Page 2 - POWER WAVE CALIBRATION; INDEX OF PROCEDURES; CALIBRATION
2 2 POWER WAVE CALIBRATION INDEX OF PROCEDURES Capacitor discharge procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4Setup after Display Board replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ....
Page 3 - Electric Shock Can Kill; CAUTION
If the sensor calibration is not done, the display boardmay have some problems sensing the correct overlayon power up. The display is shipped with the water cooler disabled.If an internal water cooler is being used with the PowerWave, you must use the Setup Overlay L9660 toenable the water cooler be...
Page 4 - CAPACITOR DISCHARGE PROCEDURE; PURPOSE FOR THE PROCEDURE; WARNING
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 ormachine operator and will invalidate your factory warranty. For your safety and to avoid e...
Page 5 - TEST PROCEDURE; FIGURE 1 – RESISTOR LOCATIONS
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. Wi...
Page 6 - FIGURE 2 – DISCHARGE LABEL; ELECTRIC SHOCK can kill.
POWER WAVE CALIBRATION 6 6 CAPACITOR DISCHARGE PROCEDURE (continued) FIGURE 2 – DISCHARGE LABEL D I S CHAR G E D I SCHAR G E D I SCHAR G E D I SCHAR G E D I SCHAR G E CALIBRATION 9. Using the insulated, needle nose type jumper leads and insulated gloves, con-nect one jumper lead to one end of theres...
Page 7 - FIGURE 3 - RESISTOR WITH LEADS CONNECTED.
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 #9has positive polarity and terminal #12 hasnegative polarity. Voltage should be zero.If any voltage remains, repeat t...
Page 8 - SETUP FOR POWER WAVE 450 AFTER DISPLAY BOARD REPLACEMENT
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 app...
Page 9 - SENSOR CALIBRATION TEST (FOR DISPLAY BOARD); TEST DESCRIPTION
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 ormachine operator and will invalidate your factory warranty. For your safety ...
Page 10 - Figure 4 - SENSOR LOCATION BEHIND OVERLAY; PROCEDURE
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 themachine ON with no overlay in place and refer toFigure 4 to identify the keys...
Page 11 - SEMIAUTOMATIC PW450 QUICK VOLTAGE CALIBRATION; PROCEDURE DESCRIPTION
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 ormachine operator and will invalidate your factory warranty. For your safet...
Page 12 - Figure 5 - TEST AND CALIBRATION OVERLAY
12 12 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) (100) (101) (132) (133) (128) (130) (129) (131) CALIBRATION PROCEDURE 1. Before changing or disturbing the defective display board,...
Page 13 - ROBOTIC PW450 QUICK VOLTAGE CALIBRATION
CALIBRATION 13 13 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 ormachine operator and will invalidate your factory warranty. Fo...
Page 15 - SEMIAUTOMATIC PW450 FULL VOLTAGE CALIBRATION; SETUP PROCEDURE
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 ormachine operator and will invalidate your factory warranty. For your safety...
Page 16 - Figure 6 - TEST AND CALIBRATION OVERLAY
PROCEDURE 1. The voltage calibration numbers are stored in the display board. They are program-mable from the front panel using the Testand Calibration Overlay. 2. Change the PC board in question. 3. Install the Test and Calibration Overlay L9660-255 and power up the machine. SeeFigure 6. 4. Press t...
Page 17 - ROBOTIC PW450 FULL VOLTAGE CALIBRATION
CALIBRATION 17 17 POWER WAVE 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 ormachine operator and will invalidate you...
Page 18 - POWER
CALIBRATION 18 18 POWER PROCEDURE 1. The voltage calibration numbers are stored in the display board. They are program-mable from the front panel using the Testand Calibration Overlay. 2. Change the PC board in question. 3. Install the Test and Calibration Overlay L9660-255 and power up the machine....
Page 20 - Figure 7 - TEST AND CALIBRATION OVERLAY
20 20 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) (100) (101) (132) (133) (128) (130) (129) (131) CALIBRATION PROCEDURE 1. The voltage calibration numbers are sto...
Page 22 - SEMIAUTOMATIC PW450 CURRENT 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 ormachine operator and will invalidate your factory warranty. For your safety and ...
Page 23 - CURRENT CALIBRATION; EXPLODING PARTS CAN CAUSE INJURY.; FIGURE 9 – RESISTANCE GRID LOAD CONNECTIONS
23 23 SEMIAUTOMATIC PW450 CURRENT CALIBRATION (continued) CALIBRATION 2. Locate the 10 turn trimmer potentiometer located on the control board. It is the onlytrimmer on the board. If the trimmer is notaccessible with the control board installed,then the board must be removed and laidon the top of th...
Page 24 - Figure 10 – TEST AND CALIBRATION OVERLAY
24 24 SEMIAUTOMATIC PW450 CURRENT CALIBRATION (continued) CALIBRATION 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 K...
Page 25 - ROBOTIC PW450 CURRENT CALIBRATION; Figure 8 – PC BOARD REMOVED BUT STILL CONNECTED
CALIBRATION 25 25 POWER WAVE 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 ormachine operator and will invalidate your fac...
Page 28 - EXTERNAL TRIGGERING CIRCUIT; Voltage / Switch Signal; ROBOT
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. Connect a normally open switch and a 24VDC sup- ply either to the large connect...
Page 29 - QUICK SHUNT BOARD TEST; output; welding feed back test.
CALIBRATION 29 29 POWER WAVE 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-con-ductive insulating material is protecting the control board from touching any conductive surface. Locate the J1...
Page 30 - ROBOTIC INTERFACE CONNECTIONS; POWER WAVE INTERFACE BOARD
ROBOTIC INTERFACE CONNECTIONS 30 30 POWER WAVE CALIBRATION 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 Voltage signal CTRL J21-4 J104-2 Current signal CTRL J21-7 J104-3 Water ...
Page 31 - TEST PROCEDURE AFTER REPAIR
TEST PROCEDURE AFTER REPAIR 31 31 POWER WAVE CALIBRATION The following five steps should be completed after examining and or repairing a Power Wave 450R. These stepswill insure that all aspects and systems of the Power Wave are functioning. This procedure does not include fanoperation, or proper wat...
