Lincoln Electric IM986 User 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: w

A-1INSTALLATION POWER WAVE® i400A-1TECHNICAL SPECIFICATIONS - POWER WAVE® i400 (K2669-2, K2673-2)RATED OUTPUTRECOMMENDED INPUT WIRE AND FUSE SIZES 1

A-2INSTALLATION POWER WAVE® i400A-2TECHNICAL SPECIFICATIONS - POWER WAVE® i400 (K2669-2, K2673-2)3Chassis ratings applicable only when installed as

A-3INSTALLATION POWER WAVE® i400A-3LOCATION AND MOUNTINGThe POWER WAVE® i400 case is designed to sup-port the Fanuc R30iA controller and op box (up

A-4INSTALLATION POWER WAVE® i400A-4ELECTROMAGNETIC COMPATIBILITY (EMC)The EMC classification of the POWER WAVE® i400 isIndustrial, Scientific and Me

A-5INSTALLATION POWER WAVE® i400A-5SystemIdentifierPower SourceIntegration KitWire DrivePower Sourceto Wire DriveControl CableWeld CablesRobot ArmRo

A-6INSTALLATION POWER WAVE i400A-6SystemIdentifierCoaxial Weld CableExternal DressCable for RobotArmPersonal ComputerReplacementChassisPart No.K1796

A-7INSTALLATION POWER WAVE® i400A-7FANUC R30iA CONTROLLER MOUNTINGFANUC Robotics R-30iA "a-cabinet" Controller with Integrated Op BoxPower

A-8INSTALLATION POWER WAVE® i400A-8TYPICAL INTEGRATED SYSTEMS (SINGLE ARM)ArcLink XTEthernet ConnectionVoltage SenseConnectorWire FeederConnectorPow

A-9INSTALLATION POWER WAVE® i400A-9TYPICAL STAND ALONE SYSTEMS (SINGLE ARM)DevicenetConnectorWire Feeder ConnectorCircuit Breaker(15 Amp)ArcLink XTE

A-10INSTALLATION POWER WAVE® i400A-10TYPICAL MASTER / SLAVE SYSTEM (DUAL ARM)FANUC Robotics R-30iA "a-cabinet" Controllerwith Integrated O

FOR ENGINEpowered equipment.1.a. Turn the engine off before troubleshooting and maintenancework unless the maintenance work requires it to be running.

A-11INSTALLATION POWER WAVE® i400A-11TYPICAL F355i RETROFIT (SINGLE ARM)Power Wave i400K2669-2FANUC RoboticsR-J3iB Controller* Electrode Cable (+)

GENERAL GUIDELINES• Select the appropriate size cables per the“Output Cable Guidelines” in Table A.1.Excessive voltage drops caused by undersizedweldi

A-13INSTALLATION POWER WAVE® i400A-13General Guidelines for Voltage Sense LeadsSense leads should be attached as close to the weldas practical, and

If a remote work voltage sense lead is used, itmust be enabled through the Fanuc TeachPendant or with the Weld Manager Utility (includ-ed on the Power

A-15INSTALLATION POWER WAVE® i400A-15• For circumferential applications, connect all work leads on one side of the weld joint, and all of the work v

A-16INSTALLATION POWER WAVE® i400A-16CONTROL CABLE CONNECTIONSGeneral GuidelinesGenuine Lincoln control cables should be used at alltimes (except wh

A-17INSTALLATION POWER WAVE® i400A-17Connections Between Power Source and OptionalDeviceNet PLC Controller. Hard Automation applica-tions and some

B-1OPERATIONB-1POWER WAVE® i400SAFETY PRECAUTIONSRead this entire section of operating instructionsbefore operating the machine.ELECTRIC SHOCK can kil

B-2OPERATIONB-2POWER WAVE® i400INPUT POWERONOFFHIGH TEMPERATUREMACHINE STATUSCIRCUIT BREAKERWIRE FEEDERPOSITIVE OUTPUTNEGATIVE OUTPUT3 PHASE INVERTERI

B-3OPERATIONB-3PRODUCT DESCRIPTIONPRODUCT SUMMARYGeneral Physical DescriptionThe POWER WAVE® i400 is intended as a replace-ment for the PW355i using a

ARC RAYS can burn.4.a. Use a shield with the proper filter and coverplates to protect your eyes from sparks andthe rays of the arc when welding or obs

B-4OPERATIONB-4CASE FRONT CONTROL DESCRIPTION1. Machine Status Indicator: A two color LED thatindicates system errors. The POWER WAVE® i400is equipped

B-5OPERATIONB-5POWER WAVE® i4002. THERMAL INDICATOR (THERMAL OVERLOAD): Ayellow light that comes on when an over temperature sit-uation occurs. Outp

INTERNAL CONTROLS DESCRIPTION1. FUSE (F1): Primary circuit protection for auxiliary power(10A/600V).2. ROBOT POWER TERMINAL BLOCK (4TB): Power sup-ply

B-7OPERATIONB-7POWER WAVE® i400Choose the electrode material, electrode size, shield-ing gas, and process (GMAW, GMAW-P etc.) appro-priate for the mat

B-8OPERATIONPOWER WAVE® i400B-8Pulse welding modes are synergic; using wire feedspeed as the main control parameter. As the wirefeed speed is adjuste

C-1ACCESSORIESC-1OPTIONAL EQUIPMENTFACTORY INSTALLEDNone Available.FIELD INSTALLED K940-Work Voltage Sense Lead KitK2670-[ ] CE Filter KitK2677-1 Inte

CHASSIS REMOVAL PROCEDUREELECTRIC SHOCK can kill.• Disconnect input power beforeservicing.• Do not operate with covers removed.• Do not touch electric

D-2MAINTENANCED-2POWER WAVE® i400FIGURE D.1a4. Remove the left case side by pulling out from thebottom.5. Disconnect the chassis input power leads (1E

E-1TROUBLESHOOTINGE-1POWER WAVE® i400If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, co

E-2TROUBLESHOOTINGE-2POWER WAVE® i400USING THE STATUS LED TOTROUBLESHOOT SYSTEM PROBLEMSThe POWER WAVE® i400 is equipped with two exter-nally mounted

FOR ELECTRICALLYpowered equipment.8.a. Turn off input power using the disconnectswitch at the fuse box before working onthe equipment.8.b. Install equ

LECO(FANUC#)49505152535455576784see com-plete listingPOWER SOURCE–––WELD CONTROLLERE-3TROUBLESHOOTINGE-3POWER WAVE® i400Observe all Safety Guidelines

LECO(FANUC#)129130131132E-4TROUBLESHOOTINGE-4POWER WAVE® i400If for any reason you do not understand the test procedures or are unable to perform the

E-5TROUBLESHOOTINGE-5POWER WAVE® i400Observe all Safety Guidelines detailed throughout this manualTROUBLESHOOTING GUIDE Observe Safety Guidelinesdetai

E-6TROUBLESHOOTINGE-6POWER WAVE® i400Observe all Safety Guidelines detailed throughout this manualTROUBLESHOOTING GUIDE Observe Safety Guidelinesdetai

E-7TROUBLESHOOTINGE-7POWER WAVE® i400Observe all Safety Guidelines detailed throughout this manualTROUBLESHOOTING GUIDE Observe Safety Guidelinesdetai

E-8TROUBLESHOOTINGE-8POWER WAVE® i400Observe all Safety Guidelines detailed throughout this manualIf for any reason you do not understand the test pro

E-9TROUBLESHOOTINGE-9POWER WAVE® i400Observe all Safety Guidelines detailed throughout this manualIf for any reason you do not understand the test pro

E-10TROUBLESHOOTINGE-10POWER WAVE® i400Observe all Safety Guidelines detailed throughout this manualIf for any reason you do not understand the test p

E-11TROUBLESHOOTINGE-11POWER WAVE® i400Observe all Safety Guidelines detailed throughout this manualIf for any reason you do not understand the test p

E-12TROUBLESHOOTINGE-12POWER WAVE® i400Observe all Safety Guidelines detailed throughout this manualIf for any reason you do not understand the test p

Mar. ʻ93ivSAFETYivPRÉCAUTIONS DE SÛRETÉPour votre propre protection lire et observer toutes les instructionset les précautions de sûreté specifiques q

E-13TROUBLESHOOTINGE-13POWER WAVE® i400Observe all Safety Guidelines detailed throughout this manualIf for any reason you do not understand the test p

E-14TROUBLESHOOTINGE-14POWER WAVE® i400If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely,

F-1DIAGRAMSF-1POWER WAVE® i400NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. The specif

F-2DIMENSION PRINTF-2POWER WAVE® i400G6044A.0120.3419.4921.5421.4623.6222.7420.9918.8121.54ISO VIEWREFERENCEONLY25.05DETAIL VIEW OF CHASSIS REMOVED FR

NOTES POWER WAVE® i400

WARNINGAVISO DEPRECAUCIONATTENTIONWARNUNGATENÇÃOSpanishFrenchGermanPortugueseJapaneseChineseKoreanArabicREAD AND UNDERSTAND THE MANUFACTURER’S INSTRUC

WARNINGAVISO DEPRECAUCIONATTENTIONWARNUNGATENÇÃOSpanishFrenchGermanPortugueseJapaneseChineseKoreanArabicLEIA E COMPREENDA AS INSTRUÇÕES DO FABRICANTE

• Sales and Service through Subsidiaries and Distributors Worldwide •Cleveland, Ohio 44117-1199 U.S.A. TEL: 216.481.8100 FAX: 216.486.1751 WEB

vSAFETYvElectromagnetic Compatibility (EMC)ConformanceProducts displaying the CE mark are in conformity with European Community Council Directive of 3

viSAFETYviElectromagnetic Compatibility (EMC)The size of the surrounding area to be considered will depend on the structure of the building and othera

viiviiThank Youfor selecting a QUALITY product by Lincoln Electric. We want youto take pride in operating this Lincoln Electric Company product••• as

viiiTABLE OF CONTENTSPageInstallation ..........................Section A