Lincoln Electric IM573 Calibration Information Manual
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Lincoln Electric IM573 Calibration Information Manual

Lincoln Electric IM573 Calibration Information Manual

Power wave pc board replacement calibration procedures
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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.
Date of Purchase:
Serial Number:
Code Number:
Model:
Where Purchased:
• Sales and Service through Subsidiaries and Distributors Worldwide •
Cleveland, Ohio 44117-1199 U.S.A. TEL: 216.481.8100 FAX: 216.486.1751 WEB SITE: www.lincolnelectric.com
RETURN TO MAIN MENU
CALIBRATION PROCEDURES
• World's Leader in Welding and Cutting Products •
September, 2002
Copyright © 2002 Lincoln Global Inc.
IM573

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  • Page 1 • World's Leader in Welding and Cutting Products • • Sales and Service through Subsidiaries and Distributors Worldwide • Cleveland, Ohio 44117-1199 U.S.A. TEL: 216.481.8100 FAX: 216.486.1751 WEB SITE: www.lincolnelectric.com RETURN TO MAIN MENU Copyright © 2002 Lincoln Global Inc. IM573 September, 2002...

  • Page 2: Table Of Contents

    Capacitor discharge procedure ..........4 Setup after Display Board replacement .
  • Page 3 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. WARNING Electric Shock Can Kill •...

  • Page 4: Capacitor Discharge Procedure

    CALIBRATION CAPACITOR DISCHARGE PROCEDURE 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.
  • Page 5 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.
  • Page 6 CAPACITOR DISCHARGE PROCEDURE (continued) 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, con- nect one jumper lead to one end of the resistor obtained in step 6.
  • Page 7 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.

  • Page 8: Setup After Display Board Replacement

    SETUP FOR POWER WAVE 450 AFTER DISPLAY BOARD REPLACEMENT 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.

  • Page 9: Display Sensor Calibration

    CALIBRATION SENSOR CALIBRATION TEST (FOR DISPLAY BOARD) 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.
  • Page 10 SENSOR CALIBRATION TEST (FOR DISPLAY BOARD) (continued) Figure 4 - SENSOR LOCATION BEHIND OVERLAY (32) (34) (36) (64) 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.

  • Page 11: Semiautomatic Pw450 Quick Voltage Calibration

    CALIBRATION SEMIAUTOMATIC PW450 QUICK VOLTAGE CALIBRATION 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.
  • Page 12 SEMIAUTOMATIC PW450 QUICK VOLTAGE CALIBRATION (continued) Figure 5 - TEST AND CALIBRATION OVERLAY (32) (34) (36) (64) 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.

  • Page 13: Robotic Pw450 Quick Voltage Calibration

    CALIBRATION ROBOTIC PW450 QUICK VOLTAGE CALIBRATION 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.
  • Page 14 CALIBRATION ROBOTIC PW450 QUICK VOLTAGE CALIBRATION (continued) Figure 5 - TEST AND CALIBRATION OVERLAY (32) (33) (34) (35) (36) (37) (96) (64) (65) (97) (67) PROCEDURE 1. Before changing or disturbing the defective display board, power up the machine with the L9660-255 Test and Calibration overlay in place.

  • Page 15: Semiautomatic Pw450 Full Voltage Calibration With Grid Load

    CALIBRATION SEMIAUTOMATIC PW450 FULL VOLTAGE CALIBRATION 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.
  • Page 16 SEMIAUTOMATIC PW450 FULL VOLTAGE CALIBRATION(continued) Figure 6 - TEST AND CALIBRATION OVERLAY (32) (34) (36) (64) 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.

  • Page 17: Robotic Pw450 Full Voltage Calibration With Grid Load

    CALIBRATION ROBOTIC PW450 FULL VOLTAGE CALIBRATION 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.
  • Page 18 ROBOTIC PW450 FULL VOLTAGE CALIBRATION(continued) Figure 6 - TEST AND CALIBRATION OVERLAY (32) (33) (34) (36) (65) (64) (67) 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.

  • Page 19: Semiautomatic Pw450 Full Voltage Calibration Using A Welding Arc

    SEMIAUTOMATIC PW450 FULL VOLTAGE CALIBRATION USING A WELDING ARC 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.
  • Page 20 SEMIAUTOMATIC PW450 FULL VOLTAGE CALIBRATION USING A WELDING ARC (continued) Figure 7 - TEST AND CALIBRATION OVERLAY (32) (34) (36) (64) PROCEDURE 1. The voltage calibration numbers are stored in the display board. They are programma- ble from the front panel using the Test and Calibration Overlay.
  • Page 21 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 volt- meter sense lead from the conductor block of the wire feeder to the positive output terminal on the front of the...

  • Page 22: Semiautomatic Pw450 Current Calibration

    CALIBRATION SEMIAUTOMATIC PW450 CURRENT CALIBRATION 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.
  • Page 23 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.
  • Page 24 SEMIAUTOMATIC PW450 CURRENT CALIBRATION (continued) Figure 10 – TEST AND CALIBRATION OVERLAY (32) (33) (34) (35) (36) (37) (65) (64) (67) 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 3.

  • Page 25: Robotic Pw450 Current Calibration

    CALIBRATION ROBOTIC PW450 CURRENT CALIBRATION 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.
  • Page 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.
  • Page 27 ROBOTIC PW450 CURRENT CALIBRATION (continued) Figure 10 – TEST AND CALIBRATION OVERLAY (32) (33) (34) (35) (36) (37) (64) (65) (67) 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 3.
  • Page 28 EXTERNAL 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 rear of the PW450. (As viewed from the front of the machine). 2.

  • Page 29: Robotic Interface P.c.board Calibration And Quick Shunt Board Test

    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.

  • Page 30: Robotic Interface Connections

    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...

  • Page 31: Test Procedures After Repair

    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.
  • Page 32 • World's Leader in Welding and Cutting Products • • Sales and Service through Subsidiaries and Distributors Worldwide • Cleveland, Ohio 44117-1199 U.S.A. TEL: 216.481.8100 FAX: 216.486.1751 WEB SITE: www.lincolnelectric.com...

This manual is also suitable for:

Power wave series

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