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4. CHECK OF POWER MODULES
The power modules will be measured in dead condition.
Attention! Wait 5 minutes after switching off
Set your measurements to diode check range and check
on the primary rectifiers V1 and V21. (Red and blue cable)
Measurement:
foreward direction: OL
blocking direction: 0,6 - 0,9 V
Display if faulty:
0 V or 0,3 - 0,5 V —>
exchange of power module
4.1 Measurements after power module replacement
Before starting up check following:
disconnect the drive supplies
(3pole plugs X14/X15/X6/X7) on STP 3 and STPSP.
8 times 9,6 V AC
(middle connection is reference point)
Check the secondary diodes V2, V22 on diode check
range
Foreward direction ~ 0,15 V
Blocking direction OL
Attention! Exchange always all 8 parallel connected
diodes if they are faulty.
5. ADJUSTMENT OF ACTUAL-CURRENT VALUE
If there is a voltage of 3 V at the input of the "command value
PC" dial (measuring point: testing adapter on RTR-B), then a
welding current of 150 A must flow when the welding-current
circuit is closed.
These 150 A are measured by the current sensor HP 3 and
converted into a voltage —> 150 A = 1.5 V.
For making the adjustment, there are two dials on the HP 3 - one
for the offset adjustment (0V adjustment without welding cur-
rent), and one for the gain-adjustment in the medium welding-
current range (command value must be the same as the actual
welding current).
ADJUSTING MANUAL PLI3
I. INTERFACE
ADJUSTMENT
Fig. 3
PLI3
1. Allow unit to warm through for approx. 10 min.
2. OFFSET ADJUSTMENT
Connect the measuring unit to the TP 63 / GND -> RTR board
and set 0V +/-3mV on the "Offset" setting dial on the HP4.
3. GAIN ADJUSTMENT
Specify a command value of 75A and set 0.75 V on the TP63
(-RTR) with the P1 PLI3 board. Now adjust the output current
to 75A (as measured with the current measuring rod), using the
gain-adjustment dial on the HP4.
4. MINIMUM CORRECTION
Specify a command value of 20A and set an output current of
20A (as measured with the current measuring rod), using the
offset dial on the HP4. (Accuracy: +/-2A)
5. Repeat Pt. 3 (Accuracy: +/-0.5%)
6. Specify a command value of 50A for the current. On the TP63,
a voltage of 0.5V must be set with P1 (on the PLI3 board).
(Accuracy: +/-0.5%)
7. At an actual current value of 50A, set the value displayed by the
SPC to 50A, using P3 on the PLI3. (Accuracy: +/-1%)
8. Compare the command values and the actual values over the
entire range. Deviations: max. +/-2 DIGIT +/-2%.
9. ADJUSTING THE ACTUAL VOLTAGE VALUE
The welding voltage is measured on the current connectors of
the cathode. Set a voltage of 75V with P2 on the PLI3 board. Set
the SPC display to 75V. Check the minimum and maximum
values 10V - 150V. Accuracy: +/-2 DIGIT +/-2%.
II. ADJUSTING THE ARC CUT-OFF PARAMETERS
Any changes in the jumpers will only be recognised while the
machine is being switched on. Reconnecting the jumpers during
machine operation does not cause any change in the parameters.
If more than 5 arcs are detected within the pre-set period, the
machine cuts out. The yellow LED on board PLI3 lights up, a total
machine fault is triggered (interruption of digital interface X9, Pins
C1 and C2), and an additional fault is outputted (interruption of
digital interface X9, Pins C4 and C5). After the start signal is
removed, the faults are re-set.
If all the jumpers for the ARC counting time are opened, the arc
cut-off function is deactivated.
Blanking time
Dead time
Number of arcs
Counting interval
Threshold voltage
Start-up ramp
Start-up ramp
Threshold voltage: 3 jumpers
Designation S0 - S2
000
10%
001
21%
010
33%
011
44%
100
56%
101
67%
110
79%
111
90%
Counting interval: 7 jumpers
Designation
adjustable in 10 ms
000.0000
111.1111
14
permanent, 2.4 ms
permanent, 4.8 ms
permanent, 5
0.01 - 1.27 s
127 steps
10 - 90 %
8 steps
0 - 2 s
8 steps
0 - 60 V
8 steps
ZZ0 - ZZ6
Arc cut-off deactivated
127 * 10 ms 1.27 s
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