Lincoln Electric IM573 User Manual

September, 2002

RETURN TO MAIN MENU

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: [phone] FAX: [phone] 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

11 11

CALIBRATION

SEMIAUTOMATIC PW450 QUICK VOLTAGE CALIBRATION

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).

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

12 12

CALIBRATION

SEMIAUTOMATIC PW450 QUICK VOLTAGE CALIBRATION (continued)

Figure 5 - TEST AND CALIBRATION OVERLAY

(32)

(34)

(36)

(64)

(33)

(35)

(37)

(65)

(67)

(96)

(97)

(98)

(99)

PROCEDURE

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

CALIBRATION #=XX

NOTE: Here “XX” indicates a particular cali­bration number for a given voltage sensing
point.

WARNING

The machine’s output terminals will be electri­cally “HOT” when the Enter Key is pressed.

(128)

(129)

(130)

(131)

(100)

(101) (132)

(133)

5. Repeat the process by pressing the Voltage
Calibration function again. The next sens­ing lead may be selected by pressing the
down Arrow Key (101). The above proce­dure 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

6. Install the “new” replacement display
board.

7. With the L9660-255 overlay installed, apply
power to the machine. Press the Voltage
Calibration function (32). Enter the re­corded calibration numbers for each of the
six voltage sensing points. The calibration
numbers are entered by selecting the prop­er sensing point (lead), pressing the Enter
Key (133) and obtaining the display that
reads:

4. Record the number displayed for the +67
wire and press the Enter Key (133) again.

POWER WAVE CALIBRATION

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 dis­played.

8. Repeat the process for all six sensing
points (leads).

9. Perform the Sensor Calibration Test.

13 13

CALIBRATION

ROBOTIC PW450 QUICK VOLTAGE CALIBRATION

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).

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

14 14

CALIBRATION

ROBOTIC PW450 QUICK VOLTAGE CALIBRATION (continued)

Figure 5 - TEST AND CALIBRATION OVERLAY

(32)

(34)

(36)

(64)

(33)

(35)

(37)

(65)

(67)

(96)

(97)

(98)

(99)

PROCEDURE

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

CALIBRATION #=XX

NOTE: Here “XX” indicates a particular cali­bration number for a given voltage sensing
point.

WARNING

The machine’s output terminals will be electri­cally “HOT” when the Enter Key is pressed.

(128)

(129)

(130)

(131)

(100)

(101) (132)

(133)

5. Repeat the process by pressing the Voltage
Calibration function again. The next sens­ing lead may be selected by pressing the
down Arrow Key (101). The above proce­dure 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

6. Install the “new” replacement display
board.

7. With the L9660-255 overlay installed, apply
power to the machine. Press the Voltage
Calibration function (32). Enter the re­corded calibration numbers for each of the
six voltage sensing points. The calibration
numbers are entered by selecting the prop­er sensing point (lead), pressing the Enter
Key (133) and obtaining the display that
reads:

ADJUST TO 30V

CALIBRATION #=XX

4. Record the number displayed for the +67
wire and press the Enter Key (133) again.

POWER WAVE CALIBRATION

The calibration number is changed using the
up/down Arrow Keys (100, 101). Press the
Enter Key when the desired number is dis­played.

8. Repeat the process for all six sensing
points (leads).

9. Perform the Sensor Calibration Test.

15 15

CALIBRATION

SEMIAUTOMATIC PW450 FULL VOLTAGE CALIBRATION

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).

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 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 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 volt­meter to the load. This avoids erroneous readings due to cable drop.

POWER WAVE CALIBRATION

16 16

CALIBRATION

SEMIAUTOMATIC PW450 FULL VOLTAGE CALIBRATION(continued)

Figure 6 - TEST AND CALIBRATION OVERLAY

(32)

(34)

(36)

(64)

(33)

(35)

(37)

(65)

(67)

(96)

(97)

(98)

(99)

PROCEDURE

1. The voltage calibration numbers are stored
in the display board. They are program­mable from the front panel using the Test
and Calibration Overlay.

2. Change the PC board in question.

3. Install the Test and Calibration Overlay
L9660-255 and power up the machine. See
Figure 6.

4. Press the Voltage Calibration function (32).
The machine should display the following:

VOLTAGE WIRE

+ POLARITY (+67A)

(128)

(129)

(130)

(131)

(100)

(101) (132)

(133)

6. With the machine loaded, 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 voltmeter reads 30.0
volts. Press the Enter Key.

CAUTION

WHEN LOADING THE MACHINE WITH THE
CASE PARTS REMOVED, BE CAREFUL NOT
TO OVERHEAT THE MACHINE.

5. 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.

WARNING

The machine’s output terminals will be electri­cally “HOT” when the Enter Key is pressed.

POWER WAVE CALIBRATION

7. Repeat the process by pressing the Voltage
Calibration function again. The next volt­age 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 dis­turbed, perform the Sensor Calibration
Test.

17 17

CALIBRATION

ROBOTIC PW450 FULL VOLTAGE CALIBRATION

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).

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 leads, 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 volt­meter to the load. This avoids erroneous readings due to cable drop.

POWER WAVE CALIBRATION

18 18

CALIBRATION

ROBOTIC PW450 FULL VOLTAGE CALIBRATION(continued)

Figure 6 - TEST AND CALIBRATION OVERLAY

(32)

(34)

(36)

(64)

(33)

(35)

(37)

(65)

(67)

(96)

(97)

(98)

(99)

PROCEDURE

1. The voltage calibration numbers are stored

in the display board. They are program­mable from the front panel using the Test
and Calibration Overlay.

2. Change the PC board in question.

3. Install the Test and Calibration Overlay

L9660-255 and power up the machine. See
Figure 6.

4. Press the Voltage Calibration function (32).

The machine should display the following:

VOLTAGE WIRE

+ POLARITY (+67A)

(128)

(129)

(130)

(131)

(100)

(101) (132)

(133)

6. With the machine loaded, 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 voltmeter reads 30.0
volts. Press the Enter Key.

CAUTION

WHEN LOADING THE MACHINE WITH THE
CASE PARTS REMOVED, BE CAREFUL NOT
TO OVERHEAT THE MACHINE.

POWER

5. 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.

WARNING

The machine’s output terminals will be electri­cally “HOT” when the Enter Key is pressed.

7. Repeat the process by pressing the Voltage
Calibration function again. The next volt­age sensing point (lead) may be selected by
pressing the down Arrow Key (101). The
above procedure must be repeated four
times to set the four sensing points (leads)
to 30.0 volts. The four test points (leads)
are the following:

+ Polarity (+67A)

- Polarity (+21A)
+ Polarity

- Polarity

8. If the display board is replaced or dis­turbed, perform the Sensor Calibration
Test.

19 19

CALIBRATION

SEMIAUTOMATIC PW450 FULL VOLTAGE CALIBRATION

USING A WELDING ARC

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).

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% CO2blend 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

20 20

CALIBRATION

SEMIAUTOMATIC PW450 FULL VOLTAGE CALIBRATION USING A WELDING ARC (continued)

Figure 7 - TEST AND CALIBRATION OVERLAY

(32)

(34)

(36)

(64)

(33)

(35)

(37)

(65)

(67)

(96)

(97)

(98)

(99)

PROCEDURE

1. The voltage calibration numbers are stored
in the display board. They are programma­ble from the front panel using the Test and
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
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:

ADJUST TO 30V

CALIBRATION# = XX

NOTE: Here “xx” indicates a particular cali-

bration number for a given voltage
sense point.

(128)

(129)

(130)

(131)

(100)

(101) (132)

(133)

6. Adjust the wire feed speed on the Synergic
7 to 500 IPM (some wire feed speed to get
into the spray range).

NOTE: When the Enter Key is pressed it will

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.

7. Pull the trigger on the torch and start to
weld. Hold a long stick out. This is not nor­mally a welding technique. The starting will
be poor. The welding may be poor. Main­tain a long, steady welding arc. While weld­ing, 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 volt­meter reads 30.0 volts. Record the number
on the display, “xx”. Press the Enter Key.
Release the trigger on the torch.

8. 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.

WARNING

The machine’s output terminals will be electri­cally “HOT” when the Enter Key is pressed.

POWER WAVE CALIBRATION

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

(+21A). Set the number to the same as
recorded for +Polarity (+67A). Also for
+Polarity and –Polarity, move the volt­meter 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

(+21B). Set the number to the same as
recorded for +Polarity (+67B).

POWER WAVE CALIBRATION

22 22

CALIBRATION

SEMIAUTOMATIC PW450 CURRENT CALIBRATION

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).

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 ground
plane assembly and insulated from the
case and other components.

Leads

POWER WAVE CALIBRATION

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 con­trol board. See Figure 8.

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

CAUTION

to the Power Wave the machine
may not display output volts.

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.

FIGURE 9 – RESISTANCE GRID LOAD CONNECTIONS

POWER WAVE

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.

–

VOLT METER

+

AMMETER

RESISTANCE

GRID

LOAD

POWER WAVE CALIBRATION

24 24

(32)

(34)

(36)

(64)

(33)

(35)

(37)

(65)

(67)

(96)

(97)

(98)

(99)

(100)

(101) (132)

(133)

(128)

(130)

(129)

(131)

CALIBRATION

SEMIAUTOMATIC PW450 CURRENT CALIBRATION (continued)

Figure 10 – TEST AND CALIBRATION OVERLAY

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.

WARNING

The machine’s output terminals will be electri­cally “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

25 25

CALIBRATION

ROBOTIC PW450 CURRENT CALIBRATION

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).

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.

Leads

POWER WAVE CALIBRATION

26 26

CALIBRATION

ROBOTIC 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 con­trol board. See Figure 8.

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

CAUTION

to the Power Wave the machine
may not display output volts.

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.

FIGURE 9 – RESISTANCE GRID LOAD CONNECTIONS

POWER WAVE

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.

–

VOLT METER

+

AMMETER

RESISTANCE

GRID

LOAD

POWER WAVE CALIBRATION

27 27

(32)

(34)

(36)

(64)

(33)

(35)

(37)

(65)

(67)

(96)

(97)

(98)

(99)

(100)

(101) (132)

(133)

(128)

(130)

(129)

(131)

CALIBRATION

ROBOTIC PW450 CURRENT CALIBRATION (continued)

Figure 10 – TEST AND CALIBRATION OVERLAY

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. Trigger the PW450 and apply the load. (See
EXTERNAL TRIGGERING CIRCUIT) on the
next page.

WARNING

The machine’s output terminals will be electri­cally “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

28 28

CALIBRATION

EXTERNAL TRIGGERING CIRCUIT

The Power Wave 450 Robotic may be triggered inde­pendent of the robot using the following circuit and pro­cedure.

1. Remove the large connector plug on the rear of the
PW450. (As viewed from the front of the machine).

2. Connect a normally open switch and a 24VDC sup-

ply either to the large connector plug (P82) or to the
harness connectors on the interface board. See the
following table and figure.

3. When the 24VDC supply is correctly wired in place
and turned on the welding output terminals can be
energized by closing the switch.

Voltage / Switch Signal P82 Connector Pins Interface Board

Connectors

24VDC @ 100ma P82 - r(+) J106 - 3 Wire #534

P82 - a(-) J106 - 4 Wire #535

Normally open switch P82 - R J105 - 4 Wire #518

P82 - P J105 - 12 Wire #527

A
B

P

R
S

Z
a

b
c

m
n
p
r
s

P82

ROBOT

RECEPTACLE

ARC START SWITCH

NEGATIVE

24VDC SUPPLY

POSITIVE

POWER WAVE CALIBRATION

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-con­ductive 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 trim­mer, the R 194, (reference Interface P.C.board drawing below). Once you have located the three trimmers, fol­low 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 the contactor pulls in, read the volt­meter. 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 nega­tive 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

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 (“ I =”) reading on the front of the power wave, while the
output is on.

The value shown must be less than (5) amps with the machine triggered. If after several triggers the value of the
shunt reading (“ I =”) 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

30 30

ROBOTIC INTERFACE CONNECTIONS

POWER WAVE INTERFACE BOARD

J101-1 +Serial loop CTRL J27-1
J101-2 High speed sense 1 P83-K
J101-3 High speed sense 2 P83-L
J101-4 -Serial loop CTRL J27-4

J103-1 +42VDC Full wave bridge
J103-2 -42VDC Full wave bridge
J103-3 Touch 2-4 output (2) PROT J34-4
J103-4 Touch 2-4 output (4) PROT J34-7
J103-5 Tach PWR P83-G
J103-6 Tach signal P83-F
J103-7 Tach GND P83-H
J103-8 Motor+ P83-A
J103-9 Motor- P83-B
J103-10 Weld 2-4 output (2) PROT J34-11
J103-11 Weld 2-4 output (4) PROT J34-14
J103-12 Gas solenoid+ P83-C
J103-13 Gas solenoid- P83-D
J103-14 67 Sense lead P83-N
J103-15
J103-16

J104-1 Voltage signal CTRL J21-4
J104-2 Current signal CTRL J21-7
J104-3 Water PWR D.K. J16-4
J104-4 +output signal SNUB J60-3
J104-5 -output signal SNUB J61-4
J104-6 Water signal D.K. J16-5
J104-7 Control GND CTRL J24-11
J104-8 TRIM command D.K. J10-12 (TIG)
J104-9 WFS command D.K. J10-2 (WF1)
J104-10 Display analog GND D.K. J10-13
J104-11 Water GND D.K. J16-12
J104-12 67 Sense lead SNUB J60-8

J105-1 Isolated voltage signal P82-J (ADCH1)
J105-2 Isolated current signal P82-L (ADCH2)
J105-3 Abnormal operation signal P82-h (WDI6)
J105-4 Arc start command P82-[ ]* (WDO1)
J105-5 Arc detect signal P82-d (WDI2)
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)
J105-10 Negative inch command P82-V (WDO5)
J105-11 Short detect signal (+) P82-N (WDI-)
J105-12 Short detect signal (-) P82-P (WDI-)
J105-13 Isolated water signal P82-g (WDI5)
J105-14 Touch sense command P82-T (WDO3)
J105-15 Voltage command P82-A (DACH1)
J105-16 WFS command P82-E (DACH2)

ARCTOOL WELDING INPUTS AND OUT­PUTS

CRW1-1 DACH1 Voltage command P82-A
CRW1-2 COMDA1 P82-F
CRW1-3 DACH2 WFS command P82-E
CRW1-4 COMDA2 WFS command GND P82-F
CRW1-5 WDI1 (Touch sense signal) P82-c
CRW1-6 WDI2 Arc detect P82-d
CRW1-7 WDI3 Gas fault P82-e
CRW1-8 WDI4 P82-f
CRW1-9 WDI5 Water fault P82-g
CRW1-10 WDI6 Power fault P82-h
CRW1-11 WDI7 P82-j
CRW1-12 WDI8 P82-k
CRW1-13 ADCH1 Voltage feedback P82-J
CRW1-14 COMAD1 P82-K
CRW1-15 ADCH2 Current feedback P82-L
CRW1-16 COMAD2 P82-M
CRW1-17
CRW1-18
CRW1-19 0V Robot GND P82-a
CRW1-20 0V P82-b
CRW1-21 0V P82-m
CRW1-22 0V P82-n
CRW1-23 WDO1 Weld start P82-R
CRW1-24 WDO2 Gas start P82-S
CRW1-25 WDO3 (Touch sense P82-T

CRW1-26 WDO4 Wire+ P82-U
CRW1-27 WDO5 Wire- P82-V
CRW1-28 WDO6 P82-W
CRW1-29 WDO7 (Dual procedure switch P82-X

CRW1-30 WDO8 (Spare robot output) P82-Z
CRW1-31 WDI+ Wire stick detect P82-N
CRW1-32 WDI- Wire stick detect P82-P
CRW1-33 +24V Robot PWR P82-r
CRW1-34 +24V Robot PWR P82-r

command)

command)

P82-H
P82-s

P82-R Fanuc models

*

P82-C Motoman models

MISCELLANEOUS CONNECTIONS

P84-A Gas shortage input
P84-B Gas shortage GND

J106-1 Touch sense signal CTRLJ24-4
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

POWER WAVE CALIBRATION

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 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 tech­nician.

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. Atripping breaker indicates a faulty I 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 indi­vidual 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
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

• World's Leader in Welding and Cutting Products •

• Sales and Service through Subsidiaries and Distributors Worldwide •

Cleveland, Ohio 44117-1199 U.S.A. TEL: [phone] FAX: [phone] WEB SITE: www.lincolnelectric.com