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Lincoln Electric POWER WAVE I400 manual

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Table of contents for the manual

  • Page 1

    • 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 IM943 October, 2009 Safety Depends on You L i n c o l n a r c w e l d[...]

  • Page 2

    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. ________________________________________________[...]

  • Page 3

    ii SAFETY ii ARC R A Y S can bur n. 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 [...]

  • Page 4

    iii SAFETY iii FOR ELECTRIC ALL Y pow er ed 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 manufacturer’s recommendations. 8.c. Ground the equipment in accordance with the U.S. N[...]

  • Page 5

    Mar. ‘93 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 L’Arc 1. Protegez-vous contre la secousse électrique: a. Les[...]

  • Page 6

    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 [...]

  • Page 7

    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[...]

  • Page 8

    vii vii T T h h a a n n k k Y Y o o u u 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 hand[...]

  • Page 9

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

  • Page 10

    A-1 INST ALLA TION POWER WAVE® i400 A-1 TECHNICAL SPECIFICA TIONS - POWER W A VE® i400 (K2669-1, K2673-1) RA TED OUTPUT RECOMMENDED INPUT WIRE AND FUSE SIZES 1 PHYSICAL DIMENSIONS TEMPERA TURE RANGES INPUT A T RA TED OUTPUT - THREE PHASE ONL Y Model K2669-1 K2673-1 (Chassis Only) Duty Cycle 40% rating 60% rating 100% rating 3 PHASE INPUT VOLTAGE [...]

  • Page 11

    A-2 INST ALLA TION POWER WAVE® i400 A-2 TECHNICAL SPECIFICA TIONS - POWER W A VE® i400 (K2669-1, K2673-1) 3 Chassis ratings applicable only when installed as a replacement in the POWER WAVE® i400 cabinet. 4 K2670-[ ] CE Filter Kit is required to meet CE and C-Tick conducted emission requirements. REGULA T ORY REQUIREMENTS Market Europe China US [...]

  • Page 12

    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 controller’s footprint and styling. Mounting is externally accessible for simplified inte- gration. The flexibility of the POWER WAVE® i400 also allows it to be ope[...]

  • Page 13

    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[...]

  • Page 14

    A-5 INST ALLA TION POWER WAVE® i400 A-5 Reconnect Diagram for K2669-1 POWER W A VE® i400 FIGURE A.1[...]

  • Page 15

    A-6 INST ALLA TION POWER WAVE® i400 A-6 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[...]

  • Page 16

    A-7 INST ALLA TION POWER WAVE i400 A-7 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 K2673-1 Description Coax Cable. Recommended to minimize the effects of the weld cable loop inductance and maximize perfor- mance in critical high [...]

  • Page 17

    A-8 INST ALLA TION POWER WAVE® i400 A-8 F A N U C R 3 0 i A C O N T R O L L E R MO U N T I N G FA NU C R obo tics R- 30 iA "a-cab i ne t" C on tro ll er with Int eg ra t ed Op Box Power Wave i 400 K2669 -1 * A rcLin k XT Et herne t cable * P ower cable DETAI L A A * Refer to Outpu t Cable guide line s for r ec omm ended cable size in Pow[...]

  • Page 18

    A-9 INST ALLA TION POWER WAVE® i400 A-9 TYPICAL INTEGRATED SYSTEMS (SINGLE ARM) ArcLink X T Ethernet Connection Voltage Sense Connector W ire Feeder Connector Power W ave i400 K2669-1 Optional Work Sense Lead (21) W ire Feeder Contro l Cable K1785-X X ArcLink X T Ethernet Cable (Internal) * Electrode Cable (+) K2163-xx or K1842-xx * Refer to Outpu[...]

  • Page 19

    A-10 INST ALLA TION POWER WAVE® i400 A-10 TYPICAL STAND ALONE SYSTEMS (SINGLE ARM) Devicenet Connector Wire Feeder Connector Circu i t Breaker (15 Amp) ArcLink X T Ethernet Connector Voltage Sense Connector ArcL ink Connector ArcLink X T Ethernet Cable FANU C Robotics R -30iA "a-cabinet" Contro ller with Integrated Op Box Power W ave i40[...]

  • Page 20

    A-11 INST ALLA TION POWER WAVE® i400 A-11 TYPICAL MASTER / SLAVE SYSTEM (DUAL ARM) FANU C Robotics R -30iA "a-cabinet" Contro ller with Integrated Op Box (Master) FANU C Robotics R-30iA "a-cabinet" Contr oller with Integrated Op Box (Slave) Optional Work Sense Lead (21) Optional Work Sense Lead (21) * W ork Cable (-) * W ork Ca[...]

  • Page 21

    A-12 INST ALLA TION POWER WAVE® i400 A-12 TYPICAL F355i RETROFIT (SINGLE ARM) Power W ave i400 K2669-1 FANU C Robotics R-J3 iB Controller * Electrode Cable (+) K2163-xx or K1842-xx Optional Work Sense Lead (21) Wire Feeder Control C able K1785-X X ArcLink Control Cab l e K1543-X X * Refer to Output Cable G uidelines for re commend ed cable s ize i[...]

  • Page 22

    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[...]

  • Page 23

    A-14 INST ALLA TION POWER WAVE® i400 A-14 General Guidelines for Voltage Sense Leads Sense leads should be attached as close to the weld as practical, and out of the weld cur rent 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.[...]

  • Page 24

    If a remo te 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 CD’s or available at www.powerwavesoftware.com). ------------------------------------------------------------------------ Voltage Sensing Considerations for[...]

  • Page 25

    A-16 INST ALLA TION POWER WAVE® i400 A-16 • 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 S OURCE #2 PO WER SOURCE #1 PO WER SOURCE #1 PO WER SOURCE #2 PO WER SOURCE #2 P O WER S OURCE #1[...]

  • Page 26

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

  • Page 27

    A-18 INST ALLA TION POWER WAVE® i400 A-18 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 [...]

  • Page 28

    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 [...]

  • Page 29

    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[...]

  • Page 30

    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 us ing 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 P[...]

  • Page 31

    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[...]

  • Page 32

    B-5 OPERA TION B-5 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 for the feeder an[...]

  • Page 33

    I NTERNAL CONTROLS DESCRIPTION 1. MAI N RECO NNE CT: Selects main capacitor configura- tion for 208-230V or 380-575V input. 2. AUXILIARY RECONNECT: Configures auxiliary power for specified input voltage (208/230/380/460/575V). 3. FUSE (F1): Primary circuit protection for auxiliary power (10A/600V). 4. ROBOT POWER TERMINAL BLOCK (4TB): Power sup- pl[...]

  • Page 34

    B-7 OPERA TION B-7 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 ne[...]

  • Page 35

    Pulse welding modes are s ynergic; 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. In this configuration, as the amper[...]

  • Page 36

    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 K2 685 -2 Auto Drive 4R90 Wire feeder (14-pin control cable). K1780-2 Power Feed 10 Robotic Wire Drive For additional Information see Optional Eq[...]

  • Page 37

    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[...]

  • Page 38

    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[...]

  • Page 39

    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 yo u locate and repa[...]

  • Page 40

    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[...]

  • Page 41

    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[...]

  • Page 42

    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 [...]

  • Page 43

    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[...]

  • Page 44

    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[...]

  • Page 45

    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[...]

  • Page 46

    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[...]

  • Page 47

    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[...]

  • Page 48

    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[...]

  • Page 49

    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[...]

  • Page 50

    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[...]

  • Page 51

    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[...]

  • Page 52

    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[...]

  • Page 53

    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[...]

  • Page 54

    F-2 DIMENSION PRINT F-2 POWER WAVE® i400 G6 044 A.01 20.3 4 19.4 9 21.5 4 21.4 6 23.6 2 22.7 4 20.9 9 18.8 1 21.5 4 ISO V IEW REFE RENCE ONLY 25.0 5 DET AIL VIEW OF CHA SSI S REMO VED FRO M CABI NET 24.3 7 18.5 2[...]

  • Page 55

    NOTES POWER WAVE® i400[...]

  • Page 56

    W ARNING A VISO DE 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 EL [...]

  • Page 57

    W ARNING A VISO DE 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 o f fumes . ● Use ventil atio n or e xhaust to remo ve fum[...]

  • Page 58

    • 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 •[...]