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RETURN TO MAIN MENU
IM986
November, 2008
POWER WAVE
i400
®
11536, 11536R
For use with machines having Code Numbers:
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 thought-
ful operation on your part.
And, most
importantly, think before you act
and be careful.
Copyright © Lincoln Global Inc.
• World's Leader in Welding and Cutting Products •
• 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
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Related Manuals for Lincoln Electric POWER WAVE IM986
Summary of Contents for Lincoln Electric POWER WAVE IM986
- Page 1 RETURN TO MAIN MENU IM986 November, 2008 POWER WAVE i400 ® 11536, 11536R For use with machines having Code Numbers: 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 ...
- Page 2 351040, Miami, Florida 33135 or CSA Standard W117.2-1974. A Free copy of “Arc Welding Safety” booklet E205 is available from the Lincoln Electric Company, 22801 St. Clair Avenue, Cleveland, Ohio 44117-1199. BE SURE THAT ALL INSTALLATION, OPERATION, MAINTENANCE AND REPAIR PROCEDURES ARE PERFORMED ONLY BY QUALIFIED INDIVIDUALS.
- Page 3 ELECTRIC SHOCK can kill. 3.a. The electrode and work (or ground) circuits are electrically “hot” when the welder is on. Do not touch these “hot” parts with your bare skin or wet clothing. Wear dry, hole-free gloves to insulate hands.
- Page 4 WELDING and CUTTING SPARKS can cause fire or explosion. 6.a. Remove fire hazards from the welding area. If this is not possible, cover them to prevent the welding sparks from starting a fire. Remember that welding materials from welding can easily go through small cracks and openings to adjacent areas.
- Page 5 PRÉCAUTIONS DE SÛRETÉ Pour votre propre protection lire et observer toutes les instructions et les précautions de sûreté specifiques qui parraissent dans ce manuel aussi bien que les précautions de sûreté générales suiv- antes: Sûreté Pour Soudage A LʼArc 1. Protegez-vous contre la secousse électrique: a.
- Page 6 (89/336/EEC). It was manufactured in conformity with a national standard that implements a harmonized standard: EN 60974-10 Electromagnetic Compatibility (EMC) Product Standard for Arc Welding Equipment. It is for use with other Lincoln Electric equipment. It is designed for industrial and professional use. Introduction All electrical equipment generates small amounts of electromagnetic emission.
- Page 7 SAFETY Electromagnetic Compatibility (EMC) The size of the surrounding area to be considered will depend on the structure of the building and other activities that are taking place. The surrounding area may extend beyond the boundaries of the premises. Methods of Reducing Emissions Mains Supply Welding equipment should be connected to the mains supply according to the manufacturerʼs recommenda- tions.
- Page 8 Electric for advice or information about their use of our products. We respond to our customers based on the best information in our posses- sion at that time. Lincoln Electric is not in a position to warrant or guarantee such advice, and assumes no liability, with respect to such infor- mation or advice.
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Page 9: Table Of Contents
viii Installation ...Section A Technical Specifications - POWER WAVE® i400...A-1, A-2 Safety Precautions...A-3 Location and Mounting ...A-3 Environmental Considerations...A-3 Lifting ...A-3 Stacking ...A-3 Electromagnetic Compatibility ...A-4 Input and Grounding Connections ...A-4 Input Connection...A-4 Connection Diagrams and Systems...A-5,A-6 Fanuc R30iA Controller Mounting ...A-7 Typical Integrated Systems (Single Arm)...A-8 Typical Stand Alone Systems (Single Arm) ...A-9 Typical Master / Slave System (Dual Arm) ...A-10... -
Page 10: Installation
TECHNICAL SPECIFICATIONS - JAPANESE POWER SOURCES - INPUT VOLTAGE AND CURRENT Model Duty Cycle 40% rating K2669-2 60% rating K2673-2 (Chassis Only) 100% rating Process Duty Cycle GMAW GMAW-Pulse FCAW GTAW-DC 100% RECOMMENDED INPUT WIRE AND FUSE SIZES Input 3 PHASE INPUT Amperes VOLTAGE (incl. - Page 11 INSTALLATION TECHNICAL SPECIFICATIONS - POWER WAVE® i400 (K2669-2, K2673-2) REGULATORY REQUIREMENTS (JAPANESE MODELS) MODEL Standard Enclosure Insulation Rating Class K2669-2 EN 60974-1 Class F EN 50199 IP21S (155°C) K2673-2 (Chassis Only) 3 Chassis ratings applicable only when installed as a replacement in the POWER WAVE® i400 cabinet. POWER WAVE®...
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Page 12: Location And Mounting
Read this entire installation section before you start installation. WARNING ELECTRIC SHOCK can kill. • Only qualified personnel should per- form this installation. • Turn the input power OFF at the dis- connect switch or fuse box before working on this equipment. Turn off the input power to any other equip- ment connected to the welding sys- tem at the disconnect switch or fuse... -
Page 13: Electromagnetic Compatibility
Using input wire sizes, fuses or circuit breakers smaller than recommended may result in "nuisance" shut-offs from welder inrush currents, even if the machine is not being used at high currents. Power Supply Connection for the Fanuc R30iA Controller The POWER WAVE®... -
Page 14: Connection Diagrams And Systems
CONNECTION DIAGRAMS AND SYSTEM System Part No. Identifier Power Source K2669-1 Integration Kit K2677-1 Integration Kit for Fanuc R30iA Controller. Includes industrial ethernet cable, power Wire Drive K2685-2 Power Source to Wire Drive K1785-xx 1 Control Cable K2163-xx Weld Cables -or- K1842-xx Robot Arm... -
Page 15: Optional Equipment
System Part No. Identifier K1796-xx mance in critical high speed pulse applications. Note: K1796 coaxial cable is equivalent to 1/0 standard cable. K2539 coaxial cable is equivalent to AWG #1 Coaxial Weld Cable standard cable. Connecting coaxial cables in parallel to increase current carrying capacity can significantly K2593-xx reduce their inductance minimizing properties, and is therefore NOT RECOMMENDED. -
Page 16: Fanuc R30Ia Controller Mounting
FANUC R30iA CONTROLLER MOUNTING FANUC Robotics R-30iA "a-cabinet" Controller with Integrated Op Box Power Wave i400 K2669-2 * Refer to Output Cable guidelines for recommended cable size in PowerWave i400 Instruction Manual. INSTALLATION * ArcLink XT Ethernet cable * Power cable ** Refer to Intergration kit K2677-1 instruction sheet POWER WAVE®... -
Page 17: Typical Integrated Systems (Single Arm
INSTALLATION TYPICAL INTEGRATED SYSTEMS (SINGLE ARM) POWER WAVE® i400... -
Page 18: Typical Stand Alone Systems (Single Arm
INSTALLATION TYPICAL STAND ALONE SYSTEMS (SINGLE ARM) POWER WAVE® i400... -
Page 19: Typical Master / Slave System (Dual Arm
A-10 A-10 INSTALLATION TYPICAL MASTER / SLAVE SYSTEM (DUAL ARM) POWER WAVE® i400... -
Page 20: Typical F355I Retrofit (Single Arm
A-11 A-11 INSTALLATION TYPICAL F355i RETROFIT (SINGLE ARM) POWER WAVE® i400... -
Page 21: Electrode And Work Connections, General Guidelines
In Table A.1 are copper cable sizes recommended for different currents and duty cycles. Lengths stipulated are the distance from the welder to work and back to the welder again. Cable sizes are increased for greater lengths primarily for the purpose of minimizing cable drop. -
Page 22: Cable Inductance, And Its Effects On Welding
Depending upon the process, inductance within the electrode and work cables can influence the volt- age apparent at the studs of the welder, and have a dramatic effect on performance. Remote voltage sense leads are used to improve the accuracy of the arc voltage information supplied to the control pc board. - Page 23 A-14 Work Voltage Sensing The POWER WAVE® i400 is configured at the factory to sense work voltage at the negative output stud (positive output polarity with remote Work Voltage Sensing disabled). CAUTION Negative electrode polarity operation WITHOUT use of a remote work sense lead (21) requires the Negative Electrode Polarity attribute to be set via the Fanuc Teach Pendant or with the Weld Manager Utility (included on the Power Wave...
- Page 24 A-15 • For circumferential applications, connect all work leads on one side of the weld joint, and all of the work volt- age sense leads on the opposite side, such that they are out of the current path. POWER SOURCE INSTALLATION POWER SOURCE...
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Page 25: Control Cable Connections
It is highly recommended that all external Ethernet equip- ment (cables, switches, etc.), as defined by the connection diagrams, be obtained through the Lincoln Electric Automation Division. It is critical that all Ethernet cables external to either a conduit or an enclosure are solid con- ductor, shielded cat 5e cable, with a drain. - Page 26 A-17 A-17 INSTALLATION Connections Between Power Source and Optional DeviceNet PLC Controller. Hard Automation applica- tions and some earlier model controllers may require DeviceNet connectivity to control the power source. DeviceNet can also be used to monitor welding data, and system status information. The optional K2780-1 DeviceNet Kit is available for this purpose.
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Page 27: Operation
ELECTRIC SHOCK can kill. FUMES AND GASES can be dangerous. WELDING SPARKS can cause fire or explosion. ARC RAYS can burn. OPERATION POWER WAVE® i400... -
Page 28: Graphic Symbols
GRAPHIC SYMBOLS THAT APPEAR ON THIS MACHINE OR IN THIS MANUAL INPUT POWER HIGH TEMPERATURE MACHINE STATUS CIRCUIT BREAKER WIRE FEEDER POSITIVE OUTPUT NEGATIVE OUTPUT 3 PHASE INVERTER INPUT POWER THREE PHASE DIRECT CURRENT OPERATION POWER WAVE® i400 OPEN CIRCUIT VOLTAGE INPUT VOLTAGE OUTPUT VOLTAGE... -
Page 29: Product Description
PRODUCT DESCRIPTION PRODUCT SUMMARY General Physical Description The POWER WAVE® i400 is intended as a replace- ment for the PW355i using an updated power and control platform to enhance performance and reliabili- ty. The POWER WAVE® i400 includes an integrated wire drive module and 14-pin MS-Style connection to support the PF-10R and Auto Drive 4R90. -
Page 30: Case Front Controls
CASE FRONT CASE FRONT CONTROL DESCRIPTION 1. Machine Status Indicator: A two color LED that indicates system errors. The POWER WAVE® i400 is equipped with two indicators. One is for the inverter power source, while the other indicates the status of the feeder control system. Normal opera- tion is a steady green light. -
Page 31: Case Back Controls
2. THERMAL INDICATOR (THERMAL OVERLOAD): A yellow light that comes on when an over temperature sit- uation occurs. Output is disabled and the fan continues to run, until the machine cools down. When cool, the light goes out and output is enabled. 3. -
Page 32: Duty Cycle
INTERNAL CONTROLS FIGURE B.3 INTERNAL CONTROLS DESCRIPTION 1. FUSE (F1): Primary circuit protection for auxiliary power (10A/600V). 2. ROBOT POWER TERMINAL BLOCK (4TB): Power sup- ply connection for Fanuc R30iA controller. Supplies pri- mary power through the ON/OFF switch directly to the robot controller. -
Page 33: Basic Welding Controls
Choose the electrode material, electrode size, shield- ing gas, and process (GMAW, GMAW-P etc.) appro- priate for the material to be welded. Select the weld mode that best matches the desired welding process. The standard weld set shipped with the Power Wave i400 encompasses a wide range of common processes that will meet most needs. - Page 34 Non Synergic CV In non-synergic modes, the machine behaves like a conventional power source. The WFS and voltage are independent adjustments. Therefore, to maintain the arc characteristics, the operator must adjust the voltage to compensate for any changes made to the WFS.
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Page 35: Accessories
ACCESSORIES OPTIONAL EQUIPMENT FACTORY INSTALLED None Available. FIELD INSTALLED K940-Work Voltage Sense Lead Kit K2670-[ ] CE Filter Kit K2677-1 Integration Kit COMPATIBLE LINCOLN EQUIPMENT K2685-2 Auto Drive 4R90 Wire feeder (14-pin control cable). K1780-2 Power Feed 10 Robotic Wire Drive For additional Information see Optional Equipment in the Installation Section. -
Page 36: Maintenance
WARNING ELECTRIC SHOCK can kill. • Do not touch electrically live parts or electrode with skin or wet clothing. • Insulate yourself from work and ground • Always wear dry insulating gloves. ------------------------------------------------------------------------ EXPLODING PARTS can cause injury. • Failed parts can explode or cause other parts to explode when power is applied. - Page 37 4. Remove the left case side by pulling out from the bottom. 5. Disconnect the chassis input power leads (1E, 2E & 3E) from terminal block “3TB” located in the cabinet reconnect area, and remove the chassis ground from the stud located in front the terminal block. 6.
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Page 38: Troubleshooting
HOW TO USE TROUBLESHOOTING GUIDE Service and Repair should only be performed by Lincoln Electric Factory Trained Personnel. Unauthorized repairs performed on this equipment may result in danger to the technician and 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. -
Page 39: Using The Status Led To Troubleshoot System Problems
USING THE STATUS LED TO TROUBLESHOOT SYSTEM PROBLEMS The POWER WAVE® i400 is equipped with two exter- nally mounted status lights, one for the power source, and one for the wire drive module contained in the power source. If a problem occurs it is important to note the condition of the status lights. -
Page 40: Error Codes For Power Wave
Observe all Safety Guidelines detailed throughout this manual ERROR CODES FOR THE POWER WAVE® The following is a partial list of possible error codes for the POWER WAVE® i400. For a complete listing consult the Service Manual for this machine. Error Code # Primary (Input) overcurrent error. - Page 41 Observe all Safety Guidelines detailed throughout this manual ERROR CODES FOR THE POWER WAVE® The following is a partial list of possible error codes for the POWER WAVE® i400. For a complete listing consult the Service Manual for this machine. Error Code # (FANUC#) Motor Overload...
- Page 42 Machine will not power up (no lights) If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, con- tact your local authorized Lincoln Electric Field Service Facility for technical assistance. TROUBLESHOOTING POSSIBLE...
- Page 43 Thermal LED is ON. If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, con- tact your local authorized Lincoln Electric Field Service Facility for technical assistance. TROUBLESHOOTING POSSIBLE CAUSE 1.
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Page 44: Troubleshooting Guide
Wire burns back to tip when the arc is initiated. If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, con- tact your local authorized Lincoln Electric Field Service Facility for technical assistance. TROUBLESHOOTING POSSIBLE CAUSE 1. - Page 45 Observe all Safety Guidelines detailed throughout this manual PROBLEMS (SYMPTOMS) Wire burns back to tip at the end of the weld. Machine output shuts down during a weld. Machine wonʼt produce full output. Excessively long and erratic arc. Arc loss fault on robot. If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed.
- Page 46 Observe all Safety Guidelines detailed throughout this manual PROBLEMS (SYMPTOMS) Arc loss fault on robot. PROBLEMS (SYMPTOMS) Device does not go on Line. If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed.
- Page 47 E-10 Observe all Safety Guidelines detailed throughout this manual PROBLEMS (SYMPTOMS) Device goes off line during welding. Output will not come on. If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed.
- Page 48 E-11 Observe all Safety Guidelines detailed throughout this manual PROBLEMS (SYMPTOMS) Output will not come on. Bad Weld Starting. If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed.
- Page 49 E-12 Observe all Safety Guidelines detailed throughout this manual PROBLEMS (SYMPTOMS) Analog Inputs donʼt respond or donʼt respond quickly. Gas purge not working. If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed.
- Page 50 E-13 Observe all Safety Guidelines detailed throughout this manual PROBLEMS (SYMPTOMS) Bad Weld Ending. Bad Welding. If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed. TROUBLESHOOTING POSSIBLE CAUSE...
- Page 51 E-14 Observe all Safety Guidelines detailed throughout this manual PROBLEMS (SYMPTOMS) Bad Welding. PROBLEMS (SYMPTOMS) Cannot Connect. Connection Drops while welding. If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed.
- Page 52 DIAGRAMS Enhanced Diagam POWER WAVE® i400...
- Page 53 DIMENSION PRINT POWER WAVE® i400...
- Page 54 NOTES POWER WAVE® i400...
- Page 55 WARNING Spanish AVISO DE PRECAUCION French ATTENTION German WARNUNG Portuguese ATENÇÃO Japanese Chinese Korean Arabic...
- Page 56 Spanish PRECAUCION French ATTENTION German WARNUNG Portuguese Japanese Chinese Korean Arabic WARNING AVISO DE ATENÇÃO...
- Page 57 • World's Leader in Welding and Cutting Products • • 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...