Lincoln Electric POWER WAVE I400 Operator'S Manual Download Page 57

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Summary of Contents for POWER WAVE I400

Page 1: ...machine www lincolnelectric com register Authorized Service and Distributor Locator www lincolnelectric com locator Need Help Call 1 888 935 3877 to talk to a Service Representative Hours of Operatio...

Page 2: ...KER WEARERS SHOULD CONSULT WITH THEIR DOCTOR BEFORE OPERATING Read and understand the following safety highlights For additional safety information it is strongly recommended that you purchase a copy...

Page 3: ...r cooling 3 h Never simultaneously touch electrically hot parts of electrode holders connected to two welders because voltage between the two can be the total of the open circuit voltage of both welde...

Page 4: ...to adjacent areas Avoid welding near hydraulic lines Have a fire extinguisher readily available 6 b Where compressed gases are to be used at the job site special precautions should be used to prevent...

Page 5: ...opri s et non inflammables 4 Des gouttes de laitier en fusion sont mises de l arc de soudage Se prot ger avec des v tements de protection libres de l huile tels que les gants en cuir chemise paisse pa...

Page 6: ...he situation with the technical assistance of the manufacturer In some cases this remedial action may be as simple as earthing grounding the welding circuit see Note In other cases it could involve co...

Page 7: ...ns Welding Cables The welding cables should be kept as short as possible and should be positioned close together running at or close to floor level Equipotential Bonding Bonding of all metallic compon...

Page 8: ...ly important when identifying the correct replacement parts On Line Product Registration Register your machine with Lincoln Electric either via fax or over the Internet For faxing Complete the form on...

Page 9: ...sses and Equipment B 3 Recommended Processes B 3 Process and Equipment Limitations B 3 Case Front Controls B 4 B 5 Case Back Controls B 5 Internal Controls Power Up Sequence B 6 Duty Cycle B 6 Basic W...

Page 10: ...10 8 10 10 6 10 6 10 6 Type 75 C Copper Wire in Conduit AWG mm2 4 25 4 25 8 10 8 10 10 6 Volts at Rated Amperes 35 34 31 5 Amperes 420 400 350 Duty Cycle 40 60 100 Process GMAW GMAW Pulse FCAW GTAW D...

Page 11: ...the POWER WAVE i400 cabinet 4 K2670 CE Filter Kit is required to meet CE and C Tick conducted emission requirements REGULATORY REQUIREMENTS Market Europe China US and Canada MODEL K2669 1 K2673 13 Cha...

Page 12: ...t switch or fuse box before working on the equip ment Do not touch electrically hot parts Always connect the POWER WAVE grounding lug located inside the reconnect input access door to a proper safety...

Page 13: ...g wire size according to local or national electrical codes Using input wire sizes fuses or circuit breakers smaller than recommended may result in nuisance shut offs from welder inrush currents even...

Page 14: ...A 5 INSTALLATION POWER WAVE i400 A 5 Reconnect Diagram for K2669 1 POWER WAVE i400 FIGURE A 1...

Page 15: ...Description Remote Sense Lead Kit Recommended for sensitive or critical applications to more accurately monitor the arc voltage DeviceNet Kit Allows Power Wave i400 to communicate via DeviceNet protoc...

Page 16: ...l cables in parallel to increase current carrying capacity can significantly reduce their inductance minimizing properties and is therefore NOT RECOMMENDED Consult the Output Cable Guidelines for furt...

Page 17: ...botics R 30iA a cabinet Controller with Integrated Op Box Power Wave i400 K2669 1 ArcLink XT Ethernet cable Power cable DETAIL A A Refer to Output Cable guidelines for recommended cable size in PowerW...

Page 18: ...K1785 XX ArcLink XT Ethernet Cable Internal Electrode Cable K2163 xx or K1842 xx Refer to Output Cable Guidelines for recommended cable size in PowerWave i400 Instruction Manual Wire Feeder Gas Electr...

Page 19: ...thernet Cable FANUC Robotics R 30iA a cabinet Controller with Integrated Op Box Power Wave i400 K2669 1 Electrode Cable K2163 xx or K1842 xx Work Cable K2163 xx or K1842 xx Optional Work Sense Lead 21...

Page 20: ...trol Cable K1785 XX ArcLink XT Control Cable Electrode Cable Electrode Cable ArcLink XT Ethernet cable Internal Refer to Output Cable Guidelines for recommended cable size in PowerWave i400 Instructio...

Page 21: ...ntrol Cable K1543 XX Refer to Output Cable Guidelines for recommended cable size in PowerWave i400 Instruction manual Robotic Torch ARC Mate 1XXiBe Power Feed 10R K1780 2 18 Adapter Cable K1785 2 Wire...

Page 22: ...ectrode being positive For those applications connect the electrode cable between the wire drive feed plate and the positive output stud on the power source Connect a work lead from the negative power...

Page 23: ...for applications that do not use the standard wire feeder control cable K1785 This can be easily accessed with the optional K940 Sense Lead kit CABLE INDUCTANCE AND ITS EFFECTS ON WELDING Excessive c...

Page 24: ...Perform welding in the direction away from the work leads and toward the sense leads See Figure A 3 A 15 INSTALLATION POWER WAVE i400 A 15 Work Voltage Sensing The POWER WAVE i400 is configured at th...

Page 25: ...pplications 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 2 POWER SOURCE 1...

Page 26: ...00 is equipped with an IP67 rated ODVA compliant RJ 45 Ethernet connector which is located on the recessed control panel above the output studs A special access chute is provided above the Ethernet co...

Page 27: ...must be sourced locally by the customer For additional guide lines refer to the DeviceNet Cable Planning and Installation Manual Allen Bradley publication DN 6 7 2 The DeviceNet MAC ID and baud rate...

Page 28: ...g ceases Do not touch electrically live parts or electrodes with your skin or wet clothing Insulate yourself from the work and ground Always wear dry insulating gloves FUMES AND GASES can be dangerous...

Page 29: ...TIVE OUTPUT NEGATIVE OUTPUT 3 PHASE INVERTER INPUT POWER THREE PHASE DIRECT CURRENT OPEN CIRCUIT VOLTAGE INPUT VOLTAGE OUTPUT VOLTAGE INPUT CURRENT OUTPUT CURRENT PROTECTIVE GROUND WARNING or CAUTION...

Page 30: ...access holes in the top of the power source The K2677 2 Integration Kit includes all necessary cables and hardware to complete this task General Functional Description The POWER WAVE i400 is a high p...

Page 31: ...3 5 8 7 9 CASE FRONT FIGURE B 1 Light Condition Steady Green Blinking Green Alternating Green and Red Steady Red Blinking Red Meaning System is okay Power source communicating normally with the wire...

Page 32: ...s and repro gramming the POWER WAVE i400 Pin Function 1 Transmit 2 Transmit 3 Receive 4 5 6 Receive 7 8 7 WIRE FEEDER RECEPTACLE 14 PIN For connection to the AutoDrive and PF10R series wire feeders Pi...

Page 33: ...S1large OFF S2small ON Feed Head Board L11087 Series Hardware S11 thru 8 OFF POWER UP SEQUENCE The POWER WAVE i400 will typically be powered up at the same time as the robotic controller The status l...

Page 34: ...cted weld mode This alternate configuration is regionally enabled based on the robot controller software Refer to the Fanuc documentation for manual configuration information In non synergic modes the...

Page 35: ...ION POWER WAVE i400 B 8 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 charact...

Page 36: ...Work Voltage Sense Lead Kit K2670 CE Filter Kit K2677 2 Integration Kit COMPATIBLE LINCOLN EQUIPMENT K2685 2 Auto Drive 4R90 Wire feeder 14 pin control cable K1780 2 Power Feed 10 Robotic Wire Drive F...

Page 37: ...i400 is critical to its operation Generally speaking the calibration will not need adjustment However neglected or improperly calibrated machines may not yield satisfactory weld performance To ensure...

Page 38: ...letely dis charged 1 Use a DC voltmeter to check that NO voltage is present across the terminals of both capacitors Note Presence of capacitors voltage is also indi cated by LED s See figure D 1a 2 If...

Page 39: ...BLE CAUSE lists the obvious external possibilities that may contribute to the machine symptom Step 3 RECOMMENDED COURSE OF ACTION This column provides a course of action for the Possible Cause general...

Page 40: ...POWER WAVE i400 is mapping identifying each component in the system Normal for first 1 10 seconds after power is turned on or if the system configuration is changed during operation Under normal condi...

Page 41: ...improper input configuration or an open short circuit in the primary side of the machine Excess voltage on the main capacitors May be caused by improper input configuration excessive line voltage or...

Page 42: ...ible error codes for the POWER WAVE i400 For a complete listing consult the Service Manual for this machine Error Code 81 Motor Overload 82 Motor Overcurrent 83 Shutdown 1 84 Shutdown 2 Indication Lon...

Page 43: ...machine rating 3 Major physical or electrical damage is evident when the sheet metal covers are removed 1 No Input Power 2 Fuse F1 in reconnect area may have blown 3 Circuit breaker CB1 on the control...

Page 44: ...Inverter Fault switch pc board contactor problem etc 1 Improper fan operation 2 Output Rectifier board or Choke thermostat 3 DC Bus PC board thermostat 4 Open thermostat circuit 1 Make certain that in...

Page 45: ...BLEMS General degradation of weld per formance Wire burns back to tip when the arc is initiated 1 Wire feed problem 2 Cabling problems 3 Loss of or improper Shielding Gas 4 Verify weld mode is correct...

Page 46: ...Shielding Gas 4 Machine calibration 1 Possibly caused by wire feeding problem 1 Reduce burnback time and or workpoint 1 A non recoverable inverter fault will interrupt welding and open the main conta...

Page 47: ...conduit PROBLEMS SYMPTOMS POSSIBLE CAUSE RECOMMENDED COURSE OF ACTION DeviceNet PLC Controlled System Device does not go on Line 1 24v bus power 2 Baud rate 3 MAC ID 4 Termination 5 Wiring 6 EDS Files...

Page 48: ...ing is cor rectly grounded at the bus power sup ply The shield should be tied into the bus ground at only one point 4 Verify that the DeviceNet bus power supply can supply sufficient current for the d...

Page 49: ...ults in the sys tem 1 Verify Feeders drive roll tension is not too low allowing the wire to slip in the rolls Verify wire can be pulled easily through the wire conduit Verify Contact tip is not blocke...

Page 50: ...log Scans Between Updates is of I O Scans Sec value 2 From the DeviceNet tab of the Diagnostics Utility select Configure Verify in Analog Input Channels that the required channels are set active 3 Fro...

Page 51: ...e other than 0 3 The DeviceNet tab of the Diagnostics Utility displays the POWER WAVE s Analog Scans Between Updates and I O Scans Sec Verify that Analog Scans Between Updates is of I O Scans Sec valu...

Page 52: ...twork device 2 Use Weld Manager included on the POWER WAVE Utilities and Service Navigator CD s or available at www powerwavesoftware com to verify the correct IP address infor mation has been entered...

Page 53: ...t 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 t...

Page 54: ...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 CABINET 24 37 18 52...

Page 55: ...electrically live parts or electrode with skin or wet clothing Insulate yourself from work and ground No toque las partes o los electrodos bajo carga con la piel o ropa moja da Aislese del trabajo y...

Page 56: ...e Be und Entl ftung des Arbeitsplatzes Mantenha seu rosto da fuma a Use ventila o e exhaust o para remover fumo da zona respirat ria Turn power off before servicing Desconectar el cable de ali mentaci...

Page 57: ...later than the following business day For Service outside the USA Email globalservice lincolnelectric com Cleveland Ohio 44117 1199 USA TEL 1 216 481 8100 FAX 1 216 486 1751 WEB SITE lincolnelectric...

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