Polysoude PS 254 Operating, Programming And Maintenance Manual

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Page 1

OPERATING,

PROGRAMMING AND

MAINTENANCE MANUAL

POWER SOURCE PS 254

Page 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 [email protected]

2 MAN. PS 254 EN – Ind. 2

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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

1.5. 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

MAN. PS 254 EN – Ind. 2 3

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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

4 MAN. PS 254 EN – Ind. 2

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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.

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 subassembly work.

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 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.

MAN. PS 254 EN – Ind. 2 5

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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.

TS 73 the standard welding head for tube to tubesheet applications.

MU IV AVC/BL with AVC and oscillation.

Modular design. Microprocesso controlled AVC and oscillation slides, driven by precision stepper motors.

POLYCAR welding carriage to weld large diameter pipes.

Microprocessor controlled AVC and oscillation. Integrated wire feeder. Possibility to adapt equipment fo distance controlled or mechanised welding processes.

Open welding head for protruding, flush o recessed tubes.

POLYFIL external wire feeder.

Wire feeder with four roll linear drive system to minimise wire deformation and surface distortion.

External wire feeder.

6 MAN. PS 254 EN – Ind. 2

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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.

daption kits for the welding o accessories (elbows, flanges, valves, connections, etc.) available.

MAN. PS 254 EN – Ind. 2 7

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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

④

⑤

②

③

⑥

1 Screen 5 Printer 2 Synoptic programmation board 6 Connection panel 3 Key board 4 Memo card drive

8 MAN. PS 254 EN – Ind. 2

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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.

MAN. PS 254 EN – Ind. 2 9

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1.4.3. Technical characteristics

Power input

Open circuit voltage

Insulation class

Protection class

Welding current range

Duty cycle

Current resolution

Pulse frequency

Movement controls

Precision on movements

Gas control

Power source cooling

Torch cooling

Display of real values during cycle

Programs in user memory

Display

Program sectors

Program library

Program storage

Auto-diagnostic system

Immediate exploitation

Three phase +ground

400V - (as an option : multi voltage ; 200 – 460 V)

± 10 % 50 or 60 Hz

105 V

IP 21 IK04

4 - 250 A D.C.

250 A / 60 % - 190 A / 100 %

1 % when I ≥ 100 A - 1 A when I ≤ 100 A

from 10 to 9999 ms

Direct or pulsed current

Constant or pulsed command of torch rotation

Constant or pulsed wire feed, wire-retract at the end of

the weld

± 1 %

Gas torch with security

second gas (option)

Forced ventilation

By water in closed circuit with flow safety valve

Continuous display:

. of arc voltage

. of welding current

. of impulses of movements

4 lines of 20 characters, with 8 characters reserved to

the designation of programs

10 maximum

On memory card

Display of code number

with welding heads :

. tube/plate

. tube/tube MU* - MW - H - K, UHP

. direct use of wire feeder Polyfil

. PO motor mechanised application

Specific functions

Size L x W x H (mm)

Weight

Standard

10 MAN. PS 254 EN – Ind. 2

Possibility of connecting a manual TIG torch

As an option : possibility of controlling welding heads

with tachometer feedback

890 x 500 x 890

100 kg

EN 60974-1/EN 50199

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1.5. Safety precautions

1.5.1. General rules

All aspects of work should be planned with caution. To carry it out, safety related actions are continuously required. All hook up or maintenance operations described in this manual, which may be harmful, are always indicated by the ATTENTION symbol.

Warning Situation with the risk to

injure persons or even danger of life

Procedures to avoid malfunction or damage of equipment are indicated by the mention Note.

1.5.2. Training of the operators

One copy of the operating and maintenance manual is always delivered with the equipment. The different operators (welder, controller, maintenance people, ...) must always have at their disposal at least one spare copy (respect the copy right). The qualification they need for their work depends on the level of responsibility they carry during their mission.

1.5.3. Maintenance and adjustments

If maintenance or adjustment work has to be carried out on the upper parts of the equipment, a scaffold has to be erected. It is strictly forbidden to pull on cables or hoses to move welding heads or the power source or to push on consoles or panels.

1.5.4. Ergonomics

! Identification

Identification by means of colours, especially on safety relevant elements like buttons or pilot lamps, must not be altered or changed. Components with worn out colours have to be replaced.

! Lighting of the work area

Lighting equipment should give regular light without spots or too much light concentration. Glare-free light without deep shadows can help to avoid fatigue of the operators.

1.5.5. Protection during breakdown or

incidents

Before taking action in the case of a breakdown or incident, the machines must be disconnected from the power supply.

1.5.6. Electric disconnect or shut off

devices

! Disposition of equipment isolators

The presence of electric disconnect or shut off devices is imposed by law. In case of mobile equipment or when Polysoude supplies only a part of the entire machine, the customer is responsible to install the necessary missing devices.

! Operation of electric disconnect or shut

off devices

Before electric disconnect or shut off devices are operated, it has to be checked that this action is of no danger for operators or visitors.

1.5.7. Fire prevention and explosion

protection

The working environment for the welding machines must be free of combustible material and solvents. The PS 254 should never be used for the purpose of defrosting.

1.5.8. Protection against burns

Operators and visitors must wear protection against sparks.

1.5.9. Gases and vapors

A sufficient ventilation has to be installed in the workshop to avoid health hazards caused by gases or vapors generated during the weld process. A protection against the radiation emitted from the arc has to be worn.

MAN. PS 254 EN – Ind. 2 11

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1.5.10. Failure elimination

Only qualified electricians are allowed to work on electric or electronic equipment of the welding machines and their connection to the power supply. Directly before beginning any work, the isolation from the power supply has to be controlled.

Warning Electric or electronic devices

may be under high voltage even when disconnected from the power supply. Capacitors keep their charge during a long period of time.

It is forbidden to alter or remove safety devices from the machines. Working on electric devices is only allowed when standing on a dry floor. 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.

12 MAN. PS 254 EN – Ind. 2

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2. INSTALLATION

2.1. Preparation of the PS 254

The PS 254 is delivered in a transport protection case. You will find:

• The remote control pendant BP 1436 or

BP 1737(1).

• A ground cable 9 m (30') in length (2).

②

③

⑤

④

• A gas connection (two other ones in case

of an optional second gas) (3).

• This operating and maintenance

manual (4).

• One memo card (5).

•

①

Fig. 2.1 : Accessories of the PS 254

MAN. PS 254 EN – Ind. 2 13

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Warning Do not move the PS 254 with

a fork-lift truck if it is not place on its original pallet.

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. 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 maintained between these openings and any surface.

2.2.3. Input power connection

Warning All connections must be

made by a qualified technician respecting the

 General

safety rules given by law or quoted in this manual.

The PS 254 is connected to the main power supply with a cable of 3 conductors + ground, which comes with the machine (length 3,5 m). 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 input power requirements. For example, to work with an input voltage of 230 V, a 21 A fuse is required.

Warning It is essential to connect the

ground cable in order to ensure the safety of the operators.

Fig. 2.2 : Name plate of the PS 254 multivoltage

Fig. 2.3 : Name plate of the PS 254 single voltage

14 MAN. PS 254 EN – Ind.2

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 Input voltage taps

Do not consider this paragraph if the PS 254 has to be connected in 400 V only. 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 input power of the power source is 500 V when it is delivered to you.

Coupling is made on the terminal connection of the power transformer. Unscrew the four shackles on the top of the power source and remove the roof in order to get access. Before proceeding on any electrical part, make sure the machine is not connected to the electrical mains supply. The power transformer being three-phase, coupling has to be made in these three different points.

wire to the “+” terminal if your voltage is too high or to the “-“ terminal if it is too low. Refer to the following table to know the acceptable variations depending on connections and nominal voltage (Un).

MAXIMUM

CONNECTION

MAXIMUM VOLTAGE

MINIMUM

VOLTAGE

U Un + 10 % Un – 10%

- Un + 5 % Un – 15 %

+ Un + 20 % Un

Fig. 2.4 : Input voltage taps

The value of the mains voltage is beyond standards.

The PS 254 is designed to work with a mains voltage which can fluctuate by ± 10 % from the nominal value. If the mains voltage of your equipment is not comprised within this range, you can intervene. In the connection terminal situated near the transformer,move the "U"

MAN. PS 254 EN – Ind. 2 14 bis

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2.2.4. Connection with gas supply

Connection with the gas supply is made at the rearside of the power source with the appropriate fittings. Flow regulators should be used to adjust 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.

Gaz 1

Gaz 2 (option)

2.3. Preparation for work

2.3.1. Connection of the remote control

pendant

Connection of the remote control pendant is made with the plug on the right side of the PS 254 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 properly connected.

Fig. 2.4 : Gas connections at the right side of the PS 254

Fig. 2.5 : Connection of the remote control pendant with the PS 254

2.3.2. Connection of an MU welding head

or a TP or TS tube/tubeplate welding head

Liquid cooled welding heads of these types need to be used with the integral cooling unit.

! 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 15

Page 17

! 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 tightened, otherwise the system may not function correctly.

! Connection of the torch shielding gas

hose

Connection is made with a quick push-type self sealing 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 ).

! 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 connector (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 sealing coupling disconnect fitting situated at the bottom left hand corner of the front panel of the PS 254 (symbol

").

! Connection of a bipass plug for the

coolant circuit security for use with air cooled welding heads.

It is necessary to introduce the bipass plug to isolate the cooling circuit security in order to avoid a continuously detected fault.

Torch rotati on connection

Gas coupling

Electrode connection

Workpiece connection

Water coupling

Fig. 2.6 : Connection of an MU welding head or a TP/TS welding head

2.3.3. Connection of an air cooled closed

chamber welding head

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.

Gas coupling

Torch rotation connection

Electrode connection

Workpiece connection

Shunt supplied with H heads

Fig. 2.7 : Connection of an air cooled closed chamber welding head

16 MAN. PS 254 EN – Ind. 2

Page 18

2.3.4. Connection of a liquid cooled

closed chamber welding head

This is the case for type K and MW Astro Arc Polysoude closed welding heads.

Gas coupling

! 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 otherwise 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.

Torch rotation connection

Manual commands cable

Electrode connection

Workpiece connection

Water outlet Water retu rn

Fig. 2.8 : Connection of a liquid cooled closed chamber welding head ( for heads with integrated commands)

2.3.5. Connection of a wire feed unit

The wire feed unit is connected at the connection panel of the PS 254 (symbol ). Make sure that the securing ring is tight otherwise the system may not function correctly.

! 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 254 (symbol

").

Fig. 2.9 : Connection of a wire feed unit

MAN. PS 254 EN – Ind. 2 17

Page 19

2.3.6. Connection of a manual torch with

double command

! 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 ground cable

Connect the ground cable to the "+" terminal surrounded by a red ring. Connection is made with a quick connector, with right hand locking. 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 command cable

The command cable of the manual torch has to be joined to the socket FA 5 (Fig. 2.12).

! Connection of the coolant circuit

Connection is made by 2 quick push type self sealing couplings on the front panel (symbols and ).

! Connection of the torch shielding gas

hose

Connection is made with a quick push-type coupling located on the connection plate of the power source (symbol

" ).

2.3.7. Connection of a liquid cooled closed chamber welding head with tachometry (optional)

Adapters are mounted between every circuit from welding head and connections on power source :

• Gas circuit.

• Torch rotation.

• Electrode connection and water return.

• Workpiece connection and water outlet.

Connections of these adapters on the power source are identical with those of a liquid cooled closed chamber welding head.

Torch rotati on

Gas

Electrode connection

Water retu rn

Workpiece connection

Water outlet

Fig. 2.11 : Connection of a liquid cooled closed chamber welding head with tachometry

Gas coupling

Torch command connection

Electrode connection

Workpiece connection

Water outlet

Water retu rn

Fig. 2.10 : Connection of a manual torch

18 MAN. PS 254 EN – Ind. 2

Page 20

2.4. Controls

2.4.1. Front panel

FA 1 On/off switch. FA 2 Connection for the remote control

pendant cable.

FA 3 Connection for the rotation motor

cable.

FA 4 Connection for the wire feed unit cable. FA 5 Connection for manual torch

commands or for manual commands for MW heads.

FA 6 Connection of a second gas inlet

[backing gas] (option).

FA 7 Connection for a second gas [bac king

gas] (option).

FA 8 Connection of the torch shielding gas

inlet.

FA 9 Connection for the torch shielding gas. FA 10 Connection for the ground cable. FA 11 Connection for the electrode cable. FA 12 Coolant outlet. FA 13 Coolant return.

FA 1 FA 3

FA 2

FA 5

FA 4

FA 6

FA 7

FA 8

FA 9

FA 10

FA 11

Fig. 2.12 : Front panel

FA 12

FA 13

MAN. PS 254 EN – Ind. 2 19

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2.4.2. Synopsis

SY 1 Indicator "Printer mode".

SY 2 Indicator "Print report when weld cycle

is finished".

SY 3 Indicator "Current mode".

SY 4 Indicator "With pulsed current".

SY 5 Indicator "Forward rotation".

SY 6 Indicator "Rotation mode".

SY 7 Indicator "Pulsed rotation speed".

SY 8 Indicator "With wire ".

SY 9 Indicator "Wire pushing mode".

SY 10 Indicator "Pulsed wire speed".

SY 11 Print a program key and indicator

"Printing in process".

SY 12 Loading a program from the memo

card key and indicator "Loading in process".

SY 13 Saving a program on the memo card

key and indicator "Saving in process".

SY 14 Key to program sector positioning or

for entering the date, time and name of your company.

SY 15 Key to choose built-in programs from the machine memory.

SY 16 Keys for moving inside the synoptic.

SY 17 Keys for moving inside the synoptic.

SY 18 Keys for moving inside the synoptic.

SY 19 Keys for moving inside the synoptic.

SY 20 Key for increasing parameter values.

SY 21 Key for decreasing parameter values.

SY 22 Enter key.

SY 23 Key for deleting programs or sectors

(trash can).

SY 24 Screen

SY 25 Key operated switch "Modification

permitted or not".

SY 26 Port for memo card.

SY 27 Printer.

SY 28 Paper advance / reprint weld cycle

report.

SY 1

SY 2

SY 3

SY 4

SY 5

SY 6

SY 7

SY 8

SY 9

SY 10

SY 11

SY 16

SY 17

SY 24

SY 14

SY 12

SY 18

SY 13

SY 20

SY 19

SY 21

SY 15

SY 22

SY 23

Fig. 2.14 : Synopsis

SY 26

SY 25

SY 27

SY 28

20 MAN. PS 254 EN – Ind. 2

Page 22

2.4.3. The remote control pendant

BT 1 Selection switch - "Set up / weld". BT 2 Emergency stop button. BT 3 Indicator

Illuminated : Cycle in process. Flashing : Fault detected.

BT 4 Switch for selecting the number of a

user program.

BT 5 Push button "Start cycle". BT 6 Push button "Stop cycle with

downslope".

BT 7 Push button "Stop cycle immediately". BT 8 Push button "Increase current (+)". BT 9 Push button "Decrease current (-)". BT 10 Push button with two functions:

Out of weld cycle: Forward rotation. During weld cycle: Increase rotation speed.

BT 11 Push button with two functions:

Out of weld cycle: Backward rotation. During weld cycle: Decrease rotation speed.

BT 12 Wire start "Automatic / Manual". BT 13 Push button with two functions:

Out of weld cycle: Wire forward. During weld cycle: Increase wire speed..

BT 14 Push button with two functions:

Out of weld cycle: Wire reverse. During weld cycle: Decrease wire speed.

BT 15 Push button to start the cooling pump

"Test cooling circuit".

BT 16 Push button "Gas test".

BT 1

BT 4

BT 5

BT 7

BT 14

BT 9

BT 11

BT 16

BT 3

BT 2

BT 6

BT 12

BT 13

BT 8

BT 10

BT 15

Fig. 2.15 : The remote control pendant

MAN. PS 254 EN – Ind. 2 21

Page 23

3. OPERATION OF THE PS 254

3.1. Fundamental procedures

3.1.1. Switching on

With the installation properly connected (see chapter 2), turn the switch FA 1 to the position

1. After a short period the power source is ready to be used, the screen should be lit.

Note: The remote control must be connected to the PS 254 in order to make the power source work.

If a problem should occur, please refer to Chapter 4.2.2 "Maintenance and Troubleshooting".

3.1.2. Positioning the welding head on

the workpiece

Please read the manual supplied with each welding head before positioning a POLYSOUDE or ASTRO ARC POLYSOUDE welding head on a workpiece. Once the welding head is positioned, you can drive the electrode exactly where you want the cycle to start by using the head rotation buttons BT 13 and BT 14 on the remote control pendant. Warning : with some enclosed welding heads, the cycle can only be started with the electrode in home position.

If the switch BT 12 is in the "Auto" position, pressing one of these buttons advances (BT 8) or retracts (BT 9) the wire. This action is comprised of 2 speeds: during the first 2 seconds the wire moves at a reduced speed of 20 % of the maximum speed, afterwards it moves at 100 %. This allows both rapid and precise positioning of the wire. If the switch is in the "Manual" position, the function of the wire retract button BT 9 remains as stated above. However, by pressing the wire advance button for a first time the wire is advanced at a high speed, a second pressing of the button causes the wire to stop. This function is particularly useful when loading the wire into the wire guide sheath.

Fig. 3.2 : Remote control pendant buttons for wire positioning

3.1.4. Adjustment of the gas flow

The gas flow has to be adjusted with a flowmeter at the gas source. The push button

BT 16 energises the gas valve.

Fig. 3.1 : Buttons for manual rotation of the welding head on the remote control pendant

This action is comprised of two stages: during the first two seconds the rotation speed is reduced to 20 % of the maximum speed, afterwards the rotation speed becomes 100 %. This allows both quick and accurate positioning of the electrode. In the case of welding heads fitted with a home position contact, the manual rotation stops when the head is in the "open" position. By releasing the button and pressing it again the rotation can be continued. This command is very useful because a closed welding head

can only start in the open position.

3.1.3. Wire setting

Combined with the "Auto / Manual Wire" switch (BT 12), the two buttons BT 9 and BT 8 on the remote control pendant permit precise positioning of the wire.

Fig. 3.3 : Gas test button

3.1.5. Manual cooling system start

After changing a welding head, and particularly if you use an extension cable, it is possible that the coolant system contains some air. After the start of a cycle a fault in the cooling system can be detected (11 is the number of this error code). With the button BT 15 you can switch on the cooling circuit pump to replenish the system before starting the next cycle.

Fig. 3.4 : Push button "cooling circuit"Start pump "cooling circuit"

22 MAN. PS 254 EN – Ind. 2

Page 24

3.2. Programmation surface

General explanation of the functions

! Updating the date and time

The time and date can be entered into the memory of the PS 254. Both the time and the date then appear on any printed weld cycle report.

! Entering your company name

The name of the company can be stored in the PS 254. This name also appears on any printed weld cycle report. However, it is not stored on the memo card.

! Entering the program name

The switch BT 4 on the remote control pendant is used to select a program allocation. Furthermore, each time a program is created it can be given a name. This makes it easier later on to look for a specific program.

Warning Before the name of a

program is input, the range of current must be chosen with the SY 30 selector

The name of the program can consist of up to 8 characters. A character can be any letter of the alphabet, any number, a space, a full stop or a comma. The name is shown on the display of the power source after a program is selected, it is printed on the program lists and the weld cycle reports, and it is saved on the corresponding memo card.

! Making a program

There are two different ways to make a welding program. You can make a copy of a built-in program which already exists in the machine memory and modify it, or you can create a completely new program.

! Creating a new program

When creating a program, the dialogue will guide you by indicating when to introduce parameter values. Proposed values correspond to most regularly encountered ones in orbital welding. For a program to be created, the proposed parameters are for example:

• Forward rotation without pulsation.

• Pulsed current.

• Wire without pulsation, if the selected

range of current is 160 A.

• Without wire, if the selected range of

current is 50 A

For a list of the proposed parameter values, please refer to chapter 3.3.11. You are not obliged to enter all the choices if some of the parameters and conditions already correspond to what you require.

! Modifying a program

Outside of a weld cycle you can modify every program present in the power source's memory using the synopsis. The operating mode is the same as that for creating a program.

! Saving a program in the power source

memory

The creation and modification of programs in the memory of a PS 254 is only possible if the key operated switch «Modification authorised or not» is in the position «Modification

authorised» (symbol

). You can protect your programs by positioning the key operated switch in the "Modification not authorised"

position (symbol

) and remove the key.

! Copy and modification of an existing

program

The power source PS 254 comes with more than 60 built-in programs already stored in the machine memory. These programs correspond to the most often faced orbital welding problems. Knowing the tube material, diameter and wall thickness, you can choose a program which is similar to your application, copy it in one of the 16 user programs and modify it exactly to your requirements. A list of the 60 stored built-in programs is given in Appendix

5.1.

MAN. PS 254 EN – Ind. 2 23

Page 25

3.3. Programming

The titles of the following chapters are:

3.3.1 Entering the program name.

3.3.2 Modifying the program name.

3.3.3 Choice of a built-in program.

3.3.4 Programming and modifying the welding parameters:

- Configuration.

-Gas.

- Current.

- Rotation.

-Wire.

3.3.5 Programming of sectors:

- Creation of a sector.

- Modification of sector start position.

- Deleting a sector.

3.3.6 Deleting a program from the source memory.

3.3.7 Entering the time and date.

3.3.8 Entering/modifying the company name.

3.3.9 Saving, loading a program

- Saving a program.

- Loading a program.

3.3.10 Printing a program.

3.3.11 Programmable parameters

Explanation of symbols used

SYMBOL MEANING

Press once to

increase

Press and hold to

increase

Press once to

decrease

Press and hold to

decrease

Press once

Press and hold for at least 2 seconds

Indicator not

illuminated

Indicator flashing

Indicator

illuminated

24 MAN. PS 254 EN – Ind. 2

Page 26

3.3.1. Entering the program name

To choose the number of the program, the switch of the remote control pendant has to be used. The current range (50A/160A) is set with the key operated switch on the front panel of the power source. The key operated switch SY 26 for choosing the "modification permitted or not" mode of the machine has to be in the "modification

permitted" position (symbol

POLY SOUDE

PS 2 5 4

3.3.2. Modifying the program name

01 PARI S

01 PARIS

01 PARI S

01 P

0 1 P A

01 PARI S

01 NAR I S

01 NANTE

01 NANTES

MAN. PS 254 EN – Ind. 2 25

Page 27

3.3.3. Choice of a built-in program

The choice of a basic program is only possible after a program name is entered.

After a basic program is chosen, the reference number of a weld head must be entered to allow the machine to calculate the travel speed.

01 NANTES

01-NANTES

01 S005 . 0x1 . 0- 0 ?

01-NANTES

1 0S012.7x0.8-0?

01-NANTES

10 S012 . 7x0 . 8- 0

R30=A001

01-NANTES

10 S012 . 7x0 . 8- 0

R30=B0 0 1

^^^

01-NANTES

10 S012 . 7x0 . 8- 0

R30=B0 0 7

^^^

01-NANTES

10 S012 . 7x0 . 8- 0

R30=B0 0 7

01-NANTES

10 S012 . 7x0 . 8- 0

R30=B001

26 MAN. PS 254 EN – Ind. 2

Page 28

3.3.4. Programming and modifying the

welding parameters

3.3.4.1. Configuration

01 NANTES

MAN. PS 254 EN – Ind. 2 27

Page 29

3.3.4.2. Gas

T10 = pregas time

A short press of the key (less than one second) increases the value of a parameter by one increment.

T11 = postgas time A maintened press of the key increases the value of a parameter by one increment, then after one second the value continues to rise automatically until the key is released. The value rises by one increment until the value 9 is reached, at which point it begins to rise in units of ten and afterwards in units of hundred.

01- NANTES

T10=005 s

0 1 NANTES

T10=006s

01 NANTES

T10=01 0s

01 NANTES

T10=1 20 s

01 NANTES

T10=119s

(

28 MAN. PS 254 EN – Ind. 2

Page 30

01- NANTES

T11=005 s

01- NANTES

T11=005 s

01- NANTES

T11=005 s

MAN. PS 254 EN – Ind. 2 29

Page 31

3.3.4.3. Current

! Prefusion

I21 = prefusion current T21 = time of prefusion current.

A maintened press of the key increases the value of a parameter by one increment, then after one second the value continues to rise automatically until the key is released. The value rises by one increment until the value 9 is reached, at which point it begins to rise in units of ten and afterwards in units of hundred. Prefusion current will be graduate if selected choice is within configuration. Prefusion current will be pulsed if selected choice is within configuration and background current is within the limits : I21*I23 I22

01- NANTES

I21=090 A

01- NANTES

I21=095A

01- NANTES

T21=03. 0 s

01- NANTES

T21=02 .0 s

30 MAN. PS 254 EN – Ind. 2

Page 32

Current

I22 = pulse current T22 = time of pulse current I23 = background current T23 = time of background current

01- NANTES

I22=090 A

01- NANTES

I22=1 00 A

01- NANTES

T22=0100 ms

01- NANTES

I23=045 A

01- NANTES

T23=0100 ms

MAN. PS 254 EN – Ind. 2 31

Page 33

Downslope

N20 = start of downslope T25 = time of downslope

0 1 - NANT ES

N20=0365 D

0 1 - NANT ES

T25=05 s

0 1 NANTES

T25=10 s

32 MAN. PS 254 EN – Ind. 2

Page 34

3.3.4.4. Rotation

! Calculation of the value to program to

get a required linear travel speed

The table give a reference number R30 for the identification of every standard weld head. The reference number contains a letter and a three digit number. It has to be correctly introduced during programming to assure the proper functioning of the movements. In order to get a required linear travel speed VL for a tube diameter D, the value to program VP (V32 for single travel speed, V33 for step pulse travel speed) has to be calculated with the formula:

- VP = C*VL/D

C is a factor due to every type of weld head and given in the last column of the tables. Example :

• Weld head MW 65)C = 60 (see table

enclosed welding heads).

• Required linear travel speed VL = 152.5

mm (6 IPM).

• Tube OD D = 25.4 mm (1").

• VP = 60*152,5 mm/min: 25.4 mm (6 IPM:

1").

• VP = 360 = V32..

01-NANTES

R30=A001

01-NANTES

R30=D001

01-NANTES

R30=D001

^ ^^

01-NANTES

R30 = Reference number of the welding head

R30=D034

^^^

R30=D034

R30=D034 C

MAN. PS 254 EN – Ind. 2 33

Page 35

V32 = Smooth welding speed or pendant T22 if

pulsed rotation

01-NANTES

V32=070

01-NANTES

V32=3 60

34 MAN. PS 254 EN – Ind. 2

Page 36

! Characteristics of the welding heads

Open welding heads MU III and MU IV

Weld head

type

Minimum

diameter

(mm)

Maximum

diameter

(mm)

Reference

number

(R30)

Number of

impulses per

revolution

Factor C

(VP=C*VL/D)

MU III 16 4 16 A014 357 24

MU III 25 8 26 A028 357 48

MU III 34 20 34 A033 364 58

MU III 8/34 8 34 A033 364 58

MU III 51 25 51 A086 361 150

MU III 20/80 20 80 A073 360 127

MU III 80 32 80 A073 360 127

MU III S 80 32 80 A073 360 127

MU III 114 70 114 A100 360 174

MU III 30/114 30 114 A100 360 174

MU III S 115 17 114 A100 360 174

MU III 170 76 170 A183 359 317

MU III S 170 60 170 A183 359 317

MU III 220 102 220 A322 360 559

MU III 370 150 370 A360 360 625

MU IV 28 8 28 A024 358 41

MU IV 38 8 38 A028 357 48

MU IV 64 14 64 A040 360 69

MU IV 80 19 80 A051 361 89

MU IV 104 19 104 A062 361 108

MU IV 115 10 115 A069 362 120

MU IV 128 25 128 A082 360 142

MU IV 195 76 195 A137 360 238

MU IV 245 101.6 245 A200 360 347

MU IV 275 114 275 A197 360 342

MAN. PS 254 EN – Ind. 2 35

Page 37

Positioners Polyturn

Weld head

type

Minimum

diameter

(mm)

Maximum

diameter

(mm)

Reference

number

(R30)

Number of

impulses per

revolution

Factor C

(VP=C*VL/D)

Polyturn 11 3 180 A017 354 29

Polyturn 50 10 600 A038 356 65

Polyturn 175 35 1000 A132 360 229

36 MAN. PS 254 EN – Ind. 2

Page 38

Closed chamber welding heads with impulse generator

Weld head

type

Minimum

diameter

(mm)

Maximum

diameter

(mm)

Reference

number

(R30)

Number of

impulses per

revolution

Factor C

(VP=C*VL/D)

H 500A 3.17 12.7 B007 366 12

HD 500 P 3.17 12.7 B007 366 12

HD 750 P 4.75 19.05 B009 369 16

HD 1500 P 6 38.1 B015 364 26

K 375 a 1.6 9.5 B009 341 15

K 375 n 1.6 9.5 A016 367 28

K 875 a 3.17 22.2 B010 355 17

K 875 n 3.17 22.2 A018 367 32

K 1500 6.35 38.1 B025 362 44

K 2000 12.7 50.8 B025 356 43

K 2500 12.7 63.5 B028 360 49

K 3000 25.4 76.2 B031 363 54

K 4000 38.1 101.6 B038 359 66

K 6000-T 50.8 152.4 A110 362 190

K 7000 76.2 177.8 A200 360 347

MW40 6 40 D023 C 360 40

MW65 10 65 D034 C 365 60

MW115 10 115 D073 C 358 126

MW170 10 170 C103 C 359 178

MW1250 6 33.4 C017 369 30

MW2500 9.5 63.5 C047 358 81

MW4500 25 114.3 A119 359 206

UHP 250 1.6 6.35 D006 384 11

UHP 500 3.0 12.7 D009 360 16

UHP 1500 6.0 38.1 D023 360 40

* a : previous n : new

MAN. PS 254 EN – Ind. 2 37

Page 39

Tachometer controlled closed chamber welding heads

Weld head

type

Minimum

diameter

(mm)

Maximum

diameter

(mm)

Reference

number

(R30)

Number of

impulses per

revolution

Factor C

(VP=C*VL/D)

K 375 1/16 3/8 G018 367 32

K 875 1/8 7/8 G018 367 32

K 875 (option) 1/8 7/8 G009 367 16

K 1500 1/4 1/12 G018 367 32

K 2000 1/2 2 F037 357 64

K 2500 1/2 2 1/2 F037 357 64

K 300 1 3 F037 357 64

K 4000 1 1/2 4 F037 357 64

K 6000 2 6 G183 361 318

K 7000 3 7 G183 361 318

H 500 1/8 1/2 G018 367 32

H 750 1/8 1/4 G018 367 32

H 1500 3/16 1 1/2 G018 367 32

MW 1250 1/8 1 5/16 G018 367 32

MW 2500 1/2 2 1/2 F037 357 64

MW 4500 2 4 1/2 F073 362 127

UHP 250 A 1/16 1/4 G006 367 11

UHP 500 A 1/8 1/2 G009 367 16

UHP 1500 A 1/2 1 1/2 G018 367 32

38 MAN. PS 254 EN – Ind. 2

Page 40

Welding heads TS-TP for tube to tubesheet welding

Reference number R30 :

• Axxx * Welding heads without switch to

detect the home position.

• Hxxx * Welding heads with switch to

return to the home position after the end of the weld cycle, using the shortest way.

• Jxxx * Welding heads return to the home

position after the end of the weld cycle, in the opposite direction of the welding.

Weld head

type

TS 25 6 25

TS 73 8,5 60

TS – TP 60 8,5 60

TS 2000 10 60

Minimum

diameter

(mm)

Maximum

diameter

(mm)

Reference

number

(R30)

A014

(H014, J014)

A044

(H044, J014)

A044

(H044, J014)

A032

(H032, J032)

Number of

impulses per

revolution

359 24

364 77

357 55

SCK 20 20 C021 365 37

Factor C

(VP=C*VL/D)

MAN. PS 254 EN – Ind. 2 39

Page 41

Tachometer controlled closed chamber welding heads

Control of an external speed variator

It is possible to adjust the rotation speed of closed chamber welding heads with tachometer. Find out the code of the reference R30 for the closed chamber welding head in the table hereabove. Enter this reference code into the power source and validate. To start one revolution of the head, push the sector key SY 14. The rotation speed can be calculated by the time the weld head needs for one revolution.

Welding heads with home position switch

If the measured speed is included in a range of 9 % of the theorical speed, the speed will be automatically adjusted during weld cycles. If the speed difference is more than ± 9 %, an arrow * or + will appear on the sceen to indicate the correction to be applied on the welding head.

• In the case of an arrow * showing to the

right, increase the rotation speed by turning the potentiometer inside the welding head clockwise.

• In the case of an arrow + showing to the

left, decrease the rotation speed by turning the potentiometer in the welding head counterclockwise.

• Push the sector key SY 15 again and

repeat adjustments, if necessary, until no arrow will appear on the screen. The speed difference is now less than ± 9 % and corrections will be made automatically.

Welding heads without home position switch

After a push on the sector key SY 15, the welding head should do a whole revolution. If not the speed must be adjusted by turning the potentiometer inside the weldhead:

It is possible to control an external speed variator. There are two possibilities to program the reference number R30:

• For a time base of 1/10 seconds the letter

I followed by 0,1 s has to be introduced (R30 = I0,1s).

• For a time base of seconds the letter I

followed by 1 s has to be introduced (R30

= I1s). The weld cycle is now controlled by time (1/10 seconds or seconds) and not by the position of the welding head (impulse control). The internal clock of the power source is generating the impulse signals. To command the external speed variator, an interface (signal generation for start and direction of rotation) has to be connected to the rotation plug FA 3 of the power source.

Control of the power source by prise manual welding head

• Use of a manual torch

R30=yyyy

, Working cycle without movements and

pulsing

, Downslope , End of cycle

• Use of a welding head ♦ R30=yyyy C (MW40, MW65, MW115 and

MW170)

, Forward rotation of the head , Test gas and cooling agent , Working cycle without considering the

open position of the weld head but with the head going back to the open position at the end of the cycle

, Downslope , End of cycle

• If the rotation of the welding head is less

than one revolution, its speed must be increased by turning the potentiometer clockwise.

• If the rotation of the welding head is more

than one revolution, its speed must be decreased by turning the potentiometer

counterclockwise. Push the sector key SY 15 again and repeat adjustments, if necessary, until the rotation stops exactly after one revolution.

40 MAN. PS 254 EN – Ind. 2

♦ R30=yyyy X (other heads)

, Forward rotatio the head , Test gas and cooling agent , Working cycle considering the open

position of the head and with the head going back to the open position at the end of the cycle

, Downslope , End of cycle

Page 42

3.3.4.5. Wire

‰

R40 = Selection of wire feeder

A = Polyfil B B = Polyfil

T40 = Wire start V42 = Wire speed with unpulsed wire feeding

or wire speed during pulse current period

01-NANTES

R4 0=A

01-NANTES

R4 0=B

01-NANTES

R4 0=B

01-NANTES

T4 0=003 s

01-NANTES

S1 V4 2=200

01-NANTES

S1 V4 2=4 0 0

01-NANTES

S1 V4 2=400

MAN. PS 254 EN – Ind. 2 41

Page 43

V43 = Wire speed during background current

‰

period.

N40 = Wire stop. T41 = Wire retract.

01-NANTES

S1V4 3=050

01-NANTES

N40=360 D

01-NANTES

T41=2.0 s

01-NANTES

T41=2.5s

01-NANTES

T41=2.5 s

42 MAN. PS 254 EN – Ind. 2

Page 44

3.3.5. Programming of sectors

‰

3.3.5.1. Creation of a sector

A sector is characterized by its number (S) and the value (N) indicating the sector start position. If a sector is created, the actual values of the weld parameters are automatically transfered (that's why the programming of a sector should be completely finished before the next one is created).

The value of the parameter "N" for the actual sector must be higher than the value of the preceeding sector and lower than the value "N30" (start of the downslope). If this is not the case, the value will not be accepted.

01-NANTES

V32=2 00

Other

01-NANTES

S1 V3 2=200 S2?

01-NANTES N=0001D

S1 V32=200 S2 V3 2=200

01-NANTES N=0 1 00 D

S1 V32=200 S2 V3 2=200

01-NANTES N=0100 D

S1 V32=200 S2 V3 2=200

MAN. PS 254 EN – Ind. 2 43

Page 45

‰

01-NANTES N=0100 D

S1 V32=200 S2 V3 2=1 80

01-NANTES N=0100 D

S1 V32=200 S2 V3 2=180

01-NANTES N=0100 D

S1 V32=200 S2 V3 2=180

S3 ?

01-NANTES N=0100 D

S1 V32=200 S2 V3 2=180 S3 V3 2=180

01-NANTES N=0 1 50 D

S1 V32=200 S2 V3 2=180 S3 V3 2=180

44 MAN. PS 254 EN – Ind. 2

Page 46

3.3.5.2. Modification of sector start

‰

position

During modification, the value of parameter "N" must be between the values of the preceeding and the following sector. If this is not the case, the value will not be accepted.

01-NANTES

S1 V32=200 S2 V3 2=180

S3 V32=180

01-NANTES N=0100 D

S1 V32=200 S2 V3 2=180 S3 V3 2=180

01-NANTES N=0100D

S1 V32=200 S2 V3 2=180 S3 V3 2=180

01-NANTES N=01 3 0D

S1 V32=200 S2 V3 2=180 S3 V3 2=180

01-NANTES N=0130 D

S1 V32=200 S2 V3 2=180 S3 V3 2=180

MAN. PS 254 EN – Ind. 2 45

Page 47

3.3.5.3. Deleting a sector

C1 - NANTES N=0 1 3 0 D

S1 I 22=100 A S2I22=105 A S3 I 22=120 A

01-NANTES N=0130 D

S1 I 22=100 A S2I22=105 A? S3 I 22=120 A

Other button

01-NANTES N=0150 D

S1 I 22=100 A S2I22=120 A S3 I 22=125 A

3.3.6. Deleting a program from the

source memory

To select the program to be deleted, enter the program number with the remote control pendant.

00 PARI S

00 PARI S ?

01 NANTES N=0130 D

S1 I 22=100 A S2I22=105 A S3 I 22=120 A

POLYSOUDE

PS 2 5 4

46 MAN. PS 254 EN – Ind. 2

Page 48

3.3.7. Entering the time and date

With the key switch in the open position, and when creating or modifying the name of a program, you can also access the mode for entering or modifying the time, the date and the company name by pressing the "sector" key. By pressing the "enter" key you can change between the displays for the time, the date and the company name. You can exit this mode by pressing the "sector" key.

01 NANTES

PS 254 0->24H

20: 30 : 20 04- 08 - 96

PS 254 0->12H

08: 30 : 20pm 08 - 04- 96

3.3.8. Entering / modifiying the company

name

PS 254 0->12H

10: 31 : 20pm 08 - 24- 96

PS 254 0->12H

10: 31 : 20pm 08 - 25- 96

PS 254 0->12H

10: 31 : 20pm 08 - 25- 96

C U

PS 254 0->12H

08: 30 : 20pm 08 - 04- 96

PS 254 0->12H

1 0 : 30 : 20pm 08 - 04- 96

c PS 254

0->12H

10 30 : 2 0 pm 0 8 - 0 4 - 9 6

PS 254 0->12H

10: 31 : 20pm 08 2 5 -96

PS 254 0->12H

10: 31 : 20pm 08 - 25- 96

C U

PS 254 0->12H

10: 31 : 20pm 08 - 25- 96

CUSTOMER

PS 254 0->12H

10 31 : 2 0 pm 0 8 - 2 5 - 9 6

CUSTOMER

01 NANTES

MAN. PS 254 EN – Ind. 2 47

Page 49

3.3.9. Saving, loading a program

! Saving a program on a memo card

Each program can be saved on a memo card, 16 programs per card is possible. The procedure is described in the programming manual. A brief summary is given below.

2 possibilities :

* Saving a single program

• Check that the key switch SY 26 is in the

position "Modification authorised".

• Insert the memo card.

• Choose the number of the program to be

saved with the switch BT 4 on the remote

control pendant.

• Press the transfer button to save the

information on the memo card

(symbol ).

• If the name of the program to be saved

already exists on the memo card, the

name of this program is displayed with a

question mark.

• If you validate the saving with the button

SY 23, the program which has been stored

on the memo card will be replaced by the

new one. The indicator corresponding to

the saving function will illuminate. Wait for

the indicator to extinguish before removing

the memo card.

• If the memo card is full, the error code !77

! is shown on the display SY 25.

* Saving several programs

• Check that the key switch SY 26 is in the

position "Modification authorised".

• Insert the memo card.

• Press the transfer button to save the

information on the memo card

(symbol ).

• Press the button « plus » (symbol ),

the characters 0 -> 15 ? are shown on the

display. The button «minus »

(symbol ) enables to come back to the

loading function of a single program.

• If you validate the saving with the button

SY 23, all the programs which are in the

memory of the power source

will be saved and the indicator corresponding to the saving will illuminate. Wait for the indicator to extinguish before removing the memo card.

If, during the transfer, a fault is detected, the operation is stopped and an error code is shown on the display of the PS 254. Refer to Appendix 3 and Chapter 8.5 for the error codes and corrections to be made. The program name is stored on the memo card together with the program. However, the number under which it is stored in the PS 254 is not saved. You can load the program under a new number or in another power source. A label on each card allows you to write manually any information which you deem to be useful.

! Loading a program from a memo card

To load a program from a memo card, the procedure is as follows:

*2 possibilities :

* Loading of a single program

• Insert the memo card.

• Choose the number you wish to give to the

program with the switch BT 4 on the remote control pendant. This number cannot already be attributed to another program, but can correspond to a program that you wish to replace.

• Press the button to load a program from

the memo card (symbol ).

• The first program stored on the memo

card is indicated on the display SY25.

• The keys SY 17 and SY 19 are used to

scroll up or down the programs.

• Validate the transfer by pressing . The

corresponding indicator will illuminate.

• Wait for the indicator to extinguish before

removing the card.

Warning If the program that is

registered in the card is not compatible with the SY 30 selected range of current, it will not be loaded up and !75! error code is displayed on the screen.

48 MAN. PS 254 EN – Ind. 2

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* Loading of all the programs

• Insert the memo card.

• Press the button to load a program from

the memo card (symbol ).

• Press the button « plus » (symbol ),

the characters 0 -> 15 ? are shown on the

display. The button « minus »

(symbol ) enables to come back to the

loading function of a single program.

• Validate by pressing the button . The

corresponding indicator will illuminate.

• Wait for the indicator to extinguish before

removing the memo card.

pulsed speed rotation) or V42 parameters with the "Delta" buttons. The modification values of the delta buttons cannot be changed by the user. It depends on the value of the parameter which is being acted upon. The table below gives the relationship between the parameter value and the correction made by each press of the delta button. When a delta button is used, the value of the parameter concerned is displayed during 5 seconds on the front face of the PS 254.

Wire feeder rotation speed :

! Deleting a program from the memo card

• Check that the key switch SY 26 is in the

position « Modification authorised ».

• Insert the memo card.

• Press the button « trash » (symbol ), the

name of the first program stored on the

memo card is shown on the display.

• The keys SY 17 and SY 19 are used to

scroll up and down the program you wish

to delete.

• Validate the transfer by pressing . The

corresponding indicator will illuminate.

• You can cancel the suppression of a

programme by pressing again the button

« trash ».

3.3.10. Printing a program

To print a program from a memo card, the procedure is as follows:

• With the switch BT 4 on the remote control

pendant, choose the number of the

program to print.

• Press the print button (symbol ).

• Validate. The printing indicator is

illuminated.

• After the printing is finished, this indicator

will extinguish.

• Modifications of the values of weld

parameters can be done in two different

modes, one during development of a weld

procedure and the second in production.

! Modifying the parameters before

starting a program

To select this mode, turn the key operated switch SY 26 to the "Modification authorised" position (symbol ). The key can be removed afterwards. In this mode you can increase (+) or decrease (-) during the weld cycle the values of the I22, V32 (for no-pulsed speed rotation), V33 (for

Value of parameter Delta

<= 99

100 - 199 2

200 – 299 3

300 – 399 4

400 – 499 5

500 – 599 6

600 – 699 7

700 – 799 8

800 – 899 9

900 – 999 10

All actions on the delta buttons are taken into account (within the parameter limits) and stored in the memory of the relevant sector. After moving from one sector to another, the corrections made in the preceding one are carried through to the next. The modifications are not forgotten or lost. The number of deltas in this mode is not limited.

! Modifications made during the weld

cycle

To access the production mode, the key operated switch SY 26 has to be turned to the "Program modification not authorised" position (symbol ). The key can be removed afterwards to avoid unauthorised modifications being made to the programs. This mode includes two differences:

• The number of deltas per parameter is

limited to 10 (10 increments or 10 decrements)

• The modifications are not stored in the

memory.

MAN. PS 254 EN – Ind. 2 49

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For program version L633 5.0 onwards, if the last character (the eigth) of the program name consists of a dollar symbol ($), no modification of the welding parameters by the remote control pendant is possible.

! Fault detecting during cycle

During every welding cycle, important parameter values are monitored periodically at different delicate points. When a fault is detected, an immediate stop or a stop with downslope is initiated depending on the seriousness of the fault. The fault is indicated by a flashing light on the remote control pendant. An error code will also appear on the display of the PS 254. Appendix 5.2 gives the error codes, their meaning and their consequences. We advise you to take careful notice as to which error code is shown. This can make maintenance or repair work easier and highly efficient.

3.3.11. Programmable parameters

For each parameter, the following table shows:

• The synoptic reference (Ref.).

• The corresponding name.

• The maximum value programmable.

• The minimum value programmable.

• The increment value that will be added or

taken away when the buttons « + » or « - » are pressed on the synoptic.

• The default value proposed during the

creation of a new program.

• The units used. In each column, the

abbreviations stand for:

A Amperage. V Voltage. D Movement. /M A thousandth of the maximum value. s A second. ms A millisecond.

50 MAN. PS 254 EN – Ind. 2

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REF DESIGNATION MAX. MIN. OUTPUT INCREMENT

DEFAULT

VALUE

Gas

Current

Rotation

T10 Pre-gas time 320 1 s 1 5

T11 Post-gas time 320 1 s 1

I21 Prefusion current

T21 Prefusion time 30 0,1 S 0,1 3

I22 Pulse current

T22 Pulse time 9999 10 Ms 1 100

I23 Background current

T23 Background time 9999 10 Ms 1 100

N20 Downslope 9999 1 D 1 365

T25 Downslope time 60 1 S 1 5

R30

Welding head

reference

200

2A 1 90

100

200

2A 1 90

100

200

2A 1 45

100

See pages 35 to 39

Wire

V32 Rotation speed (high) 999

V33 Rotation speed (base) 999

T40 Delay for wire start 40 0 S 1 3

V42 Wire feed speed (high) 999

V43

N40 Wire stop 9999 1 D 1 360

T41 Delay for wire retract 9,9 0 S 0,1 2

Wire feed speed

(base)

999

then 0

/M 1 70

/M 1 50

/M 1 200

MAN. PS 254 EN – Ind. 2 51

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3.4. Execution of a weld program

3.4.1. Safety precautions

Warning Before starting any

manipulation on the equipment please refer to chapter 1.2 "Safety precautions".

3.4.2. Choosing the program to be

executed

The program to be executed is selected with the switch BT 4 on the remote control pendant. You can check the name of the program on the display of the PS 254. If only "POLYSOUDE PS 254" appears, you have selected the number of a user program place where nothing is stored in the memory of the PS 254. If !75! is displayed on the screen, the right range of current is not selected.

3.4.3. Simulation

After the correct program has been selected, you can run a simulation without affecting the workpiece to be welded. In this case, all the functions of the selected program are carried out except those concerning the arc and the coolant circuit.

The gas controls are executed but the flow rates are not considered. So it is possible to check flow adjustment or reduce gas consumption during the simulation. The choice between a simulated or a real weld cycle is made with the switch BT 1 on the remote control pendant.

3.4.4. Weld cycle

! Starting the weld cycle

The weld cycle is initiated by pressing the button BT 5 on the remote control pendant. The indicator BT 3 becomes illuminated when the cycle starts. If for the selected number a program does not exist in the memory of the PS 254, no cycle will be started and the indicator will flash. The flashing can be turned off by pressing any button on the remote control pendant.

Fig. 3.7 : "Start cycle" button

! Modification of a weld cycle

Parameter values can be modified during the weld cycle with the remote control pendant. The values of the modifiable parameters in each sector are:

• The current or maximum current in the

case of pulsed current (I22).

• The rotation speed (V32) or low rotation

speed in case of pulsed rotation (V33).

• The wire speed or the high wire speed in

the case of pulsed wire (V42).

BT 14

BT 9

BT 11

BT 13

BT 10

Fig. 3.8 : "Delta" buttons for modifications of parameter values

Fig. 3.6 : "Set up / weld" selector switch

52 MAN. PS 254 EN – Ind. 2

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3.4.5. End of welding cycle

! Normal end of welding cycle

In the case of a normal end of the welding cycle, the indicator on the remote control pendant extinguishes. The power source is now ready to start a new cycle.

N.B.: welding head that is fitted out with an "open head" position sensor will be automatically positioned in this way at the regular end of a cycle.

! Weld cycle report

At the end of every weld, you can print a weld cycle report indicating periodically the real values of the main weld parameters. This listing is provided automatically if preprogrammed. After a weld cycle in simulation mode, no weld report can be given. The weld cycle report consists of:

• The name of your company.

• The program name.

• Values of periodically taken

measurements of the voltage, amperage, rotation speed and wire speed during the cycle.

• Reason for stop ("OK" for a normal cycle

end, if not, error code).

• Time of cycle start.

• Date of weld.

• Length of cycle.

• Tungsten location.

! Reprint of a weld cycle report

Fig. 3.9 Fig. 3.10

If the printout of a weld cycle report fails, for example because of a lack of paper, it is possible to restart it by pushing the switch SY 29 situated at the right of the printer upwards.

Fig. 3.9 : Example of a weld cycle report with manual downslope, denoted by error code >>>> ! 52 ! <<<<

Fig. 3.10 : Example of a weld cycle report with a normal cycle end, denoted by >>>> ! 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 53

Page 55

downslope sequence. This function provides the workpiece as much as possible from being damaged. The indicator will flash because this is not a regular cycle end.

Fig. 3.12 : Manual downslope button

! Immediate cycle stop

When the stop button BT 7 of the remote control pendant is pressed, the arc and all movements are stopped immediately. The shielding gas is maintained during the programmed post gas period T25. The indicator will flash because this is not a regular cycle end.

The arc is struck by pressing the manual command button. The weld current value is equal to the programmed ignition current. If you release this button, the high current value I22 is applied. If you press this button again, the low current I23 will be used. The next release restarts the high current and so on. The cycle stop is made either by pressing on the downslope button, or for an immediate cycle stop, by pressing on both ends of the manual command button.

Fig. 3.13 : Immediate manual stop button

! Emergency stop

The remote control pendant is fitted with an emergency button BT 2. By pressing this button, the PS 254 is immediately disconnected from the mains power supply. The weld, the movements and the gas flow are stopped suddenly.

This function may cause serious damages to the workpiece and equipment. Polysoude advises you, if possible, to choose a stop with the downslope button or with the immediate stop button.

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.

54 MAN. PS 254 EN – Ind. 2

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4. SERVICING, MAINTENANCE AND TROUBLESHOOTING

4.1. Servicing

4.1.1. Adjustments

! General

The expression calibration is defined by regulating standards and is used when the generator has to meet special requirements, for example Quality Assurance or ISO 9000 quality system. Calibration needs specific testing equipment and procedures: we can perform it on special request, in your company or in our workshop. Following informations concern routine adjustment that you can perform, outside these cases, as frequently as you think it advisable, for example as it is said further.

! Necessary equipment

To be able to make adjustments, it is recommanded to have at your disposal:

• A voltmeter.

• A shunt or any other means of measuring

continuous current of a current at least

equal to 200 A and of the class 0.2.

• A TIG (GTAW) welding torch of a sufficient

capacity.

• A resistance of 2 Ω/200 W.

! How to adjust?

Before carrying out a regulation check, leave the generator switched on for approximately 15 minutes. This will allow the generator to reach its normal working temperature. If this is not done, the adjustments that you make will be altered because of the rise in temperature during a normal cycle. To access the cards, remove the front panel of the generator. It will also be necessary to bypass the short circuit security of the inverter unit. To do this, put the switch S3/2 of the 21700633 card and the switch S1/4 of the 21700634 synoptic card to the CLOSED position.

Warning After the adjustments have

been made put the switches to the "OPEN" position, otherwise the short circuit security system of the generator will not work properly.

! When to adjust?

A drift may occur with time ; it results from ageing of components. So we recommend you to check power source adjustments on an average of one year.

! Exchange of cards or the inverter unit

The 21700633 sequencer card and the 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 55

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F ig. 4.1 : Inverter switch S3/2 for shunt circuit security system of monitoring welding current in « CLOSED » position for adjustments (sequencer card)

S32

Fig 4.2 : Inverter switch S1/4 in « CLOSED » position (21700634 synoptic card)

S14

56 MAN. PS 254 EN – Ind. 2

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4.1.2. Adjustment of the inverter unit

! Verification of the current reference

signal

The current reference signal is generated on the sequencer card (217 00 633). The signal is adjusted in the factory, for readjustment please contact the Polysoude after-sales service.

A Move the key-operated switch on the

programming board at the front side to the 160 A position.

B Connect a voltmeter between TP21 0

V analog and the test point TP27.

C Introduce a program without

pulsation with a current of 160 A.

D Start a weld cycle with the switch

"Set up/Weld" in the "Set up" position. The voltage read must be 10 V. If not, use the potentiometer T9.

E Start a new cycle with a current

programmed at 4 A. Now the voltage read must be 0,25 V. If not, use the potentiometer T10.

F Repeat operations D and E until the

set-up is correct.

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 57

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! Regulation of the current

As long as the settings are correct, the current is rated by the TRDC2 card of the generator. To gain access, remove the panel on the right side of the generator. To measure the current, use a shunt of 300 A / 300 mV class 0.2. The values given below correspond to this type of shunt.

A Insert the shunt into the ground cable

and connect a root mean square voltmeter. Use a torch capable of supporting 200 A.

B Start a cycle "with arc" without

pulsation, with a programmed current of 200 A. The value read must be 200 mV, if not, use the potentiometer P5 to adjust it.

C Start another cycle with a current of 10

A. The value read must be 10 mV. If not, use the potentiometer P4 to adjust it.

D Repeat operations B and C until the

setup is correct.

The other potentiometers of the generator are factory regulated. Please do not modify them.

Fig. 4.4 :Potentiometers for the regulation of the current (interface card 2170069)

58 MAN. PS 254 EN – Ind. 2

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! Regulation of the measured current

voltage

The adjustment of the measured current voltage is done on the card 217 00 636 after a correct setup of the inverter unit. In order to verify the supplied current, you can insert a shunt between the power source and the torch.

A Connect a voltmeter between the test

points TP3 (0 V) and TP1.

B Connect a torch capable of supporting

200 A.

C Start a "with arc" cycle without

pulsation, with a current of 200 A. The value read must be 4 V. If not, adjust it with the potentiometer T3.

D Start another cycle with a current of 10

A. The value read must be 0.2 V. If not, adjust it with the potentiometer T4.

E Repeat operations C and D until the

setup is correct.

Fig. 4.4: Potentiometer for adjusting the current voltage measurement

MAN. PS 254 EN – Ind. 2 59

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! Adjusting the contrast and brightness

of the display

These adjustments are made on the 21700634 synoptic card. The contrast adjustment is made with potentiometer T1, and the brightness adjustment with potentiometer T2.

Fig. 4.5 : Adjusting the contrast and brightness of the display (synoptic card

21700634)

60 MAN. PS 254 EN – Ind. 2

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4.1.3. Adjusting the rotation speed of

welding heads with tachometry (optional)

! Regulation of tacho card 21700647

A Select the G009 factor of R30

parameter.

B Connect a power supply adjustable

from 0 V to 10 V between pins J (+ of the power supply) and F (0 V of the power supply) of rotation plug FA3.

C Connect a frequency measurer

between the test points TP5 and TP8.

D With 10 V from power supply, adjust

potentiometer T4 to read a frequency of 1100 Hz.

E With 1 V from power supply, adjust

potentiometer T1 to read a frequency of 110 Hz.

F Repeat operations D and E until the

set-up is correct.

G Connect a power supply adjustable

from 0 V to 10 V between pins J (0 V of the power supply) and F (+ of the power supply) of rotation plug FA3.

H Connect a frequency measurer

between the test points TP5 and TP8.

I With 10 V from power supply, adjust

potentiometer T2 to read a frequency of 1100 Hz.

J With 1 V from power supply, adjust

potentiometer T3 to read a frequency of 110 Hz.

K Repeat operations I and J 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 61

Page 63

4.1.4. Coolant

Please make sure that the coolant level in the reservoir of the power source is always maintained. We advise you to change the coolant once a year. Pump out the used liquid by connecting a hose to the coolant outlet (symbol ) and press the button BT 15 (symbol )on the remote control pendant. Pure, clean water should be used for rinsing the cooling circuit. The refilling of the coolant reservoir is made by the top of the power source. NOTE : Only use coolant recommended by Polysoude. The use of any other coolant will void any warranty commitment.

Fig. 4.8 : Change of paper roll

! Change of ribbon

To change the ribbon in the printer, you have to open the cover (unscrew the 2 screws). The ribbon is situated below the printer block. Press on «PUSH» to take it out. To insert a new ribbon, push it slightly to the top when inserting it. Insert the paper into the slot of the cover before closing it.

Fig. 4.7 : Coolant inlet

4.1.5. Printer

! Loading paper to the printer

The paper has to be loaded with the power source turned on. To change the paper roll, you have to open the cover (unscrew the 2 screws). Take out the empty roll and insert the end of the new paper roll into the printer. 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.

62 MAN. PS 254 EN – Ind. 2

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4.2. Maintenance and

troubleshooting

4.2.1. Replacing fuses

Warning A fuse blowing out indicates

in most cases a problem somewhere in the electrical installation. You must resolve the problem before replacing the fuse. Be careful when switching on the machine after you change a fuse.

You will find the fuses in four areas:

• The sector fuses F1, F2, F3 are situated in

the main divider. To access this, you need to remove the left side plate of the generator, after having already removed the roof.

• The fuses protecting the secondary

transformer (FU1 - FU7) can be found on the top level and are accessible just by removing the roof of the generator.

• Two fuses RF1 and RF2 are situated on

the relay card WK-3 A2 and another one is located on the +12V/ +5V power supply card.

Fig. 4.14: Location of the fuses

MAN. PS 254 EN – Ind. 2 63

Page 65

4.2.2. Trouble shooting

! Noted defect when operating

defect cause What to do

Impossible to switch the power source on

The power source is working while the main switch is in the Off-position The power source is switche off when the weld starts The weld cycle or an axis (rotation, wire, gas, cooling circuit) start by themselves

Some of the buttons on the remote control pendant don't work The program number on the display does not correspond with the number chosen on the remote control pendant Some programs are deleted from the memory of the power source

- Fuses F1, F2, F3, F4 or FU 3 defect

- Mains supply interrupted

- Plug, cables or connections defect

- Remote control pendant BP 1436 defect (emergency stop button pushed) or not connected

- Relay K1 defect or not connected

- Main switch defect

- Wrong choice of input voltage

- +12 V modul defect

- Card 217 00 634 defect

- The mains supply cable is connected to the wrong contact

One phase of the mains supply is interrupted - Check and correct

- The power source is not connected to the ground

- Remote control pendant BP 1436 defect

- Shielding of the remote control pendant cable is

damaged

- Card 217 00 634 defect

- Remote control pendant defect

- Synoptic card 21700634 defect

- - Remote control pendant BP 1436 defect

- Card 217 00 634 defect

- Wrong action (programs deleted with the button SY

23)

- Card 217 00 633 has been replaced

- RAM memory on card 217 00 633 defect

- Change (§. 4.2.1)

- Check

- Check and repair

- Check and change or repair

- Check and change

- Check and correct (§ 2.2.3).

- Replace

- Check and correct

- Make a connection

- Check and change or repair

- Replace cable

- Replace

- Check and repair or change

- Replace

- Check and change or repair

- Replace

- Reload the programs

- Replace RAM memory

64 MAN. PS 254 EN – Ind. 2

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defect cause What to do

Some parameters stored on the memocard have been altered Impossible to modify values of weld parameters (buttons ""+"" and ""-"" are not working) Some buttons of the programming keyboard don't answer Display dark - electric supply card + 5 V defect

Impossible to start a weld cycle (the indicator LED on the remote control pendant is flashing) Impossible to start a weld cycle with a manual torch

Distortion of the display during ignition of the arc Poor gas flow - gas conduit inside the welding head clogged

Any rotation movement (welding head) or wire feeding, any error message appears

- Memocard defect - Use new memocard to store

- - Key-operated switch SY 25 in position

""modification not allowed""

- keyboard defect

- card 217 00 634 defect

- RAM memory on the card 217 00 633 defect

- Fuse FU 1 or FU 2 defect

- wrong wiring of the cable connection of the manual toch

- card 217 00 633 defect

- wrong wiring of the cable connection of the manual toch

- card 217 00 633 defect

- electric supply card + 5 V defect - check fuse and change

- gas flowmeter defect

- solenoid gas valve defect

- shear pin broken - replace shear pin (see operation

programs

- Put the switch in the ""modifications allowed"" position

- can only be checked by a

qualified electrician

- change card

- check fuse and change

- change card or RAM memory

- Check and change

- check program number (§ 3.3.1)

- check and change

- change card

- check and clean

- can be checked only by a

qualified specialist

- can be checked only by a

qualified specialist

manual of the welding head or wire feeder for details)

MAN. PS 254 EN – Ind. 2 65

Page 67

! Display of an error code

Error

code

11 or 12

Possible causes What to do

- Shielding gas cylinder empty or valve closed.

- Poor connection of the shielding gas coupling.

- Fuse F 1 on card WK-3 defect.

- Solenoid valve defect.

- Level of cooling liquid low.

- Hoses of the cooling circuit buckled or knotted, filter clogge.

- Fuse F 2 on card WK-3 defect.

- Shunt for cooling circuit security not mounted (use of air cooled welding heads only).

- Quick gas coupling of the welding head not fastened.

- Pump defect.

- Hose bundle defect (welding heads MU).

- Weld current cable poorly connected or interrupted.

- Bad position of the ground cable.

- Wrong gas flow adjustm ent.

- Electrode polluted or distance workpiece / electrode too high.

- Hose bundle defect (welding head MU).

- Ignition aid defect or in wrong position (welding heads MU, TP, TS...).

- Wrong shielding gas (He).

- Power source poorly adjusted.

- Electrode tip poorly ground or worn out.

- Distance workpiece / elektrode wrong.

- Poor shielding gas protection.

- Programmed weld current too low, when the arc starts.

- Ignition aid defect or in wrong position (welding MU, TP, TS...).

- Electrode has touched the workpiece.

- Electrode has touched the filler wire.

- Ignition aid defect or in wrong position (welding MU, TP, TS...).

- Lack of insulation between welding head and wire guide support.

- Card 217 00 633 defect.

- Inverter unit defect (card TRDC2).

- Check and change or open.

- Check and connect properly.

- Check and change (§ 4.2.1).

- Can be checked only by a

qualified specialist.

- Check and correct.

- Keep in proper conditions.

- Check and change (§ 4.2.1).

- Refer to §2.3.3 to make

connections properly.

- Check and connect properly.

- Can be checked only by a

qualified specialist.

- Change.

- Check and change.

- Deplace ground cable (refer to§

3.2.3 or 2.3.7).

- Check.

- For correct electrode settings,

refer to operating manual of the welding head.

- Change.

- Position ignition aid correctly.

- Try argon.

- Can be checked only by a

qualified specialist.

- Refer to operating manual of the weld head for correct set up and change of the electrode.

- Correct.

- Check gas flow, clean or

change gas lens.

- Correct.

- Change or correct position.

- Correct

- Change the position of the wire

inlet move

- Move

- Check and correct

- Replace

- Call After Sales Service

66 MAN. PS 254 EN – Ind. 2

Page 68

Error

Possible causes What to do

code

25 - Mains input voltage too high.

- Phase failure of the mains input.

- Settings of input power jumpers wrong.

- Fuse S1 or S2 of the inverter unit defect.

- Inverter unit defect (Karte TRDC2).

- Card 217 00 633 or card 217 00 636 defect.

26 - Mains voltage too low

- Phase failure of the mains input.

- Settings of input power jumpers wrong.

- Fuse S1 or S2 of the inverter unit defect.

- Inverter unit defect (Karte TRDC2).

- Card 217 00 633 or card 217 00 636 defect.

27 - Too much power required from the power source.

- Constricted air circulation.

- Settings of input power jumpers wrong.

- Phase failure of the mains input.

- Fuse S1 or S2 of the inverter unit defect.

- Inverter unit defect (Karte TRDC2).

- Card 217 00 633 or card 217 00 636 defect.

- Fan defect.

28 - Phase failure of the mains input.

- Settings of input power jumpers wrong.

- Fuse S1 or S2 of the inverter unit defect.

- Inverter unit defect (Karte TRDC2).

- Card 217 00 633 or card 217 00 636 defect.

29 - Phase failure of the mains input.

- Settings of input power jumpers wrong.

- Fuse S1 or S2 of the inverter unit defect.

- Polygaine hose bundle defect (welding heads MU).

- Wrong position of switch S3/1 on the card 217 00 633.

- Poor adjustment of the power source.

30 Wrong reference number R30 for the identification of the welding head

programmed.

- Problems caused by friction or jamming of the weldinghead or wire

30 or 40 31 or 41 - Problems caused by friction or jamming of the weldinghead or wire

32 or 42 - Fuse FU 7 defect

feeder.

- Fuse FU 4 defect.

- Card 217 00 633 defect.

- Impulse generator of the welding head or wire feeder defect.

- Bad cable connection between the power source and the motor.

- Card 217 00 633 defect.

- Transformer T1 defect.

- Check and modify the

connection cable position of the transformer inside the power source.

- Check and correct.

- Correct.

- Check and correct.

- Can be checked only by a

qualified specialist.

- Change.

- Check and modify the connection cable position of the transformer inside the power source.

- Check and correct.

- Correct.

- Check and correct.

- Can be checked only by a

qualified specialist.

- Change.

- Respect duty cycle of the power

source (§ 1.3.2).

- Watch for minimal distance

between the power source and surrounds (§ 2.2.2).

- Correct.

- Check and correct.

- Can be checked only by a

qualified specialist.

- Change.

- Check. The fan can be changed

only by a qualified specialist.

- Check and correct.

- Correct.

- Check and correct.

- Can be checked only by a

qualified specialist.

- Change.

- Check and correct.

- Correct.

- Check and correct.

- Change.

- Check and correct.

- Adjustments can be carried out

only by a qualified specialist.

- Correct.

- Check and remove dirt and

foreign parts.

- Check and remove dirt and foreign parts.

- Change.

- Check and change.

- Can be checked only by a

qualified specialist.

- Change.

- Can be checked only by a

qualified specialist.

MAN. PS 254 EN – Ind. 2 67

Page 69

Error

Possible causes What to do

code

51 - No ground connection of the power source.

- Remote control pendant BP 1436 defect.

- Shielding of the cable of the remote control pendant BP 1436 defect.

- Card 217 00 634 defect.

52 - Phase failure of the mains input.

- Fuse S1 or S2 of the inverter unit defect.

- Remote control pendant BP 1436 defect.

- Card 217 00 633 or card 217 00 634 defect.

53 - Kurzzeitiger Netzspannungseinbruch.

- Karte 217 00 633 defect.

a) Closed welding heads of the MW, H or UHP type:

- Welding head is not in the home-position.

56 - Memo card upside down in the card reader.

60 - Printer defect

62 - After the end of the last weld cycle, the power source has been

70 - Memo card is not introduced into the card reader SY 26.

71 Memo card has been removed from the card reader before the end of

72 - The card 217 00 633 has been changed. - Choose with the switch BT 4 for

73 - Any program stored on the memo card.

74 - Load from a memo card that has been removed from the card reader

- Limit switch of the welding head defect or badly adjusted. b) Welding heads of other types (without tacho):

- The pins D and E of the rotation motor cable are not short-circuited in the plug connector. c) All types of welding heads:

- Card 217 00 633 defect.

- Wrong reference number R30 for the identification of the welding head programmed.

- Flat cable for the connection between card 217 00 633 and card 217 00 634 defect or loose.

- Switch S1/1 on the card 217 00 634 in the wrong position.

- 21700634 card defect

turned off and on again.

- The program number (YY) used for the weld cycle is different from the program number (XX), which is actually chosen.

- Memo card is not introduced correctly into the card reader SY 26.

the storage.

- Memo card introduced in the wrong way into the card reader SY 26.

before the end of the storage.

- The program stored on the memo card comes from a different tye of power source.

- Correct.

- Check.

- Replace cable.

- Change.

- Check and correct.

- Check.

- Change.

- Prüfen und Schweißstromquelle erneut einschalten.

- Austauschen.

- Turn welding head in the homeposition.

- Check and change or correct.

- Correct.

- Change.

- Correct.

- Watch for right position if you

introduce a memo card.

- Change or correct.

- Check and call for

maintenance.

- Replace

- Change

- Operate a new weld cycle.

- Choose program number YY

and restart printing of the weld cycle report with the switch SY

28.

- Introduce memo card.

- Remove the memo card and

introduce it correctly.

Repeat storage (before removing the memocard, wait until indicator SY 13 becomes dark).

selecting the program number all numbers from 0 to 15 one after another.

- Use memo card with a program stored on it.

- Remove card and introduce it correctly into the card reader SY

26.

- Use a new memocard.

- - Use only programs made for a power source PS 254.

- The position of the switch S3/1 or S3/4 on the card 217 00 633 is wrong.

- Set switches to the ""OPEN"" position.

68 MAN. PS 254 EN – Ind. 2

Page 70

4.2.3. Spare parts ( See “summary spare parts” pages 84/85)

Désignation Repère Référence Ribbon for printer 25 00590064 Printer 26 00629078 Paper for printer 27 00590066

Fig. 4.16 : Front view

Désignation Repère Référence Remote control pendant 14360000 Remote control pendant plug 28 00563085 Câble télécommande complet 29 14369999 Toggle switch for pendant 30 00542006 Grey remote control pendant button 31 00549067 Red remote control pendant button 32 00549065 Black remote control pendant button 33 00549066 Emergency stop button 34 00542070 Red cover for emergency stop button 35 00542071 Coding wheel 36 00543016 Interconnection card 37 21700627 Coque caoutchouc pour télécommande 38 17375299

34,35

MAN. PS 254 EN – Ind. 2 69

Page 71

Fig. 4.17 : Remote control

Désignation Référence Ground cable 64599801 Flowmeter Argon 75501002 Flowmeter Argon/Hydrogen 71701421 Cooling liquid 75110071 Fuses 75501207

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 1737 xx xx) as well as to the sequencer card (Ref. 217 00 633), the synoptic card (Ref. 217 00 634), the source interface card 217 00 690, the memory circuit interface card (Ref. 217 00

680), and the interface tacho-impulses (Ref. 217 00 647). The signals are described by an abbreviated name corresponding to their function. It is useful to recognise that a signal preceded by a bar " / "signifies that it is active at the low level (0 V). The numbers inscribed at the bottom right of the synoptic blocks relate to the folio numbers of the corresponding dossiers. For example, the number 08 in the block "Gas control" of the sequencer card corresponds to folio 08 of dossier number 21700633.

! The power switch

The power switch consists of a self holding switch K2. When the power is turned on, the K2 switch is activated. It then remains in this state until the power is turned off (K1 is activated). K1 is directly linked to the emergency stop button via the synoptic card (folio 21700634). The loss of voltage or the pressing of the emergency stop button activates K1, which immediately cuts off the power supply. To restart the weld cycle you must turn on the machine again with the power switch. This system has been designed for safety reasons.

! General presentation and wiring

scheme

The functioning of the PS 254 is principally controlled by 2 cards: the 21700633 sequencer card and the 21700634 synoptic card. These two cards are linked together by a data bus I²C. This connection is built up via the memory circuit interface card 217 00 680. The sequencer card ensures the correct follow up of weld cycles by the power source. It is linked to the power supply, the rotation motor, the wire feed motor, and watches for the correct functioning of the gas valves and the cooling circuit. The microchip is also found on this card. The synoptic card, controlled by the sequencer card, controls the peripheral units (keyboard, indicators and display screen), the memo card, the remote control pendant and the printer.

70 MAN. PS 254 EN – Ind. 2

Page 72

Fig. 4.18 : Wiring scheme of PS 254

MAN. PS 254 EN – Ind. 2 71

Page 73

! The sequencer card (21700633)

The sequencer card includes several block functions:

• Central program unit (CPU) composed

principally of the microchip and the memory.

• Power control.

• Rotation motor control, based on the

principle of PWM (Pulse Width Modulation).

• Wire motor control, identical to the control

of the rotation motor.

• Shielding gas control.

• Coolant control.

• Interface with the manual torch

• Interface with the I²C bus for the external

links and especially with the synoptic card.

• Power supplies.

Fig. 4.19 : Sequencer card

72 MAN. PS 254 EN – Ind. 2

Page 74

! The synoptic card (21700634)

The synoptic card interfaces with the following peripheral units:

• Remote control pendant.

• Programming keyboard.

• Synoptic on the front panel.

• Display on the front panel.

• Printer.

• Memo card.

It is controlled by the sequencer card via an I²C link. The interface with the remote control pendant is made by constantly checking the state of the buttons with a line and column system. By successively activating the different lines and testing the columns it is determined which buttons or switches have been activated. The stop command BT 7 is linked directly to the sequencer card, without passing via the I²C bus. The emergency stop button BT 2 on the remote control pendant is linked also to the power on/off switch. This ensures the safety of the users in the case of a cycle stop or an emergency stop. The programming keyboard is based on the same principle. Only the key switch "Modification authorised or not" has a direct link. The interface with the synoptic indicators is made by multiplexing. The indicators are not permanently supplied with power, but instead by a signal (multiplexing supply) which has a frequency of several hundred Hertz. The contrast and brightness of the screen is controlled by the synoptic card. 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. The card is thus protected from overloads during its insertion and its removal.

MAN. PS 254 EN – Ind. 2 73

Page 75

Fig. 4.20 : Synoptic card

74 MAN. PS 254 EN – Ind. 2

Page 76

! The source

The power command, generated by the sequencer card, is an analogical signal 0 to 10 V. At 10 V, it corresponds to 160 A, and at 0 V it corresponds to the minimum current of the source, 4 A, for the 160A range; at 10 V it corresponds 50 A, and at 0 V it corresponds 4 A, for the 50 A range. A logic order active at high level (15 V) controls the running of the source. The source sends a signal indicating that it is overheated. The signal is released by the sequencer card to stop the weld cycle and display the code of the detected fault (27). The high frequency generator is controlled by a signal emitted from the sequencer card. A relay contact ensures that this action occurs. The other pole of contact is linked to an alternative voltage of 42 V.

! The remote control pendant

The buttons on the control pendant are controlled by the synoptic card (21700634). Most of the buttons are tested by the line and column method: A high level signal is placed on a line and the columns are tested. If a column is at a high level, this shows that the button associated with this line and column has been pressed. The next line is tested afterwards, and so on. Only the two safety buttons are directly linked. The «In cycle» indicator is a light emitting diode LED.

Fig. 4.21 : Remote control pendant logic

LINE COLUMN BUTTON

11BT 1

12BT 16

13BT 11

14BT 14

21BT 5

22BT 15

23BT 12

24BT 9

31BT 6

32BT 10

33BT 13

34BT 8

41BT 4 (1)

42BT 4 (2)

43BT 4 (4)

44BT 4 (8)

MAN. PS 254 EN – Ind. 2 75

Page 77

5. APPENDIX

5.1. Built-in programs

The Polysoude weld lab developed these programs for mild steel and stainless steel tubes. Starting from frequent applications they represent the base to work out rapidly your own weld programs. Please look for a program close to your application in order to modify it. Before you can use such a built-in program you have to copy it in one of the 16 user program places in the memory of the power source (for detailed information, see Programming Manual). Afterwards you can modify the program to fit your special application. For all applications, Argon is used as shielding gas. The programs are listed in function of the welding head (closed chamber, MU III, or TS/TP), the material (mild steel or stainless steel), the diameter and the wall thickness of the tubes to be welded. In case of tube to tubeplate welds, a difference is made between "flush" and "protruding" tubes.

If filler wire is used, its diameter is always 0.8 mm. The set-up of a weld may influence considerably its result. The set-up is explained below and, whenever necessary, added to the programs.

1: Tube end preparation. 2: Electrode diameter. 3: Tip angle. 4: Flat. 5: Distance electrode-workpiece. 6: Diam eter of filler wire. 7: Angle between wire and workpiece. 8: Start position of the weld. 9: Start position of the weld. 10: Weld preparation angle. 11: Thickness of land. 12: Length of the land (for J

preparation).

Warning If multipass welding is

necessary, the parameter values for the passes are given in the tables without repeating diameter and thickness of the tubes.

Fig. 5.1 : Weld set-up

Fig. 5.2 : Weld preparation

76 MAN. PS 254 EN – Ind. 2

Page 78

5.1.1. Closed chamber welding heads or

MU heads without filler wire

To use these programs for enclosed welding heads, a square-butt preparation is necessary. The programs which are valid for MU III welding heads are indicated by a star in the appropriate column.

Tubes to be welded Set-up before welding Range

Material Ø OD

mm mm mm degree mm mm

Stainless

5 1 1.6200.2 0.8 1 X

Wall

thicknessØelectrode

Tip angle Nose

Distance

electrode/w

orkpiece

Number

of built-in

program

Also valid

for MU III

welding

heads

PS 254

Stainless

6 0.6 1.6 20 0.1 0.8 2 X

6.35 0.9 1.6 20 0.2 0.8 3 * X

8 1 1 20 01 0.8 4 * X

9.52 1.65 1.6 15 0.1 0.8 5 X

10 1.55 1.6 20 0.1 1 6 * X

10.5 0.4 1.6 20 0.1 0.8 7 * X

11 0.2 1.6 15 / 0.35 8

12 1 1.6 20 0.1 0.8 9 * X

12.7 0.8 1.6 20 0.1 0.8 10 * X

15.8 0.2 1.6 15 / 0.4 11

16 0.8 1.6 20 0.1 0.8 12 X

16 2.25 2.4 20 0.2 0.8 13 * X

17.2 2.3 2.4 30 0.2 0.8 14 * X

22 1.25 2.4 30 0.2 1 15 * X

25 1 2.4 30 0.2 1 16 * X

MAN. PS 254 EN – Ind. 2 77

Page 79

Tubes to be welded Set-up before welding Range

Material Ø OD

mm mm mm degrés mm mm

Stainless

25 1.2 2.4 30 0.2 1 17 * X

Wall

thicknessØelectrode

Tip angle Nose

Distance

electrode

workpiece

Number

of built- in

program

Also valid

for MU III

welding

heads

PS 254

Stainless

25 2.5 2.4 30 0.2 1.2 18 * X

26.9 3.6 2.4 30 0.2 1.2 19 * X

38 1.2 2.4 30 0.2 1 20 * X

40.5 0.4 2.4 20 0.1 0.6 21 * X

48.7 2 2.4 30 0.2 1.2 22 * X

51 1.2 2.4 30 0.2 1 23 * X

51 1.8 2.4 30 0.2 1.2 24 * X

63.5 0.7 2.4 20 0.2 0.9 25 * X

63.5 1.5 2.4 30 0.2 1.2 26 * X

88.9 1.6 2.4 30 0.2 1.2 27 * X

88.9 2 2.4 30 0.2 1.4 28 * X

88.9 3 2.4 30 0.2 1.6 29 * X

114.3 3 2.4 30 0.2 1.6 30 * X

78 MAN. PS 254 EN – Ind. 2

Page 80

5.1.2. MU open welding heads with filler

wire

Warning For some welds the distance

electrode-workpiece has to be modified at the end of the cycle when the beginning of the seam is overwelded. These programs are marked with a star in the last column of the set-up before welding.

Tubes to be welded

Ø OD

Material

Stainless

Mild steel

33.7 3.2

51 1.8

51 3

60.3 2.5

60.3 4

114.3 2.5

114.3 3

168 4

25 3.2

38 3

51 3

51 4

60.3 3

88.9 4

114.3 3.9

Wall thickness

V 37.5° 0.4

Square-butt

V 37.5° 0.2

Square-butt

V 37.5° 0.2

1.5mm land

V 37.5° 0.2

1 mm nose

V 37.5° 0.2

Preparation

mm nose

J 30°

0.9 mm nose 1.5 mm land

mm nose

J 30° 1.4 mm nose

mm nose

J 30°

1.5 mm

land

mm nose

Set-up before welding Range

Nose

Tip angle

Ø Electrode

2.4 40 0.3 2.5 25 3 12 H 41 *

2.4 40 0.3 2.5 20 3 12 H 43

2.4 40 0.3 2.5 25 3 10H30 44 *

2.4 40 0.3 2 20 2.5 10H30 46 *

2.4 40 0.3 2 25 3 10H30 47 *

2.4 40 0.3 3 20 3.5 12 H 2 48

2.4 40 0.3 2.5 20 3 12 H 51 *

2.4 30 0.3 2 25 2.5 10H30 52 *

2.4 40 0.2 2 25 2 10H30 56 *

2.4 40 0.2 2 20 2.5 10H30 1 57 *

2.4 40 0.2 2.5 20 3 12 H 2 58

2.4 40 0.2 2 15 2.5 10H30 59 *

2.4 40 0.2 2 30 2 10H30 1 61 *

2.4 40 0.2 2.5 20 3 12 H 2 62

2.4 40 0.2 1.5 25 2.5 10H30 1 63 *

2.4 40 0.2 2.5 20 3 12 H 2 64

2.4 40 0.4 2 35 1.5 10H30 1 65

2.4 40 0.2 2 10 2.5 12H 2 66

2.4 40 0.2 1.5 25 2 10H30 1 67 *

2.4 40 0.2 3 10 3.5 12 H 2 68

degrees

piece

Distance

electrode/work

Distance

Wire angle

électrode/wire

Layer

Start position

degrees

1 53

2 54

Built-in program number

PS 254

Adjust at the end of cycle

X X X X X

X X X

MAN. PS 254 EN – Ind. 2 79

Page 81

5.1.3. TS/TP welding heads for welding

of tubes to tubesheet

Tube to tubesheet welds may have two geometrical shapes : flushing or protruding tubes. For welds of flushing tubes, one pass is required. For welds of protruding tubes, make two passes (one with wire and one without wire). In this case a welding bevel is needed on the workpiece (angle = 45°, height: 1.5 mm). For leak resistant welds of protruding tubes, make one pass (without a bevel) and then a second pass corresponding to the tube to be welded.

Tubes to be welded

Material

Stainless

Mild

steel

Ø OD

25 2

26.7 1.5

25 2.5

Wall thickness

Tube

Flushing

Prot ruding

Flushing

Prot ruding

Flushing

Set-up before welding Range

Distance

Angle of torch

protruding/flushing

électrode/plaque

piece

Distance

electrode/work

Distance

electrode/wire

Ø Electrode

Nose

Ø wire

N° of layer

Tip angle

degrees

number

Built-in program

0° 2.5 1 2 2.4 30° 0.2 0.8 1/1 81 X

15° 0.5 1.2 2.4 30° 0.2 1/2 83 X

15° 2 2 1.2 2.4 30° 0.2 0.8 2/2 84 X

0° 3 1 2.2 2.4 30° 0.2 0.8 1/1 85 X

15° 0.5 1.2 2.4 30° 0.2 1/2 87 X

15° 2 2 1.2 2.4 30° 0.2 0.8 2/2 88 X

30° 2 2 1.2 2.4 30° 0.2 0.8 1/1 90 X

PS 254

Mild

steel

Mild

steel

Mild

steel

25 2.5

25 3

Prot ruding

Flushing

Prot ruding

30° 0.5 1.2 0.5 2.4 30° 0.2 1/2 91 X

30° 2 2.2 1.2 2.4 30° 0.2 0.8 2/2 92 X

0° 2 1 1.2 2.4 30° 0.2 0.8 1/1 93 X

15° 0.5 1.2 2.4 30° 0.2 0.8 1/2 95 X

15° 2 2 1.2 2.4 30° 0.2 0.8 2/2 96 X

80 MAN. PS 254 EN – Ind. 2

Page 82

Page 83

CONFIGURATION OF DIPS FOR PS 254

Card 21700633 21700634

S3 Function S1

Tachy

Extension

cable

current display

Without

With

Without

With

Analog

Digital

1 2 3 4

Convention

Closed

Open

1 2 3 4

PS 254

Voltage and

84 MAN. PS 254 FR – Ind. 3

Page 84

RETURN OF MATERIAL

Please fill out and join this sheet when returning materiel to

POLYSOUDE

Z.I du Bois Briand

2 rue Paul Beaupère

BP 41606

44606 Nantes Cedex 3

Reseller / Person in charge : Customer / Person in charge / Tel. :

EQUIPMENT RETURNED :

! Power source Type : Serial number :

! Welding head Type : Serial number :

! Coolant Type : Serial number :

! Other (specify designation) :

taken from :

! Power source Type : Serial number :

! Welding head Type : Serial number :

! Coolant Type : Serial number :

! Other(to be specified) : Serial number :

REASON FOR RETURN :

! Return after loan / of demonstration material ! Return of hired equipment ! Deficient delivery / incorrect order ! Return for modification (to be specified) : ! 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 83

Page 85

Date : Signature:

84 MAN. PS 254 EN – Ind. 2

Page 86

SUMMARY SPARE PARTS

PARTN° DESIGNATION QTY

00503026 Display remote control pendant 1

00629079 Memory card (1 programme) 10

00629087 Relay-PC board 1

14360000 Remote control pendant 1

21700633 Sequencer PC board 1

21700634 Synoptic PC board 1

21700627 PC board interface for remote control pendant 1

00629086 H.F. striking unit 1

00545111 Main switch 1

00545112 Key locking switch 1

00629076 Current supply (+5 V) 1

14909804 Programming keyboard 1

17375299 Protection box for remote control pendant 1

71701418 Flowmeter Argon (Export) 1

00629078 Printer 1

75501002 Flowmeter Argon (France) 1

71701421 Flowmeter Argon/Hydrogen 1

14369999 Cable complet for remote control pendant 1

21700636 Current/voltage interface 1

21700647 Interface tacho impulse 1

00629080 Power unit 250 A 1

75501207 Set of fuses 1

64599801 Return cable 9 m 1

75301335 Electrovalve 42VAC 1

00629085 Gas flow detection 1

00629084 Water security 1

00699017 Housing water filter 2

00699018 Element for water filter 3

75110071 Coolant 10 L

00629073 Cooling pump 230V 50Hz 1

00629074 Cooling pump 230V 60Hz 1

15545401 Quick coupling water connectors (inlet+outlet) 1

01514008 Quick coupling connector gas female 1

00542071 Red cap for emergency stop 1

00542070 Emergency stop button (without red cap) 1

00549067 Remote pendant button grey 1

00549066 Remote pendant button black 3

00549065 Remote pendant button red 1

00542006 Switch remote pendant 2 positions 1

MAN. PS 254 EN – Ind. 2 85

Page 87

PARTN° DESIGNATION QTY

00543016 Digit coding wheel 2

00563085 Plug remote control pendant 1

00320042 Supply unit + 12 V 1

00544031 Relay 12 VDC 1

41410144 Transformer 1

00590065 Printer paper 10

00590064 Ribbon 3

86 MAN. PS 254 EN – Ind. 2