Lincoln Electric IM573 Gebrauchs- und Pflegehandbuch

CALIBRATION PROCEDURES

IM573

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:

• 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

• World's Leader in Welding and Cutting Products •

2 2

POWER WAVE 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

CALIBRATION

CAPACITOR

DISCHARGE

PROCEDURE

DISPLAY

BOARD

REPLACED

ROBOTIC

PW450

SETUP

SEMI-

AUTOMATIC

PW450

SETUP

CONTROL

BOARD

REPLACED

DISPLAY

SENSOR

CALIBRATION

CURRENT

CALIBRATION

CURRENT

CALIBRATION

QUICK

VOLTAGE

CALIBRATION

(IF POSSIBLE)

FULL

VOLTAGE

CALIBRATION

INTERFACE

BOARD

CALIBRATION

INTERFACE

BOARD

REPLACEMENT

INTERFACE

BOARD

REPLACEMENT

INTERFACE

BOARD

CALIBRATION

FULL

VOLTAGE

CALIBRATION

SNUBBER

BOARD

REPLACED

SHUNT AMPLIFIER

BOARD

REPLACED

CURRENT

CALIBRATION

FULL

VOLTAGE

CALIBRATION

ROBOT TEST PROCEDURES AFTER REPAIR

If the sensor calibration is not done, the display board

may have some problems sensing the correct overlay

on power up.

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.

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.

Electric Shock Can Kill

• Only qualified personnel should ser-

vice this equipment.

• Do not touch electrically hot parts.

• 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.

CALIBRATION

3 3

POWER WAVE CALIBRATION

CAUTION

WARNING

POWER WAVE PC BOARD REPLACEMENT CALIBRATION PROCEDURES

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.

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 requires 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

WARNING

CALIBRATION

4 4

POWER WAVE CALIBRATION

5 5

CAPACITOR DISCHARGE PROCEDURE (continued)

CALIBRATION

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 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.

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

FIGURE 1 – RESISTOR LOCATIONS

5 PAIRS OF RESISTORS

CHECK VOLTAGES BETWEEN

EACH TERMINAL AND FROM

EACH RESISTOR TO CASE

GROUND

POWER WAVE CALIBRATION

6 6

CAPACITOR DISCHARGE PROCEDURE (continued)

FIGURE 2 – DISCHARGE LABEL

CALIBRATION

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!

WARNING

ELECTRIC SHOCK can kill.

Proceed with caution. Be careful not to touch any internal machine components

during the discharge procedure.

7 7

CAPACITOR DISCHARGE PROCEDURE (continued)

FIGURE 3 - RESISTOR WITH LEADS CONNECTED.

CALIBRATION

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.

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

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 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 offby 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.

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. 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

CALIBRATION

8 8

POWER WAVE CALIBRATION

WARNING

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.

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

WARNING

CALIBRATION

9 9

POWER WAVE CALIBRATION

10 10

SENSOR CALIBRATION TEST (FOR DISPLAY BOARD) (continued)

Figure 4 - SENSOR LOCATION BEHIND OVERLAY

CALIBRATION

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 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.

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-

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 the DISPLAY

board.

6. 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 . . .

7. Press key #133 - 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

(32)

(34)

(36)

(64)

(33)

(35)

(37)

(65)

(67)

(96)

(97)

(98)

(99)

(100)

(101) (132) (133)

(128)

(130)

(129)

(131)

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