IM986-A RETURN TO MAIN MENU POWER WAVE i400 ® For use with machines having Code Numbers: April, 2011 11536, 11536R, 11775 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 thoughtful operation on your part. DO NOT I NSTAL L , OPERATE OR REPAI R THI S EQUI PMENT WI THOUT READI NG THI S MANUAL AND THE SAFETY PRECAUTI ONS CONTAI NED THROUGHOUT.
i i SAFETY WARNING CALIFORNIA PROPOSITION 65 WARNINGS Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer, birth defects, and other reproductive harm. The Above For Diesel Engines The engine exhaust from this product contains chemicals known to the State of California to cause cancer, birth defects, or other reproductive harm. The Above For Gasoline Engines ARC WELDING CAN BE HAZARDOUS.
ii ii SAFETY 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. 3.b. Insulate yourself from work and ground using dry insulation. Make certain the insulation is large enough to cover your full area of physical contact with work and ground.
iii iii SAFETY 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 sparks and hot materials from welding can easily go through small cracks and openings to adjacent areas. Avoid welding near hydraulic lines. Have a fire extinguisher readily available. 6.b.
iv SAFETY 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 suivantes: Sûreté Pour Soudage A LʼArc 1. Protegez-vous contre la secousse électrique: a. Les circuits à lʼélectrode et à la piéce sont sous tension quand la machine à souder est en marche.
v SAFETY Electromagnetic Compatibility (EMC) Conformance Products displaying the CE mark are in conformity with European Community Council Directive of 15 Dec 2004 on the approximation of the laws of the Member States relating to electromagnetic compatibility, 2004/108/EC. 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.
vi 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 manufacturer’s recommendations.
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! CUSTOMER ASSISTANCE POLICY The business of The Lincoln Electric Company is manufacturing and selling high quality welding equipment, consumables, and cutting equipment. Our challenge is to meet the needs of our customers and to exceed their expectations.
viii viii TABLE OF CONTENTS Page Installation .......................................................................................................Section A Technical Specifications - POWER WAVE® i400..........................................A-1, A-2 Safety Precautions.................................................................................................A-3 Location and Mounting ..........................................................................................
A-1 A-1 INSTALLATION TECHNICAL SPECIFICATIONS - POWER WAVE® i400 (K2669-2, K2673-2) JAPANESE POWER SOURCES - INPUT VOLTAGE AND CURRENT Model Duty Cycle Input Voltage ± 10% 40% rating K2669-2 60% rating K2673-2 (Chassis Only) 200/208 3 phase 50/60 Hz 100% rating Input Amperes (incl. robot and aux. load) 66 (86) 61 (81) 50 (70) Idle Power Power Factor @ Rated Output 475 Watts Max. (fan on) .80 RATED OUTPUT Process Duty Cycle Volts at Rated Amperes Amperes 40% 35 420 60% 34 400 100% 31.
A-2 A-2 INSTALLATION TECHNICAL SPECIFICATIONS - POWER WAVE® i400 (K2669-2, K2673-2) REGULATORY REQUIREMENTS (JAPANESE MODELS) MODEL Standard K2669-2 EN 60974-1 EN 50199 K2673-23 (Chassis Only) 3 Chassis ratings applicable only when installed as a replacement in the POWER WAVE® i400 cabinet.
A-3 A-3 INSTALLATION SAFETY PRECAUTIONS Read this entire installation section before you start installation. WARNING ELECTRIC SHOCK can kill. • Only qualified personnel should perform this installation. • Turn the input power OFF at the disconnect switch or fuse box before working on this equipment. Turn off the input power to any other equipment connected to the welding system at the disconnect switch or fuse box before working on the equipment. • Do not touch electrically hot parts.
A-4 A-4 INSTALLATION ELECTROMAGNETIC COMPATIBILITY (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 WAVE® i400 away from radio controlled machinery.
A-5 INSTALLATION A-5 CONNECTION DIAGRAMS AND SYSTEM RECOMMENDED EQUIPMENT System Identifier Part No. Description Power Source K2669-1 POWER WAVE® i400 Power Source (includes S26064 POWER WAVE® Utilities CD) Integration Kit K2677-1 Integration Kit for Fanuc R30iA Controller. Includes industrial ethernet cable, power cable, protective grommets, mounting plate, and dust proof strain relief.
A-6 INSTALLATION A-6 OPTIONAL EQUIPMENT System Identifier Part No. Description K1796-xx Coax Cable. Recommended to minimize the effects of the weld cable loop inductance and maximize performance in critical high speed pulse applications. K2593-xx Note: K1796 coaxial cable is equivalent to 1/0 standard cable. K2539 coaxial cable is equivalent to AWG #1 standard cable.
A-7 A-7 INSTALLATION FANUC R30iA CONTROLLER MOUNTING FANUC Robotics R-30iA "a-cabinet" Controller with Integrated Op Box * Power cable * ArcLink XT Ethernet cable Power Wave i400 K2669-2 ** DETAIL A R O * Refer to Output Cable guidelines for recommended cable size in PowerWave i400 Instruction Manual.
Wire Feeder Control Cable K1785-XX Air Gas Wire Feeder POWER WAVE® i400 * Work Cable (-) K2163-xx or K1842-xx R O * Refer to Output Cable Guidelines for recommended cable size in PowerWave i400 Instruction Manual.
Air Gas Wire Feeder Wire Feeder Control cable K1785-xx Electrode Connection POWER WAVE® i400 * Electrode Cable (+) K2163-xx or K1842-xx * Work Cable (-) K2163-xx or K1842-xx Power Wave i400 K2669-2 ArcLink XT Ethernet Cable FANUC Robotics R-30iA "a-cabinet" Controller with Integrated Op Box R O * Refer to Output Cable guidelines for recommended cable size in PowerWave i400 Instruction Manual.
Air Gas Wire Feeder * Electrode Cable (+) * Electrode Cable (+) POWER WAVE® i400 * Work Cable (-) * Work Cable (-) Power Wave i400 K2669-2 Wire Feeder Control Cable K1785-XX R O ArcLink XT Ethernet cable (Internal) Power Wave i400 K2669-2 FANUC Robotics R-30iA "a-cabinet" Controller with Integrated Op Box (Master) ArcLink XT Control Cable Wire Feeder Control Cable K1785-XX FANUC Robotics R-30iA "a-cabinet" Controller with Integrated Op Box (Slave) * Refer to Output Cable Guidelines for recom
Wire Feeder Air POWER WAVE® i400 Wire Feeder Control Cable K1785-XX Gas Robotic Torch * Work Cable (-) K2163-xx or K1842-xx * Electrode Cable (+) K2163-xx or K1842-xx Electrode Connection R O Power Wave i400 K2669-2 FANUC Robotics R-J3iB Controller * Refer to Output Cable Guidelines for recommended cable size in PowerWave i400 Instruction manual.
A-12 A-12 INSTALLATION ELECTRODE AND WORK CONNECTIONS GENERAL GUIDELINES Connect the electrode and work cables between the appropriate output studs of the POWER WAVE® i400 and the robot weld cell per the connection diagrams included in this document. Size and route the cables per the following. • Select the appropriate size cables per the “Output Cable Guidelines” in Table A.1.
A-13 INSTALLATION CABLE INDUCTANCE, AND ITS EFFECTS ON WELDING Excessive cable inductance will cause the welding performance to degrade. There are several factors that contribute to the overall inductance of the cabling system including cable size, and loop area. The loop area is defined by the separation distance between the electrode and work cables, and the overall welding loop length.
A-14 A-14 INSTALLATION Work Voltage Sensing WARNING 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).
A-15 INSTALLATION A-15 • For circumferential applications, connect all work leads on one side of the weld joint, and all of the work voltage sense leads on the opposite side, such that they are out of the current path.
A-16 INSTALLATION 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 systems. Most are designed to be connected end to end for ease of extension. Generally, it is recommended that the total length not exceed 100 ft. (30.5 m). The use of nonstandard cables, especially in lengths greater than 25 ft. (7.
A-17 INSTALLATION Connections Between Power Source and Optional DeviceNet PLC Controller. Hard Automation applications 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.
B-1 OPERATION SAFETY PRECAUTIONS Read this entire section of operating instructions before operating the machine. WARNING ELECTRIC SHOCK can kill. • Unless using cold feed feature, when feeding with gun trigger, the electrode and drive mechanism are always electrically energized and could remain energized several seconds after the welding ceases. • Do not touch electrically live parts or electrodes with your skin or wet clothing. • Insulate yourself from the work and ground.
B-2 B-2 OPERATION GRAPHIC SYMBOLS THAT APPEAR ON THIS MACHINE OR IN THIS MANUAL INPUT POWER ON U0 OPEN CIRCUIT VOLTAGE OFF U1 INPUT VOLTAGE HIGH TEMPERATURE U2 OUTPUT VOLTAGE MACHINE STATUS I1 INPUT CURRENT CIRCUIT BREAKER I2 OUTPUT CURRENT PROTECTIVE GROUND WIRE FEEDER POSITIVE OUTPUT NEGATIVE OUTPUT WARNING or CAUTION 3 PHASE INVERTER Explosion INPUT POWER Dangerous Voltage THREE PHASE Shock Hazard DIRECT CURRENT POWER WAVE® i400
B-3 OPERATION PRODUCT DESCRIPTION PRODUCT SUMMARY General Physical Description The POWER WAVE® i400 is intended as a replacement for the PW355i using an updated power and control platform to enhance performance and reliability. 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. ArcLink® communication is supported through the 5 pin MSstyle interface.
B-4 B-4 OPERATION CASE FRONT FIGURE B.1 10 3 6 5 7 11 12 4 1 2 8 9 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 operation is a steady green light. . Basic error conditions are indicated in the table below.
B-5 B-5 OPERATION 2. THERMAL INDICATOR (THERMAL OVERLOAD): A yellow light that comes on when an over temperature situation 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 and machine controls. 4. VOLTAGE SENSE CONNECTOR: Allows for separate remote electrode and work sense leads.
B-6 B-6 OPERATION 3. CHASSIS POWER TERMINAL BLOCK (3TB): Power connection for internal chassis. Provides power for the inverter and all auxiliary supplies. 4. INPUT POWER TERMINAL BLOCK (1TB): Input power connection from main service disconnect. 5. GROUND TERMINAL: Earth ground connection. 6.
B-7 OPERATION Choose the electrode material, electrode size, shielding gas, and process (GMAW, GMAW-P etc.) appropriate 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. If a special weld mode is desired, contact the local Lincoln Electric sales representative.
B-8 OPERATION 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. 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 characteristics.
C-1 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.
D-1 D-1 MAINTENANCE SAFETY PRECAUTIONS CHASSIS REMOVAL PROCEDURE WARNING 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.
D-2 MAINTENANCE 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 chassis from the cabinet by pulling on the fan bracket. (see “Location and Mounting” section of this document for instructions on lifting the chassis).
E-1 TROUBLESHOOTING E-1 HOW TO USE TROUBLESHOOTING GUIDE WARNING 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.
E-2 TROUBLESHOOTING USING THE STATUS LED TO TROUBLESHOOT SYSTEM PROBLEMS The POWER WAVE® i400 is equipped with two externally 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. Therefore, prior to cycling power to the system, check the power source status light for error sequences as noted below.
E-3 E-3 TROUBLESHOOTING 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. POWER SOURCE–––WELD CONTROLLER Error Code # LECO (FANUC#) Indication 31 Primary (Input) overcurrent error. 49 Excessive Primary current present. May be related to a switch board or output rectifier failure.
E-4 TROUBLESHOOTING E-4 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. WIRE DRIVE MODULE Error Code # LECO (FANUC#) Indication 129 Long term average motor current limit has been exceeded. Typically indicates mechanical overload of system.
E-5 E-5 TROUBLESHOOTING Observe all Safety Guidelines detailed throughout this manual TROUBLESHOOTING GUIDE Observe Safety Guidelines detailed in the beginning of this manual. PROBLEMS (SYMPTOMS) POSSIBLE RECOMMENDED CAUSE COURSE OF ACTION BASIC MACHINE PROBLEMS Major physical or electrical damage None is evident when the sheet metal covers are removed. 1. Contact your local authorized Lincoln Electric Field Service facility for technical assistance.
E-6 E-6 TROUBLESHOOTING Observe all Safety Guidelines detailed throughout this manual Observe Safety Guidelines detailed in the beginning of this manual. TROUBLESHOOTING GUIDE PROBLEMS (SYMPTOMS) POSSIBLE RECOMMENDED CAUSE COURSE OF ACTION BASIC MACHINE PROBLEMS Machine wonʼt weld, canʼt get any 1. Input voltage is too low or too high. output. (CR1 will not pull in.) This problem will normally be accompanied by an error code. 2. Thermal Error.
E-7 E-7 TROUBLESHOOTING Observe all Safety Guidelines detailed throughout this manual Observe Safety Guidelines detailed in the beginning of this manual. TROUBLESHOOTING GUIDE PROBLEMS (SYMPTOMS) POSSIBLE RECOMMENDED CAUSE COURSE OF ACTION BASIC MACHINE PROBLEMS Auxiliary receptacle is dead. “Real Time Clock” no longer functioning PROBLEMS (SYMPTOMS) 1. Circuit breaker CB2 (near the 115V receptacle) may have tripped. 1. Power down and reset CB2. 2. Fuse F1 (in reconnect area) may have blown. 2.
E-8 E-8 TROUBLESHOOTING Observe all Safety Guidelines detailed throughout this manual PROBLEMS (SYMPTOMS) POSSIBLE RECOMMENDED CAUSE COURSE OF ACTION WELD AND ARC QUALITY PROBLEMS Wire burns back to tip at the end of the weld. 1. Burnback Time. 1. Reduce burnback time and/or workpoint. Machine output shuts down during a weld. 1.Inverter or System Fault 1. A non-recoverable inverter fault will interrupt welding, and open the main contactor.
E-9 E-9 TROUBLESHOOTING Observe all Safety Guidelines detailed throughout this manual PROBLEMS (SYMPTOMS) Arc loss fault on robot. POSSIBLE RECOMMENDED CAUSE COURSE OF ACTION WELD AND ARC QUALITY PROBLEMS 2. Conduit leading to the wire feeder has bends or twists, which can reduce the wire feed speed. 2. Remove bends and twists in conduit leading to the feeder. 3. Conduit leading up to the wire feeder from the wire reel is too long. 3. Use a shorter piece of conduit.
E-10 E-10 TROUBLESHOOTING Observe all Safety Guidelines detailed throughout this manual PROBLEMS (SYMPTOMS) Device goes off line during welding. Output will not come on. POSSIBLE CAUSE RECOMMENDED COURSE OF ACTION 1. Interference / Noise. 1. Verify that DeviceNet cables are not running next to (in close proximity with) current carrying conductors. This includes the welding cables, input cables, etc. 2. Termination. 2. Verify that the DeviceNet bus is terminated correctly. 3. Shielding. 3.
E-11 E-11 TROUBLESHOOTING Observe all Safety Guidelines detailed throughout this manual PROBLEMS (SYMPTOMS) POSSIBLE CAUSE RECOMMENDED COURSE OF ACTION Output will not come on. 6. Other modules faulted. 6. Verify no other modules are faulted (all system Status Lights should be steady green). Use Diagnostics Utility to display any current faults in the system. Bad Weld Starting. 1. Wire Feed problem 1. Verify Feeders drive roll tension is not too low allowing the wire to slip in the rolls.
E-12 E-12 TROUBLESHOOTING Observe all Safety Guidelines detailed throughout this manual PROBLEMS (SYMPTOMS) POSSIBLE CAUSE Analog Inputs donʼt respond or donʼt 1. Analog Scans Between Updates. respond quickly. Gas purge not working. RECOMMENDED COURSE OF ACTION 1. The DeviceNet tab of the Diagnostics Utility displays the POWER WAVE®ʼs “Analog Scans Between Updates” and “I/O Scans/Sec.” Verify that “Analog Scans Between Updates” is ¼ of “I/O Scans/Sec” value. 2. Analog In Active Selections. 2.
E-13 E-13 TROUBLESHOOTING Observe all Safety Guidelines detailed throughout this manual PROBLEMS (SYMPTOMS) Bad Weld Ending. POSSIBLE CAUSE RECOMMENDED COURSE OF ACTION 1. Burnback Disabled. 1. From the DeviceNet tab of the Diagnostics Utility, select Monitor. The Monitor window will be displayed. Verify under the “State Enabled” that “Burnback” is present. 2. Burnback Time. 2. Verify that Burnback Time has a value other than 0. 3. Analog Scans Between Updates. 3.
E-14 E-14 TROUBLESHOOTING Observe all Safety Guidelines detailed throughout this manual PROBLEMS (SYMPTOMS) POSSIBLE RECOMMENDED CAUSE COURSE OF ACTION DeviceNet – PLC Controlled System Bad Welding. 4. Limit Errors 5. Gas 6. Welding set points 7. Wire Drive / Gear selection PROBLEMS (SYMPTOMS) Cannot Connect. POSSIBLE CAUSE ETHERNET 1. Physical connection. 2. IP address information. 3. Ethernet Speed. Connection Drops while welding. 1. Cable Location. 4.
H1 1E TP2 2E TP1 3E B 209 203 207 31 AUXILIARY TRANSFORMER +D E C A _ F _ INPUT BRIDGE 115V RECEPTACLE 31A 33 F1 444 31A 1 2 115V 31 42 600V .05uF C1 FAN RELAY 52V 41 H2 FAN H1 H2 H3 H4 H5 H6 200208V A1 33A TP4 444 7 POWER WAVE® i400 1 3W 3R 5 6 2 505 xxxxxxx 504 X3 J20 201 207 N.H.
ISO VIEW REFERENCE ONLY 21.54 18.81 20.99 22.74 DETAIL VIEW OF CHASSIS REMOVED FROM CABINET 25.05 21.54 20.34 POWER WAVE® i400 23.62 24.37 21.46 19.49 G6044 A.01 18.
G Keep your head out of fumes. G Use ventilation or exhaust to G Turn power off before servicing. G Do not operate with panel open or guards off. remove fumes from breathing zone. G Los humos fuera de la zona de res- piración. G Mantenga la cabeza fuera de los humos. Utilice ventilación o aspiración para gases. G Gardez la tête à l’écart des fumées. G Utilisez un ventilateur ou un aspira- G Desconectar el cable de ali- mentación de poder de la máquina antes de iniciar cualquier servicio.
G Do not touch electrically live parts or WARNING Spanish AVISO DE PRECAUCION French ATTENTION German WARNUNG Portuguese ATENÇÃO G Keep flammable materials away. G Wear eye, ear and body protection. G Mantenga el material combustible G Protéjase los ojos, los oídos y el electrode with skin or wet clothing. G Insulate yourself from work and ground. G No toque las partes o los electrodos bajo carga con la piel o ropa mojada. G Aislese del trabajo y de la tierra.
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