Polysoude PS 254 User manual

OPERATING,
PROGRAMMING AND
MAINTENANCE MANUAL
POWER SOURCE PS 254

2MAN. PS 254 EN – Ind. 2
LIMITS OF WARRANTY
Original features of the equipment and maintenance
The liability of the Polysoude company for delivered welding equipment is ending
immediately if:
-One or several components have been removed, distorted or altered without permission
in writing from the manufacturer, especially concerning safety facilities, electronic circuit
design or fluid systems...
-The essential maintenance procedures necessary for the faultless operation of the
machine have not been carried out.
Transformation of the original designation of the equipment
If approved equipment is used by the purchaser or a third party as part of a special
machine or an assembly line, instead of an examination part after part the responsible
party has to prove the conformity of the entire unit.
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.
Stability of the machines
The stability of the machines has to be assured by strictly respecting the handling and
transport procedures specified by Polysoude (refer particularly to the specific chapter in
the Operating and Maintenance Manual).
Handling conditions
To move or displace equipment, the lifting eyebolts or integrated connection rods have to
be used.
In order not to overcharge lifting equipment, the operator must know the weight of the
equipment.
2002 Polysoude
Original edition: Polysoude S. A. Nantes France
All rights reserved. No part of this manual may be reproduced in any form or by any
electronic or mechanical means, including information storage and retrieval systems,
without permission in writing from the publisher, except by a reviewer who may quote
brief passages in a review.
Printed in France.
Published by Polysoude, Nantes, France.
www.polysoude.com [e-mail]

MAN. PS 254 EN – Ind. 2 3
Index
1. INTRODUCTION ..................................................................................................................... 5
1.1. The PS power sources ......................................................................................................... 5
1.2. The orbital welding heads..................................................................................................... 6
1.2.1. 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. Technical characteristics ............................................................................................. 10
1.4.3. Technical characteristics ............................................................................................. 10
1.5. Safety precautions.............................................................................................................. 11
1.5.1. General rules............................................................................................................... 11
1.5.2. Training of the operators.............................................................................................. 11
1.5.3. Maintenance and adjustments ..................................................................................... 11
1.5.4. Ergonomics ................................................................................................................. 11
1.5.5. Protection during breakdown or incidents..................................................................... 11
1.5.6. Electric disconnect or shut off devices ......................................................................... 11
1.5.7. Fire prevention and explosion protection...................................................................... 11
1.5.8. Protection against burns .............................................................................................. 11
1.5.9. Gases and vapors ....................................................................................................... 11
1.5.10. Failure elimination.................................................................................................... 12
2. INSTALLATION ..................................................................................................................... 13
2.1. Preparation of the PS 16 .................................................................................................... 13
2.2. Installation.......................................................................................................................... 14
2.2.1. Handling...................................................................................................................... 14
2.2.2. Installation................................................................................................................... 14
2.2.3. Input power connection................................................................................................ 14
2.2.4. Connection with gas supply ......................................................................................... 15
2.3. Preparation for work ........................................................................................................... 15
2.3.1. Connection of the remote control pendant.................................................................... 15
2.3.2. Connection of an MU welding head or a TP or TS tube/tubeplate welding head ........... 15
2.3.3. Connection of an air cooled closed chamber welding head .......................................... 16
2.3.4. Connection of a liquid cooled closed chamber welding head ........................................ 17
2.3.5. Connection of a wire feed unit ..................................................................................... 17
2.3.6. Connection of a manual torch with double command ................................................... 18
2.3.7. Connection of a liquid cooled closed chamber welding head with tachometry (optional) 18
2.4. Controls ............................................................................................................................. 19
2.4.1. Front panel.................................................................................................................. 19
2.4.2. Synopsis ..................................................................................................................... 20
2.4.3. The remote control pendant......................................................................................... 21
3. OPERATION OF THE PS 254 ............................................................................................... 22
3.1. Fundamental procedures.................................................................................................... 22
3.1.1. Switching on................................................................................................................ 22
3.1.2. Positioning the welding head on the workpiece ............................................................ 22
3.1.3. Wire setting ................................................................................................................. 22
3.1.4. Adjustment of the gas flow........................................................................................... 22
3.1.5. Manual cooling system start ........................................................................................ 22
3.2. Programmation surface ...................................................................................................... 23
3.3. Programming ..................................................................................................................... 24
3.3.1. Entering the program name ......................................................................................... 25
3.3.2. Modifying the program name ....................................................................................... 25
3.3.3. Choice of a built-in program......................................................................................... 26
3.3.4. Programming and modifying the welding parameters................................................... 27
3.3.5. Programming of sectors............................................................................................... 43
3.3.6. Deleting a program from the source memory ............................................................... 46
3.3.7. Entering the time and date........................................................................................... 47
3.3.8. Entering / modifiying the company name ..................................................................... 47

4MAN. PS 254 EN – Ind. 2
3.3.9. Saving, loading a program ........................................................................................... 48
3.3.10. Printing a program ................................................................................................... 49
3.3.11. Programmable parameters....................................................................................... 50
3.4. Execution of a weld program .............................................................................................. 52
3.4.1. Safety precautions....................................................................................................... 52
3.4.2. Choosing the program to be executed ......................................................................... 52
3.4.3. Simulation ................................................................................................................... 52
3.4.4. Weld cycle................................................................................................................... 52
3.4.5. End of welding cycle.................................................................................................... 53
3.4.6. Manual weld cycle stop................................................................................................ 53
4. SERVICING, MAINTENANCE AND TROUBLESHOOTING ................................................... 55
4.1. Servicing ............................................................................................................................ 55
4.1.1. Adjustments ................................................................................................................ 55
4.1.2. Adjustment of the inverter unit ..................................................................................... 57
4.1.3. Adjusting the rotation speed of welding heads with tachometry (optional)..................... 61
4.1.4. Coolant ....................................................................................................................... 62
4.1.5. Printer ......................................................................................................................... 62
4.2. Maintenance and troubleshooting ....................................................................................... 63
4.2.1. Replacing fuses...........................................................................................................63
Fig. 4.14: Location of the fuses.................................................................................................. 63
4.2.2. Trouble shooting.......................................................................................................... 64
4.2.3. Spare parts ( See “summary spare parts” pages 84/85) ............................................... 69
4.2.4. Circuit description........................................................................................................ 70
5. APPENDIX ............................................................................................................................ 76
5.1. Built-in programs ................................................................................................................ 76
5.1.1. Closed chamber welding heads or MU heads without filler wire.................................... 77
5.1.2. 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 5
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:
•Welding sequences entirely programmable
in the language of the welder.
•Ease of use due to an intuitive
programming.
•Integrated program library for quick
welding parameter research.
•Real time monitoring system.
•Integrated printer for documentation of
welds according 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 several passes without interruption is
possible.
•Oscillation.
•Programmable mass flowmeter for the
shielding gas.
PS 204
Portable 200 A, single phase
input power source.
Ideal for on site use.
PS 254
Power source 250 A.
Ideal for shop, site and sub-
assembly work.
PS 256
Portable power source 250 A.
Comes with AVC and oscillation.
PS 356
Power source 350 A.
Programming like PS 256.
Universality for all welding needs.

6MAN. PS 254 EN – Ind. 2
1.2. The orbital welding heads
The PS power sources support most of the
Polysoude orbital welding heads.
1.2.1.The open welding heads
•MU IV type for standard applications and
all weld problems where AVC and
oscillation is required.
•Polycar welding carriage to weld large
diameter pipes.
1.3. The tube to tubesheet welding
heads
•TS heads with different productivity to
meet all requirements.
POLYCAR welding carriage to weld
large diameter pipes.
Microprocessor controlled AVC and
oscillation. Integrated wire feeder.
Possibility to adapt equipment fo
r
distance controlled or mechanised
welding processes.
TS 73 the standard welding head for tube
to tubesheet applications.
Open welding head for protruding, flush o
r
recessed tubes.
POLYFIL external wire feeder.
Wire feeder with four roll linear drive
system to minimise wire deformation and
surface distortion.
External wire feeder.
MU IV AVC/BL with AVC and
oscillation.
Modular design. Microprocesso
r
controlled AVC and oscillation slides,
driven by precision stepper motors.

MAN. PS 254 EN – Ind. 2 7
1.3.1.The closed chamber weld heads
•Sentry UHP for the demands of high purity
industries.
•HD when the access to the weld area is
reduced.
•MW for high production rates.
•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.
A
daption kits for the welding o
f
accessories (elbows, flanges, valves,
connections, etc.) available.

8MAN. PS 254 EN – Ind. 2
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
or IV open welding heads, TS and TP heads
for welding tube to tube plates and K, H, MW
and UHP enclosed heads of the Astro Arc
Polysoude range. The Polyturn positioner and
the Polyfil wire feed unit can be used. Welding
with a manual TIG (GTAW) torch is also
possible.
1 Screen 5 Printer
2 Synoptic programmation board 6 Connection panel
3 Key board
4 Memo card drive
①
②
④
⑤
③
⑥

MAN. PS 254 EN – Ind. 2 9
1.4.2.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
emergency.

10 MAN. PS 254 EN – Ind. 2
1.4.3.Technical characteristics
Power input Three phase +ground
400V - (as an option : multi voltage ; 200 – 460 V)
± 10 % 50 or 60 Hz
Open circuit voltage 105 V
Insulation class F
Protection class IP 21 IK04
Welding current range 4 - 250 A D.C.
Duty cycle 250 A / 60 % - 190 A / 100 %
Current resolution 1 % when I ≥100 A - 1 A when I ≤100 A
Pulse frequency from 10 to 9999 ms
Movement controls Direct or pulsed current
Constant or pulsed command of torch rotation
Constant or pulsed wire feed, wire-retract at the end of
the weld
Precision on movements ± 1 %
Gas control Gas torch with security
second gas (option)
Power source cooling Forced ventilation
Torch cooling By water in closed circuit with flow safety valve
Display of real values during cycle Continuous display:
. of arc voltage
. of welding current
. of impulses of movements
Programs in user memory 16
Display 4 lines of 20 characters, with 8 characters reserved to
the designation of programs
Program sectors 10 maximum
Program library 60
Program storage On memory card
Auto-diagnostic system Display of code number
Immediate exploitation with welding heads :
. tube/plate
. tube/tube MU* - MW - H - K, UHP
. direct use of wire feeder Polyfil
. PO motor mechanised application
Specific functions Possibility of connecting a manual TIG torch
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