Lincoln Electric IM986 User Manual

POWER WAVE®i400

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IM986

November, 2008

For use with machines having Code Numbers:

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 INSTALL, OPERATE OR REPAIR THIS EQUIPMENT WITHOUT READING THIS MANUAL AND THE SAFETY PRECAUTIONS CONTAINED THROUGHOUT. And, most

importantly, think before you act and be careful.

11536, 11536R

OPERATOR’S MANUAL

• World's Leader in Welding and Cutting Products •

• 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

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

ARC WELDING CAN BE HAZARDOUS. PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY OR DEATH. KEEP CHILDREN AWAY. PACEMAKER 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 of “Safety in Welding & Cutting - ANSI Standard Z49.1” from the American Welding Society, P.O. Box 351040, Miami, Florida 33135 or CSA Standard W117.2-1974. A Free copy of “Arc Welding Safety” booklet E205 is available from the Lincoln Electric Company, 22801 St. Clair Avenue, Cleveland, Ohio 44117-1199.

BE SURE THAT ALL INSTALLATION, OPERATION, MAINTENANCE AND REPAIR PROCEDURES ARE PERFORMED ONLY BY QUALIFIED INDIVIDUALS.

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

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.d. Keep all equipment safety guards, covers and devices in

position and in tools away from V-belts, gears, fans and all other moving parts when starting, operating or repairing equipment.

____________________________________________________

1.e. In some cases it may be necessary to remove safety guards to perform guards only when necessary and replace them when the maintenance requiring their removal is complete. Always use the greatest care when working near moving parts.

___________________________________________________

1.b. Operate engines in open, well-ventilated areas or vent outdoors.

1.c. Do not add the fuel near an open flame welding arc or Stop the engine and allow it to cool before refueling to prevent spilled fuel from vaporizing on contact with hot engine parts and igniting. Do not spill fuel when filling tank. If fuel is spilled, wipe it up and do not start engine until fumes have been eliminated.

good repair.Keep hands, hair, clothing and

1.f. Do not put your hands near the engine fan.

Do not attempt idler by pushing on the throttle control rods while the engine is running.

the engine exhaust fumes

when the engine is running.

required maintenance. Remove

to override the governor or

1.h. To avoid scalding, do not remove the radiator pressure cap when the engine is hot.

ELECTRIC AND MAGNETIC FIELDS may be dangerous

2.a. Electric current flowing through any conductor causes localized Electric and Magnetic Fields (EMF). Welding current creates EMF fields around welding cables and welding machines

2.b. EMF fields may interfere with some pacemakers, and welders having a pacemaker should consult their physician before welding.

2.c. Exposure to EMF fields in welding may have other health effects which are now not known.

2.d. All welders should use the following procedures in order to minimize exposure to EMF fields from the welding circuit:

2.d.1.

Route the electrode and work cables together - Secure them with tape when possible.

2.d.2. Never coil the electrode lead around your body.

2.d.3. Do not place your body between the electrode and

work cables. If the electrode cable is on your right side, the work cable should also be on your right side.

___________________________________________________

1.g. To prevent accidentally starting gasoline engines while turning the engine work, disconnect the spark plug wires, distributor cap or magneto wire as appropriate.

or welding generator during maintenance

2.d.4. Connect the work cable to the workpiece as close as possible to the area being welded.

2.d.5. Do not work next to welding power source.

Mar ʻ95

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.

In addition to the normal safety precautions, if welding must be performed under electrically hazardous conditions (in damp locations or while wearing wet clothing; on metal structures such as floors, gratings or scaffolds; when in cramped positions such as sitting, kneeling or lying, if there is a high risk of unavoidable or accidental contact with the workpiece or ground) use the following equipment:

• Semiautomatic DC Constant Voltage (Wire) Welder.

• DC Manual (Stick) Welder.

• AC Welder with Reduced Voltage Control.

3.c. In semiautomatic or automatic wire welding, the electrode, electrode reel, welding head, nozzle or semiautomatic welding gun are also electrically “hot”.

3.d. Always be sure the work cable makes a good electrical connection with the metal being welded. The connection should be as close as possible to the area being welded.

3.e. Ground the work or metal to be welded to a good electrical (earth) ground.

ARC RAYS can burn.

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 skin and that of your helpers from the arc rays.

4.c. Protect other nearby personnel with suitable, non-flammable screening and/or warn them not to watch the arc nor expose themselves to the arc rays or to hot spatter or metal.

FUMES AND GASES can be dangerous.

5.a. Welding may produce fumes and gases hazardous to health. Avoid breathing these fumes and gases. When welding, keep your head out of the fume. Use enough ventilation and/or exhaust at the arc to keep

fumes and gases away from the breathing zone. When

welding with electrodes which require special ventilation such as stainless or hard facing (see instructions on container or MSDS) or on lead or cadmium plated steel and other metals or coatings which produce highly toxic fumes, keep exposure as low as possible and below Threshold Limit Values (TLV) using local exhaust or mechanical ventilation. In confined spaces or in some circumstances, outdoors, a respirator may be required. Additional precautions are also required when welding on galvanized steel.

3.f.

Maintain the electrode holder, work clamp, welding cable and welding machine in good, safe operating condition. Replace damaged insulation.

3.g. Never dip the electrode in water for 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 welders.

3.i. When working above floor level, use a safety belt to protect yourself from a fall should you get a shock.

3.j. Also see Items 6.c. and 8.

5. b. The operation of welding fume control equipment is affected by various factors including proper use and positioning of the equipment, maintenance of the equipment and the specific welding procedure and application involved. Worker exposure level should be checked upon installation and periodically thereafter to be certain it is within applicable OSHA PEL and ACGIH TLV limits.

5.c.

Do not weld in locations near chlorinated hydrocarbon coming from degreasing, cleaning or spraying operations. The heat and rays of the arc can react with solvent vapors form phosgene, a highly toxic gas, and other irritating products.

5.d. Shielding gases used for arc welding can displace air and

cause injury or death. Always use enough ventilation, especially in confined areas, to insure breathing air is safe.

5.e. Read and understand the manufacturerʼs instructions for this

equipment and the consumables to be used, including the material safety data sheet (MSDS) and follow your employerʼs safety practices. MSDS forms are available from your welding distributor or from the manufacturer.

5.f. Also see item 1.b.

vapors

AUG 06

iii

SAFETY

iii

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

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. Where compressed gases are to be used at the job site, special precautions should be used to prevent hazardous situations. Refer to “Safety in Welding and Cutting” (ANSI Standard Z49.1) and the operating information for the equipment being used.

6.c. When not welding, make certain no part of the electrode circuit is touching the work or ground. Accidental contact can cause overheating and create a fire hazard.

6.d. Do not heat, cut or weld tanks, drums or containers until the proper steps have been taken to insure that such procedures will not cause flammable or toxic vapors from substances inside. They can cause an explosion even been “cleaned”. For information, purchase “Recommended Safe Practices for the Containers and Piping That Have Held Hazardous Substances”, AWS F4.1 from the American Welding Society

(see address above).

6.e. Vent hollow castings or containers before heating, cutting or welding. They may explode.

Sparks and spatter are thrown from the welding arc. Wear oil

6.f. free protective garments such as leather gloves, heavy shirt, cuffless trousers, high shoes and a cap over your hair. Wear ear plugs when welding out of position or in confined places. Always wear safety glasses with side shields when in a welding area.

6.g. Connect the work cable to the work as close to the welding area as practical. Work cables connected to the building framework or other locations away from the welding area increase the possibility of the welding current passing through lifting chains, crane cables or other alternate circuits. This can create fire hazards or overheat lifting chains or cables until they fail.

6.h. Also see item 1.c.

the welding sparks from starting a fire.

though

they have

Preparation

for Welding and Cutting of

CYLINDER may explode if damaged.

7.a. Use only compressed gas cylinders containing the correct shielding gas for the process used and properly operating regulators designed for the gas and

pressure used. All hoses, fittings, etc. should be suitable for the application and maintained in good condition.

7.b. Always keep cylinders in an upright position securely chained to an undercarriage or fixed support.

7.c. Cylinders should be located:

• Away from areas where they may be struck or subjected to

physical damage.

• A safe distance from arc welding or cutting operations and

any other source of heat, sparks, or flame.

7.d. Never allow the electrode, electrode holder or any other electrically “hot” parts to touch a cylinder.

7.e. Keep your head and face away from the cylinder valve outlet when opening the cylinder valve.

7.f. Valve protection caps should always be in place and hand tight except when the cylinder is in use or connected for use.

7.g. Read and follow the instructions on compressed gas cylinders, associated equipment, and CGA publication P-l, “Precautions for Safe Handling of Compressed Gases in Cylinders,” available from the Compressed Gas Association 1235 Jefferson Davis Highway, Arlington, VA 22202.

FOR ELECTRICALLY powered 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 manufacturerʼs recommendations.

8.c. Ground the equipment in accordance with the U.S. National Electrical Code and the manufacturerʼs recommendations.

6.I. Read and follow NFPA 51B “ Standard for Fire Prevention During Welding, Cutting and Other Hot Work”, available from NFPA, 1 Batterymarch Park,PO box 9101, Quincy, Ma 022690-9101.

6.j. Do not use a welding power source for pipe thawing.

Jan, 07

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. Eviter toujours tout contact entre les parties sous tension et la peau nue ou les vétements mouillés. Porter des gants secs et sans trous pour isoler les mains.

b. Faire trés attention de bien sʼisoler de la masse quand on

soude dans des endroits humides, ou sur un plancher metallique ou des grilles metalliques, principalement dans les positions assis ou couché pour lesquelles une grande partie du corps peut être en contact avec la masse.

c. Maintenir le porte-électrode, la pince de masse, le câble

de soudage et la machine à souder en bon et sûr état defonctionnement.

d.Ne jamais plonger le porte-électrode dans lʼeau pour le

refroidir.

e. Ne jamais toucher simultanément les parties sous tension

des porte-électrodes connectés à deux machines à souder parce que la tension entre les deux pinces peut être le total de la tension à vide des deux machines.

f. Si on utilise la machine à souder comme une source de

courant pour soudage semi-automatique, ces precautions pour le porte-électrode sʼapplicuent aussi au pistolet de soudage.

2. Dans le cas de travail au dessus du niveau du sol, se protéger contre les chutes dans le cas ou on recoit un choc. Ne jamais enrouler le câble-électrode autour de nʼimporte quelle partie du corps.

3. Un coup dʼarc peut être plus sévère quʼun coup de soliel, donc:

a. Utiliser un bon masque avec un verre filtrant approprié

ainsi quʼun verre blanc afin de se protéger les yeux du rayonnement de lʼarc et des projections quand on soude ou quand on regarde lʼarc.

b. Porter des vêtements convenables afin de protéger la

peau de soudeur et des aides contre le rayonnement de lʻarc.

c. Protéger lʼautre personnel travaillant à proximité au

soudage à lʼaide dʼécrans appropriés et non-inflammables.

4. Des gouttes de laitier en fusion sont émises de lʼarc de soudage. Se protéger avec des vêtements de protection libres de lʼhuile, tels que les gants en cuir, chemise épaisse, pantalons sans revers, et chaussures montantes.

5. Toujours porter des lunettes de sécurité dans la zone de soudage. Utiliser des lunettes avec écrans lateraux dans les zones où lʼon pique le laitier.

6. Eloigner les matériaux inflammables ou les recouvrir afin de prévenir tout risque dʼincendie dû aux étincelles.

7. Quand on ne soude pas, poser la pince à une endroit isolé de la masse. Un court-circuit accidental peut provoquer un échauffement et un risque dʼincendie.

8. Sʼassurer que la masse est connectée le plus prés possible de la zone de travail quʼil est pratique de le faire. Si on place la masse sur la charpente de la construction ou dʼautres endroits éloignés de la zone de travail, on augmente le risque de voir passer le courant de soudage par les chaines de levage, câbles de grue, ou autres circuits. Cela peut provoquer des risques dʼincendie ou dʼechauffement des chaines et des câbles jusquʼà ce quʼils se rompent.

9. Assurer une ventilation suffisante dans la zone de soudage. Ceci est particuliérement important pour le soudage de tôles galvanisées plombées, ou cadmiées ou tout autre métal qui produit des fumeés toxiques.

10. Ne pas souder en présence de vapeurs de chlore provenant dʼopérations de dégraissage, nettoyage ou pistolage. La chaleur ou les rayons de lʼarc peuvent réagir avec les vapeurs du solvant pour produire du phosgéne (gas fortement toxique) ou autres produits irritants.

11. Pour obtenir de plus amples renseignements sur la sûreté, voir le code “Code for safety in welding and cutting” CSA Standard W 117.2-1974.

PRÉCAUTIONS DE SÛRETÉ POUR LES MACHINES À SOUDER À TRANSFORMATEUR ET À REDRESSEUR

1. Relier à la terre le chassis du poste conformement au code de lʼélectricité et aux recommendations du fabricant. Le dispositif de montage ou la piece à souder doit être branché à une bonne mise à la terre.

2. Autant que possible, Iʼinstallation et lʼentretien du poste seront effectués par un électricien qualifié.

3. Avant de faires des travaux à lʼinterieur de poste, la debrancher à lʼinterrupteur à la boite de fusibles.

4. Garder tous les couvercles et dispositifs de sûreté à leur place.

Mar. ʻ93

SAFETY

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 a harmonized standard: EN 60974-10 Electromagnetic Compatibility (EMC) Product Standard for Arc Welding Equipment. It is for use with other Lincoln Electric equipment. It is designed for industrial and professional use.

Introduction All electrical equipment generates small amounts of electromagnetic emission. Electrical emission may be transmitted through power lines or radiated through space, similar to a radio transmitter. When emissions are received by other equipment, electrical interference may result. Electrical emissions may affect many kinds of electrical equipment; other nearby welding equipment, radio and TV reception, numerical controlled machines, telephone systems, computers, etc. Be aware that interference may result and extra precautions may be required when a welding power source is used in a domestic establishment.

Installation and Use The user is responsible for installing and using the welding equipment according to the manufacturerʼs instructions. If electromagnetic disturbances are detected then it shall be the responsibility of the user of the welding equipment to resolve the 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 construction an electromagnetic screen enclosing the power source and the work complete with associated input filters. In all cases electromagnetic disturbances must be reduced to the point where they are no longer troublesome.

Note: The welding circuit may or may not be earthed for safety reasons according to national codes.

Changing the earthing arrangements should only be authorized by a person who is competent to access whether the changes will increase the risk of injury, e.g., by allowing parallel welding current return paths which may damage the earth circuits of other equipment.

Assessment of Area Before installing welding equipment the user shall make an assessment of potential electromagnetic problems in the surrounding area. The following shall be taken into account:

a) other supply cables, control cables, signaling and telephone cables; above, below and adjacent to the

welding equipment;

b) radio and television transmitters and receivers;

c) computer and other control equipment;

d) safety critical equipment, e.g., guarding of industrial equipment;

e) the health of the people around, e.g., the use of pacemakers and hearing aids;

f) equipment used for calibration or measurement

g) the immunity of other equipment in the environment. The user shall ensure that other equipment being

used in the environment is compatible. This may require additional protection measures;

h) the time of day that welding or other activities are to be carried out.

L10093 3-1-96H

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 manufacturerʼs recommendations. If interference occurs, it may be necessary to take additional precautions such as filtering of the mains supply. Consideration should be given to shielding the supply cable of permanently installed welding equipment, in metallic conduit or equivalent. Shielding should be electrically continuous throughout its length. The shielding should be connected to the welding power source so that good electrical contact is maintained between the conduit and the welding power source enclosure.

Maintenance of the Welding Equipment The welding equipment should be routinely maintained according to the manufacturerʼs recommendations. All access and service doors and covers should be closed and properly fastened when the welding equipment is in operation. The welding equipment should not be modified in any way except for those changes and adjustments covered in the manufacturers instructions. In particular, the spark gaps of arc striking and stabilizing devices should be adjusted and maintained according to the manufacturerʼs recommendations.

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 components in the welding installation and adjacent to it should be considered. However, metallic components bonded to the work piece will increase the risk that the operator could receive a shock by touching these metallic components and the electrode at the same time. The operator should be insulated from all such bonded metallic components.

Earthing of the Workpiece Where the workpiece is not bonded to earth for electrical safety, not connected to earth because of its size and position, e.g., ships hull or building steelwork, a connection bonding the workpiece to earth may reduce emissions in some, but not all instances. Care should be taken to prevent the earthing of the workpiece increasing the risk of injury to users, or damage to other electrical equipment. Where necessary, the connection of the workpiece to earth should be made by a direct connection to the workpiece, but in some countries where direct connection is not permitted, the bonding should be achieved by suitable capacitance, selected according to national regulations.

Screening and Shielding Selective screening and shielding of other cables and equipment in the surrounding area may alleviate problems of interference. Screening of the entire welding installation may be considered for special applications. 1

_________________________

Portions of the preceding text are contained in EN 60974-10: “Electromagnetic Compatibility (EMC) product standard for arc welding equipment.”

L10093 3-1-96H

Thank You

viivii

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!

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 advice or information about their use of our products. We respond to our customers based on the best information in our possession at that time. Lincoln Electric is not in a position to warrant or guarantee such advice, and assumes no liability, with respect to such information or advice. We expressly disclaim any warranty of any kind, including any warranty of fitness for any customerʼs particular purpose, with respect to such information or advice. As a matter of practical consideration, we also cannot assume any responsibility for updating or correcting any such information or advice once it has been given, nor does the provision of information or advice create, expand or alter any warranty with respect to the sale of our products.

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.

CUSTOMER ASSISTANCE POLICY

Please Examine Carton and Equipment For Damage Immediately

When this equipment is shipped, title passes to the purchaser upon receipt by the carrier. Consequently, Claims for material damaged in shipment must be made by the purchaser against the transportation company at the time the shipment is received.

Please record your equipment identification information below for future reference. This information can be found on your machine nameplate.

Product _________________________________________________________________________________

Model Number ___________________________________________________________________________

Code Number or Date Code_________________________________________________________________

Serial Number____________________________________________________________________________

Date Purchased___________________________________________________________________________

Where Purchased_________________________________________________________________________

Whenever you request replacement parts or information on this equipment, always supply the information you have recorded above. The code number is especially 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 the back of the warranty statement included in the literature packet accompanying this machine and fax the form per the instructions printed on it.

• For On-Line Registration: Go to our

“Product Registration”. Please complete the form and submit your registration.

Read this Operators Manual completely before attempting to use this equipment. Save this manual and keep it handy for quick reference. Pay particular attention to the safety instructions we have provided for your protection. The level of seriousness to be applied to each is explained below:

WEB SITE at www.lincolnelectric.com. Choose “Quick Links” and then

WARNING

This statement appears where the information must be followed exactly to avoid serious personal injury or loss of life.

CAUTION

This statement appears where the information must be followed to avoid minor personal injury or damage to this equipment.

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-3

Environmental Considerations...............................................................................A-3

Lifting .....................................................................................................................A-3

Stacking.................................................................................................................A-3

Electromagnetic Compatibility ...............................................................................A-4

Input and Grounding Connections.........................................................................A-4

Input Connection....................................................................................................A-4

Connection Diagrams and Systems................................................................A-5,A-6

Fanuc R30iA Controller Mounting ...................................................................A-7

Typical Integrated Systems (Single Arm)........................................................A-8

Typical Stand Alone Systems (Single Arm) ....................................................A-9

Typical Master / Slave System (Dual Arm) ...................................................A-10

Typical F355i Retrofit (Single Arm) ...............................................................A-11

Electrode and Work Connections, General Guidelines .......................................A-12

Cable Inductance, and its Effects on Welding .....................................................A-13

Remote Sense Lead Connections .............................................................A-13,A-14

Sense Lead Diagrams of Circumferential Applications........................................A-15

Control Cable Connections..................................................................................A-16

Common Equipment Connections ..............................................................A-16,A-17

DeviceNet Configuration, Other Set-up Issues...................................................A-17

________________________________________________________________________

Operation .........................................................................................................Section B

Safety Precautions.................................................................................................B-1

Graphic Symbols ...................................................................................................B-2

Product Description ...............................................................................................B-3

Recommended Processes 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 Welding Controls ...................................................................................B-7

Constant Voltage Welding...............................................................................B-7

________________________________________________________________________

Accessories.....................................................................................................Section C

________________________________________________________________________

Maintenance ....................................................................................................Section D

________________________________________________________________________

Troubleshooting..............................................................................................Section E

________________________________________________________________________

Wiring Diagram.............................................................................................Section F-1

Dimension Print............................................................................................Section F-2

________________________________________________________________________

Parts Lists...............................................................................................................P-588

________________________________________________________________________

Pulse Welding .................................................................................................B-8

Optional Equipment...............................................................................................C-1

Factory Installed..............................................................................................C-1

Field Installed..................................................................................................C-1

Compatible Lincoln Equipment .......................................................................C-1

Safety Precautions ................................................................................................D-1

Routine and Periodic Maintenance........................................................................D-1

Calibration Specification, Chassis Removal Procedure ........................................D-1

Capacitor Discharge Procedure ............................................................................D-2

How to use Troubleshooting Guide .......................................................................E-1

Using the Status LED to Troubleshoot System Problems .....................................E-2

Error Codes For POWER WAVE® ................................................................E-3, E-4

Troubleshooting Guide...........................................................................E-5 thru E-14

viii

A-1

INSTALLATION

TECHNICAL SPECIFICATIONS - POWER WAVE® i400 (K2669-2, K2673-2)

JAPANESE POWER SOURCES - INPUT VOLTAGE AND CURRENT

Model

K2669-2

K2673-2

(Chassis Only)

Process

Duty Cycle

40% rating

60% rating

100% rating

Duty Cycle

Input Voltage ± 10%

200/208

3 phase 50/60 Hz

RATED OUTPUT

Volts at Rated Amperes

Input Amperes

(incl. robot and

aux. load)

(86)

(81)

(70)

Idle Power

475 Watts

Max.

(fan on)

Amperes

Power Factor @

Rated Output

A-1

.80

40%

420

GMAW

GMAW-Pulse

60%

400

FCAW

GTAW-DC

3 PHASE INPUT

VOLTAGE

50/60Hz

200/208

Wire and Fuse Sizes based upon the U.S. National Electric Code and maximum output for 40°C (104°) ambient.

Also called “inverse time” or “thermal/magnetic” circuit breakers; circuit breakers that have a delay in tripping action that decreases as the magnitude of current increases.

Japanese Model Codes 11536, 11536R.

100%

RECOMMENDED INPUT WIRE AND FUSE SIZES

Input

Amperes

31.5

Type 75°C Copper

Wire in Conduit

COPPER GROUNDING

CONDUCTOR

350

Fuse (Super Lag) or

Breaker Size

(incl. robot and

aux. load)

66 (86)

AWG (mm

4 (25)

)

AWG (mm

8 (10)

)

100

PHYSICAL DIMENSIONS

MODEL

K2669-2

K2673-2

HEIGHT

22.7 in. (577 mm)

21.0 in. (533 mm)

WIDTH

24.4 in. (620 mm)

22.6 in. (574 mm)

DEPTH

21.5 in. (546 mm)

18.5 in. (470 mm)

WEIGHT

188 lbs. (85.5 kg.)

126 lbs. (57.3 kg.)

TEMPERATURE RANGES

OPERATING TEMPERATURE RANGE

14°F to 104°F (-10C to 40C)

POWER WAVE® i400

STORAGE TEMPERATURE RANGE

-40°F to 185°F(-40°C to 85°C)

A-2

INSTALLATION

TECHNICAL SPECIFICATIONS - POWER WAVE® i400 (K2669-2, K2673-2)

REGULATORY REQUIREMENTS (JAPANESE MODELS)

MODEL

Standard

Enclosure

Rating

A-2

Insulation

Class

K2669-2

K2673-2

(Chassis Only)

Chassis ratings applicable only when installed as a replacement in the POWER WAVE® i400 cabinet.

EN 60974-1

EN 50199

IP21S

Class F (155°C)

POWER WAVE® i400

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.

• Always connect the POWER WAVE® grounding lug (located inside the reconnect input access door) to a proper safety (Earth) ground.

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LOCATION AND MOUNTING

The POWER WAVE® i400 case is designed to support the Fanuc R30iA controller and op box (up to 300lbs), matching the controllerʼs footprint and styling. Mounting is externally accessible for simplified integration. The flexibility of the POWER WAVE® i400 also allows it to be operated as a stand alone unit. In either case, bolting the unit to the floor or a suitable platform is recommended to provide maximum stability.The minimum recommended clearance for chassis removal is 26” (66cm) from the rear of the machine as viewed from the output studs. See the Chassis Removal Procedure for additional information.

CAUTION

• DO NOT MOUNT OVER COMBUSTIBLE SURFACES. Where there is a combustible surface directly under stationary or fixed electrical equipment, that surface shall be covered with a steel plate at least .06”(1.6mm) thick, which shall extend not less than 5.90”(150mm) beyond the equipment on all sides.

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ENVIRONMENTAL CONSIDERATIONS

The POWER WAVE® i400 will operate in harsh environments. Even so, it is important that simple preventative measures are followed in order to assure long life and reliable operation.

A-3

• Dirt and dust that can be drawn into the POWER WAVE® i400 should be kept to a minimum. The use of air filters on the air intake is not recommended because normal air flow may be restricted. Failure to observe these precautions can result in excessive operating temperatures and nuisance shutdown.

• Do not use the POWER WAVE® i400 in an outdoor environment. The power source should not be subjected to falling water, nor should any parts of it be submerged in water. Doing so may cause improper operation as well as pose a safety hazard. The best practice is to keep the machine in a dry, sheltered area.

LIFTING

WARNING

• Lift only with equipment of adequate lifting capacity.

• Be sure machine is stable when lifting.

• Do not lift this machine using lift bail if it is equipped with a heavy accessory such as trailer or gas cylinder.

FALLING • Do not lift machine if lift bail is

EQUIPMENT can damaged.

cause injury. • Do not operate machine while

suspended from lift bail.

----------------------------------------------------------------------POWER WAVE® i400:

ner mounted lift bails only. Do not attempt to lift the POWER WAVE® i400 with accessories attached to it.

POWER WAVE® i400 with the Fanuc R30iA Controller: When properly mounted the complete

integrated unit (power source and controller) can be lifted using the lift hooks provided on the Fanuc R30iA controller. Consult the Fanuc instruction manual for details and precautions.

NOTE: The POWER WAVE® i400 external corner

mounted lift bales must be removed when mounted to the Fanuc R30iA controller.

Lift the machine by the cor-

• The POWER WAVE® i400 must be located where there is free circulation of clean air such that air movement in the louvered sections of the machine will not be restricted.

POWER WAVE® i400

POWER WAVE® i400 Replacement Chassis:

the chassis by the lift bail on top of the harmonic filter assembly.

Lift

STACKING

The POWER WAVE® i400 cannot be stacked.

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. The normal operation of the POWER WAVE® i400 may adversely affect the operation of RF controlled equipment, which may result in bodily injury or damage to the equipment.

INPUT AND GROUNDING CONNECTIONS

A-4

Choose input and grounding 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 if the machine is not being used at high currents.

Power Supply Connection for the Fanuc R30iA Controller

The POWER WAVE® i400 is equipped with a dedicated robot power terminal block (4TB) specifically designed to feed input power directly to the Fanuc R30iA controller through the power source rotary ON/OFF switch. The K2677-1 Integration kit provides the proper cable and installations instructions to make this connection.

MACHINE GROUNDING

The frame of the welder must be grounded. A ground terminal marked with the symbol shown is located inside the reconnect/input access door for this purpose. See your local and national electrical codes for proper grounding methods.

INPUT CONNECTIONS

WARNING

ELECTRIC SHOCK can kill.

• Only a qualified electrician should connect the input leads to the POWER WAVE®. Connections should be made in accordance with all local and National Electrical Codes and the connection diagram located on the inside of the reconnect / input access door of the machine. Failure to do so may result in bodily injury or death.

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Use a three-phase supply line. A 1.75 inch (45 mm) diameter access hole for the input supply is located on the case back. Connect L1, L2, L3 and ground according to the input supply and ground connection decals located near the input power terminal block (1TB) and ground block inside of the rear input reconnect box.

WARNING

The POWER WAVE® i400 on/off switch is not intended as a service disconnect for this equipment. Only a qualified electrician should connect the input leads to the POWER WAVE®. Connections should be made in accordance with all local and national electrical codes and the connection diagram located on the inside of the reconnect access door of the machine. Failure to do so may result in bodily injury or death.

Do not attempt to back feed input power though the robot power terminal block (4TB) into the POWER WAVE® i400. This is not its intended purpose and may result in machine damage, bodily injury or death.

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Input Fuse and Supply Wire Considerations Refer to Specification in Installation Section for recommended fuse, wire sizes and type of the copper wires. Fuse the input circuit with the recommended super lag fuse or delay type breakers (also called "inverse time" or "thermal/magnetic" circuit breakers).

POWER WAVE® i400

A-5

INSTALLATION

CONNECTION DIAGRAMS AND SYSTEM

RECOMMENDED EQUIPMENT

System

Identifier

Power Source

Part No.

K2669-1

POWER WAVE® i400 Power Source

(includes S26064 POWER WAVE® Utilities CD)

A-5

Description

Integration Kit

Wire Drive

Power Source

to Wire Drive

Control Cable

Weld Cables

Robot Arm

Robot Controller

Torch

Maximum length 100 ft.(30.5 m) Cannot be connected end to end.

K2677-1

K2685-2

K1785-xx

K2163-xx

-or-

K1842-xx

Kxxxx Kxxxx Kxxxx

Integration Kit for Fanuc R30iA Controller. Includes industrial ethernet cable, power

cable, protective grommets, mounting plate, and dust proof strain relief.

See Price Book for details and bulk cable availability.

OPTIONAL EQUIPMENT

System

Identifier

Sense Lead Kit

Part No.

K940-xx

Remote Sense Lead Kit. Recommended for sensitive or critical applications to more accurately monitor the arc voltage.

AutoDrive 4R90 Wire Drive

Feeder Control Cable (14 pin).

Welding Power Cables

Power Source to Wire Drive,

and Power Source to Work

K2163 Series cables sold in pairs.

K1842 Series cables sold individually.

Consult Automation Division

Description

DeviceNet Kit

Sync-Tandem Kit

ArcLink Digital

Communication

Cable

External Ethernet

Network Equipment

DeviceNet Cables

and Accessories

Cables can be connected end to end to extend length (recommended maximum 200 ft [61.0m]).

K2780-1

K2781-1

K1543-xx

K2683-xx

Consult

Automation

Division

Customer

Supplied

DeviceNet Kit. Allows Power Wave i400 to communicate via DeviceNet protocol.

Sync-Tandem Kit. Allows two Power Wave i400s to perform synchronized tandem pulse welding. Includes all necessary harnesses and cabling for 2 machines. Also provides access to special Sync-Tandem welding software.

ArcLink Control Cable (5 pin). Required for earlier controllers communicating via traditional ArcLink® over a

standard 2 wire CAN based network.

K2683 Recommended on Sever Duty application.

Ethernet Switch, Cables, etc. Required for external Ethernet system connectivity typically associated with multiple arm or multiple power source applications.

DeviceNet Cables, Tees, and Terminators (5 pin sealed "mini style") Typically required for PLC or earlier model controllers communicating via DeviceNet. For additional information refer to the “DeviceNet Cable Planning and Installation Manual” (Allen Bradley publication DN-6.7.2).

POWER WAVE® i400

A-6

System

Identifier

Part No.

K1796-xx

INSTALLATION

A-6

OPTIONAL EQUIPMENT

Description

Coax Cable. Recommended to minimize the effects of the weld cable loop inductance and maximize perfor-

mance in critical high speed pulse applications.

Coaxial Weld Cable

External Dress

Cable for Robot

Arm

Personal Computer

Replacement

Chassis

K2593-xx

K2709-xx

Customer

Supplied

K2673-2

Note: K1796 coaxial cable is equivalent to 1/0 standard cable. K2539 coaxial cable is equivalent to AWG #1 standard cable. Connecting coaxial 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 further information.

External Dress Cable. Heavy duty externally mounted 14pin wire feeder cable for use with robot arms not equipped with an integral cable.

IBM Compatible PC (Windows NT SP6, Windows 2000, Windows XP, or greater) required for use with all POWER WAVE® Utilities

POWER WAVE® i400 Replacement Chassis. Complete inverter power section. Intended only as a replacement to be installed in the POWER WAVE® i400 cabinet (includes S26064 POWER WAVE® Utilities CD).

POWER WAVE i400

A-7

FANUC Robotics R-30iA "a-cabinet" Controller with Integrated Op Box

INSTALLATION

FANUC R30iA CONTROLLER MOUNTING

A-7

Power Wave i400 K2669-2

* ArcLink XT

* Power cable

Ethernet cable

* Refer to Output Cable guidelines for recommended cable size in PowerWave i400 Instruction Manual.

** Refer to Intergration kit K2677-1 instruction sheet

DETAIL A

POWER WAVE® i400

A-8

INSTALLATION

TYPICAL INTEGRATED SYSTEMS (SINGLE ARM)

Wire Feeder

Connector

Voltage Sense

Connector

ArcLink

Connector

ArcLink XT

Devicenet

Circuit Breaker

ArcLink XT

Ethernet Cable

(Internal)

Connector

(15 Amp)

Ethernet Connection

A-8

Electrode

Power Wave i400

K2669-2

FANUC Robotics R-30iA

"a-cabinet" Controller

with Integrated Op Box

* Work

Cable (-)

K2163-xx or

* Electrode

Cable (+)

K2163-xx or

K1842-xx

Work

AutoDrive 4R90

K2685-2

Connection

Air

Gas

Wire Feeder

ARC Mate 1XXiC

Optional Work

Sense Lead (21)

Wire Feeder

Control Cable

K1785-XX

K1842-xx

Piece

* Refer to Output Cable Guidelines for recommended cable size in PowerWave i400 Instruction Manual.

POWER WAVE® i400

A-9

INSTALLATION

TYPICAL STAND ALONE SYSTEMS (SINGLE ARM)

Wire Feeder

Devicenet

Connector

Circuit Breaker

(15 Amp)

Connector

ArcLink

Connector

Voltage Sense

Connector

ArcLink XT

Ethernet Connector

A-9

Electrode

ArcLink XT

Ethernet Cable

FANUC Robotics R-30iA

"a-cabinet" Controller

with Integrated Op Box

Power Wave i400

K2669-2

* Work

Cable (-)

K2163-xx or

K1842-xx

* Electrode

Cable (+)

K2163-xx or

K1842-xx

Work

Piece

AutoDrive 4R90

K2685-2

Connection

ARC Mate 1XXiC

Optional Work

Sense Lead (21)

Wire Feeder

Control cable

K1785-xx

* Refer to Output Cable guidelines for recommended cable size in PowerWave i400 Instruction Manual.

Air

Gas

Wire Feeder

POWER WAVE® i400

+ 39 hidden pages