CALIBRATION
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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 J109
receptacle. Directly next to the receptacle, are three trimmers side-by–side. We are interested in the center trim-
mer, the R 194, (reference Interface P.C.board drawing below). Once you have located the three trimmers, fol-
low 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 volt-
meter. 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 nega-
tive 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).
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.
INTERFACE P.C. BOARD
