R obotic Welding
Power Wave®i400 Power Source &
AutoDrive™ 4R90 Wire Feeder
Intelligent Robotic Solution
Integrated System Design
Innovative Features
Industry Leading Design
The Power Wave®i400 & AutoDrive™ 4R90
solution delivers Lincoln’s best performance
technologies and welding processes all rolled
into one highly efficient inverter power source
paired with a compact, durable wire feeder
designed for high-end robotic welding.
With the increasing demands on welding
performance, choose the industry leader in
power, performance, and technology, Lincoln
Electric’s Power Wave
4R90 system.
®
i400 and AutoDrive™
AUTOMATED SOLUTIONS
AutoDrive™ 4R90
Power Wave®i400
Publication E10.11 01/08
www.lincolnelectric.com
A CLOSER LOOK
Power Wave®i400
DVANTAGE LINCOLN
A
• Flexible Design - Designed for simple, seamless integration with the
FANUC®Robotics R-30iA Controller, or use as a separated configuration
to meet your weld cell requirements.
• Quality and Consistent Welding Results - Lincoln’s Waveform Control
Technology
application – that means the arc has been optimized for each wire type
and size for exceptionally smooth arc performance.
• High Performance Digital Communications - High speed digital
communication via ArcLink
ArcLink
Ethernet cable.
• Best in Class Power - 10-420 amps output delivers the power you need
for a wide range of processes and materials, with no derating for pulse
waveforms.
• Ready to Perform - Auxiliary outlet offers flexibility to add fume extraction,
water cooler, computer or other accessories quickly and easily.
DESIGN FEATURES
• Industry best 120 kHz inverter:
- Operates at a high efficiency and (.95) power factor at rated output.
- Capable of operating from a universal input voltage (208 to 575 volts).
• Fan-As-Needed™ (F.A.N.) - reduces power consumption and the amount
of debris that gets drawn into the machine by shutting the fan down
when it is not needed.
• Engineered Power Distribution:
- Single power drop saves time and cost.
- 3 phase input power supplied to robot
- 115VAC, 15 amp capacity auxiliary duplex receptacle to power
• Recessed connection panel for protection against accidental impact.
• External access to controller mounting hardware.
®
gives you the ability to select the right waveform for each
®
®
XT™, the ArcLink®protocol can be communicated over an
protocol, a CAN connection or now the
controller via dedicated reconnect block.
optional water cooler, fume extraction, grinder, and computer.
What is Coaxial Transformer Technology™?
Coaxial Transformer Technology™ eliminates inefficiency and power
loss. Regardless of the size (power level) a coaxial transformer has
superior coupling and efficiency. This is obtained through the coaxial
orientation of the primary and secondary windings.
The benefits for the customer include:
• Higher power capabilities with a less
complex design.
• Higher efficiency (reduced energy costs).
• Higher reliability (lower stresses on components).
• Proven reliability.
MAINTENANCE AND SERVICE
• Removable left side panel permits easy access to internal components
for routine maintenance or repair, even when integrated in a robotic cell.
• Panel mounted status LED indicators allow for quick and easy
troubleshooting.
• Lockable on/off power switch on power source for controller/robot for
maintenance purposes (power must be disconnected at the wall).
• Mechanical connection to R-30iA Controller accessible from exterior
of Power Wave
®
i400 for easy removal of controller.
• Full support of Lincoln Electric Diagnostic Utility software for easy
troubleshooting through the Teach Pendant.
[2]
Publication E10.11
www.lincolnelectric.com
A CLOSER LOOK
AutoDrive™4R90
ADVANTAGE LINCOLN
• Integrated Design - Designed to “nest” in the upper arm of the FANUC
Robotics ARC Mate®100iC arm.
®
• Durable and Rugged - Patented MAXTRAC
wire drive is precision cast
aluminum designed to provide reliable feed force.
• Ease of Use - Unlike competitive models, no tools are required for drive
roll, wire guide or pressure arm adjustment.
• High Performance - Brass-to-brass gun connections provide more
reliable electrical connectivity and more efficient energy transfer.
• Best in Class Torque - Results in faster acceleration and reliably pulls
wire through conduit.
• Precise Control - Dual spring pressure arms offer clear-cut adjustment
for optimizing pressure for different wire types.
• Welding Results - High resolution tachometer for accurate wire feed
speed control.
• Optimized Robotic Solution - Compact, lighter weight packaging
maximizes robot acceleration performance and throughput.
®
[3]
A new unique robotic wire feeder package
focused on .035-.045 wire applications.
High performance wire drive system featuring:
• Compact package
• Lightweight
• Tool-less design
• Durable and rugged
Publication E10.11
www.lincolnelectric.com
WAVEFORM CONTROL TECHNOLOGY
®
DRIVING SUPERIOR WELDING PERFORMANCE
Lincoln’s Waveform Control Technology®controls and shapes the output waveforms (or weld modes).
It is the modulation of the welding current that achieves a specific desired welding result. High
performance, digital welding waveforms are developed based on the application and take into account
he process, gas, and wire size combinations.
t
The desired welding result is efficient, reliable, consistent, high performance welding which is delivered
with the Power Wave
®
i400 solution.
For more information see Nextweld®Document #NX-1.10
LINCOLN NEXTWELD®INNOVATIONS FOR CHALLENGING APPLICATIONS
Waveform Control Technology®makes it possible to take advantage of Lincoln Nextweld®innovations like
these patented processes using the Power Wave
®
i400 and the AutoDrive™4R90 wire feeder:
Lincoln Electric Welding Feature Overview
Rapid-Arc
®
- High Speed Welding • Wide range of filler metals
TM
Power Mode
- Consistent stability and penetration • Wide range of filler metals
• Stable at very short arc lengths
• Good at high travel speeds
Very low spatter
•
Out of position
•
• Wide range of operating procedures
Low heat input
•
• Join materials thinner than 20 gauge (0.7 mm)
• Consistent arc stability & penetration profile
• A stable arc despite stickout fluctuation
TOTAL s2f
TM
TOTAL s2f™- Aluminum Welding Solution
• Pulse-on-Pulse
• Pulse Spray Transfer
TM
• Spatter reduction
• Excellent cleaning action
• Wide range of frequency modulation (ripple affect) for uniform beads on welds in
which appearance is critical
• Control of heat input on thinner materials
• Spatter reduction
• Excellent cleaning action
• Synergic - "one knob control"
The industry’s first web resource exclusively for fabricators
who rely on Lincoln Electric welding equipment.
PowerWaveSoftware.com offers users access to new
product software releases, system upgrades, welding
improvements, and Power Wave
Go to PowerWaveSoftware.com today!
®
Utilities.
[4]
Publication E10.11
www.lincolnelectric.com
DIGITAL COMMUNICATIONS TECHNOLOGY
®
®
The Lincoln Electric Company led the industry with the introduction of ArcLink®, the first digital
ommunications protocol for the arc welding industry introduced in 2002. ArcLink
c
means of communicating and sharing information between intelligent components for seamless, timecritical data transfer in an arc welding system.
Continuing this leading position, Lincoln Electric has now introduced another industry first with
®
ArcLink
XT, which takes all of the same features and benefits of traditional ArcLink communication,
but eXtends this communication protocol on an Ethernet connection directly to the FANUC
R30iA controller.
For more information see Nextweld
®
Document #NX-1.30
®
s a protocol, or
i
®
Robotics
LINCOLN ELECTRIC AND FANUC®ROBOTICS ADVANTAGES:
ArcLink! XT Features:
New Standard Features - Ethernet is a standard feature on the Power Wave®i400 with no
additional hardware cost and also offers Lincoln Electric's Production Monitoring™ utility as a
part of the robotic solution.
Performance Based Design - 100 MHz, full duplex Ethernet interface offers a reliable and
consistent hardware platform for industrial environments, and facilitates future feature expansion.
Lower Cost System - Lower cost system for multi-equipment (multi-arm) through addition of a
network Ethernet switch. No additional cards or hardware required.
ArcLink! Features:
Common User Interface - The Teach Pendant can display actual volts,
wire feed speed, etc, in process specific units.
Reduced Set-up Time - As an ArcLink®device, all communication with the
robot controller, power source, wire feeder are automatically recognized.
Full Access to Welding Database - Search by process, material, and
procedure right from the Teach Pendant and access all set-up variables.
HIGH SPEED DIGITAL CONTROL TECHNOLOGY & FEATURES:
Lincoln Electric emerges as an industry leader with a distributed control architecture
design in the Power Wave
future expansion capabilities and features.
The state-of-the-art technology used in this system is designed with the highest
performance digital controls in the robotic power source marketplace:
• Over 5000 MIPS processing power
• 100 Mbps full duplex data transfer rate
• 32 Mbytes SDRAM memory
• More than 16 Mbytes FLASH Memory
®
i400 system created with a flexible design that ensures
Publication E4.20
[5]
www.lincolnelectric.com
A CLOSER LOOK
SYSTEM DIAGRAMS
Easy connection and installation provides for a stress-free commissioning stage. The ease of use and servicing ensures users
are efficient and productive with their time.
FANUC Robotics R-30iA
“a-cabinet” Controller
with Integrated Op Box
*ArcLink®XT
Ethernet
cable
**DETAIL A
Power Wave®i400
2669-1
K
Power
*
cable
A
New FANUC®Robotics/Lincoln Electric solution providing the latest technology and features together - the best of
robotics and robotic welding combined.
Electrode
Connection
AutoDrive™ 4R90
K2685-2
FANUC Robotics R-30iA
“a-cabinet” Controller
Wire Feeder
Gas
Air
ARC Mate™ 1XXiC
with Integrated Op Box
ArcLink®XT
Ethernet Cable
(Internal)
Circuit Breaker
(15 Amp)
Devicenet
Connector
Wire Feeder
Control Cable
K1785-xx
Optional Work
Sense Lead (21)
* Electrode
Cable (+)
K2163-xx or
K1842-xx
Work
Piece
* Work Cable (+)
K2163-xx or
K1842-xx
Power Wave®i400
K2669-1
* Refer to Output Cable Guidlines for recommended cable size in Power Wave®i400 Instruction Manual.
[6]
Wire Feeder
Connector
Voltage Sense
Connector
®
ArcLink
Connector
ArcLink®XT
Ethernet Connection
Publication E10.11
www.lincolnelectric.com
A CLOSER LOOK
SYSTEM DIAGRAMS
Flexible solution for integrated or
separated installations. The system
accommodates to your needs.
Electrode
Connection
AutoDrive™
4R90
K2685-2
Wire Feeder
Gas
Air
ARC Mate™
1XXiC (Master)
* Electrode
Cable (+)
ptional Work
O
ense Lead (21)
S
AutoDrive™ 4R90
K2685-2
ARC Mate™ 1XXiC (Slave)
* Electrode
Cable (+)
ptional Work
O
Sense Lead (21)
Work
iece
P
Electrode
Connection
AutoDrive™ 4R90
K2685-2
FANUC Robotics R-30iA
“a-cabinet” Controller
with Integrated Op Box
Wire Feeder
Gas
Air
ARC Mate™ 1XXiC
* Electrode
Power Wave®i400
able (+)
C
K2669-1
2163-xx or
K
K1842-xx
Optional Work
Sense Lead (21)
ire Feeder
W
Control Cable
K1785-xx
Work
Piece
ArcLink®XT
Control Cable
Work Cable (+)
*
2163-xx or
K
1842-xx
K
FANUC Robotics R-30iA
“a-cabinet” Controller
with Integrated Op Box
(Master)
Circuit Breaker
(15 Amp)
Devicenet
Connector
Wire
Feeder
Connector
Voltage
Sense
Connector
ArcLink
Connector
ArcLink®XT
Ethernet
Connection
Wire Feeder
Control Cable
K1785-xx
FANUC Robotics R-30iA
“a-cabinet” Controller
with Integrated Op Box
(Slave)
®
Power Wave
i400
K2669-1
Work
iece
P
Work
*
Cable (+)
*
C
Work
able (+)
Wire Feeder
Control Cable
1785-xx
K
Power Wave
i400
K2669-1
ArcLink®XT
Ethernet cable
(Internal)
®
ArcLink®XT
Ethernet Cable
Dual Arm System
®
Circuit Breaker
(15 Amp)
Devicenet
Connector
Wire
Feeder
Connector
Voltage
Sense
Connector
ArcLink
Connector
ArcLink®XT
Ethernet
Connection
®
Backward compatibility is supported
to ensure existing robotic cells can
be integrated with Power Wave
(shown here is a Power Wave
®
i400
®
F355i replacement).
Air
Wire Feeder
Gas
Air
Wire Feeder
ARC Mate™ 1XXiBe
Wire Feeder
Control Cable
K1785-xx
FANUC Robotics
Electrode
Connection
* Electrode
Cable (+)
K2163-xx or
K1842-xx
R-J3iB Controller
* Work Cable (+)
K2163-xx or
K1842-xx
Power Wave®i400
K2669-1
®
ArcLink
Control Cable
K1543-xx
Circuit Breaker
(15 Amp)
Devicenet
Connector
Wire
Feeder
Connector
Voltage
Sense
Connector
®
ArcLink
Connector
ArcLink®XT
Ethernet
Connection
Power Feed 10R
K1780-2
8” Adaper Cable
1
K1785-2
Robotic
Torch
Gas
Optional Work
Sense Lead (21)
Work
Piece
Publication E10.11
[7]
www.lincolnelectric.com
TECHNICAL SPECIFICATIONS
POWER WAVE®i400
Input Power 200/230/380-415/460/575
Duty Cycle 350A/34V/100%
Output Current Range 5-420 ADC
Output Voltage Range 10-37 VDC
Cooling Method Fan As Needed™ (F.A.N.)
Power Factor at Rated Output .95
IP Rating IP21S
Welding Output CV/DC
Welding Processes CV-MIG, Pulsed-MIG, Flux-cored, Metal-cored, Stainless, Aluminum
Dimensions - H x W x D in (mm) 21 x 18.5 x 23.6 in (533 x 470 x 600 mm )
Net Weight - lbs (kg) 209 lbs. (95 kg)
Volume 0.150 m
Universal Certifications CE, CSA
3 Phase Input
50/60 Hz
Single product number - CE compliance is provided with a CE Filter
*
Kit. Input voltage is limited to 380-415/3/50/60 with kit installed.
400A/36V/60%
420A/37V/40%
* No derating for CV versus Pulse modes.
* Best in class rated machine for power.
* Cooling fan runs when the output is energized, and for 5 minutes after
he output has been turned off.
t
3
, C-Tick
C/UL
AUTODRIVE™4R90
Wire Drive 4 Driven Rolls
* 4 Gear powered rolls versus competitive 2 gear driven rolls & 2 idle rolls
Motor Type Permanent Magnet DC Motor
Tachometer Type Magnetic High Resolution Dual Channel
Wire Feed Speed Range in/min (m/min) AutoDrive™ 4R90 - 50 to 800 in/min (0.8 to 20.3 m/min)
Max Wire Size Range AutoDrive™ 4R90
Solid: .023 - .045” (0.6 – 1.2 mm)
Cored: .035 - .045 (0.9 - 1.2 mm)
Dimensions – L x W x H inches (mm) 9.1 x 7.5 x 8.4 inches (231 x 141 x 213 mm)
Net Weight - lbs (kg) 14.5 lbs. (6.5 kg)
Universal Certifications CE, CSA
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. On occasion, purchasers may ask Lincoln Electric for information or advice about their use of our products. Our employees respond to
inquiries to the best of their ability based on information provided to them by the customers and the knowledge they may have concerning the application. Our employees, however, are not
in a position to verify the information provided or to evaluate the engineering requirements for the particular weldment. Accordingly, Lincoln Electric does not warrant or guarantee or assume
any liability with respect to such information or advice. Moreover, the provision of such information or advice does not create, expand, or alter any warranty on our products. Any express or
implied warranty that might arise from the information or advice, including any implied warranty of merchantability or any warranty of fitness for any customers’ particular purpose is
specifically disclaimed.
Lincoln Electric is a responsive manufacturer, but the selection and use of specific products sold by Lincoln Electric is solely within the control of, and remains the sole responsibility of the
customer. Many variables beyond the control of Lincoln Electric affect the results obtained in applying these types of fabrication methods and service requirements.
Subject to Change – This information is accurate to the best of our knowledge at the time of printing. Please refer to www.lincolnelectric.com for any updated information.
C U S T O M E R A S S I S T A N C E P O L I C Y
C/UL
, C-Tick
THE L IN CO LN E LE CT RI C C OM PANY
22801 St. Clair Ave., Cleveland, OH 44117-1199 • 216.481.8100 • www.lincolnelectric.com
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