Lincoln Electric POWER WAVE IM986 manual

• 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 • World's Leader in Welding and Cutting Products • PO WER W A VE ® i400 OPERA TOR’S MANUAL IM986 November , 2008 Safety Depends on You Lincoln arc welding and c[...]

FOR ENGINE powered equipment. 1.a. Turn the engine off before troubleshooting and maintenance work unless the maintenance work requires it to be running. ____________________________________________________ 1.b. Operate engines in open, well-ventilated areas or vent the engine exhaust fumes outdoors. ________________________________________________[...]

ARC RA YS can burn. 4.a. Use a shield with the proper filter and cover plates to protect your eyes from sparks and the rays of the arc when welding or observing open arc welding. Headshield and filter lens should conform to ANSI Z87. I standards. 4. b. Use suitable clothing made from durable flame-resistant material to protect your skin and that of[...]

FOR ELECTRICALL Y powered equipment. 8.a. Turn off input power using the disconnect switch at the fuse box before working on the equipment. 8 .b . Install equipment in accordance with the U.S. National Electrical Code, all local codes and the manufacturerʼs recommendations. 8.c. Ground the equipment in accordance with the U.S. National Electrical [...]

Mar. ʻ93 iv SAFETY iv 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. Les c[...]

v SAFETY v Electromagnetic Compatibility (EMC) Conformance Products displaying the CE mark are in conformity with European Community Council Directive of 3 May 1989 on the approximation of the laws of the Member States relating to electromagnetic compatibility (89/336/EEC). It was manufactured in conformity with a national standard that implements [...]

vi SAFETY vi 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 mai[...]

vii vii Thank You for selecting a QUALITY product by Lincoln Electric. We want you to take pride in operating this Lincoln Electric Company product ••• as much pride as we have in bringing this product to you! Read this Operators Manual completely before attempting to use this equipment. Save this manual and keep it handy for quick reference.[...]

viii T ABLE OF CONTENTS Page Installation .......................................................................................................Section A Technical Specifications - POWER WAVE® i400 ..........................................A-1, A-2 Safety Precautions.................................................................................[...]

A-1 INST ALLA TION POWER WAVE® i400 A-1 TECHNICAL SPECIFICA TIONS - POWER W A VE® i400 (K2669-2, K2673-2) RA TED OUTPUT RECOMMENDED INPUT WIRE AND FUSE SIZES 1 PHYSICAL DIMENSIONS TEMPERA TURE RANGES 3 PHASE INPUT VOLTAGE 50/60Hz 200/208 3 Input Amperes (incl. robot and aux. load) 66 (86) HEIGHT 22.7 in. (577 mm) 21.0 in. (533 mm) MODEL K2669-2 K[...]

A-2 INST ALLA TION POWER WAVE® i400 A-2 TECHNICAL SPECIFICA TIONS - POWER W A VE® i400 (K2669-2, K2673-2) 3 Chassis ratings applicable only when installed as a replacement in the POWER WAVE® i400 cabinet. REGULA T ORY REQUIREMENTS (JAP ANESE MODELS) MODEL K2669-2 K2673-2 3 (Chassis Only) Standard EN 60974-1 EN 50199 Enclosure Rating IP21S Insula[...]

A-3 INST ALLA TION POWER WAVE® i400 A-3 LOCA TION AND MOUNTING The POWER WAVE® i400 case is designed to sup- port the Fanuc R30iA controller and op box (up to 300lbs), matching the controllerʼs footprint and styling. Mounting is externally accessible for simplified inte- gration. The flexibility of the POWER WAVE® i400 also allows it to be oper[...]

A-4 INST ALLA TION POWER WAVE® i400 A-4 ELECTROMAGNETIC COMP A TIBILITY (EMC) The EMC classification of the POWER WAVE® i400 is Industrial, Scientific and Medical (ISM) group 2, class A. The POWER WAVE® i400 is for industrial use only. (See prints L10093-1, -2 Safety Pages in the front of Instruction Manual for further details). Locate the POWER[...]

A-5 INST ALLA TION POWER WAVE® i400 A-5 System Identifier Power Source Integration Kit Wire Drive Power Source to Wire Drive Control Cable Weld Cables Robot Arm Robot Controller Torch Part No . K2669-1 K2677-1 K2685-2 K1785-xx 1 K2163-xx -or- K1842-xx Kxxxx Kxxxx Kxxxx Description POWER WAVE® i400 Power Source (includes S26064 POWER WAVE® Utilit[...]

A-6 INST ALLA TION POWER WAVE i400 A-6 System Identifier Coaxial Weld Cable External Dress Cable for Robot Arm Personal Computer Replacement Chassis Part No . K1796-xx K2593-xx K2709-xx Customer Supplied K2673-2 Description Coax Cable. Recommended to minimize the effects of the weld cable loop inductance and maximize perfor- mance in critical high [...]

A-7 INST ALLA TION POWER WAVE® i400 A-7 FANUC R30iA CONTROLLER MOUNTING FANU C Robotics R-30i A "a-cabinet" C ontroller with Integrat ed Op Box Power W ave i400 K2669-2 * ArcLink XT Ethernet cab le * Power cable DETAI L A A * Refer to Output Cable guidelines for recommended cable si ze in PowerWave i400 Instruction Manua l . ** Refer to [...]

A-8 INST ALLA TION POWER WAVE® i400 A-8 TYPICAL INTEGRATED SYSTEMS (SINGLE ARM) ArcL ink X T Ethernet Connection Voltage Sens e Connec t or Wire Feeder Connector Power W av e i400 K2669-2 Optional Work Sense Lead (21) Wire Feeder Control Cabl e K1785-X X ArcL ink X T Ethe rnet C able (Interna l) * Electrode Cabl e (+) K2163-xx or K1842-xx * Refer [...]

A-9 INST ALLA TION POWER WAVE® i400 A-9 TYPICAL STAND ALONE SYSTEMS (SINGLE ARM) Device net Connector Wire Feeder Connector Circuit Bre aker (15 Amp) ArcL ink XT Ethernet Connec t or Voltage Sense Connector ArcLink Connector ArcL ink XT Ethernet Cab l e FANU C Robotics R-30i A "a-cabinet" C ontroller with Integrated Op Box Power W a ve i[...]

A-10 INST ALLA TION POWER WAVE® i400 A-10 TYPICAL MASTER / SLAVE SYSTEM (DUAL ARM) FANU C Robotics R-30i A "a-cabinet" Co ntroller with Integ rated Op Box (Master) FANU C Robotics R-30iA "a-cabinet " Controller with Integrated Op Box (Slave) Optional Work Sense Lead (21) Optional Work Sense Lead (21) * W ork Cabl e (-) * W ork [...]

A-11 INST ALLA TION POWER WAVE® i400 A-11 TYPICAL F355i RETROFIT (SINGLE ARM) Power W av e i400 K2669-2 FANU C Robotics R-J 3iB Contro ller * Electrode Cable (+) K2163-xx or K1842-xx Optiona l W or k Sense Lead (21) Wire Feeder Control Cabl e K1785-X X ArcLink Contro l Cable K1543-X X * Refer to Output Cab le Gu i delines for recomm ended cab l e [...]

GENERAL GUIDELINES • Select the appropriate size cables per the “Output Cable Guidelines” in Table A.1 . Excessive voltage drops caused by undersized welding cables and poor connections often result in unsatisfactory welding performance. Always use the largest welding cables (electrode and work) that are practical, and be sure all connections[...]

A-13 INST ALLA TION POWER WAVE® i400 A-13 General Guidelines for Voltage Sense Leads Sense leads should be attached as close to the weld as practical, and out of the weld current path when possible. In extremely sensitive applications it may be necessary to route cables that contain the sense leads away from the electrode and work welding cables. [...]

If a remote work voltage sense lead is used, it must be enabled through the Fanuc Teach Pendant or with the Weld Manager Utility (includ- ed on the Power Wave Utilities and Service Navigator CDʼs or available at www.powerwavesoftware.com). ------------------------------------------------------------------------ Voltage Sensing Considerations for M[...]

A-15 INST ALLA TION POWER WAVE® i400 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. PO WER SOURCE #2 PO WER SOURCE #1 PO WER SOURCE #1 PO WER SOURCE #2 PO WER SOURCE #2 PO WER SOURCE #1[...]

A-16 INST ALLA TION POWER WAVE® i400 A-16 CONTROL CABLE CONNECTIONS General Guidelines Genuine Lincoln control cables should be used at all times (except where noted otherwise). Lincoln cables are specifically designed for the communication and power needs of the POWER WAVE® / Power Feed sys- tems. Most are designed to be connected end to end for[...]

A-17 INST ALLA TION POWER WAVE® i400 A-17 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 [...]

B-1 OPERA TION B-1 POWER WAVE® i400 SAFETY PRECAUTIONS Read this entire section of operating instructions before operating the machine. ELECTRIC SHOCK can kill. • Unless using cold feed feature, when feeding with gun trigger, the elec- trode and drive mechanism are always electrically energized and could remain energized several sec- onds after [...]

B-2 OPERA TION B-2 POWER WAVE® i400 INPUT POWER ON OFF HIGH TEMPERA TURE MACHINE ST A TUS CIRCUIT BREAKER WIRE FEEDER POSITIVE OUTPUT NEGA TIVE OUTPUT 3 PHASE INVERTER INPUT POWER THREE PHASE DIRECT CURRENT OPEN CIRCUIT VOL T AGE INPUT VOL T AGE OUTPUT VOL T AGE INPUT CURRENT OUTPUT CURRENT PROTECTIVE GROUND W ARNING or CAUTION Explosion Dangerous[...]

B-3 OPERA TION B-3 PRODUCT DESCRIPTION PRODUCT SUMMAR Y 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[...]

B-4 OPERA TION B-4 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. . Basic error conditi[...]

B-5 OPERA TION B-5 POWER WAVE® i400 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. CIRCUIT BREAKER (CB1 - 15 AMP): Protects the 40 volt DC supply[...]

I NTERNAL 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. This input power pass-through connection is intended to supply power e[...]

B-7 OPERA TION B-7 POWER WAVE® i400 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[...]

B-8 OPERA TION POWER WAVE® i400 B-8 Pulse welding modes are synergic; using wire feed speed as the main control parameter. As the wire feed speed is adjusted, the power source adjusts the waveform parameters to maintain good welding char- acteristics. The Power Wave i400 can also be config- ured to use amperage as the dominant control para- meter.[...]

C-1 ACCESSORIES C-1 OPTIONAL EQUIPMENT F ACTOR Y INST ALLED None Available. FIELD INST ALLED K940-Work Voltage Sense Lead Kit K2670-[ ] CE Filter Kit K2677-1 Integration Kit COMP A TIBLE 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 Equi[...]

CHASSIS REMOV AL PROCEDURE ELECTRIC SHOCK can kill. • Disconnect input power before servicing. • Do not operate with covers removed. • Do not touch electrically live parts. • Only qualified persons should install, use or service this equipment. ------------------------------------------------------------------------ (See Figure D.1) 1. Turn[...]

D-2 MAINTENANCE D-2 POWER WAVE® i400 FIGURE D.1a 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 . Carefully slide the cha[...]

E-1 TROUBLESHOOTING E-1 POWER WAVE® i400 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. CAUTION This Troubleshooting Guide is provided to help you locate and repai[...]

E-2 TROUBLESHOOTING E-2 POWER WAVE® i400 USING THE ST A TUS 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. The[...]

LECO (FANUC#) 49 50 51 52 53 54 55 57 67 84 see com- plete listing POWER SOURCE ––– WELD CONTROLLER E-3 TROUBLESHOOTING E-3 POWER WAVE® i400 Observe all Safety Guidelines detailed throughout this manual If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your Local Lincoln Au[...]

LECO (FANUC#) 129 130 131 132 E-4 TROUBLESHOOTING E-4 POWER WAVE® i400 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. CAUTION WIRE DRIVE MODULE Observe all Safety [...]

E-5 TROUBLESHOOTING E-5 POWER WAVE® i400 Observe all Safety Guidelines detailed throughout this manual TROUBLESHOOTING GUIDE Observe Safety Guidelines detailed in the beginning of this manual. CAUTION 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 Linco[...]

E-6 TROUBLESHOOTING E-6 POWER WAVE® i400 Observe all Safety Guidelines detailed throughout this manual TROUBLESHOOTING GUIDE Observe Safety Guidelines detailed in the beginning of this manual. CAUTION 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 Linco[...]

E-7 TROUBLESHOOTING E-7 POWER WAVE® i400 Observe all Safety Guidelines detailed throughout this manual TROUBLESHOOTING GUIDE Observe Safety Guidelines detailed in the beginning of this manual. CAUTION 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 Linco[...]

E-8 TROUBLESHOOTING E-8 POWER WAVE® i400 Observe all Safety Guidelines detailed throughout this manual 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. CAUTION PROBL[...]

E-9 TROUBLESHOOTING E-9 POWER WAVE® i400 Observe all Safety Guidelines detailed throughout this manual 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. CAUTION PROBL[...]

E-10 TROUBLESHOOTING E-10 POWER WAVE® i400 Observe all Safety Guidelines detailed throughout this manual 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. CAUTION PRO[...]

E-11 TROUBLESHOOTING E-11 POWER WAVE® i400 Observe all Safety Guidelines detailed throughout this manual 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. CAUTION PRO[...]

E-12 TROUBLESHOOTING E-12 POWER WAVE® i400 Observe all Safety Guidelines detailed throughout this manual 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. CAUTION PRO[...]

E-13 TROUBLESHOOTING E-13 POWER WAVE® i400 Observe all Safety Guidelines detailed throughout this manual 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. CAUTION PRO[...]

E-14 TROUBLESHOOTING E-14 POWER WAVE® i400 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. CAUTION PROBLEMS (SYMPTOMS) POSSIBLE CAUSE RECOMMENDED COURSE OF ACTION E[...]

F-1 DIAGRAMS F-1 POWER WAVE® i400 NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. The specific diagram for a particular code is pasted inside the machine on one of the enclosure panels. If the diagram is illegible, write to the Service Department for a replacement. Give the equipment code n[...]

F-2 DIMENSION PRINT F-2 POWER WAVE® i400 G6044 A.01 20.34 19.49 21.54 21.46 23.62 22.74 20.99 18.81 21.54 ISO VIEW REFERENCE ONLY 25.05 DETAIL VIEW OF CHASSIS REMOVED FROM CA BI NET 24.37 18.52[...]

NOTES POWER WAVE® i400[...]

W ARNING AV I S O D E PRECAUCION A TTENTION W ARNUNG A TENÇÃO Spanish French German Portuguese Japanese Chinese Korean Arabic READ AND UNDERST AND THE MANUFACTURER’S INSTRUCTION FOR THIS EQUIPMENT AND THE CONSUMABLES TO BE USED AND FOLLOW YOUR EMPLOYER’S SAFETY PRACTICES. SE RECOMIENDA LEER Y ENTENDER LAS INSTRUCCIONES DEL F ABRICANTE P ARA E[...]

W ARNING AV I S O D E PRECAUCION A TTENTION W ARNUNG A TENÇÃO Spanish French German Portuguese Japanese Chinese Korean Arabic LEIA E COMPREENDA AS INSTRUÇÕES DO F ABRICANTE P ARA ESTE EQUIPAMENTO E AS P ARTES DE USO, E SIGA AS PRÁTICAS DE SEGURANÇA DO EMPREGADOR. ● Keep your head out of fumes. ● Use ventilation or exhaust to remove fumes [...]

• 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 • World's Leader in Welding and Cutting Products •[...]