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Lincoln Electric IM573 User's Manual

1. Obtain a high resistance and high wattage resistor 25 1000 ohms 25 watts mini mum This resistor is not supplied with the machine Secure this resistor to a piece of insulating material such as a glastic board See Figure 3 NEVER USE A SHORTING STRAP FOR THIS PROCEDURE 7 Locate the two sets of two resistors on the left side of the machine and three sets of two resistors on the right side of the machine See Figure 1 Do not touch the resistors or any other internal machine component Using a DC voltmeter check for any DC voltage that may be present across the terminals of each resistor and from each resistor to case ground 20 mea surements in all If a voltage is present be careful not to touch these resistors Locate terminals 9 and 12 on the switch boards They can be identified by the Discharge labels which are located on each of the four switch boards See Figure 2 FIGURE 1 RESISTOR LOCATIONS GROUND 5 PAIRS OF RESISTORS CHECK VOLTAGES BETWEEN EACH TERMINAL AND FROM EACH RESISTOR TO CASE POWER WAVE CALIBRATION LINCOLN amp CALIBRATION CAPACITOR DISCHARGE PROCEDURE continued FIGURE 2 DISCHARGE LABEL v a v z a mom rou o zg m A gt rITOH oO v a v z a maa gt rou o 2 MOAPION U lt T13086 117 A WARNING o ELECTRIC SHO
2. September 2002 POWER WAVE PC BOARD REPLACEMENT CALIBRATION PROCEDURES Safety Depends on You Lincoln arc welding and cutting equipment is designed and built with safety in mind However your overall safety can be increased by proper installation and thoughtful operation on your part DO NOT INSTALL OPERATE OR REPAIR THIS EQUIPMENT WITHOUT READING THIS MANUAL AND THE SAFETY PRECAUTIONS CONTAINED THROUGHOUT And most importantly think before you act and be careful Date of Purchase Serial Number Code Number Model Where Purchased LI NCOLN Copyright 2002 Lincoln Global Inc ELECTRIC e World s Leader in Welding and Cutting Products e e Sales and Service through Subsidiaries and Distributors Worldwide e Cleveland Ohio 44117 1199 U S A TEL 216 481 8100 FAX 216 486 1751 WEB SITE www lincolnelectric com 2 CALIBRATION INDEX OF PROCEDURES Capacitor discharge procedure 4 Setup after Display Board replacement 8 Display sensor calibration AA rire Saree Gein CSS eee Pee be ba eae SEER D OEE ERE 9 Semiautomatic PW450 Quick voltage calibration 11 Robotic PW450 Quick voltage calibration 13 Semiautomatic PW450 Full voltage calibration with grid load 15 Robotic PW450 Full voltage calibration with g
3. into the harness you are checking and replace or repair the condition Recheck 4 Complete the voltage current and Interface board calibration The calibration procedures are provided in the IM 573 and additional up dated information appears the latest service CD 5 Replace covers on the machine and attempt to trigger the unit following the procedure listed in the EXTERNAL TRIGGERING CIRCUIT procedure in the Power Wave PC Board Replacement Calibration Procedures IM 573 Pay close attention to the polarity of the 24V DC Incorrect polarity will result in damage to the Interface board Verify O C V These steps along with the expected contactor closure and display information will insure that all circuits of the Power Wave 450 are operational POWER WAVE CALIBRATION LINCOLN 9 LINCOLN amp e World s Leader in Welding and Cutting Products e e Sales and Service through Subsidiaries and Distributors Worldwide gt Cleveland Ohio 44117 1199 U S A TEL 216 481 8100 FAX 216 486 1751 WEB SITE www lincolnelectric com
4. 101 132 A PROCEDURE 1 Insert the CALIBRATION AND TEST overlay L9660 255 If this overlay is not available turn the machine ON with no overlay in place and refer to Figure 4 to identify the keys The overlay ID number is momentarily displayed if the overlay is in place The number on the display should be 255 When the display reads SELECT A FUNCTION press key 34 OVERLAY CALIBRATE The OVER LAY CALIBRATE light turns on and momentarily the display reads OVERLAY SENSOR CALIBRATION Then the display changes to read INSERT REF OVRLY PRESS ENTER Insert the SETUP overlay L9660 4 Press key 133 ENTER This key is not identified on the SETUP overlay It is located in the lower right hand corner Refer to Figure 4 above for loca tion The machine will begin to calibrate the eight overlay sensors If one of the sensors could not be calibrated the display reads SENSOR X FAILED ENTER TO RETRY Make sure the overlay is lined up properly and press key 133 ENTER This will cause the machine to try to calibrate the sensor again If a particular sensor continues to fail clean the sen 7 Press key 133 ENTER sors or remove the case top and make sure the DISPLAY board is seated all the way down on the mounting posts Also check wiring connections If calibration still fails record the calibration num bers if possible using the QUICK VOLTAGE CALI BRATION procedure before removing t
5. Figure 6 Press the Voltage Calibration function 32 The machine should display the following VOLTAGE WIRE POLARITY 67A Press the Enter Key 133 on the lower right side of the overlay The machine should display the following ADJUST TO 30V CALIBRATION XX NOTE Here XX indicates a particular cali bration number for a given voltage sensing point A WARNING The machine s output terminals will be electri cally HOT when the Enter Key is pressed 6 With the machine loaded monitor the refer ence voltage only external voltmeter It is the only important reading Adjust the volt age using the Arrow Keys 100 and 101 until the reference voltmeter reads 30 0 volts Press the Enter Key A CAUTION WHEN LOADING THE MACHINE WITH THE CASE PARTS REMOVED BE CAREFUL NOT TO OVERHEAT THE MACHINE 7 Repeat the process by pressing the Voltage Calibration function again The next volt age sensing point lead may be selected by pressing the down Arrow Key 101 The above procedure must be repeated six times to set the six sensing points leads to 30 0 volts The six test points leads are the following Polarity 67A Polarity 21A Polarity 67B Polarity 21B Polarity Polarity 8 If the display board is replaced or dis turbed perform the Sensor Calibration Test POWER WAVE CALIBRATION LINCOLN amp ROBOTIC PW450 FULL VOLTAGE CALIBRATION A WARNING
6. Service and repair should be performed by only Lincoln Electric factory trained personnel Unauthorized repairs performed on this eguipment may result in danger to the technician or machine operator and will invalidate your factory warranty For your safety and to avoid elec trical shock please observe all safety notes and precautions detailed throughout this manual If for any reason you do not understand the test procedures or are unable to perform the test repairs safely contact the Lincoln Electric Service Department for electrical trou bleshooting assistance before you proceed Call 1 800 833 9353 WELD PROCEDURE DESCRIPTION This procedure is necessary if the display board is replaced and the Quick Voltage Calibration is NOT possible The Full Voltage Calibration is also necessary if the snubber and or control boards are replaced MATERIALS NEEDED A Test and Calibration Overlay L9660 255 A 300 amp 10 30 volt resistive grid load A MIG welding load may be used if a grid load is not available Choose an argon rich 30 volt spray procedure See the topic Full Voltage Calibration Using a Welding Arc in this section of the manual A calibrated DC voltmeter accurate to 30 0 volts 0 1 volt A set of jumper leads to access the remote voltage sensing leads in the wire feeder amphenol receptacles Some voltmeters will not read accurately because of the 40 KHz ripple present on the output SETUP PROCEDURE 1 Using the jumper le
7. TEST FOR DISPLAY BOARD A WARNING Service and repair should be performed by only Lincoln Electric factory trained personnel Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty For your safety and to avoid elec trical shock please observe all safety notes and precautions detailed throughout this manual If for any reason you do not understand the test procedures or are unable to perform the test repairs safely contact the Lincoln Electric Service Department for electrical trou bleshooting assistance before you proceed Call 1 800 833 9353 WELD TEST DESCRIPTION This procedure recalibrates the eight overlay sensors of the Power Wave MATERIALS NEEDED Power Wave Test and Calibration Overlay L9660 255 Set Up Overlay L9660 POWER WAVE CALIBRATION LINCOLN 10 10 CALIBRATION SENSOR CALIBRATION TEST FOR DISPLAY BOARD continued Figure 4 SENSOR LOCATION BEHIND OVERLAY COPWIOHI 1994 THE LINCOLN ELECTRIC COMPANY CLEVELAND OHIO USA m N 19660 255 CALIBRATION amp TEST OVERLAY LINCOLN amp ELECTRIC 4a Awarnine IWERTIEC POWER WAVE VOLIAGE O ara fo REMOTE OVERLAY O CARANE O PA MANUAL WATER O overiay O cooler O ENTRY ENABLE PRIME O WAER COOLER O onorr WATER O cooler PRESSURE O ra 128 129 oo 130 o 131 O O 100 fe fe ENTER 133
8. THE MACHINE WITH THE The machine should display the following CASE PARTS REMOVED BE CAREFUL NOT VOLTAGE WIRE TO OVERHEAT THE MACHINE POLARITY 67A 7 Repeat the process by pressing the Voltage 5 Press the Enter Key 133 on the lower right Calibration function again The next volt side of the overlay The machine should age sensing point lead may be selected by display the following pressing the down Arrow Key 101 The ADJUST TO 30V above procedure must be repeated four CALIBRATION XX times to set the four sensing points leads to 30 0 volts The four test points leads NOTE Here XX indicates a particular cali are the following bration number for a given voltage sensing point Polarity 67A Polarity 21A Polarity A WARNING Polarity The machine s output terminals will be electri 8 If the display board is replaced or dis cally HOT when the Enter Key is pressed a perform the Sensor Calibration est POWER LINCOLN amp SEMIAUTOMATIC PW450 FULL VOLTAGE CALIBRATION USING A WELDING ARC A WARNING Service and repair should be performed by only Lincoln Electric factory trained personnel Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty For your safety and to avoid elec trical shock please observe all safety notes and precautions detailed throughout this manual If for any reason you do not un
9. precautions detailed throughout this manual If for any reason you do not understand the test procedures or are unable to perform the test repairs safely contact the Lincoln Electric Service Department for electrical trou bleshooting assistance before you proceed Call 1 800 833 9353 WELD PURPOSE FOR THE PROCEDURE This procedure will drain off any charge stored in the four large capacitors that are part of the FET switch board assembly This procedure MUST be performed as a safety precaution before conducting any test or repair procedure that reguires you to touch internal compo nents of the machine MATERIALS NEEDED Volt Ohmmeter Multimeter 5 16 Nut driver 3 8 Nut driver Insulated gloves Jumper wire with insulated leads and needle nose ends High wattage resistor 25 to 1000 ohms 25 watts minimum Piece of glastic board or similar insulating materials on which to secure the resistor POWER WAVE CALIBRATION LINCOLN CALIBRATION CAPACITOR DISCHARGE PROCEDURE continued TEST PROCEDURE 1 Remove main input supply power to the machine With the 3 8 nut driver remove the screws that hold the handle to the machine Remove the rubber gasket cover seal from the lift bail With the 5 16 nut driver remove the sheet metal screws from the case top With the 5 16 nut driver remove the screws holding the right and left case sides Remove the case sides by lifting up and out
10. technician is familiar with the basic functions of the Power Wave and how to determine that the machine is powering up correctly and understands the overlay system and memory operations Additionally those systems if not functioning properly should be clearly apparent to the tech nician After completing repairs and or cleaning the unit and while bearing in mind and following all safety precautions listed in the service manual proceed as follows 1 Check to insure the 5 Amp circuit breaker on the lower front of the machine does not trip when the machine is on A tripping breaker indicates a faulty full wave bridge rectifier mounted on the left side of the control box or a defective Interface printed circuit board 2 Remove the cover to the control box look at the component side of the Interface board and with the power on observe a flashing LED on the Interface board If LED is not flashing replace Interface board 3 Disconnect the power and measure the resistance from P83 feeder connector pin F to J103 pin 6 at the Interface board connector P83 feeder connector pin G to J103 pin 5 at the Interface board connector P83 feeder connector pin H to J103 pin 7 at the Interface board connector Each resistance check should yield a maximum resistance of 6 5 ohms with no continuity between any two indi vidual F G or H pins If a high resistance on one lead is found or two leads shorting together locate the T12218 7 inductors soldered
11. the 10 turn trimmer potentiometer located on the control board It is the only trimmer on the board If the trimmer is not accessible with the control board installed then the board must be removed and laid on the top of the PC board compartment Be sure the control board is insulated from the other boards and the case parts All wiring plugs must be connected to the con trol board See Figure 8 A WARNING WHEN THE MACHINE CASE IS REMOVED HIGH VOLTAGE POINTS ARE EXPOSED STAND DIRECTLY IN FRONT OF MACHINE UNDER TEST EXPLODING PARTS CAN CAUSE INJURY FAILED PARTS CAN EXPLODE OR CAUSE OTHER PARTS TO EXPLODE WHEN POWER IS APPLIED ALWAYS WEAR A FACE SHIELD AND LONG SLEEVES WHEN SERVICING A CAUTION WHEN LOADING THE MACHINE WITH THE CASE PARTS REMOVED BE CAREFUL NOT TO OVER HEAT THE MACHINE 3 NOTE If a wire feeder is NOT connected to the Power Wave the machine may not display output volts 4 Connect the resistance grid load to the machine s output terminals Connect the reference ammeter in series with the grid load See Figure 9 FIGURE 9 RESISTANCE GRID LOAD CONNECTIONS POWER WAVE LONT AMMETER VOLT METER ae RESISTANCE GRID LOAD POWER WAVE CALIBRATION LINCOLN amp 27 27 CALIBRATION ROBOTIC PW450 CURRENT CALIBRATION continued Figure 10 TEST AND CALIBRATION OVERLAY COPRIGH 1994 THE LINCOLN ELECTRIC COMPANY CLEVELAND OHIO USA L96
12. the technician or machine operator and will invalidate your factory warranty For your safety and to avoid elec trical shock please observe all safety notes and precautions detailed throughout this manual If for any reason you do not understand the test procedures or are unable to perform the test repairs safely contact the Lincoln Electric Service Department for electrical trou bleshooting assistance before you proceed Call 1 800 833 9353 WELD PROCEDURE DESCRIPTION This procedure is a quick way of calibrating the voltage sensing points leads provided that the existing display board is capable of displaying the calibration numbers that are stored in the display board MATERIALS NEEDED A known good replacement display board A Test and Calibration overlay L9660 255 POWER WAVE CALIBRATION LINCOLN amp 14 CALIBRATION 14 ROBOTIC PW450 QUICK VOLTAGE CALIBRATION continued Figure 5 TEST AND CALIBRATION OVERLAY comm 1994 THE LINCOLN ELECIRIC COMPANY CLEVELAND OHIO USA L9660 255 CALIBRATION amp TEST OVERLAY LINCOLN B oS INVERIEC POWER WAVE S 67 Oo O O Oo 129 128 129 131 Oo ENTER 132 133 PROCEDURE 5 1 Before changing or disturbing the defective display board power up the machine with the L9660 255 Test and Calibration overlay in place See Figure 5 2 Press the Voltage Calibration function 32 The machine should display
13. you proceed Call 1 800 833 9353 WELD PROCEDURE DESCRIPTION This procedure is a quick way of calibrating the voltage sensing points leads provided that the existing display board is capable of displaying the calibration numbers that are stored in the display board MATERIALS NEEDED A known good replacement display board A Test and Calibration overlay L9660 255 POWER WAVE CALIBRATION LINCOLN 12 CALIBRATION 12 SEMIAUTOMATIC PW450 GUICK VOLTAGE CALIBRATION continued Figure 5 TEST AND CALIBRATION OVERLAY comm 194 THE LINCOLN ELECTRIC COMPANY CLEVELAND OHIO UBA L9660 255 CALIBRATION amp TEST OVERLAY LINCOLN amp os CHa Merc POWER WAVE S t gt os oO00 0 a 131 Oo Oo Oo ENTER 132 133 PROCEDURE 5 1 Before changing or disturbing the defective display board power up the machine with the L9660 255 Test and Calibration overlay in place See Figure 5 2 Press the Voltage Calibration function 32 The machine should display the following VOLTAGE WIRE POLARITY 67A 3 Press the Enter Key 133 on the lower right side of the overlay The machine should display the following ADJUST TO 30V 6 CALIBRATION XX NOTE Here XX indicates a particular cali 7 bration number for a given voltage sensing point A WARNING The machine s output terminals will be electri cally HOT when the Enter Key is pressed 4 Rec
14. 1 9 WDIS Water fault P82 g J103 4 Touch 2 4 output 4 PROT J34 7 CGRW1 10 WDI6 Power fault P82 h J103 5 Tach PWR P83 G GCRW1 11 WDI7 P82 j J103 6 Tach signal P83 F J103 7 Tach GND P83 H CBWE Te WDIS peek CRW1 13 ADCH1 Voltage feedback P82 J JOS Malate coon CRW1 14 COMAD1 P82 K J103 9 Motor P83 B J103 10 Weld 2 4 output 2 PROT J34 11 a te n Current feedback Say J103 11 Weld 2 4 output 4 PROT J34 14 CRW1 17 J103 12 Gas solenoid P83 C J103 13 Gas solenoid P83 D case J103 14 67 Sense lead P83 N oa Bobo GND cora J103 15 CRW1 20 OV P82 b J103 16 CRW1 21 OV P82 m CRW1 22 0V P82 n CRW1 23 WDO1 Weld start P82 R J104 1 Voltage signal CTRL J21 4 CRW1 24 WDO2 Gas start P82 S J104 2 Current signal CTRL J21 7 CRW1 25 WDO3 Touch sense P82 T J104 3 Water PWR D K J16 4 command J104 4 output signal SNUB J60 3 CRW1 26 WDO4 Wire P82 U J104 5 output signal SNUB J61 4 CRW1 27 WDO5 Wire P82 V J104 6 Water signal D K J16 5 CRW1 28 WDO6 P82 W J104 7 Control GND CTRL J24 11 CRW1 29 WDO7 Dual procedure switch P82 X J104 8 TRIM command D K J10 12 TIG command J104 9 WES command D K J10 2 WF1 CRW1 30 WDO8 Spare robot output P82 Z J104 10 Display analog GND D K J10 13 CRW1 31 WDI Wire stick detect P82 N J104 11 Water GND D K J16 12 CRW1 32 WDI Wire stick detect P82 P J104 12 67 Sense lead SNUB J60 8 CRW1 33 24V Robot PWR P82 r CRW1 34 24V Robot PWR P82 r J105 1 Isolated voltage si
15. 21B Set the number to the same as recorded for Polarity 67B POWER WAVE CALIBRATION LINCOLN amp 22 CALIBRATION SEMIAUTOMATIC PW450 CURRENT CALIBRATION A WARNING Service and repair should be performed by only Lincoln Electric factory trained personnel Unauthorized repairs performed on this eguipment may result in danger to the technician or machine operator and will invalidate your factory warranty For your safety and to avoid elec trical shock please observe all safety notes and precautions detailed throughout this manual If for any reason you do not understand the test procedures or are unable to perform the test repairs safely contact the Lincoln Electric Service Department for electrical trou bleshooting assistance before you proceed Call 1 800 833 9353 WELD PROCEDURE DESCRIPTION This procedure is necessary if the control and or the shunt amplifier boards are replaced The current control is the most critical function in the Power Wave machine MATERIALS NEEDED Test and Calibration Overlay L9660 255 A 300 amp 30 volt resistance grid load A small trimmer screwdriver A calibrated DC ammeter accurate to read 300 0 amps 1 0 amps A machine output triggering device such as the K941 1 Remote Control Kit SETUP PROCEDURE 1 Remove and install the replacement board in question Figure 8 PC BOARD REMOVED BUT STILL CONNECTED Lay Control Board on top of machine Make sure it is snapped into the g
16. 60 255 CALIBRATION amp TEST OVERLAY LINCOLN amp zi ELECTRIC INVERIEC POWER WAVE e Awan O ame O Sae oaie o g odh o oge ogi H O Sh o oO O KEYBOARD O O o 3 ef 288 aR 225 2 445 45 Q O 2e O 5 5 Gi O T ka T MANUAL PROCEDURE ENIRY is wi e m x 2 p B D s D e ke O O Q o 130 o 131 O O 100 O O oO PROCEDURE 1 Install the Test and Calibration Overlay and apply power to the machine See Figure 10 Press the Manual Procedure Entry Key 64 The machine should display the following PROCESS 1 SETUP 1 0 Toggle the Arrow Keys 100 and 101 until the display reads PROCESS 1 SETUP 1 6 Trigger the PW450 and apply the load See EXTERNAL TRIGGERING CIRCUIT on the next page POWER LINCOLN amp A WARNING The machine s output terminals will be electri cally HOT when the trigger circuit is activated Adjust the potentiometer until the reference external ammeter reads 304 amps 1 0 amps The load voltage should be greater than 15 volts but less than 35 volts Remove power to the machine If necessary re install the control board Replace the machine case parts 28 28 CALIBRATION EKTERNAL TRIGGERING CIRCUIT The Power Wave 450 Robotic may be triggered inde pendent of the robot using the following circuit and pro cedure 1 Remove the large connector plug on the rea
17. CK can kill Proceed with caution Be careful not to touch any internal machine components during the discharge procedure 9 Using the insulated needle nose type jumper leads and insulated gloves con nect one jumper lead to one end of the resistor obtained in step 6 Connect the other jumper lead to the other end of the resistor 10 Carefully connect the needle nose end of one of the jumper leads to terminal 9 See Figure 3 Connect the needle nose end of the other jumper lead to terminal 12 Terminals 9 and 12 are indicated by the Discharge label Leave the resis tor connected for 10 seconds DO NOT TOUCH TERMINALS RESISTORS OR ANY INTERNAL MACHINE COMPO NENTS DURING THIS PROCEDURE POWER WAVE CALIBRATION LINCOLN E CALIBRATION CAPACITOR DISCHARGE PROCEDURE continued FIGURE 3 RESISTOR WITH LEADS CONNECTED 11 Check the voltage across terminals 9 and 12 with the DC voltmeter Terminal 9 has positive polarity and terminal 12 has negative polarity Voltage should be zero If any voltage remains repeat this capaci tor discharge procedure OTM y 12 Repeat discharge procedure steps 9 10 and 11 for each of the other three switch boards of the FET switch board assembly POWER WAVE CALIBRATION LINCOLN amp CALIBRATION SETUP FOR POWER WAVE 450 AFTER DISPLAY BOARD REPLACEMENT A WARNING Service and repair should be performed by only Lincoln Electric factory tra
18. CURRENT CALIBRATION A WARNING Service and repair should be performed by only Lincoln Electric factory trained personnel Unauthorized repairs performed on this eguipment may result in danger to the technician or machine operator and will invalidate your factory warranty For your safety and to avoid elec trical shock please observe all safety notes and precautions detailed throughout this manual If for any reason you do not understand the test procedures or are unable to perform the test repairs safely contact the Lincoln Electric Service Department for electrical trou bleshooting assistance before you proceed Call 1 800 833 9353 WELD PROCEDURE DESCRIPTION This procedure is necessary if the control and or the shunt amplifier boards are replaced The current control is the most critical function in the Power Wave machine MATERIALS NEEDED Test and Calibration Overlay L9660 255 A 300 amp 30 volt resistance grid load A small trimmer screwdriver A calibrated DC ammeter accurate to read 300 0 amps 1 0 amps SETUP PROCEDURE 1 Remove and install the replacement board in question Figure 8 PC BOARD REMOVED BUT STILL CONNECTED Lay Control Board on top of machine Make sure it is snapped into the ground plane assembly and insulated from the case and other components POWER WAVE CALIBRATION LINCOLN amp 26 26 CALIBRATION ROBOTIC PW450 CURRENT CALIBRATION continued 2 Locate
19. ER WAVE CALIBRATION LINCOLN E 24 24 CALIBRATION SEMIAUTOMATIC PW450 CURRENT CALIBRATION continued Figure 10 TEST AND CALIBRATION OVERLAY COPYRIGHT THE LINCOLN ELECTRIC COMPANY CLEVELAND OHIO USA 9660 255 CALIBRATION amp TEST OVERLAY 4 Awarni LINCOLN O INVERIEC POWER WAVE 4 O VGE CALIBRATE O REMOTE OVERLAY o A PO oom o MANUAL WATER O overlay O cooter ENTRY ENABLE MANUAL PRIME PROCEDURE O WAER COOLER O VOUAGE KEYBOARD O LED O OVERLAY REMOTE O CALBRATE jac O O O O ono WATER COOLER PRESSURE O O O O PROCEDURE 1 Install the Test and Calibration Overlay and apply power to the machine See Figure 10 2 Press the Manual Procedure Entry Key 64 The machine should display the following PROCESS 1 SETUP 1 0 3 Toggle the Arrow Keys 100 and 101 until the display reads PROCESS 1 SETUP 1 6 4 Activate the external trigger device K941 1 and load the machine A WARNING The machine s output terminals will be electri cally HOT when the trigger circuit is activated 5 Adjust the potentiometer until the reference external ammeter reads 304 amps 1 0 amps The load voltage should be greater than 15 volts but less than 35 volts 6 Remove power to the machine 7 If necessary re install the control board 8 Replace the machine case parts POWER WAVE CALIBRATION LINCOLN amp 25 CALIBRATION ROBOTIC PW450
20. LED on WIRE FEEDER 1 4 If a water cooler is used enable and prime the water cooler using the water cooler SETUP keys 5 Power down and remove the overlay Setting up the Robotic Power Wave 450 after Display Board replacement After a Display board is installed a special setup pro cedure is required to properly initialize the machine for robotic use Proceed as follows 1 Insert the SETUP Overlay L9660 and turn the Power Wave on 2 The Wire Feeder 1 POLARITY LED should be on when the machine is first powered up If not proceed to step 4 3 Turn the POLARITY LED for WIRE FEEDER 1 off by pressing the POLARITY KEY for WIRE FEEDER 1 Note that WIRE FEEDER 2 LEDs will also change during this procedure 4 Turn the POLARITY LED for WIRE FEEDER 1 back on by again pressing the POLARITY KEY for WIRE FEEDER 1 5 When done properly the LEDs should look as follows Wire Feeder 1 Wire Feeder 2 Polarity LED ON Polarity LED ON Electrode Sense Lead Enabled Electrode Sense Lead Enabled LED ON LED OFF Work Sense Lead Enabled Work Sense Lead Enabled LED OFF LED OFF 6 If an external work sense lead 21 lead is used turn on the WORK SENSE LEAD ENABLED LED on WIRE FEEDER 1 7 If a water cooler is used enable and prime the water cooler using the water cooler SETUP keys 8 Power down and remove the overlay POWER WAVE CALIBRATION LINCOLN 9 CALIBRATION SENSOR CALIBRATION
21. ads connect wire 67 pin N located in wire drive receptacle P83 to the machine s positive output terminal 2 Using the jumper leads connect wire 21A pin H located in the auxiliary receptacle P84 to the machine s positive output terminal 3 Connect the resistive grid load or wire feeder to the machine s output terminals 4 Connect the DC voltmeter to the machine s output terminals Do not connect the volt meter to the load This avoids erroneous readings due to cable drop POWER WAVE CALIBRATION LINCOLN 9 17 CALIBRATION 18 18 CALIBRATION ROBOTIC PW450 FULL VOLTAGE CALIBRATION continued Figure 6 TEST AND CALIBRATION OVERLAY os cen ee Oa oY Oh WEREC POWER WAVE ea e ORR O E O g J o o 128 129 O O o oo L TT O o J 4J e s 96 98 100 O O 97 99 E 132 2 PROCEDURE 6 With the machine loaded monitor the refer ence voltage only external voltmeter It is 1 The voltage calibration numbers are stored the only important reading Adjust the volt inthe display Badia They are Program age using the Arrow Keys 100 and 101 MADI ami ane Moni paner usinge Test until the reference voltmeter reads 30 0 and Calibration Overlay volts Press the Enter Key 2 Change the PC board in question 3 Install the Test and Calibration Overlay L9660 255 and power up the machine See Figure 6 A CAUTION 4 Press the Voltage Calibration function 32 WHEN LOADING
22. derstand the test procedures or are unable to perform the test repairs safely contact the Lincoln Electric Service Department for electrical trou bleshooting assistance before you proceed Call 1 800 833 9353 WELD PROCEDURE DESCRIPTION This procedure is necessary if the display board is replaced and the Quick Voltage Calibration or the Normal Full Voltage Calibration is NOT possible MATERIALS NEEDED A Test and Calibration overlay L9660 255 the test procedure can be done without this A Synergic 7 wire feeder A calibrated DC voltmeter accurate to 0 1 volts at 30 0 volts The proper welding wire and gas combination to produce a Spray Arc For example 0 035 L 50 wire with a 90 Argon and 10 CO blend of gas SETUP PROCEDURE 1 Connect a DC voltmeter to the machine s negative output terminal and the conductor block of the wire feeder 2 Connect the Synergic 7 wire feeder to the Wire Feeder 1 receptacle on the back of the Power Wave POWER WAVE CALIBRATION LINCOLN amp 19 CALIBRATION 20 CALIBRATION 20 SEMIAUTOMATIC PW450 FULL VOLTAGE CALIBRATION USING A WELDING ARC continued Figure 7 TEST AND CALIBRATION OVERLAY comm 194 THE LINCOLN ELECTRIC COMPANY CLEVELAND OHIO UBA L9660 255 CALIBRATION amp TEST OVERLAY a Awannna LINCOLN Q m IWVERIEC POWER WAVE S MANU VOUAGE O Saa 0 REMOTE OVERLAY O CAIRAT O Fa MANUAL warer O MRN COOLER ENTE PRIME ATER men O o
23. ds to access the remote voltage sensing leads in the wire feeder amphenol receptacles Some voltmeters will not read accurately because of the 40 KHz ripple present on the output SETUP PROCEDURE 1 Using the jumper leads connect 21A H and 67A N located in wire feeder receptacle 1 to the machine s positive output terminal 2 Using the jumper leads connect 21B H and 67B N located in wire feeder receptacle 2 to the machine s positive output terminal 3 Connect the resistive grid load or wire feeder to the machine s output terminals 4 Connect the DC voltmeter to the machine s output terminals Do not connect the volt meter to the load This avoids erroneous readings due to cable drop POWER WAVE CALIBRATION LINCOLN amp 15 16 16 CALIBRATION SEMIAUTOMATIC PW450 FULL VOLTAGE CALIBRATION continuea Figure 6 TEST AND CALIBRATION OVERLAY commit 1994 THE LINCOLN ELECIRIC COMPANY CLEVELAND OHIO USA N 19660 255 CALIBRATION amp TEST OVERLAY LINCOLN G m OR Merc POWER wae B Ow OBB O ono o waer O sae O O Oo Oo 128 129 131 Oo 132 133 A PROCEDURE 1 The voltage calibration numbers are stored in the display board They are program mable from the front panel using the Test and Calibration Overlay 2 Change the PC board in question Install the Test and Calibration Overlay L9660 255 and power up the machine See
24. e starting will be poor The welding may be poor Main tain along steady welding arc While weld ing monitor the reference voltage only external voltmeter It is the only important reading Adjust the voltage using the Arrow Keys 100 and 101 until the reference volt meter reads 30 0 volts Record the number on the display xx Press the Enter Key Release the trigger on the torch Repeat the process by pressing the Voltage Calibration function 32 again The next voltage sensing point may be selected by pressing the down Arrow Key 101 Repeat steps 5 6 and 7 for the following test points POWER WAVE CALIBRATION LINCOLN amp 21 21 CALIBRATION SEMIAUTOMATIC PW450 FULL VOLTAGE CALIBRATION USING A WELDING ARC continued POLARITY 21A POLARITY POLARITY NOTE Do not attempt to weld for Polarity 421A Set the number to the same as recorded for Polarity 67A Also for Polarity and Polarity move the volt meter sense lead from the conductor block of the wire feeder to the positive output terminal on the front of the machine 9 Turn the machine off Connect the Synergic 7 to the Wire feeder 2 amphenol on the back of the Power Wave machine 10 Put the voltmeter sense lead back on the wire feeder conductor block and repeat the calibration process steps 5 6 and 7 for the following test points POLARITY 67B POLARITY 21B NOTE Do not attempt to weld for Polarity
25. ed Repeat the process for all six sensing points leads Perform the Sensor Calibration Test POWER WAVE CALIBRATION LINCOLN amp 15 CALIBRATION SEMIAUTOMATIC PW450 FULL VOLTAGE CALIBRATION A WARNING Service and repair should be performed by only Lincoln Electric factory trained personnel Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty For your safety and to avoid elec trical shock please observe all safety notes and precautions detailed throughout this manual If for any reason you do not understand the test procedures or are unable to perform the test repairs safely contact the Lincoln Electric Service Department for electrical trou bleshooting assistance before you proceed Call 1 800 833 9353 WELD PROCEDURE DESCRIPTION This procedure is necessary if the display board is replaced and the Quick Voltage Calibration is NOT possible The Full Voltage Calibration is also necessary if the snubber and or control boards are replaced MATERIALS NEEDED A Test and Calibration Overlay L9660 255 A 300 amp 30 volt resistive grid load A MIG welding load may be used if a grid load is not available Choose an argon rich 30 volt spray procedure See the topic Full Voltage Calibration Using a Welding Arc in this section of the manual A calibrated DC voltmeter accurate to 30 0 volts 0 1 volt A set of jumper lea
26. gnal P82 J ADCH1 sees J105 2 Isolated current signal P82 L ADCH2 J105 3 Abnormal operation signal _ P82 h WDI6 J105 4 Arc start command P82 WDO1 P82 R Fanuc models J105 5 Arc detect signal P82 d WDI2 L P82 C Motoman models J105 6 Gas flow command P82 S WDO2 J105 7 Gas shortage signal P82 e WDI3 J105 8 DPS command P82 X WDO7 J105 9 Positive inch command P82 U WDO4 MISCELLANEOUS CONNECTIONS J105 10 Negative inch command P82 V WDOS5 J105 11 Short detect signal P82 N WDI J105 12 Short detect signal P82 P WDI J105 13 Isolated water signal P82 g WDI5 hoes ORD J105 14 Touch sense command P82 T WDO3 J105 15 Voltage command P82 A DACH1 J105 16 WFS command P82 E DACH2 J106 1 Touch sense signal CTRL J24 4 J106 2 Isolated touch sense signal P82 c WDI1 J106 3 Robot 24V P82 r 24E J106 4 Robot GND P82 a 0V J106 5 Robot analog GND P82 F COMDA2 J106 6 Spare robot output P82 Z WDO8 J106 7 Gas shortage input P84 A J106 8 Gas shortage GND P84 B 31 31 TEST PROCEDURE AFTER REPAIR The following five steps should be completed after examining and or repairing a Power Wave 450R These steps will insure that all aspects and systems of the Power Wave are functioning This procedure does not include fan operation or proper water cooler operation both of which are industry standard systems not requiring specific technical interpretation It is assumed that the repair
27. he DISPLAY board If the calibration procedure is successful the dis play reads CALIBRATION SUCCESSFUL After a few seconds the display changes to read INSERT CAL OVRLY PRESS ENTER the OVERLAY CALI BRATE LED turns off the machine exits the OVER LAY CALIBRATE function and the display reads SELECT A FUNCTION 8 Turn the power switch SW1 to the OFF position To use the machine place the appropriate overlay in position and turn power switch SW1 to the ON position NOTE Turn power switch SW1 to the OFF position and get the overlay that was not recognized by the power wave Replace the TEST overlay with this overlay and turn the machine ON The machine should recognize the overlay now If it does not the overlay is faulty POWER WAVE CALIBRATION LINCOLN amp 11 11 CALIBRATION SEMIAUTOMATIC PW450 QUICK VOLTAGE CALIBRATION A WARNING Service and repair should be performed by only Lincoln Electric factory trained personnel Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty For your safety and to avoid elec trical shock please observe all safety notes and precautions detailed throughout this manual If for any reason you do not understand the test procedures or are unable to perform the test repairs safely contact the Lincoln Electric Service Department for electrical trou bleshooting assistance before
28. ined personnel Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty For your safety and to avoid electrical shock please observe all safety notes and precautions detailed throughout this manual If for any reason you do not understand the test procedures or are unable to perform the test repairs safely con tact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed Call 1 800 833 9353 WELD SETUP DESCRIPTION This procedure properly enables the work and electrode sense leads after Display Board replacement MATERIALS NEEDED Set Up Overlay L9660 Setting up the SemiAutomatic Power Wave 450 after Display Board replacement After a Display board is installed all users should veri fy the polarity sense lead and water cooler conditions Proceed as follows 1 Insert the SETUP Overlay L9660 and turn the Power Wave on 2 For the majority of applications the wire feeder LED s should look as follows change settings as required to suit special applications Wire Feeder 1 Wire Feeder 2 Polarity LED ON Polarity LED ON Electrode Sense Lead Enabled Electrode Sense Lead Enabled LED ON LED ON Work Sense Lead Enabled Work Sense Lead Enabled LED OFF LED OFF 3 If an external work sense lead 21 lead is used turn on the WORK SENSE LEAD ENABLED
29. ith the machine triggered If after several triggers the value of the shunt reading 1 is at or above 5 amps the shunt is suspect and needs to be replaced If the value of shunt offset is below 5 amps the stability is at an acceptable level If problems continue perform the output shunt welding feed back test POWER WAVE CALIBRATION LINCOLN 9 30 ROBOTIC INTERFACE CONNECTIONS POWER WAVE INTERFACE BOARD ARCTOOL WELDING INPUTS AND OUT POWER WAVE CALIBRATION LINCOLN 9 ELECTRIC PUTS J101 1 Serial loop CTRL J27 1 CRW1 1 DACH1 Voltage command P82 A J101 2 High speed sense 1 P83 K CRW1 2 COMDA1 P82 F J101 3 High speed sense 2 P83 L CRW1 3 DACH2 WFS command P82 E J101 4 Serial loop CTRL J27 4 CRW1 4 COMDA2 WFS command GND P82 F CRW1 5 WDI1 Touch sense signal P82 c Ji03 1 42VDC Full wave bridge a BE ani reed as fault P82 e J103 2 42VDC Full wave bridge CRW1 8 WDI4 P82 f J103 3 Touch 2 4 output 2 PROT J34 4 GCRW
30. nce WATER O coor PRESSURE Oo Oo Oo 0 o 0 f aL 131 Q Oo ENTER 132 133 A PROCEDURE 6 1 The voltage calibration numbers are stored in the display board They are programma Adjust the wire feed speed on the Synergic 7 to 500 IPM some wire feed speed to get into the spray range ble from the front panel using the Test and NOTE When the Enter Key is pressed it will Calibration Overlay 2 Change the display board in question 3 Install the Test and Calibration overlay L9660 255 or do not insert any overlay into 7 the machine and power up the machine See Figure 7 If the 255 overlay is not available use Figure 1 as a guide to see which keys to press 4 Press the Voltage Calibration function 32 The machine should display the following VOLTAGE WIRE POLARITY 67A 5 Press the Enter Key 133 on the lower right side of the overlay The machine should display the following 8 ADJUST TO 30V CALIBRATION XX NOTE Here xx indicates a particular cali bration number for a given voltage sense point A WARNING The machine s output terminals will be electri cally HOT when the Enter Key is pressed clear the wire feed speed to 200 IPM The wire feed speed must be adjusted after pressing the Enter Key but before starting to weld Pull the trigger on the torch and start to weld Hold along stick out This is not nor mally a welding technique Th
31. ord the number displayed for the 67 wire and press the Enter Key 133 again 9 Repeat the process by pressing the Voltage Calibration function again The next sens ing lead may be selected by pressing the down Arrow Key 101 The above proce dure must be repeated six times to obtain and record the calibration number for six different voltage sensing points These points are the following Polarity 67A Polarity 21A Polarity 67B Polarity 21B Polarity Polarity Install the new replacement display board With the L9660 255 overlay installed apply power to the machine Press the Voltage Calibration function 32 Enter the re corded calibration numbers for each of the six voltage sensing points The calibration numbers are entered by selecting the prop er sensing point lead pressing the Enter Key 133 and obtaining the display that reads ADJUST TO 30V CALIBRATION XX The calibration number is changed using the up down Arrow Keys 100 101 Press the Enter Key when the desired number is dis played Repeat the process for all six sensing points leads Perform the Sensor Calibration Test POWER WAVE CALIBRATION LINCOLN amp 13 13 CALIBRATION ROBOTIC PW450 GUICK VOLTAGE CALIBRATION A WARNING Service and repair should be performed by only Lincoln Electric factory trained personnel Unauthorized repairs performed on this equipment may result in danger to
32. r of the PW450 As viewed from the front of the machine 2 Connect a normally open switch and a 24VDC sup Voltage Switch Signal 24VDC 100ma Normally open switch P82 ROBOT RECEPTACLE ply either to the large connector plug P82 or to the harness connectors on the interface board See the following table and figure When the 24VDC supply is correctly wired in place and turned on the welding output terminals can be energized by closing the switch P82 Connector Pins Interface Board Connectors J106 3 Wire 534 J106 4 Wire 535 J105 4 Wire 518 J105 12 Wire 527 ARC START SWITCH NEGATIVE 24VDC SUPPLY POSITIVE POWER WAVE CALIBRATION LINCOLN 9 29 29 CALIBRATION ROBOTIC INTERFACE P C BOARD CALIBRATION Position Interface board on top of the power wave so that the component side is up Make certain a non con ductive insulating material is protecting the control board from touching any conductive surface Locate the J109 receptacle Directly next to the receptacle are three trimmers side by side We are interested in the center trim mer the R 194 reference Interface P C board drawing below Once you have located the three trimmers fol low on down and locate the X 12 integrated circuit With the board positioned as described and plugged into the wiring harness connect a DC voltmeter to pin 2 of J109 Positive and pin 4 J109 Negative Turn on the Power wave and after
33. rid load 17 Semiautomatic PW450 Full voltage calibration using a welding arc 19 Semiautomatic PW450 Current calibration 22 Robotic PW450 Current calibration IA eee 25 Robotic Interface P C Board Calibration and Quick Shunt Board Test 29 Robotic Interface Connections IA kaarega AA eee ee 30 Test Procedures After Repair 31 CAPACITOR DISCHARGE PROCEDURE DISPLAY BOARD REPLACED SNUBBER SHUNT AMPLIFIER BOARD BOARD REPLACED REPLACED CONTROL BOARD REPLACED INTERFACE BOARD REPLACEMENT CURRENT CURRENT CURRENT CALIBRATION CALIBRATION DISPLAY SENSOR CALIBRATION INTERFACE BOARD CALIBRATION QUICK VOLTAGE CALIBRATION IF POSSIBLE FULL VOLTAGE CALIBRATION CALIBRATION CALIBRATION INTERFACE BOARD CALIBRATION INTERFACE BOARD REPLACEMENT ROBOT TEST PROCEDURES AFTER REPAIR POWER WAVE CALIBRATION LINCOLN 9 CALIBRATION POWER WAVE PC BOARD REPLACEMENT CALIBRATION PROCEDURES The following procedures provide instructions on how to properly perform sensor calibration voltage calibra tion and current calibration on Power Wave power sources Additionally a procedure is provided to prop erly discharge the Power Wave s input filter capacitors A WARNING Electric Shock Can Kill e Only qualified personnel should ser
34. round plane assembly and insulated from the case and other components POWER WAVE CALIBRATION LINCOLN 23 23 CALIBRATION SEMIAUTOMATIC PW450 CURRENT CALIBRATION continued 2 Locate the 10 turn trimmer potentiometer located on the control board It is the only trimmer on the board If the trimmer is not accessible with the control board installed then the board must be removed and laid on the top of the PC board compartment Be sure the control board is insulated from the other boards and the case parts All wiring plugs must be connected to the con trol board See Figure 8 A WARNING WHEN THE MACHINE CASE IS REMOVED HIGH VOLTAGE POINTS ARE EXPOSED STAND DIRECTLY IN FRONT OF MACHINE UNDER TEST EXPLODING PARTS CAN CAUSE INJURY FAILED PARTS CAN EXPLODE OR CAUSE OTHER PARTS TO EXPLODE WHEN POWER IS APPLIED ALWAYS WEAR A FACE SHIELD AND LONG SLEEVES WHEN SERVICING A CAUTION WHEN LOADING THE MACHINE WITH THE CASE PARTS REMOVED BE CAREFUL NOT TO OVER HEAT THE MACHINE 3 NOTE If a wire feeder is NOT connected to the Power Wave the machine may not display output volts 4 Connect the resistance grid load to the machine s output terminals Connect the reference ammeter in series with the grid load See Figure 9 FIGURE 9 RESISTANCE GRID LOAD CONNECTIONS POWER WAVE Z AMMETER VOLT METER CN NII RESISTANCE GRID LOAD POW
35. the contactor pulls in read the volt meter A reading of 11 volts or more indicates that the R194 trimmer needs to be calibrated 1 Turn the R194 trimmer fully counter clockwise Slowly turn it clockwise until the voltage on the meter switches from 11 volts to less than 1 volt Repeat step one a couple of times starting at the full counter clockwise position until you are sure that you are just at the point of change from high voltage to low 2 Remove the positive probe from the J109 pin 2 position and attach it to lead nine of X 12 Leave the nega tive lead at J109 pin 4 The voltmeter should now be reading less than one volt Example 0 345 MV 3 Slowly continue to adjust the trimmer clockwise until the voltage reading has increased 100 MV 0 100 volt or 0 025 volt EXAMPLE 0 420 to 0 470 INTERFACE P C BOARD J109 X12 Pin 10 X12 Pin 9 AA oe SO SGI 7 ia 3 QUICK SHUNT BOARD TEST The following procedure can be used to check for instability in the Power Wave 450 Shunt circuitry 1 Disconnect the output welding leads from the machine 2 Turn on the Power Wave 450 and release the drive roll tension in the wire feeder so the machine will not feed wire 3 If semi automatic power source Pull the gun trigger and hold for several seconds 4 Trigger the machine several times and observe the 1 reading on the front of the power wave while the output is on The value shown must be less than 5 amps w
36. the following VOLTAGE WIRE POLARITY 67A 3 Press the Enter Key 133 on the lower right side of the overlay The machine should display the following 6 ADJUST TO 30V CALIBRATION XX 7 NOTE Here KK indicates a particular cali bration number for a given voltage sensing point A WARNING The machine s output terminals will be electri cally HOT when the Enter Key is pressed 4 Record the number displayed for the 67 wire and press the Enter Key 133 again 9 Repeat the process by pressing the Voltage Calibration function again The next sens ing lead may be selected by pressing the down Arrow Key 101 The above proce dure must be repeated four times to obtain and record the calibration number for four different voltage sensing points These four points are the following Polarity 67A Polarity 21A Polarity Polarity Install the new replacement display board With the L9660 255 overlay installed apply power to the machine Press the Voltage Calibration function 32 Enter the re corded calibration numbers for each of the six voltage sensing points The calibration numbers are entered by selecting the prop er sensing point lead pressing the Enter Key 133 and obtaining the display that reads ADJUST TO 30V CALIBRATION XX The calibration number is changed using the up down Arrow Keys 100 101 Press the Enter Key when the desired number is dis play
37. vice this equipment e Do not touch electrically hot parts e Prior to replacing any PC Boards or whenever work ing inside the Power Wave disconnect input power and perform the capacitor discharge procedure If the display board is replaced the display sensor cal ibration and a voltage calibration must be performed for optimum performance If the calibration is not done the voltage may be accurate only to within 3 volts If the sensor calibration is not done the display board may have some problems sensing the correct overlay on power up A CAUTION The display is shipped with the water cooler disabled If an internal water cooler is being used with the Power Wave you must use the Setup Overlay L9660 to enable the water cooler before using the system If the control board is replaced the voltage calibration and current calibration must be performed for optimum performance If the calibration is not done the voltage may be accurate only to within 3 volts and the current will be accurate only to within 15 amps POWER WAVE CALIBRATION LINCOLN 9 CALIBRATION CAPACITOR DISCHARGE PROCEDURE A WARNING Service and repair should be performed by only Lincoln Electric factory trained personnel Unauthorized repairs performed on this eguipment may result in danger to the technician or machine operator and will invalidate your factory warranty For your safety and to avoid elec trical shock please observe all safety notes and

Lincoln Electric IM573 User's Manual

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