
earthed.
• Appropriate connectors must be used.
Be careful to the open circuit voltage limited to 80 V
efficient in alternating current or 113 V in direct cur-
rent (necessary voltage for the arc ignition). Maxi-
mum power supply value for plasma cutting: 500 V.
Risk of fume or gas inhala-
tion
During welding, fumes and gases are released which
are dangerous to your health. Avoid inhaling fumes.
Origin of released fumes and gases: basic material,
filler metal, weld coating (flux) with coated rod elec-
trodes, shielding gas, solvents and materials cover-
ing the workpiece.
To prevent risks:
• Use breathing apparatus like filter masks, ventilat-
ed masks, air-supply masks, disposable masks.
• Avoid chlorinated solvents.
• Dry the workpieces thoroughly before welding.
• Do not work alone!
• Eliminate fumes and gases where they develop.
• Remove paint, oil and any other coatings from the
surface.
Risk of eye or skin burn
caused by radiation
The radiation from the arc causes eye and skin
burns.
Risk identification: exposure to radiation from the arc
emitting visible and invisible intense radiation (ultra-
violet and infrared); radiation is reflected if welding
metals like aluminium or stainless steel; flash burn,
sparks, stings caused by the tungsten electrode tip.
To prevent risks:
• Wear gloves or leather gauntlets to protect hands
and lower arms.
• Wear an apron or gaiters to protect the legs,
knees and feet.
• Carry a mask (strapped to the head, handheld or
electronic) or glasses equipped with an adequate
filter.
• Use shielding curtains to protect staff working
nearby.
• Wear a scarf around your neck and close the col-
lar of your clothing.

PN-0908073 Rev. 11 7-92
PS 164-2
THE ART OF WELDING
Warning: hot parts – Risk
of burn
• Do not touch welded or torch cut pieces. When
handling hot workpieces, use adequate tools and/
or wear thick and isolating welding gloves, avoid-
ing any burn.
• Welded parts must cool down before handling or
further weld operations.
Risk of eye or skin burn
caused by flying sparks
• Wear gloves or leather gauntlets to protect hands
and lower arms.
• Wear an apron or gaiters to protect the legs,
knees and feet.
• Carry a mask (strapped to the head, handheld or
electronic) or glasses equipped with an adequate
filter
• Use shielding curtains to protect staff working
nearby.
• Wear cotton or woollen clothes with long sleeves,
without oil or lubricant marks - avoid synthetic
fabrics.
• Wear a scarf around your neck and close the col-
lar of your clothing.
• Wear safety boots made for welders.
Risk of overheating, fire
• Keep the installation in good condition, especially
the supply cables and the current return cable.
• Keep a minimum distance of 6 m between the
welding equipment and any greasy, explosive or
dusty substance.
• Use shielding curtains to protect staff working
nearby.
Risk of explosion
These risks are caused by using and handling gas
bottles and flying sparks.
• Never use damaged gas bottles.
• Stock the gas bottles in a well-ventilated room,
allowing access only to authorised staff.
• The temperature limit of 55 °C must be respect-
ed for the storage and use of gas bottles.
• Separate clearly marked empty gas bottles from
new ones.
• Protect gas bottles from extreme temperatures
(freezing, sun, sparks, etc.).
• Inspect connections and hoses periodically.
• Use shielding curtains.
Risk of severe injuries
caused by moving parts
•
• Never place your hands near a fan or other mo–
ving parts.
• Keep all safety devices operational and in safety
mode.
Risk caused by magnetic
fields
The distance between the brain and the welding cir-
cuit is a very important parameter.
• Never wind cables around your body or, even
worse, over your shoulders.
• Make it known if you have been fitted with a
pacemaker. Possible interference must be pre-
vented by special measures in co-ordination
with a physician.
The operator must ensure
that no one is exposed to
dangerous areas

8-92 PN-0908073 Rev. 11
PS 164-2
THE ART OF WELDING
1. 4. Safety precautions related to power
sources
Work or maintenance procedures described in this
manual may be accompanied by dangers or risks.
Such procedures are indicated by the following
pictograms.
Risk or situation with dan-
ger of serious injuries or
even deadly danger
At one side of the power source, a sticker indicates
that it is necessary to read the operating manual.
1. 4. 1. Training of the operators
A copy of the operating and maintenance manual is
delivered with the equipment. The different opera-
tors (welder, controller, maintenance staff, ...) must
always have at least one spare copy (respect the
copy right). The qualification needed for their work
depends on the level of responsibility they take dur-
ing their mission.
1. 4. 2. Maintenance and adjustment work
If maintenance or adjustment work has to be carried
out on the upper parts of the equipment, a scaffold
must be erected.
It is strictly forbidden to pull on cables or hoses to
move welding heads or the power source or to push
it by consoles or panels.
1. 4. 3. Ergonomics
◊Signalisation
Elements used for the signalisation, especially safe-
ty-relevant parts (e.g. colours of push-buttons and
signals, consult applicable standards) must not be
modified in any case (inversion of the colours). Sig-
nals or buttons with indiscernible colours caused by
aging or wear must be replaced imperatively.
◊Sufficient illumination of work areas
Generally, welding equipment does not require the
use of spot light, instead a medium environmental
illumination is rather necessary (consult applicable
standards). The operating company must fit out the
workshop with a correct lighting system (avoiding
shadow areas, glares) so that there will be no incon-
venience or excessive tiredness of the operators.
1. 4. 4. Protectionincaseofbreakdownorfailureofthe
equipment
If no welding operations are carried out, the staff
must protect themselves by activating appropriate
separation devices.
1. 4. 5. Devicesforthedisconnectionofenergysources
◊Installation of disconnect or shut off de-
vices
The presence of electric disconnect or shut off devic-
es (electric, hydraulic, pneumatic, ...) is imposed by
law. In case of mobile equipment or when Polysoude
supplies only a part of the entire machine, the cus-
tomer is responsible to install the necessary missing
devices.
◊Operation of disconnect or shut off devices
Conform to the instructions of the technical docu-
mentation of the manufacturer, before operating
disconnect or shut off devices (separating a running
equipment from its energy supply), the staff must
convince themselves that anybody could be endan-
gered.
1. 4. 6. Prevention of fire and explosions
Welding equipment must not be used on premises
where inflammable, volatile or explosive products
are present.
1. 4. 7. Extraction of gas and fumes
The operating company has to evaluate inconven-
iences or unhealthy conditions inside the workshop.
It must finally adopt all necessary measures:
• To ventilate it and to extract gases and vapours.
• Protective equipment against the radiation emit-
ted from the arc must be available and has to be
used.
• Safety instructions and protective equipment
must be conform with applicable standards.
1. 4. 8. Failure elimination
Only qualified electricians are allowed to inspect,
check, adjust or repair the electric or electronic
equipment of the welding machines.
Before any maintenance work can be carried out or
an instrument is connected to a circuit, the discon-
nection of the mains supply must be ensured and a
waiting period of 2 minutes must have been elapsed.
These instructions are specified on the label at the
right side of the generator.

PN-0908073 Rev. 11 9-92
PS 164-2
THE ART OF WELDING
Check always for voltage-
free parts, even if the instal-
lation has been disconnected
from the mains. A capacitor
can store its potential for a
long period of time after it
has been separated from the
power supply.
Never shunt or eliminate safety devices or interlocks
installed to protect the user or operator of the equip-
ment.
Never stand on a wet or humid floor during interven-
tions on electric or electronic devices. Avoid impera-
tively any leakage of liquids inside electric or elec-
tronic equipment.
2. General information
Applicable directives
2004/108/EC Electromagnetic compatibility
2006/95/EC Electrical equipment designed for use certain voltage limits
Never use volatile solvents or flammable substances
next to welding machinery. The electric arc could ac-
cidentally ignite the vapours or combustible liquids.
During repair and maintenance work on electric or
electronic equipment, take off any jewellery (rings,
watches, bracelets, etc.). Insulating shoes must be
made available under the responsibility and on the
expenses of the operating company, they must be
worn by the concerned staff whenever it is neces-
sary.

10-92 PN-0908073 Rev. 11
PS 164-2
THE ART OF WELDING
3. Introduction
3. 1. The PS power sources
The power source PS 164-2 belongs to a versatile
new family of universal and easy to use orbital TIG
power sources. Special features are:
• Welding sequences entirely programmable in the
language of the welder.
• Ease of use due to an intuitive programming.
• Integrated program library for quick welding pa-
rameter research.
• Real time monitoring system.
• Integrated printer for documentation of welds ac-
cording to the ISO 9000 standard.
• Possibility of storing programs in the memory of
the power source or on 3,5" disk.
• Modern inverter based power source technology.
• Mechanised welding with the ease and comfort of
PS power sources.
With a weld current range between 1 A and 350 A and
up to six programmable axes the PS power sources
respond to a wide field of applications:
• Pulsed or continuous weld current.
• Travel speed and wire speed continuous or with
pulsation synchronised to the weld current.
• With Arc Voltage Control AVC, the welding of sev-
eral passes without interruption is possible (*).
• Oscillation (*).
• Programmable mass flowmeter for the shielding
gas.
(*) Only power sources from PSxx6 type
PS 164-2 (Fig.3.1)
Portable 160 A power source.
Ideal for on site use.
PS 406-2 (Fig.3.2)
Power source 3.15 A.
Universality for all welding needs.
Design in three versions: 4, 5 or 6-axes.
Fig. 3.1 - PS 164-2
Fig. 3.2 - PS 406-2

PN-0908073 Rev. 11 11-92
PS 164-2
THE ART OF WELDING
3. 2. The orbital welding heads
The PS power sources support most of the Polysoude
orbital welding heads.
3. 2. 1. The open welding heads
• MU IV type (Fig.3.3) for standard or special ap-
plications. Modular design. Weldhead designs to
weld pipes, butt joint type, with or without filler
wire.
• Polycar welding carriage to weld large diameter
pipes.
3. 2. 2. The closed chamber welding heads
• MW (Fig.3.4) when high production rates are
required. High duty cycle due to water cooling.
Adaption kits for welding of accessories (elbows,
flanges, valves, connections, etc.) available.
• Sentry UHP (Fig.3.5) for the demands of high pu-
rity industries. Welding head with closed chamber
designs for the welding of thin pipes, butt joint
type, close square prepared without filler wire. It
ensures high quality welds and its compact design
allows to use it in area with restricted access.
• HD when the access to the weld area is reduced.
• K to answer the demand of a very reliable shield-
ing gas protection.
Fig. 3.3 - MU IV welding head
Fig. 3.4 - MW welding head
Fig. 3.5 - UHP welding head

12-92 PN-0908073 Rev. 11
PS 164-2
THE ART OF WELDING
3. 2. 3. The tube to tubesheet welding heads
TS welding heads with different features to meet all
productivity and quality requirements.
The standard weldhead for tube to tubesheet appli-
cations.
Open weldhead for slightly protruding or flush
tubes.
3. 2. 4. Accessories
POLYFIL external wire feeder.
Wire feeder with four roll linear drive system to mini-
mise wire deformation and surface distortion.
Fig.3.6 - TS welding head
Fig. 3.7 - Polyfil wire feeder

PN-0908073 Rev. 11 13-92
PS 164-2
THE ART OF WELDING
2
4
6
1
3
5
3. 3. Technical specifications of the
power source PS 164-2
3. 3. 1. Design features
The power source groups together the current source,
the electronic control and the cooling for the torch.
All connections are plugged on the connection panel
co in front of the power source.
On the front face, there are a key board and a dis-
play for the programmation and the follow-up of the
welding cycle, the card reader and the printer.
Fig. 3.8 - Description of power source PS 164-2
1 Screen 4 Memo card drive
2 Synoptic 5 Printer
3 Key board 6 Connection panel

14-92 PN-0908073 Rev. 11
PS 164-2
THE ART OF WELDING
3. 3. 2. The remote control pendant
This allows:
• The positioning of welding heads and wire feed
units
• The starting and stopping of weld cycles
• The selection of the program to be executed
• The simulation of a cycle without welding
• 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 emer-
gency
Fig. 3.9 - Remote control pendant

PN-0908073 Rev. 11 15-92
PS 164-2
THE ART OF WELDING
3. 4. Technical characteristics
Mains power input
Single phase + earth
220/230 V ± 10 %
50 or 60 Hz
Current rating 16 A
Open circuit voltage 60 V
Insulating class F
Enclosure class IP 23
Welding current range Range 160 A: 4 to 160 A
Range 50 A: 4 to 50 A
Regulation of intensity ± 1 % when I > 100 A and ± 1 A when I ≤100 A
Duty cycle 160 A to 40 %
100 A to 100 %
Range of pulsation
Range 160 A: 4 to 160 A
Range 50 A: 4 to 50 A
Time from 10 to 9999 ms
Motor controls Torch rotation
Wire feeder
Accuracy of movements ± 1 % for Vp ≥250 (Vp=programmed speed)
± 4 for Vp < 250
Gas controls Torch gas, backing gas (option)
Power source cooling Forced ventilation
Welding torch cooling By cooling liquid in closed circuit with flow safety
valve
Display of actual values during the weld cycle Permanent display of the arc voltage and the welding
current
Storage of "User’s" programs 16 maximum
Presetting program library 60
Sectors per program 10 maximum
Storage and loading Memo chip card
Dimensions 660 x 320 x 465 mm
Weight 34 kg
Standards EN 60974-1 and EN 60974-10

16-92 PN-0908073 Rev. 11
PS 164-2
THE ART OF WELDING
2
1
5
3
6
7
4. Installation
4. 1. Preparation of the PS 164-2
The PS 164-2 is delivered in a transport protection
case. You will find:
• The remote control pendant BP 1436 (Pos. 1).
• A ground cable 9 m in length (Pos. 2).
• A gas connection (two other ones in case of an
optional second gas) (Pos. 3).
• This operating and maintenance manual (Pos.4).
• One memo card (Pos. 5).
• Devices for printer (Pos. 6)
• Two sets of keys (Pos. 7)
Fig. 4.1 - Accessories of the PS 164-2 power source
4

PN-0908073 Rev. 11 17-92
PS 164-2
THE ART OF WELDING
4. 2. Installation
4. 2. 1. Handling
The PS 164-2 comes with attached handles. Please
use these handles when moving the PS 164-2. Never
move it by pulling any cables or hoses.Movements
should be horizontal without sudden shocks or move-
ments. In case of using a truck, watch stability.
4. 2. 2. Installation
For safe work the PS 164-2 has to be placed horizon-
tally, on a firm surface. In this case a shaft system
ensures the stability of the machines.
If the equipment is used on a level which is not flat,
be careful not to topple down the power source.
Openings are provided for ventilation of the power
source. To ensure effective cooling of the system, a
minimum distance of 30 cm (12") should be main-
tained between these openings and any surface.
4. 2. 3. Input power connection
All connections must be
made by a qualified techni-
cian respecting the safety
rules given by law or
quoted in this manual.
General
The PS 164-2 is connected to the main power sup-
ply with a cable of 2 conductors + ground, which
comes with the machine. It is essential to connect
the ground cable correctly in order to ensure the
safety of the operators.
Refer to the name plate of your power source for in-
put power requirements. For example, to work with
an input Voltage of 230 V, a 16 A fuse is required.
It is essential to connect
the ground cable in order
to ensure the safety of the
operators.
If you use an extension
lead, please respect the
instructions below.
If you use an extension lead, the section of the lead
should be:
up to required section
20 m 3 x 2,5 mm²
50 m 3 x 4 mm².
Fig. 4.2 - Name plate of the PS 164-2 power source

18-92 PN-0908073 Rev. 11
PS 164-2
THE ART OF WELDING
21
1
2
PS 164-2
A
PS 164-2
1
2
132
4. 2. 4. Connection with gas supply
Connection with the gas supply is made at the rear-
side of the power source (Fig.4.3) with the appropri-
ate fittings. Flow regulators should be used to ad-
just the power source inlet gas stream to the correct
value (see appendix 4 - Spare parts). Before making
any connections, briefly open the valves to drive out
any impurities.
Fig.4.3, Fig.4.4 & Fig.4.5 - Pos 1 Gas 1
Fig.4.3, Fig.4.4 & Fig.4.5 - Pos 2 Gas 2
To ensure a successful welding cycle, please provide
for a minimum of 2.5 L/min for Argon gas flow and
8 L/min for Helium flow.
• Gas fitting female - Part number 01514008 - Item
1.
• Ribbing bush - Part number 00692055 - Item 2.
• Copper seal 13.5x18x1.5. -No part number - Item
3.
Fig. 4.3 - Gas connections at the right side of the
PS 164-2
Gas kit for UHP
This option integrated in the power source enables
to keep a continuous gas flow when the UHP head is
not welding.
Gas flow is controlled by:
• A valve integrated in the circuit if the gas used is
the welding gas (see Fig.4.4). This valve (Fig.4.4
- Pos A) is adjusted manually.
• The flowmeter in the gas source (bottle or pipe)
if the gas is different from the welding gas (see
Fig.4.5). The connection is made at the rear side
of the power source (inlet gas 2).
Fig. 4.4 - Diagram to use only one gas
Fig. 4.5 - Diagram to use two different gas
How it works :
If a UHP head is connected, the gas flows as soon
as the power source is switched on according to the
flow rate pre-set adjusted by means of the valve or
the flowmeter.
When the welding cycle is started (switch in set up or
weld position), the welding gas flows automatically
according to the flow controlled by the flowmeter
until the post gas time has elapsed after welding.
Afterwards the gas keeps on flowing with continuous
flow.
Once the head is disconnected, continuous gas is
stopped.

PN-0908073 Rev. 11 19-92
PS 164-2
THE ART OF WELDING
4. 3. Preparation for work
4. 3. 1. Connection of the remote control pendant
Connection of the remote control pendant is made
with the plug on the right side of the PS 164-2 on
the screw connector.Make sure the securing ring is
tightened properly, otherwise the system may not
function correctly. Warning: the power source will
not work if the remote control pendant is not prop-
erly connected.
Fig. 4.6 - Connection of the remote control pendant
with the PS 164-2
4. 3. 2. ConnectionofanMUweldingheadoraTPorTS
tube/tube-plate 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.
◊Connection of the current return cable
Connect the current return conductor cable onto
the "+" terminal marked by a red ring. Connection
is made with a quick connector, by a short rotation
to the right. Connect the other end of the cable to
the workpiece, as close as possible to the joint to be
welded, in an area free from grease and oxide.
◊Connection of the rotation motor cable
Join the cable on the "Rotation" connector.
(symbol ).
Make sure that the securing ring is properly tight-
ened, otherwise the system may not function cor-
rectly.
◊Connection of the torch shielding gas hose
Connection is made with a quick push-type self seal-
ing coupling situated at the connection plate of the
power source.
(symbol ).
◊Connection of the coolant circuit
Connection is made by 2 quick push type self sealing
couplings on the front view.
(symbols and ).
Fig. 4.7 - Connection of an MU welding head or a
TP/TS welding head

20-92 PN-0908073 Rev. 11
PS 164-2
THE ART OF WELDING
4. 3. 3. Connectionofanaircooledclosedchamberwelding
head
This is the case for type H or UHP Polysoude closed
welding heads.
◊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.
◊Connection of the current return cable
Connect the current return conductor cable onto the
"+" terminal marked by a red ring. Connection is
made with a quick connector by a short rotation to
the right. This cable is indicated red.
◊Connection of the rotation motor cable
Connect the cable on the "Rotation" module connec-
tor (symbol ). Make sure that the securing ring
is properly tightened, otherwise the system may not
function correctly
◊Connection of the torch shielding gas hose
Connection is made with a quickpush type self seal-
ing coupling disconnect fitting situated at the bottom
left hand corner of the front panel of the PS 164-2
(symbol 1).
◊Connection of a bipass plug for the coolant
circuit security for use with air cooled weld-
ing heads.
For UHP before 2003 and H welding heads, it is neces-
sary to introduce the bipass plug to isolate the coo-
ling circuit security in order to avoid a continuously
detected fault.
4. 3. 4. Connectionof aliquidcooledclosed chamber
welding head
This is the case for type K and MW Polysoude closed
welding heads.
◊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.
◊Connection of the current return cable
Connect the current return conductor cable to the
"+" terminal with the quick connector, locking it by
a short rotation to the right. This cable is indicated
red.
◊Connection of the rotation motor cable
Join the cable to the "Rotation" connector (symbol
). Make sure that the securing ring is tight oth-
erwise the system may not function correctly.
◊Connection of the manual command cable
on the head (MW heads)
Connect the manual commands cable on the FA 5
terminal (Fig. 2.12) on the connection plate.
◊Connection of the coolant circuit
Connection is made by 2 quick push type self sealing
couplings on the cooling unit RC 200 (symbols
and ).
◊Connection of the torch shielding gas
Connection is made with a quick disconnect fitting
situated at the connection panel of the PS 164-2
(symbol 1).
Fig. 4.8 - Connection of an air cooled closed
chamber welding head Fig. 4.9 - Connection of a liquid cooled closed
chamber welding head ( ---- for heads with
integrated commands)