Lincoln Electric IM573 User Manual
September, 2002
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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.
IM573
Date of Purchase:
Serial Number:
Code Number:
Model:
Where Purchased:
CALIBRATION PROCEDURES
Copyright © 2002 Lincoln Global Inc.
• World's Leader in Welding and Cutting Products •
Cleveland, Ohio 44117-1199 U.S.A. TEL: 216.481.8100 FAX: 216.486.1751 WEB SITE: www.lincolnelectric.com
• Sales and Service through Subsidiaries and Distributors Worldwide •
2 2
CALIBRATION
INDEX OF PROCEDURES
Capacitor discharge procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
Setup after Display Board replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
Display sensor calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .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 grid load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17
Semiautomatic PW450 Full voltage calibration using a welding arc . . . . . . . . . . . . . . . . . . . . . .19
Semiautomatic PW450 Current calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22
Robotic PW450 Current calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25
Robotic Interface P.C.Board Calibration and Quick Shunt Board Test . . . . . . . . . . . . . . . . . . . .29
Robotic Interface Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30
Test Procedures After Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31
CAPACITOR
DISCHARGE
PROCEDURE
DISPLAY
BOARD
REPLACED
ROBOTIC
PW450
AUTOMATIC
SETUP
DISPLAY
SENSOR
CALIBRATION
QUICK
VOLTAGE
CALIBRATION
(IF POSSIBLE)
SEMI-
PW450
SETUP
OR
SNUBBER
BOARD
REPLACED
FULL
VOLTAGE
CALIBRATION
FULL
VOLTAGE
CALIBRATION
SHUNT AMPLIFIER
BOARD
REPLACED
CURRENT
CALIBRATION
INTERFACE
BOARD
CALIBRATION
CONTROL
BOARD
REPLACED
CURRENT
CALIBRATION
INTERFACE
BOARD
CALIBRATION
FULL
VOLTAGE
CALIBRATION
INTERFACE
BOARD
REPLACEMENT
CURRENT
CALIBRATION
INTERFACE
BOARD
REPLACEMENT
ROBOT TEST PROCEDURES AFTER REPAIR
POWER WAVE CALIBRATION
3 3
CALIBRATION
POWER WAVE PC BOARD REPLACEMENT CALIBRATION PROCEDURES
The following procedures provide instructions on how
to properly perform sensor calibration, voltage calibration and current calibration on Power Wave power
sources. Additionally a procedure is provided to properly discharge the Power Wave’s input filter capacitors.
WARNING
Electric Shock Can Kill
• Only qualified personnel should service this equipment.
• Do not touch electrically hot parts.
• Prior to replacing any PC Boards or whenever working inside the Power Wave disconnect input power
and perform the capacitor discharge procedure.
-----------------------------------------------------------------------
If the display board is replaced
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.
, the display sensor cal-
If the sensor calibration is not done, the display board
may have some problems sensing the correct overlay
on power up.
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
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.
, the voltage calibration
POWER WAVE CALIBRATION
4 4
CALIBRATION
CAPACITOR DISCHARGE PROCEDURE
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 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, contact the Lincoln Electric Service Department for electrical troubleshooting 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 requires you to touch internal components 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
5 5
CALIBRATION
CAPACITOR DISCHARGE PROCEDURE (continued)
TEST PROCEDURE
1. Remove main input supply power to the
machine.
2. With the 3/8" nut driver, remove the screws
that hold the handle to the machine.
3. Remove the rubber gasket (cover seal)
from the lift bail.
4. With the 5/16" nut driver, remove the sheet
metal screws from the case top.
5. 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.
6. Obtain a high resistance and high wattage
resistor (25 - 1000 ohms, 25 watts minimum). 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.
FIGURE 1 – RESISTOR LOCATIONS
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 measurements in all). If a voltage is present, be
careful not to touch these resistors.
8. 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.
5 PAIRS OF RESISTORS
CHECK VOLTAGES BETWEEN
EACH TERMINAL AND FROM
EACH RESISTOR TO CASE
GROUND
POWER WAVE CALIBRATION
6 6
CALIBRATION
CAPACITOR DISCHARGE PROCEDURE (continued)
FIGURE 2 – DISCHARGE LABEL
D
I
S
C
H
A
R
G
E
D
I
S
C
H
A
R
G
E
D
I
S
C
H
A
R
D
I
S
C
H
A
R
G
E
D
I
S
C
H
A
R
G
E
WARNING
G
E
ELECTRIC SHOCK 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, connect 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.
POWER WAVE CALIBRATION
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 resistor connected for 10 seconds. DO NOT
TOUCH TERMINALS, RESISTORS, OR
ANY INTERNAL MACHINE COMPONENTS DURING THIS PROCEDURE!
7 7
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 capacitor discharge procedure.
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
8 8
CALIBRATION
SETUP FOR POWER WAVE 450 AFTER DISPLAY BOARD REPLACEMENT
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 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, contact 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 verify 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 LED
on WIRE FEEDER 1.
Setting up the Robotic Power Wave 450
after Display Board replacement
After a Display board is installed, a special setup procedure 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 of
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
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”
f by pressing
by
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.
POWER WAVE CALIBRATION
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.
9 9
CALIBRATION
SENSOR CALIBRATION TEST (FOR DISPLAY BOARD)
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 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, contact the Lincoln Electric Service Department for electrical troubleshooting 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
10 10
CALIBRATION
SENSOR CALIBRATION TEST (FOR DISPLAY BOARD) (continued)
Figure 4 - SENSOR LOCATION BEHIND OVERLAY
(32)
(34)
(36)
(64)
(33)
(35)
(37)
(65)
(67)
(96)
(97)
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.
2. When the display reads SELECT A FUNCTION,
press key #34 - OVERLAY CALIBRATE. The OVERLAY 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 location. The machine will begin to calibrate the eight
overlay sensors.
5. 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-
(98)
(99)
(128)
(130)
(100)
(101) (132)
(129)
(131)
(133)
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 numbers, if possible, using the QUICK VOLTAGE CALIBRATION procedure before removing the DISPLAY
board.
6. If the calibration procedure is successful, the display reads:
CALIBRATION
SUCCESSFUL
After a few seconds the display changes to read:
INSERT CAL OVRLY
PRESS ENTER . . .
7. Press key #133 - ENTER. the OVERLAY CALI-
BRATE LED turns off, the machine exits the OVERLAY 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
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