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Lincoln Electric IM986 User's Manual

1. Q Q B o D e 2 3 t 3 4 d j E es RS CONNECT ALL WORK LEADS AT THE BEGINNING OF THE WELD POWER WAVE 1400 LINCOLN 5 APIS INSTALLATION ae For circumferential applications 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 BAD CURRENT FLOW FROMARC 1 AFFECTS SENSE LEAD 2 Work 1 2 1 CURRENT FLOW FROM ARC 2 AFFECTS SENSE LEAD 1 NEITHER SENSE LEAD PICKS UP THE CORRECT WORK VOLTAGE CAUSING STARTING AND WELDING ARC INSTABILITY SENSE LEAD 1 IS ONLY AFFECTED BY CURRENT FLOW FROM ARC 1 SENSE LEAD 2 IS ONLY AFFECTED BY CURRENT FLOW FROM ARC 2 om D DUE TO VOLTAGE DROPS ACROSS Sense 1 THE WORKPIECE ARC VOLTAGE MAY BE LOW CAUSING NEED FOR DEVIATION FROM STANDARD PROCEDURES POWER SOURCE DEC 1 BOTH SENSE LEADS ARE OUT OF THE CURRENT PATHS BOTH SENSE LEADS DETECT ARC VOLTAGE
2. HY Sol 55578 a due le Ally oua y cl gd pus gt READ AND UNDERSTAND THE MANUFACTURER S INSTRUCTION FOR THIS EQUIPMENT AND THE CONSUMABLES TO USED AND FOLLOW YOUR EMPLOYER S SAFETY PRACTICES SE RECOMIENDA LEER Y ENTENDER LAS INSTRUCCIONES DEL FABRICANTE PARA EL USO DE ESTE EQUIPO Y LOS CONSUMIBLES QUE VA A UTILIZAR SIGA LAS MEDIDAS DE SEGURIDAD DE SU SUPERVISOR LISEZ ET COMPRENEZ LES INSTRUCTIONS DU FABRICANT EN CE QUI REGARDE CET EQUIPMENT ET LES PRODUITS A ETRE EMPLOYES ET SUIVEZ LES PROCEDURES DE SECURITE DE VOTRE EMPLOYEUR LESEN SIE UND BEFOLGEN SIE DIE BETRIEBSANLEITUNG DER ANLAGE UND DEN ELEKTRODENEINSATZ DES HER STELLERS DIE UNFALLVERHUTUNGSVORSCHRIFTEN DES ARBEITGEBERS SIND EBENFALLS ZU BEACHTEN Keep your head out of fumes Use ventilation or exhaust to remove fumes from breathing zone Los humos fuera de la zona de res piraci n e Mantenga la cabeza fuera de los humos Utilice ventilaci n o aspiraci n para gases Gardez la t te l cart des fum es Utilisez un ventilateur ou un aspira teur pour ter les fum es des zones de travail e Vermeiden Sie das Einatmen von Schweibrauch e Sorgen Sie f r gute Be und Entl ftung des Arbeitsplatzes e Mantenha seu rosto da fumaca Use ventila o exhaust o para remover fumo da zona respirat ria LEE EE KE ECKER F v CRAVHAELT TIMELTFEL CRABS Zo VE VR E 6 FR ARH
3. D 1 Calibration Specification Chassis Removal Procedure D 1 Capacitor Discharge Procedure D 2 Troubleshooting cer norte eite nere rennen Section E How to use Troubleshooting Guide E 1 Using the Status LED to Troubleshoot System E 2 Error Codes For POWER WAVES NENNEN NEEN ENNEN NNN 3 4 Troubleshooting Guides cea cech seran nari A hald E 5 thru E 14 Wiring Diagratm 2 niae Section F 1 Dimension dE Section F 2 Parts E T 588 viii 24 INSTALLATION TECHNICAL SPECIFICATIONS POWER WAVE 1400 K2669 2 K2673 2 Duty Cycle Input Voltage 10 Input Amperes Power Power Factor incl robot and Rated Output aux load SSES 200 208 e 60 rating 3 phase 50 60 Hz 475 Watts 2673 2 Chassis Only 100 rating RATED OUTPUT Duty Volts at Rated Amperes GMAW GMAW Pulse 60 GTAW DC 100 RECOMMENDED INPUT WIRE AND FUSE SIZES 1 3 PHASE INPUT Type 75 C Copper COPPER GROUNDING Fuse Super Lag VOLTAGE Amperes Wire in Conduit CONDUCTOR Breaker Size 50 60Hz incl robot and aux load AWG mm AWG mm mmi p 56185 ge 200 1 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 mag
4. do ym VIOE H gt 06H e ugoiny POWER WAVE 1400 LINCOLN amp 11 INSTALLATION A 11 TYPICAL F355i RETROFIT SINGLE ARM PAEMISMOd UI ezis 10 seu jep no ejqeo nd no oi 49JeH J0 98UU09Q JEU 1X J0 98UU02 yury XCOV8LM J0 99UU02 40 29 127 esues eBeyoA 10 98UU09 18p884 AM 4 9821 18P884 AM 12 pee1 esues jeuondo XX ZV8LM 10 XX E9 12M 4 40 99UU0D eueo eq Japee4 M dwy 91 652 012 WOU 699 OOP i gt XX EYS DA C n elqe9 Jonuo A Wi d yury D 4040 L I CES PS WY epoo9 3 9 qeo 81 08Z LM HOL J9M0d Jejl0J U0OQ dgier d ONNVA POWER WAVE i400 LINCOLN amp 12 ELECTRODE AND WORK CONNECTIONS 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 Most welding applications run with the electrode being positiv
5. Analog Input Fan Out that Burnback is present for all analogs in 9 Gas 9 Verify Gas is being turned on before the output CAUTION If for any reason you do not understand the test procedures are unable to perform the tests repairs safely contact your Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed POWER WAVE 1400 LINCOLN 5 12 TROUBLESHOOTING E 12 Observe all Safety Guidelines detailed throughout this manual Analog Inputs don t respond or don t 1 Analog Scans Between Updates 1 The DeviceNet tab of the Diagnostics respond quickly 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 value 2 Analog In Active Selections From the DeviceNet tab of the Diagnostics Utility select Configure Verify in Analog Input Channels that the required channels are set active 3 Analog Hysteresis From the DeviceNet tab of the Diagnostics Utility select Configure Verify in Analog Input Channels that the Hysteresis settings are all 0 4 Passive Mode The DeviceNet tab of the Diagnostics Utility displays the POWER WAVE s passive mode status If the status needs to be changed select Configure and make the necessary modification Gas purge not working 1 Out of gas Verify there is gas available at the input of t
6. 002 007 3AVM H3MOd IWNVH9VIG ONIHIM ALISOddO 9NLLNIOd MOHEV HLIM GALNNOW H39NOSNVEL IN 400 POWER WAVE LINCOLN amp DIMENSION PRINT 18 52 2 EI o ej 9 e j 3 3 2 2 2 E 2 2 lo 19 49 21 46 24 37 o e E E 2 is 2 4 e 2 x j is 2 2 J E k 2 2 o o e e 23 62 je g e ET mr JT ur E EI ao 5 9 lt 5 Ei o z gt 5 2 5 8 8 gt m A 2 21 54 18 81 Xew N TLE N N ISO VIEW REFERENCE POWER WAVE i400 LINCOLN 5 5 POWER WAVE 1400 LINCOLN 5 Spanish AVISO DE PRECAUCION French ATTENTION German WARNUNG Chinese Korean Do not touch electrically live parts 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 d
7. a Aislese del trabajo y de la tierra Ne laissez ni la peau des v te ments mouill s entrer en contact avec des pi ces sous tension Isolez vous du travail et de la terre e Ber hren Sie keine stromf hrenden Teile oder Elektroden mit Ihrem K rper oder feuchter Kleidung Isolieren Sie sich von den Elektroden und dem Erdboden e N o toque partes el tricas e elec trodos com a pele ou roupa molha da Isole se da e terra i Bih O HE WUN RA xiSHl t 7 5nfdcomntoc t amp SERA c3 qmmT FRE ez SUEZ xe zz su e zial Yall Gd el ill l Ye 29 d Ah ach AA ua Maus Lie Y je pus flammable materials away e Mantenga el material combustible fuera del rea de trabajo e Gardez l cart de tout mat riel inflammable Entfernen Sie brennbarres Material e Mantenha inflam veis bem guarda dos SMAPTUNENDORTOBEFR BAIL TEV ETA 1JJ 81055 BMPR We A77 uMig Gisa AN Wear eye ear and body protection Prot jase los ojos los oidos y el cuerpo Prot gez vos yeux vos oreilles et votre corps e Tragen Sie Augen Ohren und K r perschutz Use protec o para a vista ouvido e corpo EU ORNER
8. the desired welding parameters The robot controller sends the parameters from the teach pendant arc voltage wire feed speed UltimArcTM value etc to the Power Wave i400 via the ArcLink amp communication protocol over the control Ethernet or optional DeviceNet cables BASIC WELDING CONTROLS Weld Mode Selecting a weld mode determines the output charac teristics of the Power Wave i400 power source Weld modes are developed with a specific electrode materi al electrode size and shielding gas For a more com plete description of the weld modes programmed into the Power Wave at the factory refer to the Weld Set Reference Guide supplied with the machine or avail able at www powerwavesoftware com Wire Feed Speed WFS In synergic welding modes GMAW GMAW P WFS is the dominant control parameter The user adjusts WEG according to factors such as wire size penetra tion requirements heat input etc The Power Wave then uses the WFS setting to adjust the voltage and current according to the information contained in the selected weld mode Note The Power Wave i400 can be configured to use amperage as the dominant control parameter instead of WFS for synergic welding modes In this configuration the user adjusts amperage according to factors such as wire size penetration require ments heat input etc The Power Wave then uses the amperage setting to adjust the WFS and volt age according to the information contained in t
9. Controllers K1543 or K2683 ArcLink Control Cable Earlier model Fanuc controllers communicate via traditional ArcLink amp over a standard 2 wire CAN based network In these systems the 5 pin ArcLink control cable connects the power source to the controller The control cable consists of two power leads one twisted pair for digital communication and one lead for voltage sensing The sense leads and power leads are typically unused in this application The 5 pin ArcLink connection on the POWER WAVES 1400 is located on the recessed control panel above the output studs The control cable is keyed and polarized to prevent improper connection Best results will be obtained when control cables are routed separate from the weld cables especially in long distance applica tions The recommended combined length of the ArcLink control cable network should not exceed 200ft 61 0m POWER WAVE i400 LINCOLN 5 ie INSTALLATION BM Connections Between Power Source and Optional DeviceNet PLC Controller Hard Automation applica tions 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 It includes a 5 pin DeviceNet sealed mini style receptacle that mounts on the recessed control panel of the Power Wave i400 above the output studs The DeviceNet cable is k
10. DeviceNet Master The baud rate is set via the DeviceNet tab of the Diagnostics Utility Verify the DeviceNet MAC ID is correct The Mac ID is set via the DeviceNet tab of the Diagnostics Utility Verify that the DeviceNet bus is terminated correctly Verify the wiring of all multi port taps and field attachable ends Verify that the correct EDS files are being used if they are need ed The DeviceNet tab of the Diagnostics Utility displays the current Product Code and Vendor Revision of the POWER WAVE A CAUTION If for any reason you do not understand the test procedures or are unable to perform the tests repairs safely contact your Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed POWER WAVE 1400 LINCOLN 5 10 TROUBLESHOOTING E 10 Observe all Safety Guidelines detailed throughout this manual PROBLEMS POSSIBLE RECOMMENDED SYMPTOMS CAUSE COURSE OF ACTION Device goes off line during welding T1 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 termi nated correctly 3 Verify that the cable shielding is cor rectly grounded at the bus power sup ply The shield should be tied into the bus ground at only one point 4 Power Supply 4 Verify that
11. 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 amp 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 FOR ENGINE 5 avoid scalding do not remove the powered equipment 27 d radiator pressure cap when the engine is hot 1 Turn the engine off before troubleshooting and maintenance work unless the maintenance work requires it to be running 1 b Operate engines in open well ventilated areas or vent the engine exhaust fumes outdoors 1 c Do not add the fuel near an open flame welding arc or when the engine is running Stop the engine and allow it to cool before refueling to prevent spilled fuel from vaporiz ing 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 ELECTRIC AND MAGNETIC FIELDS may be dangerous 2 a Ele
12. exactly to avoid serious personal injury or loss of life A CAUTION This statement appears where the information must be followed to avoid minor personal injury or damage to this equipment viii TABLE CONTENTS Page JEE Le E Technical Specifications POWER WAVE 1400 1 A 2 3 Location and MOUNTING A 3 Environmental Considerations nnn A 3 Hiper A 3 ee ll EE 3 Electromagnetic Compatibility A 4 Input and Grounding Connections cece eee ceeeeeeeeeeeeeeeceeeeeaeeeeaeeseaeeeeaeeeeaeeees A 4 INPUT COMME CUO Br A 4 Connection Diagrams and Systems A 5 A 6 Fanuc R30iA Controller Mounting essen A 7 Typical Integrated Systems Single 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 13 Remote Sense Lead Connections 13 14 Sense Lead D
13. ft 30 5 m Cannot be connected end to end OPTIONAL EQUIPMENT System Part No Description Remote Sense Lead Kit Recommended for sensitive or critical applications to more accurately monitor the Sense Lead Kit K940 xx voltage DeviceNet Kit K2780 1 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 Sync Tandem Kit K2781 1 necessary harnesses and cabling for 2 machines Also provides access to special Sync Tandem welding soft ware ArcLink Digital 1543 2 ArcLink Control Cable 5 pin Required for earlier controllers communicating via traditional ArcLink over Communication K2683 xx2 standard 2 wire CAN based network Cable XX k2683 Recommended on Sever Duty application External Ethernet Consult Ethernet Switch Cables etc Required for external Ethernet system connectivity typically associated with Network Equipment Automation multiple arm or multiple power source applications Division 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 pub lication DN 6 7 2 DeviceNet Cables Customer and Accessories Supplied 2 Cables can be connected end to end to extend length reco
14. on off switch is not intended as a service disconnect for this equipment Only a qual ified 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 POWER WAVE i400 LINCOLN 5 5 INSTALLATION A 5 CONNECTION DIAGRAMS AND SYSTEM RECOMMENDED EQUIPMENT Identifier POWER WAVE i400 Power Source Power Source K2669 1 includes 526064 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 Wire Drive K2685 2 AutoDrive 4R90 Wire Drive Power Source to Wire Drive 1785 1 Feeder Control Cable 14 Control Cable Welding Power Cables K2163 xx Power Source to Wire Drive Weld Cables or and Power Source to Work K1842 xx K2163 Series cables sold in pairs K1842 Series cables sold individually See Price Book for details and bulk cable availability Robot Arm Robot Controller Consult Automation Division Torch 1 Maximum length 100
15. parce que la tension entre les deux pinces peut tre le total de la tension vide des deux machines Si on utilise la machine souder comme une source de courant pour soudage semi automatique ces precautions pour le porte lectrode s applicuent aussi au pistolet de soudage 2 Dans le cas de travail au dessus du niveau du sol se prot ger contre les chutes dans le cas ou on recoit un choc Ne jamais enrouler le c ble lectrode autour de n importe quelle partie du corps PR CAUTIONS DE S RET POUR soudage Utiliser des lunettes avec crans lateraux dans les zones l on pique le laitier Eloigner les mat riaux inflammables ou les recouvrir afin de pr venir tout risque d incendie aux tincelles Quand on ne soude pas poser la pince une endroit isol de la masse Un court circuit accidental peut provoquer un chauffement et un risque d incendie S assurer que la masse est connect e le plus pr s possible de la zone de travail qu il est pratique de le faire Si on place la masse sur la charpente de la construction ou d autres endroits loign s de la zone de travail on augmente le risque de voir passer le courant de soudage par les chaines de lev age c bles de grue ou autres circuits Cela peut provoquer des risques d incendie ou d echauffement des chaines et des c bles jusqu ce qu ils se rompent Assurer une ventilation suffisante dans la zone de soudage Ceci est particuli rem
16. provides a course of action for the Possible Cause generally it states to contact your local Lincoln Authorized Field Service Facility If you do not understand or are unable to perform the Recommended Course of Action safely contact your local Lincoln Authorized Field Service Facility CAUTION If for any reason you do not understand the test procedures or are unable to perform the tests repairs safely contact your Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed POWER WAVE 1400 LINCOLN B TROUBLESHOOTING USING THE STATUS LED TO TROUBLESHOOT SYSTEM PROBLEMS The POWER WAVE 1400 is equipped with two exter nally 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 Included in this section is information about the power source and Wire Drive Module Status LED s and some basic troubleshooting charts for both machine and weld performance The STATUS LIGHTS are dual color LED s that indi cate system errors Normal operation for each is steady green Error conditions are indicated in the fol lowing Table E 1 TABLE E 1 Light Condition Steady Green System OK Power source is operational and is comm
17. restricted Dirt and dust that can be drawn into the POWER WAVE i400 should be kept to a minimum use of air filters on the air intake is not recommend ed 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 1400 in an outdoor environment The power source should not be sub jected 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 shel tered area LIFTING WARNING Lift only with equipment of ade quate 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 Do not lift machine if lift bail is FALLING EQUIPMENT can damaged cause injury Do not operate machine while suspended from lift bail POWER WAVE i400 Lift the machine by the cor ner mounted lift bails only Do not attempt to lift the POWER WAVE i400 with accessories attached to it POWER WAVES 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 manu al for detail
18. technical assistance Check for proper fan operation Fans should run whenever out put power is on Check for material blocking intake or exhaust louvers or for excessive dirt clogging cooling channels in machine After machine has cooled reduce load duty cycle or both Check for material blocking intake or exhaust louvers and heat sink fins Check for excessive load on 40VDC supply Check for broken wires open connections or faulty ther mostats on the DC Bus and Output Rectifier heat sinks and Choke assembly CAUTION If for any reason you do not understand the test procedures or are unable to perform the tests repairs safely con tact your local authorized Lincoln Electric Field Service Facility for technical assistance POWER WAVE 1400 LINCOLN 5 7 TROUBLESHOOTING 7 Observe all Safety Guidelines detailed throughout this manual TROUBLESHOOTING GUIDE Observe Safety Guidelines detailed in the beginning of this manual PROBLEMS POSSIBLE RECOMMENDED SYMPTOMS CAUSE COURSE OF ACTION BASIC MACHINE PROBLEMS Auxiliary receptacle is dead 1 Circuit breaker CB2 near the 1 Power down and reset CB2 115V receptacle may have tripped 2 Fuse F1 in reconnect area may 2 Power down and replace the have blown fuse Real Time Clock no longer func 1 Control PC Board Battery 1 Replace the battery Type tioning BS2032 PROBLEMS POSSIBLE RECOMMENDED SYMPTOMS CAUSE COURSE
19. the DeviceNet bus power supply can supply sufficient current for the devices on the network 5 Expected Packet Rate 5 Verify that 1000 Expected Packet Rate lt scans per second The DeviceNet tab of the Diagnostics Utility displays these values Output will not come on 1 DeviceNet trigger not asserted 1 From the DeviceNet tab of the Diagnostics Utility select Monitor The Monitor window will be displayed Verify under the Produced Assembly that Trigger is highlighted 2 Touch Sense command 2 From the DeviceNet tab of the Diagnostics Utility select Monitor The Monitor window will be displayed Verify under the Produced Assembly that Touch Sense is NOT highlighted 3 Passive Mode 3 The DeviceNet tab of the Diagnostics Utility displays the POWER WAVE s passive mode status If the status needs to be changed select Configure and make the necessary modification 4 Welding Cables 4 Verify that welding cables are connect ed properly 5 Output Disabled 5 From the DeviceNet tab of the Diagnostics Utility select Monitor The Monitor window will be displayed Verify under the Produced Assembly that Disable Output is NOT highlighted CAUTION If for any reason you do not understand the test procedures or are unable to perform the tests repairs safely contact your Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed POWER WAVE 1400
20. ACCURATELY NO VOLTAGE DROP BETWEEN ARC AND SENSE LEAD BEST STARTS BEST ARCS MOST RELIABLE RESULTS wi Work 1 A Work 2 ARC 1 d aq WW ARC 2 Sense 1 Sense 2 POWER WAVE i400 LINCOLN 5 16 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 sys tems 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 non standard cables especially in lengths greater than 25 ft 7 6 m can lead to communication problems system shutdowns poor motor acceleration poor arc starting and low wire driving force wire feeding problems Always use the shortest length of control cable possible and DO NOT coil excess cable Regarding cable placement best results will be CAUTION obtained when control cables are routed separate from the weld cables This minimizes the possibility of interference between the high currents flowing through the weld cables and the low level signals in the control cables These recommendations apply to all communication cables including ArcLink amp and Ethernet connections COMMON EQUIPMENT CONNECTIONS
21. BRS EH7I 8 Wake e SENACESE 27 HAP siet 7912714 88718 Qa oe Lan Aul gt oia hia a d ah annal e Mpa ous ve call aac us e Turn power off before servicing Desconectar el cable de ali mentaci n de poder de la m quina antes de iniciar cualquier servicio e D branchez le courant avant l entre tien Strom vor Wartungsarbeiten abschalten Netzstrom v llig ff nen Maschine anhalten N o opere com as tampas removidas e Desligue a corrente antes de fazer servico e N o toque as partes el tricas nuas 14 EFRRAT YF PT9 CT U AHS xps Al d i Qd ily Do not operate with panel open or guards off No operar con panel abierto 0 guardas quitadas N op rez pas avec les panneaux ouverts ou avec les dispositifs de protection enlev s e Anlage nie ohne Schutzgeh use oder Innenschutzverkleidung in Betrieb setzen e Mantenha se afastado das partes moventes opere com os paineis abertos ou guardas removidas e Ph TMMRIMIHF L UTFAL CREKTMRAHRS E e gdo del Mee 4373 Aale cl AVISO DE PRECAUCION French ATTENTION German WARNUNG ATENC O Japanese te SIS A Ss LEIA E COMPREENDA AS INSTRU ES DO FABRICANTE PARA ESTE EQUIPAMENTO
22. C see Figure A 2 To minimize inductance always use the appropriate size cables and whenever possible run the electrode and work cables in close proximity to one another to minimize the loop area Since the most significant factor in cable inductance is the welding loop length avoid excessive lengths and do not coil excess cable For long work piece lengths a sliding ground should be considered to keep the total welding loop length as short as possible FIGURE A 2 REMOTE SENSE LEAD CONNECTIONS Voltage Sensing Overview The best arc performance occurs when the POWER WAVE i400 has accurate data about the arc condi tions Depending upon the process inductance within the electrode and work cables can influence the volt age apparent at the studs of the welder and have a dramatic effect on performance Remote voltage sense leads are used to improve the accuracy of the arc voltage information supplied to the control pc board Sense Lead Kits K940 xx are available for this purpose CAUTION If the remote voltage sensing is enabled but the sense leads are missing improperly connected or if the electrode polarity attribute is improperly configured extremely high welding outputs may occur INSTALLATION A 13 General Guidelines for Voltage Sense Leads Sense leads should be attached as close to the weld as practical and out of the weld current path when possible In extremely sensitive applications i
23. Connection Between Power Source and Wire Feeder K1785 or K2709 Control Cable The 14 pin wire feeder control cable connects the power Source to the wire drive It contains all of the necessary signals to drive the motor and monitor the arc including the motor power tachometer and arc voltage feedback signals The wire feeder connection on the POWER WAVE i400 is located on the recessed control panel above the output studs Fanuc robot arms are equipped with internal cabling and provide a standard 14 pin MS style connection at the base of the robot and near the wire feeder mount at the top of the arm The K2709 series external dress cable is recommended for severe duty applications such as hard automation or for robot arms not equipped with an internal control cable Best results will be obtained when control cables are routed separate from the weld cables especially in long dis tance applications Maximum cable length should not exceed 100ft 30 5m INSTALLATION A 16 Connection Between Power Source and ArcLink XT Compatible Controllers or Ethernet Networks Newer model controllers such as the Fanuc R30iA communicate via ArcLink amp XT over an industrial Ethernet connection To facilitate this the Power Wave i400 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 connection on the Powe
24. E AS PARTES DE USO E SIGA AS PRATICAS DE SEGURANCA DO EMPREGADOR 2843 8HB0x 252 0148mEtkOBRA6 38 CL TRHORSRME HTK St JE HE Fi EH BA ELLE ERA 8 FR QE BR SEE SP RONA DILE f HEAR SE o 558 HYZAAR AAS 07 4 EPEA HEJL ia Lal QU d a al og SOA Kill ail aq l LINCOLN 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
25. G E 8 Observe all Safety Guidelines detailed throughout this manual PROBLEMS SYMPTOMS POSSIBLE CAUSE RECOMMENDED COURSE OF ACTION WELD AND ARC QUALITY PROBLEMS Wire burns back to tip at the end of the weld Machine output shuts down during a weld Machine won t produce full output Excessively long and erratic arc Arc loss fault on robot 1 Burnback Time Inverter or System Fault Input voltage may be too low limiting output capability of the power source Machine calibration Wire feed problem Voltage sensing problem Loss of or improper Shielding Gas Machine calibration Possibly caused by wire feeding problem 1 Reduce burnback time and or workpoint A non recoverable inverter fault will interrupt welding and open the main contactor This condi tion will also result in an alternat ing red and green status light on the control panel See the Status Light section for more informa tion Make certain that the input volt age is proper according to the Rating Plate located on the rear of the machine Calibrate secondary current and voltage Check for feeding problems Verify proper wire drive and gear ratio has been selected Check sense lead connections Check the sense lead configura tion and arc polarity Make sure Electrode and Work connections are not reversed Verify gas flow and type are cor rect Calibrate seco
26. HLIM 3103016 LV Led lHOdd s LHOddNS V7 8 QV3131IHM HLIM 31 40 3016 1V14 109 l e 807 went mag mm erg niente 19 3sv8 SISSVHO SISSYHOGNNOHENS THNvd NOLLOSNNOO 37 xog voir are ur sran SISSVHO mun Wi 103NNOO3H KOHL NOUO OIBLO3T3 LMdNI 3SVO eoe eo eco 9 oo oo NOLLdO OH tot can Loo 3000 Y ONIAVH ABLINOHID HO SLN3NOdOO SANIHOWN TV LOVX3 3HL MOHS LON AVIN WWHOVIG SIHL 1314 09 V JO 1 JHL QN3931 193 47 LNOHLIM AVIN QVO LINOHIO GALNIHd V 40 AHLINOHIO HO SLNANOdAOO SONIS 100280102 SISSVHO NO LON 13NI8V NI 319011 SLNINOdNOD NMOHS SV ae 82 8 S x u ds al Kess 4 oN BSRR 10808 OL l H3On sNVuL Kal e 3l0V14303t 5 43111934 l3Nu3H13 T 7I0H1NOS HANHOASNVEL ABVITIXNY 24 0334 N3349 034 Snivis M 419V143934 f f ol 200 8017 voir Di 1001 43048 35119 ONAS oe DOC 3T0v1d393u 3SN3S S10v 14303t LINIOIAIQ a an 51715 quvoa 83033434M 14308 3E SoG id 40 3015 NOLLO3NNO ar 319VLd3934 830334 SHIM 5 802
27. LINCOLN 5 E 11 TROUBLESHOOTING E 11 Observe all Safety Guidelines detailed throughout this manual PROBLEMS POSSIBLE RECOMMENDED SYMPTOMS CAUSE 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 sys tem 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 Verify wire can be pulled easily through the wire conduit Verify Contact tip is not blocked 2 Strike Wire Feed Speed 2 Verify the Strike Wire Feed Speed set correctly 3 Incorrect Weld Schedule 3 Verify the correct weld schedule is selected 4 Voltage Sense Leads 4 Verify voltage sense leads are proper ly connected and configured as described in the instruction manual 5 Analog Scans Between Updates 5 The DeviceNet tab of the Diagnostics Utility displays the POWER WAVE s Analog Scans Between Updates and Scans Sec Verify that Analog Scans Between Updates is of I O Scans Sec value 6 From the DeviceNet tab of the Diagnostics Utility select Configure Verify in Analog Input Channels that the Hysteresis settings are all 0 7 Limit Error 7 Verify all analog input values are with in limits 8 From the DeviceNet tab of the Diagnostics Utility select Monitor Verify under
28. OCK can kill Unless using cold feed feature when feeding with gun trigger the elec trode and drive mechanism are always electrically energized and could remain energized several sec onds 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 Always wear dry insulating gloves FUMES AND GASES can be dangerous 9 Ap Keep your head out of fumes E Use ventilation or exhaust to remove fumes from breathing zone NE WELDING SPARKS can cause gt a 77 fire or explosion Keep flammable material away Do not weld on containers that have held combustibles ARC RAYS can burn Wear eye ear and body protection Observe additional guidelines detailed in the beginning of this manual POWER WAVE i400 LINCOLN 5 O 0 EE OPERATION GRAPHIC SYMBOLS THAT APPEAR ON THIS MACHINE OR IN THIS MANUAL INPUT POWER ON OFF HIGH TEMPERATURE MACHINE STATUS CIRCUIT BREAKER WIRE FEEDER POSITIVE OUTPUT NEGATIVE OUTPUT ZE 3 PHASE INVERTER po INPUT POWER THREE PHASE DIRECT CURRENT lo A We 1 POWER WAVE 1400 OPEN CIRCUIT VOLTAGE INPUT VOLTAGE OUTPUT VOLTAGE INPUT CURRENT OUTPUT CURRENT PROTECTIVE GROUND WARNING or CAUTION Explosion Dangerous Voltage Shock Hazard Er OPERATION E PR
29. ODUCT DESCRIPTION PRODUCT SUMMARY General Physical Description The POWER i400 is intended as a replace ment for the PW355i using an updated power and control platform to enhance performance and reliabili ty 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 amp communication is supported through the 5 pin MS style interface The new ArcLink amp XT communication protocol is supported through an RJ 45 type Ethernet connection which also provides access for the POWER WAVE Utilities software tools In addition the DeviceNet communication protocol is supported by a 5 pin sealed mini style receptacle Access to remote voltage sensing is available through the 4 pin sense lead connector work and electrode at the feeder via the 14 pin MS style connector electrode only or at the 5 pin MS style ArcLink amp connector electrode only Optional features include DeviceNet or Sync Tandem capability The POWER WAVE i400 includes an innovative new case design featuring a removable slide mounted power section for ease of service The case is designed to support the R30iA controller and op box up to 300lbs matching both the controller s 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
30. OF ACTION WELD AND ARC QUALITY PROBLEMS General degradation of weld per 1 Wire feed problem 1 Check for feeding problems Check actu formance al WFS vs preset Verify proper wire drive and gear ratio has been selected 2 Cabling problems 2 Check for bad connections excessive loops in cable etc NOTE The presence of heat in the exter nal welding circuit indicates poor connec tions or undersized cables 3 Loss of or improper Shielding Gas 3 Verify gas flow and type are correct 4 Verify weld mode is correct for process 4 Select the correct weld mode for the application 5 Machine calibration 5 Verify the calibration of the output current and voltage 6 Secondary current limit has been 6 Long term average current is limited to reached 450A Adjust procedure to reduce output demand Wire burns back to tip when the arc 1 Voltage sense lead problem 1 Check sense lead connections Check is initiated the sense lead configuration and arc polarity Make sure Electrode and Work connections are not reversed 2 Wire feed problem 2 Check for feeding problems Verify proper wire drive and gear ratio has been select ed CAUTION If for any reason you do not understand the test procedures are unable to perform the tests repairs safely con tact your local authorized Lincoln Electric Field Service Facility for technical assistance POWER WAVE 1400 LINCOLN 5 8 TROUBLESHOOTIN
31. POWER WAVES 1400 Lm For use with machines having Code Numbers 11536 11536R 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 thought ful 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 OPERATOR S MANUAL ISO 9001 DE 35 PIN AE Design 5 Quality CERTIFICATE NUMBER 55275 T NCO LN Copyright Lincoln Global Inc 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 AA WARNING CALIFORNIA PROPOSITION 65 WARNINGS 4 Diesel engine exhaust and some of its constituents The engine exhaust from this product contains are known to the State of California to cause can chemicals known to the State of California to cause cer birth defects and other reproductive harm cancer birth defects or other reproductive harm The Above For Diesel Engines The Above For Gasoline Engines ARC WELDING CAN BE HAZARDOUS PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY OR DEATH
32. TING E 6 Observe all Safety Guidelines detailed throughout this manual TROUBLESHOOTING GUIDE PROBLEMS SYMPTOMS Machine won t weld can t get any output CR1 will not pull in This problem will normally be accompanied by an error code Error codes are displayed as a series of red and green flashes by the status light s See Status Light section of this document for additional information Thermal LED is ON Observe Safety Guidelines detailed in the beginning of this manual POSSIBLE CAUSE BASIC MACHINE PROBLEMS 1 Input voltage is too low or too high Thermal Error Primary current limit has been exceeded the main contactor drops out when output is initiat ed see error 31 Inverter Fault switch pc board contactor problem etc Improper fan operation Output Rectifier board or Choke thermostat DC Bus PC board thermostat Open thermostat circuit RECOMMENDED COURSE OF ACTION 1 Make certain that input voltage is correct according to the Rating Plate located on the rear of the machine LED See Thermal is ON section Possible short in output circuit Turn machine off Remove all loads from the output of the machine Turn back on and acti vate output If condition persists turn power off and contact an authorized Lincoln Electric Field Service facility Contact your local authorized Lincoln Electric Field Service facility for
33. aims 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 WEB SITE at www lincolnelectric com Choose Quick Links and then 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 A WARNING This statement appears where the information must be followed
34. ally accompanied by codes 32 and 33 39 Misc hardware fault 57 Unknown glitch has occurred on the fault interrupt circuit ry Sometimes caused by primary over current fault or intermittent connections in the thermostat circuit 43 Capacitor delta error The maximum voltage difference between the main capac itors has been exceeded May be accompanied by errors 32 35 May be caused by an open or short in the primary or secondary circuit s 54 Secondary output over current The long term average secondary weld current limit has been exceeded This error will immediately turn off the machine output NOTE The long term average secondary current limit is 450 amps A complete list of error codes is available in the Diagnostics Utility included on the POWER WAVE Utilities and Service Navigator CD s or available at www powerwavesoftware com listing Error codes that contain three or four digits are defined as fatal errors These codes generally indicate internal errors on the Power Source Control Board If cycling the input power on the machine does not clear the error contact the Service Department CAUTION If for any reason you do not understand the test procedures are unable to perform the tests repairs safely contact your Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed POWER WAVE 1400 LINCOLN 5 TROUBLESHOOTING ata Observe all Safety Guidel
35. ation 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 POWER WAVE 1400 LINCOLN 5 D 1 SAFETY PRECAUTIONS A WARNING ELECTRIC SHOCK can kill not touch electrically live parts 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 Always wear a face shield and long sleeves when servicing See additional warning information throughout this Operator s Manual ROUTINE MAINTENANCE Routine maintenance consists of periodically blowing out the machine using a low pressure airstream to remove accumulated dust and dirt from the intake and outlet louvers and the cooling channels in the machine PERIODIC MAINTENANCE Calibration of the POWER WAVE 1400 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 optimal performance the cali bration of output Voltage and Current should be checked yearly CALIBRATION SPECIFICATION Output Voltage and Current are calibrated at the facto ry Generally speaking the machi
36. ations that do not use the standard wire feeder control cable K1785 This can be easily accessed with the optional K940 Sense Lead kit POWER WAVE 1400 LINCOLN 5 14 Work Voltage Sensing 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 CAUTION Negative electrode polarity operation WITHOUT use of a remote work sense lead 21 requires the Negative Electrode Polarity attribute to be set via the Fanuc Teach Pendant or with the Weld Manager Utility included on the Power Wave Utilities and Service Navigator CD s or available at www powerwavesoftware com While most applications perform adequately by sens ing the work voltage directly at the output stud the use of a remote work voltage sense lead is recom mended for optimal performance The remote WORK sense lead 21 can be accessed through the four pin voltage sense connector located on the control panel by using the K940 Sense Lead Kit It must be attached to the work as close to the weld as practical but out of the weld current path For more information regarding the placement of remote work voltage sense leads see the section entitled Voltage Sensing Considerations for Multiple Arc Systems FIGURE A 3 DIRECTION OF INSTALLATION A 14 A WARNING If a remote work voltage sense lead is used it must be enabled through t
37. c value 4 Limit Error reported at the end of a 4 Verify all welding settings for Burnback and Crater states 5 From the DeviceNet tab of the Diagnostics Utility select Monitor Verify under Analog Input Fan Out that Burnback is present for all analogs in 6 Welding set points 6 Verify Burnback set points for work point trim and wave values 7 Analog Hysteresis 7 From the DeviceNet tab of the Diagnostics Utility select Configure Verify in Analog Input Channels that the Hysteresis settings are all 0 8 Verify Gas is turned on Bad Welding 1 Analog Scans Between Updates f1 The DeviceNet tab of the Diagnostics Utility displays the POWER WAVEG s Analog Scans Between Updates and I O Scans Sec Verify that Analog Scans Between Updates is of I O Scans Sec value 2 Voltage Sense Leads 2 Verify voltage sense leads are proper ly connected and configured as described in the instruction manual 3 Analog Hysteresis 3 From the DeviceNet tab of the Diagnostics Utility select Configure Verify in Analog Input Channels that the Hysteresis settings are all 0 CAUTION If for any reason you do not understand the test procedures are unable to perform the tests repairs safely contact your Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed POWER WAVE 1400 LINCOLN 5 14 TROUBLESHOOTING E 14 Observe a
38. ctric current flowing through any conductor causes localized Electric and Magnetic Fields EMF Welding current creates EMF fields around welding cables and welding machines EMF fields may interfere with some pacemakers and welders having a pacemaker should consult their physician before welding 1 d Keep all equipment safety guards covers and devices in position and in good repair Keep hands hair clothing and tools away from V belts gears fans and all other moving S Exposure to EMF fields in welding may have other health parts when starting operating or repairing equipment effects which are now not known All welders should use the following procedures in order to In some cases it may be necessary to remove safety be ud minimize exposure to EMF fields from the welding circuit guards to perform required maintenance Remove 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 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 1 f Do not put your hands near the engine fan Do not attempt to override the governor or idler by pushing on the throttle control rods while the engine is running 2 d 3 Do not place your body between the electrode and work cables If the electrode cabl
39. de all local codes and the manufacturer s recommendations Ground the equipment in accordance with the U S National Electrical Code and the manufacturer s recommendations u SAFETY PR CAUTIONS DE S RET 5 Toujours porter des lunettes de s curit dans la zone de Pour votre propre protection lire et observer toutes les instructions et les pr cautions de s ret specifiques qui parraissent dans ce manuel aussi bien que les pr cautions de s ret g n rales suiv antes S ret Pour Soudage A L Arc 1 Protegez vous contre la secousse lectrique a Les circuits l lectrode et la pi ce sont sous tension quand la machine souder est en marche Eviter toujours tout contact entre les parties sous tension et la peau nue ou les v tements mouill s Porter des gants secs et sans trous pour isoler les mains Faire tr s attention de bien s isoler 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 couch pour lesquelles une grande partie du corps peut tre en contact avec la masse Maintenir le porte lectrode la pince de masse le c ble de soudage et la machine souder en bon et s r tat defonctionnement d Ne jamais plonger le porte lectrode dans l eau pour le refroidir Ne jamais toucher simultan ment les parties sous tension des porte lectrodes connect s deux machines souder
40. e 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 source output stud to the work piece When negative electrode polarity is required such as in some Innershield applications reverse the out put connections at the power source electrode cable to the negative stud and work cable to the posi tive stud CAUTION Negative electrode polarity operation WITHOUT use of a remote work sense lead 21 requires the Negative Electrode Polarity attribute to be set See the Remote Sense Lead Specification section of this document for further details For additional Safety information regarding the elec trode and work cable set up See the standard SAFE TY INFORMATION located in the front of this Instruction Manual INSTALLATION A 12 GENERAL GUIDELINES Select the appropriate size cables per the Output Cable Guidelines in Table A 1 Excessive voltage drops caused by undersized welding cables and poor connections often result in unsatisfactory welding performance Always use the largest welding cables electrode and work that are practical and be sure all connections are clean and tight Note Excessive heat in the weld circuit indicates undersized cables and or bad connections Route all cables directly to the work and wire feeder avoid excessive lengths and do n
41. e DO NOT TOUCH TERMINALS CAPACITOR VOLTAGE MAY EXCEED 400VDC Connect the resistor terminals across the two studs in the position shown Hold in each position for 10 second Repeat for both capacitors Use a DC voltmeter to check that voltage is not present across the terminals of both capacitors FIGURE D 1a TERMINALS CAPACITOR CHARGE RESISTOR INDICATORS LED S POWER WAVE 1400 LINCOLN 5 TROUBLESHOOTING 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 This Troubleshooting Guide is provided to help you locate and repair possible machine malfunctions Simply follow the three step procedure listed below Step 1 LOCATE PROBLEM SYMPTOM Look under the column labeled PROBLEM SYMP TOMS This column describes possible symptoms that the machine may exhibit Find the listing that best describes the symptom that the machine is exhibiting Step 2 POSSIBLE CAUSE The second column labeled POSSIBLE CAUSE lists the obvious external possibilities that may contribute to the machine symptom Step 3 RECOMMENDED COURSE OF ACTION This column
42. e is on your right side the work cable should also be on your right side AR 2 4 4 Connect the work cable to the workpiece as close as possible to the area being welded To prevent accidentally starting gasoline engines while turning the engine or welding generator during maintenance work disconnect the spark plug wires distributor cap or magneto wire as appropriate 2 d 5 Do not work next to welding power source Mar 95 LINCOLN 5 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 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 Welder with Reduced Voltage Control In semiautomatic or automatic w
43. ed 3 Verify that the network device con nected to the POWER WAVE is either a 10 baseT device or a 10 100 baseT device Connection Drops while welding 1 Cable Location Verify Network cable is not located next to current carrying conductors This would include input power cables and welding output cables CAUTION If for any reason you do not understand the test procedures or are unable to perform the tests repairs safely contact your Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed POWER WAVE 1400 LINCOLN 5 1 LL Enhanced Diagam DIAGRAMS Jequunu epoo 1ueuudinbe y ng e 104 jueuniedeg eu ejqiBe s eu sjeued y Jo euo uo eu paysed si e Sun Aq je 104 eq jou 3 AjUO 104 SI uiejDerp SIUL 3 10N 27599 1913 Had 5108445 121619313 MOTBA A 40 3015 IN3NOd OO 1SIX309 LONNVO 1 ONILNNOW NOWAAOO V 3HYHS SLIM 35719 ONAS L3N39IA3Q TVNOLLdO Bees 3000 1001199719 1 HAd OL 103NNO9 7 NIHOVI NINY OL LXSN 31901 0015638 1 E Th Gs E E QV310V 18
44. ed 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 manufacturer s 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 compe tent 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 prob lems in the surrounding area The following shall be taken into account a other supply cable
45. ent important pour le soudage de t les galvanis es plomb es ou cadmi es ou tout autre m tal qui produit des fume s toxiques Ne pas souder en pr sence de vapeurs de chlore provenant d op rations de d graissage nettoyage ou pistolage La chaleur ou les rayons de l arc peuvent r agir avec les vapeurs du solvant pour produire du phosg ne gas fortement toxique ou autres produits irritants Pour obtenir de plus amples renseignements sur la s ret voir le code Code for safety in welding and cutting CSA Standard W 117 2 1974 Un coup d arc peut tre plus s v re qu un coup de soliel LES MACHINES SOUDER i TRANSFORMATEUR ET a Utiliser un bon masque avec un verre filtrant appropri REDRESSEUR ainsi qu un verre blanc afin de se prot ger les yeux du ray onnement de l arc et des projections quand on soude ou quand on regarde l arc 1 b Porter des v tements convenables afin de prot ger la peau de soudeur et des aides contre le rayonnement de l arc c Prot ger l autre personnel travaillant proximit au soudage l aide d crans appropri s et non inflammables 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 pan talons sans revers et chaussures montantes LINCOLN B Relier la terre le chassis du poste conformement au code de l lectricit et aux recommendat
46. eyed and polarized to prevent improper con nection For best results route DeviceNet cables away from weld cables wire drive control cables or any other current carrying device that can create a fluctuating magnetic field DeviceNet cables 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 of the POWER WAVE 1400 can be configured with the Diagnostics Utility included on the POWER WAVE Utilities and Service Navigator CD s or available at www powerwavesoftware com OTHER SET UP ISSUES Selecting a Wire Drive and Setting the Wire Drive Gear Ratio The POWER WAVE i400 can accom modate a number of standard wire drives including the AutoDrive 4R90 default and PF 10R The feeder control system must be configured for both the wire drive type and gear ratio high or low speed range This can be accomplished via the Fanuc Teach Pendant V7 30p14 or later or with the Weld Manager Utility included on the Power Wave Utilities and Service Navigator CD s or available at www powerwavesoftware com Additional information is also available in the How To section at www powerwavesoftware com POWER WAVE i400 LINCOLN B B 1 OPERATION SAFETY PRECAUTIONS Read this entire section of operating instructions before operating the machine WARNING ELECTRIC SH
47. ghout 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 manufacturer s recommendations All access and service doors and covers should be closed and properly fastened when the welding equip ment 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 manufacturer s 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 0 ships hull or building steelwor
48. h Integrated Op Box w Power Wave i400 K2669 2 Refer to Output Cable guidelines for recommended cable size in PowerWav i400 Instruction Manual Refer to Intergration kit K2677 1 instruction sheet POWER WAVE i400 LINCOLN 5 DETAIL A 8 INSTALLATION TYPICAL INTEGRATED SYSTEMS SINGLE ARM A 8 enuen OOP SAL AMeMoOg 8215 81429 JO 81429 1ndino oj 1949H XX CV8 LM 10 XX E9 L2M Lage uonoeuuo JX yuy yuray 9821 1011009 asuas 1 p 4 12 pee esues jeuondo XX6V8 LM 10 XX 9 127 2 6992 DOP 18MOd dwy 91 jeu1e1ul 9 qe JX AUTO xog do 9UIqeo e VIO H 2 688923 eAugoiny epoaoe 3 POWER WAVE 1400 LINCOLN LELECTRIC 9 INSTALLATION A 9 TYPICAL STAND ALONE SYSTEMS SINGLE ARM enuen uononujsu 00p Meng ezis 10 ejqeo ndinO 49J8H XX ZV8 LM 10 XX E9L2M J0 99UU09Q LX
49. he selected 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 WFS control behaves like a conventional power source where WFS and voltage are independent adjustments Therefore to maintain proper arc characteristics the operator must adjust the voltage to compensate for any changes made to the WFS Volts In constant voltage modes GMAW this control adjusts the welding voltage Trim In pulse synergic welding modes GMAW P the Trim setting adjusts the arc length Trim is adjustable from 0 50 to 1 50 1 00 is the nominal setting and is a good starting point for most conditions Note The Power Wave i400 can also be configured to display Trim as a voltage value This allows the operator to pre set an approximate welding voltage rather than a unitless Trim value The pre set volt age is limited based on the process and provides the same range of operation as the corresponding Trim value This alternate configuration is regionally enabled based on the robot controller software Refer to the Fanuc documentation for manual configuration information UltimArcTM UltimArcTM allows the operator to vary the arc char acteristics from soft to crisp UltimArcTM is adjustable from 10 0 to 10 0 with a nominal setting of 0 0 CONSTANT VOLTAGE WELDING Synergic CV In synerg
50. he Fanuc Teach Pendant or with the Weld Manager Utility includ ed on the Power Wave Utilities and Service Navigator CD s or available at www powerwavesoftware com Voltage Sensing Considerations for Multiple Arc Systems Special care must be taken when more than one arc is welding simultaneously on a single part Multiple arc applications do not necessarily dictate the use of remote work voltage sense leads but they are strong ly recommended If Sense Leads ARE NOT Used Avoid common current paths Current from adja cent arcs can induce voltage into each others cur rent paths that can be misinterpreted by the power Sources and result in arc interference If Sense Leads ARE Used Position the sense leads out of the path of the weld current Especially any current paths com mon to adjacent arcs Current from adjacent arcs can induce voltage into each others current paths that can be misinterpreted by the power sources and result in arc interference For longitudinal applications connect all work leads at one end of the weldment and all of the work voltage sense leads at the opposite end of the weldment Perform welding in the direction away from the work leads and toward the sense leads See Figure A 3 CONNECT ALL SENSE LEADS AT THE END OF THE WELD
51. he gas solenoid 2 Gas Purge not asserted From the DeviceNet tab of the Diagnostics Utility select Monitor The Monitor window will be displayed Verify under the Produced Assembly that Gas Purge is highlighted 3 Passive Mode The DeviceNet tab of the Diagnostics Utility displays the POWER WAVE s passive mode status If the status needs to be changed select Configure and make the necessary modification 4 Gas Lines Verify nothing is obstructing the flow of gas CAUTION If for any reason you do not understand the test procedures are unable to perform the tests repairs safely contact your Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed POWER WAVE i400 LINCOLN B 13 TROUBLESHOOTING E 13 Observe all Safety Guidelines detailed throughout this manual PROBLEMS POSSIBLE RECOMMENDED SYMPTOMS CAUSE COURSE OF ACTION Bad Weld Ending 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 The DeviceNet tab of the Diagnostics Utility displays the POWER WAVEG s Analog Scans Between Updates and Scans Sec Verify that Analog Scans Between Updates is 4 of I O Scans Se
52. he troubleshooting section of this document or the Service Manual for this machine Light Condition Steady Green Alternating Green and Red Steady Red Blinking Red System is okay Power source communicating normally with the wire feeder and its compo nents Occurs during a reset and indicates the POWER WAVE 1400 is mapping identifying each component in the system Normally this occurs for the first 1 10 seconds after power is turned on or if the system configuration is changed during operation Non recoverable system fault Errors are present in the POWER WAVE i400 Read the error code before the machine is turned off Error code interpretation through the Status light is detailed in the Trouble Shooting section Individual code digits are flashed in red with a long pause between digits If more than one code is present the codes will be separated by a green light To clear the error turn power source off and back on to reset See Troubleshooting section Not applicable Not applicable POWER WAVE i400 LINCOLN 5 B 5 OPERATION B 847 Single Tach input 841 15V Tach supply 2 THERMAL INDICATOR THERMAL OVERLOAD A yellow light that comes on when an over temperature sit uation 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
53. iagrams of Circumferential A 15 Control Cable Connections ss A 16 Common Equipment Connections 16 17 DeviceNet Configuration Other Set up Ieeues A 17 Section B Safety Precautions sise B 1 Graphie wt DO B 2 PFOGUCEIDESCHPUON E B 3 Recommended Processes and Equipment B 3 Recommended Processes ninimi nianna rona ga ba FER SEENEN B 3 Process and Equipment Limitations ses B 3 Case Front Controls ee ee EE EE EE EE EE EE EE EE EE snnt rnnt nnne rnnt nnns B 4 B 5 Case Back Controls Hin te eed pa DES pen na ne dukan B 5 Internal Controls Power B 6 p saevo B 6 Basic Welding Controls caeca unie ed dy oe uad B 7 Constant Voltage 1 B 7 PUISG Welding H B 8 cr n Section C Optional EqQuIPMENt C 1 Factory rm 1 Field C 1 Compatible Lincoln 1 EE Section D Safety lt D 1 Routine and Periodic
54. ic welding modes WFS is the dominant con trol parameter For each wire feed speed a corre sponding voltage is programmed into the machine at the factory The user adjusts WFS according to fac tors such as wire size material thickness penetration requirements etc The Power Wave i400 then uses the WFS setting to select the appropriate nominal volt age The Power Wave i400 can also be configured to use amperage as the dominant control parameter In this configuration the Power Wave i400 uses the amperage setting to select the appropriate WFS and nominal voltage In either case the user can adjust the voltage higher or lower to compensate for material condition or individual preference POWER WAVE 1400 LINCOLN 5 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 characteristics the operator must adjust the voltage to compensate for any changes made to the WFS UltimArcTM UltimArcTM adjusts the apparent inductance of the wave shape The UltimArcTM adjustment is similar to a pinch function in that it is inversely proportional to inductance UltimArcTM is adjustable from 10 0 to 10 0 with a nominal setting of 0 Increasing UltimArcTM results in a crisper hotter arc Decreasing the UltimArcTM provides a softer colder arc Pulse Welding When pulse welding the power source primarily regu
55. ines detailed throughout this manual ERROR CODES FOR THE POWER WAVE The following is a partial list of possible error codes for POWER WAVE 1400 For a complete listing consult the Service Manual for this machine WIRE DRIVE MODULE FANUCZ 81 Motor Overload 129 Long term average motor current limit has been exceeded Typically indicates mechanical overload of system If problem continues con sider higher torque gear ratio lower speed range The Shutdown inputs on the POWER WAVE i400 have been dis abled The presence of these errors indicates the Feed Head Control PCB may contain the wrong operating software 84 Shutdown 72 1 83 Shutdown 1 82 Motor Overcurrent Absolute maximum motor current level has been exceeded This is a short term average to protect drive circuitry 130 131 32 CAUTION If for any reason you do not understand the test procedures are unable to perform the tests repairs safely contact your Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed POWER WAVE 1400 LINCOLN B 5 TROUBLESHOOTING E 5 Observe all Safety Guidelines detailed throughout this manual TROUBLESHOOTING GUIDE PROBLEMS SYMPTOMS Major physical or electrical damage is evident when the sheet metal covers are removed Input fuses keep blowing Machine will not power up no lights Observe Safety Guidelines detailed in the beginni
56. ions du fabricant Le dispositif de montage ou la piece souder doit tre branch une bonne mise la terre Autant que possible l installation et l entretien du poste seront effectu s par un lectricien qualifi Avant de faires des travaux l interieur de poste la debranch er l interrupteur la boite de fusibles Garder tous les couvercles et dispositifs de s ret leur place Mar 93 SAFETY Electromagnetic Compatibility 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 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 controll
57. ire welding the electrode electrode reel welding head nozzle or semiautomatic welding gun are also electrically hot 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 Ground the work or metal to be welded to a good electrical earth ground Maintain the electrode holder work clamp welding cable and welding machine in good safe operating condition Replace damaged insulation Never dip the electrode in water for cooling 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 When working above floor level use a safety belt to protect yourself from a fall should you get a shock Also see Items 6 c and 8 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 287 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
58. k 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 connec tion 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 prob lems of interference Screening of the entire welding installation may be considered for special applications 1 1 Portions of the preceding text are contained in EN 60974 10 Electromagnetic Compatibility EMC prod uct standard for arc welding equipment L10093 3 1 96H LINCOLN B vii vii for selecting a QUALITY product by Lincoln Electric We want you Thank You to take pride in operating this Lincoln Electric Company product as much pride as we 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 equip ment Our challenge is to meet the needs of our customers and to exceed their expectations On occasion purchase
59. lates the arc current not the arc voltage During a pulsing cycle arc current is regulated from a low background level to a high peak level and then back down to the low background level The average arc voltage increases and decreases as the average arc current is increased or decreased The peak current back ground current rise time fall time and pulse fre quency all affect the average voltage Since the aver age voltage for a given wire feed speed can only be determined when all the pulsing waveform parameters are known a unitless value called trim is used for adjusting the arc length Trim adjusts the arc length and ranges from 0 50 to 1 50 with a nominal value of 1 00 Increasing the trim value increases the arc length Decreasing the trim value decreases the arc length Alternately trim can be displayed as a quasi voltage value This allows the operator to pre set an approximate welding voltage rather than a unitless trim value The pre set voltage is limited based on the process and provides the same range of operation as the corresponding trim value OPERATION Pulse welding modes are synergic using wire feed speed as the main control parameter the wire feed speed is adjusted the power source adjusts the waveform parameters to maintain good welding char acteristics The Power Wave i400 can also be config ured to use amperage as the dominant control para meter In this configuration as the amperage is adjus
60. lding 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 manufacturer s instructions for this 5 AUG 06 LINCOLN 5 equipment and the consumables to be used including the material safety data sheet MSDS and follow your employer s safety practices MSDS forms are available from your welding distributor or from the manufacturer Also see item 1 b 6j SAFETY ME WELDING and CUTTING SPARKS 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 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 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 Do not heat cut or weld tanks drums or containers until the proper steps have been taken to insure
61. ll Safety Guidelines detailed throughout this manual PROBLEMS POSSIBLE RECOMMENDED SYMPTOMS CAUSE COURSE OF ACTION DeviceNet PLC Controlled Syst Bad Welding 4 Limit Errors Verify all welding setpoint values are within limits 5 Gas Verify Gas remains on until after the weld is complete 6 Welding set points Verify welding set points for work point trim and wave values 7 Wire Drive Gear selection Verify proper wire drive and gear ratio has been selected PROBLEMS POSSIBLE RECOMMENDED SYMPTOMS CAUSE COURSE OF ACTION ETHERNET Cannot Connect 1 Physical connection 1 Verify that the correct patch cable or cross over cable is being used refer to local IT department for assis tance NOTE For direct connection to the Fanuc R30iA Controller use only the cable provided with the K2677 1 Integration kit e Verify the cables are fully inserted into the bulk head connector LED 8 located under the PC board ethernet connector will be lit when the machine is connected to another network device 2 IP address information 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 NOTE IP address configuration MUST be set to dynamic when connected to the Fanuc R30iA Controller Verify no duplicate the IP addresses exist on the network 3 Ethernet Spe
62. located on the inside of the reconnect input access door of the machine Failure to do so may result in bodily injury or death Use a three phase supply line A 1 75 inch 45 mm diame ter access hole for the input supply is located on the case back Connect L1 L2 L8 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 Input Fuse and Supply Wire Considerations Refer to Specification in Installation Section for recommend ed 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 ther mal magnetic circuit breakers 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 2677 1 Integration kit provides the proper cable and instal lations instructions to make this connection WARNING The POWER WAVE i400
63. lowable maximum average output current is time dependent but ultimately limited to 450 amps over any 2 second period If the maximum average is exceeded the output is disabled to protect the machine Under these conditions normal operation can be resumed by cycling the output command COMMON WELDING PROCEDURES A WARNING MAKING A WELD The serviceability of a product or structure utilizing the weld ing programs is and must be the sole responsibility of the builder user Many variables beyond the control of The Lincoln Electric Company affect the results obtained in applying these programs These variables include but are not limited to weld ing procedure plate chemistry and temperature weldment design fabrication methods and service requirements The available range of a welding program may not be suitable for all applications and the build user is and must be solely responsible for welding program selection POWER WAVE 1400 LINCOLN 5 E OPERATION ad Choose the electrode material electrode size shield ing gas and process GMAW GMAW P etc appro priate 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 To make a weld the Power Wave i400 needs to know
64. machine controls 4 VOLTAGE SENSE CONNECTOR Allows for separate remote electrode and work sense leads Work Voltage Sense Electrode Voltage Sense 5 OPTIONAL DEVICENET OR SYNC TANDEM CONNECTOR Available as optional kits to support either DeviceNet communication or synchronized tandem pulse welding These options cannot coexist DEVICENET CONNECTOR 5 PIN SEALED MINI STYLE Function Function Black Green 6 ETHERNET CONNECTOR RJ 45 Used for ArcLink XT communication Also used for diagnostics and repro gramming the POWER WAVE 1400 7 WIRE FEEDER RECEPTACLE 14 PIN For connection to the Auto Drive 4R90 and Power Feed 10R wire feed ers 844 Open Reserved Tor Tuture Tach 1A differential signal 8 NEGATIVE OUTPUT TERMINAL 9 POSITIVE OUTPUT TERMINAL 10 ARCLINK RECEPTACLE Pin Leads Function B 678 67C D __ 52 52A 40V DC 51 51A 0 VDC 11 ON OFF SWITCH Controls input power to the POWER WAVE 1400 and when properly inte grated the Fanuc R30iA Controller A WARNING The POWER WAVE i400 ON OFF switch is NOT intended as a Service Disconnect for this equip ment 12 FEEDER STATUS INDICATOR See Item 1 CASE BACK FIGURE B 2 CASE BACK COMPONENTS DESCRIPTION 1 115V 15A DUPLEX RECEPTACLE 2 CIRCUIT BREAKER CB2 15 AMP Provide
65. may explode if damaged 3 7 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 Always keep cylinders in an upright position securely chained to an undercarriage or fixed support Oylinders should be located Away from areas where they be struck or subjected to physical damage safe distance from arc welding or cutting operations and any other source of heat sparks or flame Never allow the electrode electrode holder or any other electrically hot parts to touch a cylinder Keep your head and face away from the cylinder valve outlet when opening the cylinder valve Valve protection caps should always be in place and hand tight except when the cylinder is in use or connected for use Read and follow the instructions on compressed gas cylinders associated equipment and CGA publication PL 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 Install equipment in accordance with the U S National Electrical Co
66. metal FUMES AND GASES can be dangerous 5 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 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 spe cific 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 vapors coming from degreasing cleaning or spraying operations The heat and rays of the arc can react with solvent vapors to form phosgene a highly toxic gas and other irritating prod ucts 5 d Shie
67. mmended maximum 200 ft 61 0m POWER WAVE i400 LINCOLN 5 INSTALLATION A 6 OPTIONAL EQUIPMENT System Part No Description Identifier oax Cable Recommended to minimize the effects of the weld cable loop inductance and maximize perfor K1796 xx critical high speed pulse applications Coaxial Weld Cable Note K1796 coaxial cable is equivalent to 1 0 standard cable K2539 coaxial cable is equivalent to AWG 1 K2593 xx 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 for Robot K2709 xx Arm Customer IBM Compatible PC Windows NT SP6 Windows 2000 Windows XP or greater required for use with all Personal Computer Supplied POWER WAVE Utilities Replacement K2673 2 POWER WAVE i400 Replacement Chassis Complete inverter power section Intended only as a replace Chassis ment to be installed in the POWER WAVE i400 cabinet includes 526064 POWER WAVE Utilities CD External Dress Cable Heavy duty externally mounted 14pin wire feeder cable for use with robot arms not equipped with an integral cable POWER WAVE i400 LINCOLN 5 ad INSTALLATION A 7 FANUC R30iA CONTROLLER MOUNTING L L m d N FANUC Robotics R 30iA a cabinet Controller wit
68. ndary current and voltage Check for feeding problems Verify proper wire drive and gear ratio has been selected For larger diameter wire consider the highest torque lowest range gear ratio available to suit the application CAUTION If for any reason you do not understand the test procedures or are unable to perform the tests repairs safely contact your Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed POWER WAVE 1400 LINCOLN 5 TROUBLESHOOTING Observe all Safety Guidelines detailed throughout this manual PROBLEMS SYMPTOMS Arc loss fault on robot PROBLEMS SYMPTOMS Device does not go on Line POSSIBLE CAUSE 2 Conduit leading to the wire feed er has bends or twists which can reduce the wire feed speed 3 Conduit leading up to the wire feeder from the wire reel is too long POSSIBLE CAUSE 1 24v bus power 2 Baud rate 3 MAC ID 4 Termination 5 Wiring 6 EDS Files Electronic Data Sheet Files RECOMMENDED COURSE OF ACTION WELD AND ARC QUALITY PROBLEMS 2 Remove bends and twists in conduit leading to the feeder 3 Use a shorter piece of conduit RECOMMENDED COURSE OF ACTION viceNet PLC Controlled System 1 Verify that LED 10 is on when the DeviceNet network is pow ered This can be done with the POWER WAVE turned on or off Verify the baud rate setting is the same as the
69. ne calibration will not need adjustment However if the weld performance changes or the yearly calibration check reveals a problem use the calibration section of the Diagnostics Utility to make the appropriate adjustments The calibration procedure itself requires the use of a grid and certified actual meters for voltage and cur rent The accuracy of the calibration will be directly affected by the accuracy of the measuring equipment you use The Diagnostics Utility includes detailed instructions and is available on the POWER WAVEG Utilities and Service Navigator CD s or available at www powerwavesoftware com MAINTENANCE D 1 CHASSIS REMOVAL PROCEDURE A WARNING ELECTRIC SHOCK can kill Disconnect input power before servicing Do not operate with covers removed Do not touch electrically live parts Only qualified persons should install use or service this equipment See Figure D 1 1 Turn off input power to the power source and any other equipment connected to the welding system at the disconnect switch or fuse box before working on the equipment 0 2 Remove the weld cables from the output studs and disconnect all control cables including the Ethernet connection from the control panel 3 Remove the screws securing the chassis to the cabinet as listed below 6 10 24 screws securing the reconnect access panel on the front of the machine ON OFF switch must be in the OFF position fo
70. netic circuit breakers circuit breakers that have a delay in tripping action that decreases as the magnitude of current increases 3 Japanese Model Codes 11536 115368 N PHYSICAL DIMENSIONS K2669 2 22 7 in 577 mm 24 4 in 620 mm 21 5 in 546 mm 188 lbs 85 5 kg K2673 2 21 0 in 533 mm 22 6 in 574 mm 18 5 in 470 mm 126 lbs 57 3 kg TEMPERATURE RANGES OPERATING TEMPERATURE RANGE STORAGE TEMPERATURE RANGE 14 F to 104 F 10C to 400 40 F to 185 F 40 C to 85 C POWER 1400 LINCOLN 5 PE INSTALLATION gai TECHNICAL SPECIFICATIONS POWER WAVE 1400 2669 2 K2673 2 REGULATORY REQUIREMENTS JAPANESE MODELS Standard Enclosure Insulation Rating Class K2669 2 EN 60974 1 EN 50199 2673 23 Chassis Only 3 Chassis ratings applicable only when installed as a replacement in the POWER WAVE i400 cabinet POWER WAVE 1400 LINCOLN 5 A 3 INSTALLATION A 3 SAFETY PRECAUTIONS Read this entire installation section before you start installation WARNING ELECTRIC SHOCK can kill Only qualified personnel should per form this installation Turn the input power OFF at the dis connect switch or fuse box before working on this equipment Turn off the input power to any other equip ment connected to the welding sys tem at the disconnect switch or fuse box before working on the equip ment Do not touch electrically hot parts Always connect
71. ng of this manual POSSIBLE CAUSE BASIC MACHINE PROBLEMS Improperly sized input fuses Improper Weld Procedure requiring output levels in excess of machine rating Major physical or electrical damage is evident when the sheet metal covers are removed No Input Power Fuse F1 in reconnect area may have blown Circuit breaker CB1 on the control panel may have tripped Improper input voltage selec tion multiple input voltage machines only RECOMMENDED COURSE OF ACTION Contact your local authorized Lincoln Electric Field Service facility for technical assis tance Make sure fuses are properly Sized See installation section of this manual for recom mended sizes Reduce output current duty cycle or both Contact your local authorized Lincoln Electric Field Service facility for technical assis tance Make sure input supply dis connect has been turned ON Check input fuses Make cer tain that the Power Switch SW1 on the power source is in the ON position Power Down and replace the fuse Power Down and reset CB1 Power down check input volt age reconnect according to diagram on reconnect cover CAUTION If for any reason you do not understand the test procedures or are unable to perform the tests repairs safely con tact your local authorized Lincoln Electric Field Service Facility for technical assistance POWER WAVE 1400 LINCOLN 5 6 TROUBLESHOO
72. ot coil excess cable Route the electrode and work cables in close proximity to one another to minimize the loop area and therefore the inductance of the weld circuit Always weld in a direction away from the work ground connection In Table A 1 are copper cable sizes recommended for different currents and duty cycles Lengths stipulated are the distance from the welder to work and back to the welder again Cable sizes are increased for greater lengths primarily for the purpose of minimizing cable drop TABLE A 1 OUTPUT CABLE GUIDELINES Percent Duty CABLE SIZES FOR COMBINED LENGTHS OF ELECTRODE AND WORK CABLES RUBBER COVERED COPPER RATED 75 C 50 to 100 Ft 100 to 150 Ft 150 to 200 Ft 200 to 250 Ft Tabled values are for operation at ambient temperatures of 40 C and below Applications above 40 C may require cables larger than recommended or cables rated higher than 75 C POWER WAVE 1400 LINCOLN B 13 CABLE INDUCTANCE 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 The welding loop length is defined as the total of length of the electrode cable A work cable B work path
73. pecially steel aluminum and stainless PROCESS LIMITATIONS The software based weld set of the POWER i400 limit the process capability within the output range and the safe limits of the machine EQUIPMENT LIMITATIONS The POWER WAVE i400 is not directly compatible with analog machines or interfaces The input power pass through connection Terminal Block 4TB of the POWER WAVE 1400 is intended to supply power exclusively to the Fanuc R30iA con troller It is designed to support a 3kW maximum robot controller load through cable provided with the K2677 1 Integration Kit POWER WAVE 1400 LINCOLN 5 4 OPERATION BS FIGURE B 1 10 11 9 8 CASE FRONT CONTROL DESCRIPTION 1 Machine Status Indicator A two color LED that NOTE The POWER WAVE O i400 status light will indicates system errors The POWER WAVE i400 flash green and sometimes red and green for is equipped with two indicators One is for the up to one minute when the machine is first inverter power source while the other indicates the turned on This is a normal situation as the status of the feeder control system Normal opera machine goes through a self test at power up tion is a steady green light Basic error conditions are indicated in the table below For more informa tion and a detailed listing see t
74. put power for the Fanuc R30iA controller is supplied through the POWER WAVE i400 on off switch The ArcLink XT connection is provided through Ethernet Both power and communication leads are routed to the controller via access holes in the top of the power source The K2677 1 Integration Kit includes all nec essary cables and hardware to complete this task General Functional Description The POWER WAVE 1400 is a high performance multi process digitally controlled inverter power source designed as a pedestal to support the Fanuc R30iA controller It may also be used with other con trollers as a standalone power source It is capable of producing a welding output from 5 420 amperes and is rated for 350A 10096 The POWER WAVE i400 utilizes the latest genera tion high speed digital controls and communicates via ArcLink amp XT to the Fanuc controller The inverter power section utilizes state of the art power electron ics and is re connectable for 3 phase input voltages from 200 to 208VAC A 15A auxiliary receptacle is provided for fume extraction and water cooler acces sories RECOMMENDED PROCESSES AND EQUIPMENT RECOMMENDED PROCESSES The POWER WAVE i400 is a high speed multi process power source capable of regulating the cur rent voltage or power of the welding arc With an out put range of 5 to 420 amperes it supports a number of standard processes including synergic GMAW GMAW P and FCAW on various materials es
75. r Wave i400 to accommo date seamless integration with the Fanuc R30iA controller The K2677 1 Integration Kit includes a specially designed industrial rated Ethernet cable for this purpose It is highly recommended that all external Ethernet equip ment cables switches etc as defined by the connection diagrams be obtained through the Lincoln Electric Automation Division It is critical that all Ethernet cables external to either a conduit or an enclosure are solid con ductor shielded cat 5e cable with a drain The drain should be grounded at the source of transmission such as a net work switch or the Fanuc R30iA ground strip Ethernet cables will achieve optimal performance levels at distances up to 25 feet Special attention to layout may be required to support distances greater than 25 feet including specialized network equipment For best results always route Ethernet cables away from weld cables wire drive control cables or any other current carrying device that can create a fluctuat ing magnetic field For additional guidelines refer to industry standard documents for industrial Ethernet networks Failure to follow these recommendations can result in an Ethernet connection failure during welding The ethernet port of the Power Wave i400 is factory config ured with a dynamic IP address This is required for seam less operation with the Fanuc R30iA controller Connection Between Power Source and ArcLink Compatible
76. r removal 2 1 4 20 screws on either side of the control panel located on the right case side 2 1 4 20 screws just below the output studs located on the right case side 12 1 4 20 screws from the left case side FIGURE D 1 CHASSIS CONNECTION SEE WIRING DIAGRAM BA POWER WAVE i400 LINCOLN 5 4 Remove the left case side by pulling from the bottom 5 Disconnect the chassis input power leads 1E 2E amp 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 CAPACITOR DISCHARGE PROCEDURE CAUTION 9 Prior to transporting or servicing chassis it is important to verify the capacitors are completely 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 voltage is present wait for capacitors to complete ly discharge this may take several minutes or dis charge the capacitors as follows Obtain a power resistor 25 ohms 25 watts Hold resistor body with electrically insulated glov
77. rs 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 posses sion at that time Lincoln Electric is not in a position to warrant or guarantee such advice and assumes no liability with respect to such infor mation or advice We expressly disclaim any warranty of any kind including any warranty of fitness for any customer s 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 Please Examine Carton and Equipment For Damage Immediately When this equipment is shipped title passes to the purchaser upon receipt by the carrier Consequently Cl
78. s 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 110093 3 1 96H LINCOLN 5 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 recommenda tions 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 equip ment in metallic conduit or equivalent Shielding should be electrically continuous throu
79. s and precautions NOTE The POWER WAVE i400 external corner mounted lift bales must be removed when mounted to the Fanuc R30iA controller POWER WAVE i400 Replacement Chassis Lift the chassis by the lift bail on top of the harmonic filter assembly STACKING The POWER WAVE i400 cannot be stacked POWER WAVE i400 LINCOLN 5 iix INSTALLATION i ELECTROMAGNETIC COMPATIBILITY EMC EMC classification of the POWER 1400 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 con trolled machinery The normal operation of the POWER WAVE i400 may adversely affect the operation of RF con trolled equipment which may result in bodily injury or dam age to the equipment INPUT AND GROUNDING CONNECTIONS MACHINE GROUNDING The frame of the welder must be D 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 A WARNING ELECTRIC SHOCK can kill Only a qualified electrician should connect the input leads to the POWER WAVES Connections should be made in accordance with all local and National Electrical Codes and the con nection diagram
80. s pro tection for the 115V auxiliary 3 RATING PLATE POWER WAVE 1400 LINCOLN 5 6 INTERNAL CONTROLS FIGURE B 3 a NI x D S CE FE Dik 2 E 4 lo e j e GE 4 OMH P a ae NU P 8 INTERNAL CONTROLS DESCRIPTION 1 FUSE F1 Primary circuit protection for auxiliary power 10A 600V 2 ROBOT POWER TERMINAL BLOCK 4TB Power sup ply connection for Fanuc R30iA controller Supplies pri mary power through the ON OFF switch directly to the robot controller CAUTION This input power pass through connection is intended to supply power exclusively to the Fanuc R30iA con troller It is designed to support a 3kW maximum robot controller load through cable provided with the K2677 1 Integration Kit A WARNING 2 ELECTRIC SHOCK CAN KILL DO NOT ATTEMPT TO BACK FEED INPUT POWER THROUGH THE ROBOT POWER TERMINAL BLOCK 4TB INTO THE POWER WAVE 1400 THIS IS NOT ITS INTENDED PURPOSE AND MAY RESULT IN MACHINE DAMAGE BODILY INJURY OR DEATH OPERATION B 6 3 CHASSIS POWER TERMINAL BLOCK 3TB Power connec tion for in
81. t may be necessary to route cables that contain the sense leads away from the electrode and work welding cables Voltage sense leads requirements are based on the weld process as follows TABLE A 2 Electrode Voltage Sensing 67 lead 1 67 lead required 67 lead required 67 lead required Voltage sense at studs Work Voltage Sensing 21 lead 2 21 lead optional 3 21 lead optional 3 21 lead optional 3 Voltage sense at studs The electrode voltage sense lead 67 is automatically enabled by the weld process and integral to the to the 14 pin wire feeder control cable K1785 The work voltage sense lead 21 is manually enabled but ridden by constant current weld processes defined for stud sens ing Negative polarity semi automatic process operation WITHOUT use of a remote work sense lead 21 requires the Negative Electrode Polarity attribute to be set This establishes which out put stud the electrode voltage sense lead 67 will be referenced to Electrode Voltage Sensing The remote ELECTRODE sense lead 67 is built into the standard wire feeder control cable K1785 and is always connected to the wire drive feed plate when a wire feeder is present Enabling or disabling electrode voltage sensing is application specific and automati cally configured by the active weld mode The remote ELECTRODE sense lead 67 is also available in the remote Voltage Sense Connector for applic
82. ted the power source selects the appropriate wire feed speed and adjusts the waveform parame ters to maintain good welding characteristics In either case trim is used as a secondary control to change the arc length for material conditions or individual pref erence UltimArcTM adjusts the focus or shape of the arc UltimArcTM is adjustable from 10 0 to 10 0 with nominal setting of 0 0 Increasing the UltimArcTM increases the pulse frequency and background cur rent while decreasing the peak current This results in a tight stiff arc used for high speed sheet metal weld ing Decreasing the UltimArcTM decreases the pulse frequency and background current while increasing the peak current This results in a soft arc good for out of position welding The Power Wave utilizes adaptive control to compen sate for changes in the electrical stick out distance from the contact tip to the work piece while welding The Power Wave waveforms are optimized for a 5 8 to 3 4 stick out depending on the wire type and wire feed speed The adaptive behavior supports a range of stick outs from approximately 72 to 1 1 4 At low or high wire feed speeds the adaptive range may be less due to physical limitations of the welding process POWER WAVE 1400 LINCOLN 5 B 8 C 1 ACCESSORIES 1 OPTIONAL EQUIPMENT FACTORY INSTALLED None Available FIELD INSTALLED K940 Work Voltage Sense Lead Kit K2670 CE Filter Kit K2677 1 Integr
83. ternal chassis Provides power for the inverter and all auxiliary supplies 4 INPUT POWER TERMINAL BLOCK 1TB Input power connec tion from main service disconnect 5 GROUND TERMINAL Earth ground connection 6 PC BOARD DIPSWITCHES NOT SHOWN PC Board dip switches are set at the factory to allow configuration of the POWER WAVEO i400 via the Fanuc Teach Pendant or with the Weld Manager Utility included on the POWER WAVE Utilities and Service Navigator CD s or available at www powerwavesoftware com The factory default settings are as follows Control Board G4800 Series Hardware Sarge OFF 92 ON Feed Head Board L11087 Series Hardware 51 nus POWER WAVES 1400 will typically be powered up at same time as the robotic controller The status lights will blink green for about a minute while the system is configuring After this time the status lights will turn a steady green indicating the machine is ready DUTY CYCLE The POWER WAVE i400 is rated at 350 amps at 31 5 volts with a 10096 duty cycle It is further rated to provide 400 amps at 34 volts with a 60 duty cycle and 420 amps at 35 volts with a 40 duty cycle The duty cycle is based on a ten minute period A 6096 duty cycle represents 6 minutes of welding and 4 minutes of idling in a ten minute period Note The POWER WAVES 1400 is capable of producing a peak out put current of 700 amps The al
84. that such procedures will not cause flammable or toxic vapors from substances inside They can cause an explosion even though they have been cleaned For information purchase Hecommended Safe Practices for the Preparation for Welding and Cutting of Containers and Piping That Have Held Hazardous Substances AWS F4 1 from the American Welding Society see address above Vent hollow castings or containers before heating cutting or welding They may explode Sparks and spatter are thrown from the welding arc Wear oil 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 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 cir cuits This can create fire hazards or overheat lifting chains or cables until they fail Also see item 1 c 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 022690 9101 Do not use a welding power source for pipe thawing LINCOLN B CYLINDER
85. the POWER WAVE grounding lug located inside the reconnect input access door to a proper safety Earth ground LOCATION AND MOUNTING The POWER i400 case is designed to sup port the Fanuc R30iA controller and op box up to 300lbs matching the controller s footprint and styling Mounting is externally accessible for simplified inte gration The flexibility of the POWER WAVE 1400 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 stabili ty 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 ENVIRONMENTAL CONSIDERATIONS The POWER WAVE i400 will operate in harsh envi ronments Even so it is important that simple preven tative measures are followed in order to assure long life and reliable operation 0 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
86. unicating normally with all healthy peripheral equipment connected to its ArcLink network Blinking Green Occurs during power up or a system reset and indicates the POWER WAVE 1400 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 Fast Blinking Green Under normal conditions indicates Auto mapping has failed Also used by the Diagnostics Utility included on the POWER WAVE Utilities and Service Navigator CD s or available at www powerwavesoftware com to identify the selected machine when connecting to a specific IP address Alternating Green and Red Non recoverable system fault If the Status lights are flashing any combination of red and green errors are present Read the error code s before the machine is turned off Error Code interpretation through the Status light is detailed in the Service Manual Individual code digits are flashed in red with a long pause between digits If more than one code is present the codes will be separated by a green light Only active error conditions will be accessible through the Status Light Error codes can also be retrieved with the Diagnostics Utility included on the POWER WAVE Ultilities and Service Navigator CD s or available at www powerwavesoftware com This is the preferred method since it can access historical information contained in the error log To clear the acti
87. ve error s turn power source off and back on to reset Steady Red Not applicable Blinking Red Not applicable POWER WAVE 1400 LINCOLN 5 E 3 TROUBLESHOOTING E 3 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 FANUCZ 31 Primary Input overcurrent error Excessive Primary current present May be related to a switch board or output rectifier failure 32 Capacitor A under voltage 50 Low voltage on the main capacitors May be caused by right side facing the Switch PC Board improper input configuration or an open short circuit in the 33 Capacitor bank B under voltage primary side of the machine left side facing the Switch PC Board 34 Capacitor A over voltage Excess voltage on the main capacitors May be caused by right side facing the Switch PC Board improper input configuration excessive line voltage or left side facing the Switch PC Board 35 Capacitor B over voltage FH improper capacitor balance see Error 43 53 36 Thermal error Indicates over temperature Usually accompanied by 54 Thermal LED Check fan operation Be sure process does not exceed duty cycle limit of the machine 37 Softstart pre charge error 55 Capacitor precharge failed Usu
88. yuy XX G8Z LM Eu e qeo jou0D yury JepeeJ 10J 8UU09 asuas Jojoeuuo Lg pee1 esues jeuondo XX 2 8 LH 2 6992 40 291 2 i DO J9M0d ejae2 epoJiel3 J0 99UUu02 eueo eq dwy s 492919 POWER WAVE i400 LINCOLN LELECTRIC 9 qe eue 1X MIN OIXX L AEN ouv xog do pejei6eju 4eulqgo e VIOE Y 98927 06H e ugoiny INSTALLATION nm TYPICAL MASTER SLAVE SYSTEM DUAL ARM A 10 enuen uononuisu 00p eae MeMod UI ezis ejqeo 10 ejqeo nd no 98 1 OO J9p884 M 20 1X ur e qeo 1euijeui3 1X AUTO XX S82 LH age DO 18p284 M Joyauu0D Xurqouv J0 99UU02 asuas 1 p 4 eoeld 2 6992 DOE 12 pee 5 age Spoo Hasen OXX L AEN ouv 10J 8UU09 La pee 5 YO M EuOondO dwy s Jexeeag PNO 2 6992 OOP J9M0d poJ99 13 eise xog do pe e 8e u VIOE Y ONNVA 5 OXXL HEN oO 1X 5

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