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Lincoln Electric IM573 manual

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Table of contents for the manual

  • Page 1

    CALIBRA TION PROCEDURES IM573 September , 2002 PO WER W A VE PC BOARD REPLA CEMENT CALIBRA TION PROCEDURES Safety Depends on Y ou Lincoln arc welding and cutting equipment is designed and built with safety in mind. However , your overall safety can be increased by pr oper installation . . . and thoughtful operation on your part. DO NOT INST ALL, OP[...]

  • Page 2

    2 2 POWER W A VE CALIBRA TION INDEX OF PROCEDURES Capacitor discharge procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4 Setup after Display Board replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8 Display sensor calibration . . . . . . . . .[...]

  • Page 3

    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 W ave, you must use the Setup Overlay L9660 to enable the water cooler before using the system. ---------------------[...]

  • Page 4

    CAP ACITOR DISCHARGE PROCEDURE Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may r esult 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 [...]

  • Page 5

    POWER W A VE CALIBRA TION 5 5 CAP ACITOR DISCHARGE PROCEDURE (continued) CALIBRA TION TEST PROCEDURE 1. Remove main input supply power to the machine. 2. With the 3/8" nut driver , remove the scr ews 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 [...]

  • Page 6

    POWER W A VE CALIBRA TION 6 6 CAP ACITOR 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 G E D I S C H A R G E D I S C H A R G E CALIBRA TION 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[...]

  • Page 7

    7 7 CAP ACITOR DISCHARGE PROCEDURE (continued) FIGURE 3 - RESISTOR WITH LEADS CONNECTED. CALIBRA TION 11. Check the voltage acr oss terminals #9 and #12 with the DC voltmeter . T erminal #9 has positive polarity and terminal #12 has negative polarity . V oltage should be zero. If any voltage remains, r epeat this capaci- tor dischar ge procedure. 1[...]

  • Page 8

    Setting up the SemiAutomatic Power W ave 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 W ave on. 2. For the majority of applications, the wire feeder LED’s should loo[...]

  • Page 9

    SENSOR CALIBRA TION TEST (FOR DISPLA Y BOARD) Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may r esult in danger to the technician or machine operator and will invalidate your factory warranty . For your safety and to avoid elec- trical shock, please obse[...]

  • Page 10

    10 10 SENSOR CALIBRA TION TEST (FOR DISPLA Y BOARD) (continued) Figure 4 - SENSOR LOCA TION BEHIND OVERLA Y CALIBRA TION PROCEDURE 1. Insert the CALIBRA TION 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 di[...]

  • Page 11

    SEMIAUTOMA TIC PW450 QUICK VOL T AGE CALIBRA TION Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may r esult in danger to the technician or machine operator and will invalidate your factory warranty . For your safety and to avoid elec- trical shock, please [...]

  • Page 12

    12 12 SEMIAUTOMA TIC PW450 QUICK VOL T AGE CALIBRA TION (continued) Figure 5 - TEST AND CALIBRA TION OVERLA Y (32) (34) (36) (64) (33) (35) (37) (65) (67) (96) (97) (98) (99) (100) (101) (132) (133) (128) (130) (129) (131) CALIBRA TION PROCEDURE 1. Before changing or disturbing the defective display board, power up the machine with the L9660-255 T [...]

  • Page 13

    CALIBRA TION 13 13 ROBOTIC PW450 QUICK VOL T AGE CALIBRA TION Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may r esult in danger to the technician or machine operator and will invalidate your factory warranty . For your safety and to avoid elec- trical sh[...]

  • Page 14

    CALIBRA TION 14 14 POWER W A VE CALIBRA TION ROBOTIC PW450 QUICK VOL T AGE CALIBRA TION (continued) Figure 5 - TEST AND CALIBRA TION OVERLA Y (32) (34) (36) (64) (33) (35) (37) (65) (67) (96) (97) (98) (99) (100) (101) (132) (133) (128) (130) (129) (131) PROCEDURE 1. Before changing or disturbing the defective display board, power up the machine wi[...]

  • Page 15

    SEMIAUTOMA TIC PW450 FULL VOL T AGE CALIBRA TION Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may r esult in danger to the technician or machine operator and will invalidate your factory warranty . For your safety and to avoid elec- trical shock, please o[...]

  • Page 16

    PROCEDURE 1. The voltage calibration numbers ar e stored in the display board. They ar e program- mable from the fr ont panel using the T est and Calibration Overlay . 2. Change the PC board in question. 3. Install the T est and Calibration Overlay L9660-255 and power up the machine. See Figure 6. 4. Press the V oltage Calibration function (32). Th[...]

  • Page 17

    CALIBRA TION 17 17 POWER W A VE CALIBRA TION ROBOTIC PW450 FULL VOL T AGE CALIBRA TION Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may r esult in danger to the technician or machine operator and will invalidate your factory warranty . For your safety and[...]

  • Page 18

    CALIBRA TION 18 18 POWER PROCEDURE 1. The voltage calibration numbers ar e stored in the display board. They ar e program- mable from the fr ont panel using the T est and Calibration Overlay . 2. Change the PC board in question. 3. Install the T est and Calibration Overlay L9660-255 and power up the machine. See Figure 6. 4. Press the V oltage Cali[...]

  • Page 19

    SEMIAUTOMA TIC PW450 FULL VOL T AGE CALIBRA TION USING A WELDING ARC Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may r esult in danger to the technician or machine operator and will invalidate your factory warranty . For your safety and to avoid elec- tr[...]

  • Page 20

    20 20 SEMIAUTOMA TIC PW450 FULL VOL T AGE CALIBRA TION USING A WELDING ARC (continued) Figure 7 - TEST AND CALIBRA TION OVERLA Y (32) (34) (36) (64) (33) (35) (37) (65) (67) (96) (97) (98) (99) (100) (101) (132) (133) (128) (130) (129) (131) CALIBRA TION PROCEDURE 1. The voltage calibration numbers ar e stored in the display board. They ar e progra[...]

  • Page 21

    21 21 SEMIAUTOMA TIC PW450 FULL VOL T AGE CALIBRA TION USING A WELDING ARC (continued) CALIBRA TION – POLARITY (+21A) + POLARITY – POLARITY NOTE: Do not attempt to weld for –Polarity (+21A). Set the number to the same as recor ded for +Polarity (+67A). Also for +Polarity and –Polarity , move the volt- meter sense lead from the conductor blo[...]

  • Page 22

    SEMIAUTOMA TIC PW450 CURRENT CALIBRA TION Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may r esult 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 [...]

  • Page 23

    23 23 SEMIAUTOMA TIC PW450 CURRENT CALIBRA TION (continued) CALIBRA TION 2. Locate the 10 tur n trimmer potentiometer located on the control boar d. It is the only trimmer on the board. If the trimmer is not accessible with the control boar d installed, then the board must be r emoved and laid on the top of the PC board compartment. Be sure the con[...]

  • Page 24

    24 24 SEMIAUTOMA TIC PW450 CURRENT CALIBRA TION (continued) CALIBRA TION PROCEDURE 1. Install the T est and Calibration Overlay and apply power to the machine. See Figure 10. 2. Press the Manual Pr ocedure Entry Key (64). The machine should display the following: PROCESS 1 SETUP 1-0 3. T oggle the Arrow Keys (100 and 101) until the display reads: P[...]

  • Page 25

    CALIBRA TION 25 25 POWER W A VE CALIBRA TION ROBOTIC PW450 CURRENT CALIBRA TION Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may r esult in danger to the technician or machine operator and will invalidate your factory warranty . For your safety and to avo[...]

  • Page 26

    CALIBRA TION 26 26 POWER W A VE CALIBRA TION ROBOTIC PW450 CURRENT CALIBRA TION (continued) 2. Locate the 10 tur n trimmer potentiometer located on the control boar d. It is the only trimmer on the board. If the trimmer is not accessible with the control boar d installed, then the board must be r emoved and laid on the top of the PC board compartme[...]

  • Page 27

    CALIBRA TION 27 27 POWER ROBOTIC PW450 CURRENT CALIBRA TION (continued) PROCEDURE 1. Install the T est and Calibration Overlay and apply power to the machine. See Figure 10. 2. Press the Manual Pr ocedure Entry Key (64). The machine should display the following: PROCESS 1 SETUP 1-0 3. T oggle the Arrow Keys (100 and 101) until the display reads: PR[...]

  • Page 28

    The Power W ave 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. Connect a normally open switch and a 24VDC sup- ply either to the large connector plug (P82) or to the harness connectors on t[...]

  • Page 29

    CALIBRA TION 29 29 POWER W A VE CALIBRA TION ROBOTIC INTERF ACE P .C. BOARD CALIBRA TION Position Interface board on top of the power wave so that the component side is up. Make certain a non-con- ductive insulating material is protecting the control board from touching any conductive surface. Locate the J109 receptacle. Directly next to the recept[...]

  • Page 30

    ROBOTIC INTERF ACE CONNECTIONS 30 30 POWER W A VE CALIBRA TION ARCTOOL WELDING INPUTS AND OUT- PUTS 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 J104-1 V oltage signal CTRL J21-4 J104-2 Current signal CTRL J21-7 J104-3 W ater PWR D.K. J16-4 J104-4 +output signal SNUB J[...]

  • Page 31

    TEST PROCEDURE AFTER REP AIR 31 31 POWER W A VE CALIBRA TION The following five steps should be completed after examining and or repairing a Power W ave 450R. These steps will insure that all aspects and systems of the Power W ave are functioning. This procedure does not include fan operation, or proper water cooler operation, both of which are ind[...]

  • Page 32

    • Sales and Service through Subsidiaries and Distributors Worldwide • Cleveland, Ohio 441 17-1 199 U.S.A. TEL: 216.481.8100 F AX: 216.486.1751 WEB SITE: www .lincolnelectric.com • World's Leader in W elding and Cutting Products •[...]