Page 2 - SAFETY; WARNING; CALIFORNIA PROPOSITION 65 WARNINGS; The Above For Diesel Engines
FOR ENGINEpowered equipment. 1.a. 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 fumesoutdoors. ...
Page 3 - ii
ARC RAYS can burn. 4.a. Use a shield with the proper filter and cover plates to protect your eyes from sparks andthe rays of the arc when welding or observingopen arc welding. Headshield and filter lensshould conform to ANSI Z87. I standards. 4.b. Use suitable clothing made from durable flame-resist...
Page 4 - iii
FOR ELECTRICALLYpowered equipment. 8.a. Turn off input power using the disconnect switch at the fuse box before working onthe equipment. 8.b. Install equipment in accordance with the U.S. National Electrical Code, all local codes and the manufacturerʼsrecommendations. 8.c. Ground the equipment in ac...
Page 5 - iv; PRÉCAUTIONS DE SÛRETÉ
Mar. ʻ93 iv SAFETY iv PRÉCAUTIONS DE SÛRETÉ Pour votre propre protection lire et observer toutes les instructions et les précautions de sûreté specifiques qui parraissent dans ce manuel aussi bien que les précautions de sûreté générales suiv- antes: Sûreté Pour Soudage A LʼArc 1. Protegez-vous contr...
Page 8 - Thank You; Please Examine Carton and Equipment For Damage Immediately
vii vii Thank You for selecting a QUALITY product by Lincoln Electric. We want you to take pride in operating this Lincoln Electric Company product••• as much pride as we have in bringing this product to you! Read this Operators Manual completely before attempting to use this equipment. Save this ma...
Page 9 - TABLE OF CONTENTS; viii
viii TABLE OF CONTENTS Page Installation .......................................................................................................Section A Technical Specifications - POWER WAVE® i400..........................................A-1, A-2Safety Precautions......................................
Page 10 - INSTALLATION; TECHNICAL SPECIFICATIONS -; RATED OUTPUT; JAPANESE POWER SOURCES - INPUT VOLTAGE AND CURRENT
A-1 INSTALLATION POWER WAVE® i400 A-1 TECHNICAL SPECIFICATIONS - POWER WAVE® i400 (K2669-2, K2673-2) RATED OUTPUT RECOMMENDED INPUT WIRE AND FUSE SIZES 1 PHYSICAL DIMENSIONS TEMPERATURE RANGES 3 PHASE INPUT VOLTAGE 50/60Hz 200/208 3 Input Amperes (incl. robot and aux. load) 66 (86) HEIGHT 22.7 in. (...
Page 11 - REGULATORY REQUIREMENTS (JAPANESE MODELS)
A-2 INSTALLATION POWER WAVE® i400 A-2 TECHNICAL SPECIFICATIONS - POWER WAVE® i400 (K2669-2, K2673-2) 3 Chassis ratings applicable only when installed as a replacement in the POWER WAVE® i400 cabinet. REGULATORY REQUIREMENTS (JAPANESE MODELS) MODEL K2669-2 K2673-2 3 (Chassis Only) Standard EN 60974-1...
Page 12 - LOCATION AND MOUNTING; SAFETY PRECAUTIONS; LIFTING
A-3 INSTALLATION POWER WAVE® i400 A-3 LOCATION AND MOUNTING The POWER WAVE® i400 case is designed to sup-port the Fanuc R30iA controller and op box (up to300lbs), matching the controllerʼs footprint and styling.Mounting is externally accessible for simplified inte-gration. The flexibility of the POW...
Page 13 - INPUT AND GROUNDING CONNECTIONS; MACHINE GROUNDING; INPUT CONNECTIONS; ELECTRIC SHOCK can kill.
A-4 INSTALLATION POWER WAVE® i400 A-4 ELECTROMAGNETIC COMPATIBILITY (EMC) The EMC classification of the POWER WAVE® i400 isIndustrial, Scientific and Medical (ISM) group 2, class A. ThePOWER WAVE® i400 is for industrial use only. (See printsL10093-1, -2 Safety Pages in the front of Instruction Manua...
Page 14 - RECOMMENDED EQUIPMENT; CONNECTION DIAGRAMS AND SYSTEM; OPTIONAL EQUIPMENT
A-5 INSTALLATION POWER WAVE® i400 A-5 System Identifier Power Source Integration Kit Wire Drive Power Source to Wire Drive Control Cable Weld Cables Robot Arm Robot Controller Torch Part No . K2669-1 K2677-1 K2685-2 K1785-xx 1 K2163-xx -or- K1842-xx KxxxxKxxxxKxxxx Description POWER WAVE® i400 Power...
Page 16 - FANUC R30iA CONTROLLER MOUNTING; DETAIL A
A-7 INSTALLATION POWER WAVE® i400 A-7 FANUC R30iA CONTROLLER MOUNTING FANUC Robotics R-30iA "a-cabinet" Controller with Integrated Op Box Power Wave i400K2669-2 * ArcLink XTEthernet cable * Powercable DETAIL A A * Refer to Output Cable guidelines for recommended cable size in PowerW ave i400...
Page 21 - GENERAL GUIDELINES; ELECTRODE AND WORK CONNECTIONS; CAUTION; OUTPUT CABLE GUIDELINES
GENERAL GUIDELINES • S e l e c t t h e a p p r o p r i a t e s i z e c a b l e s p e r t h e “ O u t p u t C a b l e G u i d e l i n e s ” i n T a b l e A . 1 . Excessive voltage drops caused by undersizedwelding cables and poor connections often result inunsatisfactory welding performance. Always u...
Page 22 - General Guidelines for Voltage Sense Leads; Electrode Voltage Sensing; REMOTE SENSE LEAD CONNECTIONS; Voltage Sensing Overview
A-13 INSTALLATION POWER WAVE® i400 A-13 General Guidelines for Voltage Sense Leads Sense leads should be attached as close to the weldas practical, and out of the weld current path whenpossible. In extremely sensitive applications it may benecessary to route cables that contain the senseleads away f...
Page 23 - If Sense Leads ARE NOT Used:; If Sense Leads ARE Used:; For longitudinal applications; Work Voltage Sensing
If a remote work voltage sense lead is used, itm u s t b e e n a b l e d t h r o u g h t h e F a n u c T e a c hPendant or with the Weld Manager Utility (includ-e d o n t h e P o w e r W a v e U t i l i t i e s a n d S e r v i c eN a v i g a t o r C D ʼ s o r a v a i l a b l e a twww.powerwavesoftwa...
Page 24 - • For circumferential applications,
A-15 INSTALLATION POWER WAVE® i400 A-15 • 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. POWER SOURCE #2 POWER SOURCE #1 POWER SOURCE #1 POWER SOURCE #...
Page 25 - CONTROL CABLE CONNECTIONS; General Guidelines; R e g a r d i n g c a b l e p l a c e m e n t , b e s t r e s u l t s w i l l b e; COMMON EQUIPMENT CONNECTIONS
A-16 INSTALLATION POWER WAVE® i400 A-16 CONTROL CABLE CONNECTIONS General Guidelines Genuine Lincoln control cables should be used at alltimes (except where noted otherwise). Lincoln cables are specifically designed for the communication andpower needs of the POWER WAVE® / Power Feed sys-tems. Most ...
Page 26 - F a n u c T e a c h
A-17 INSTALLATION POWER WAVE® i400 A-17 Connections Between Power Source and OptionalDeviceNet PLC Controller . Hard Automation applica- tions and some earlier model controllers may requireDeviceNet connectivity to control the power source.DeviceNet can also be used to monitor welding data,and syste...
Page 27 - OPERATION
B-1 OPERATION B-1 POWER WAVE® i400 SAFETY PRECAUTIONS Read this entire section of operating instructions before operating the machine. ELECTRIC SHOCK can kill. • Unless using cold feed feature, when feeding with gun trigger, the elec- t r o d e a n d d r i v e m e c h a n i s m a r e a l w a y s e l...
Page 29 - PRODUCT DESCRIPTION; PRODUCT SUMMARY; General Physical Description; RECOMMENDED PROCESSES
B-3 OPERATION B-3 PRODUCT DESCRIPTION PRODUCT SUMMARY General Physical Description The POWER WAVE® i400 is intended as a replace-ment for the PW355i using an updated power andcontrol platform to enhance performance and reliabili-ty. The POWER WAVE® i400 includes an integratedwire drive module and 14...
Page 30 - CASE FRONT CONTROL DESCRIPTION; CASE FRONT
B-4 OPERATION B-4 CASE FRONT CONTROL DESCRIPTION 1. Machine Status Indicator: A two color LED that indicates system errors. The POWER WAVE® i400is equipped with two indicators. One is for theinverter power source, while the other indicates thestatus of the feeder control system. Normal opera-tion is...
Page 31 - Pin; CASE BACK COMPONENTS DESCRIPTION; CASE BACK
B-5 OPERATION B-5 POWER WAVE® i400 2. THERMAL INDICATOR (THERMAL OVERLOAD): A yellow light that comes on when an over temperature sit-uation occurs. Output is disabled and the fan continuesto run, until the machine cools down. When cool, thelight goes out and output is enabled. 3. CIRCUIT BREAKER (C...
Page 32 - INTERNAL CONTROLS DESCRIPTION; ELECTRIC SHOCK CAN KILL.; Fanuc Teach Pendant; DUTY CYCLE
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 therobot controller. This input power pass-t...
Page 33 - BASIC WELDING CONTROLS; Weld Mode; CONSTANT VOLTAGE WELDING; Synergic CV
B-7 OPERATION B-7 POWER WAVE® i400 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 desiredwelding process. The standard weld set shipped withthe Power Wave i400 encom...
Page 34 - Non Synergic CV; Pulse Welding
B-8 OPERATION POWER WAVE® i400 B-8 Pulse welding modes are synergic; using wire feedspeed as the main control parameter. As the wirefeed speed is adjusted, the power source adjusts thewaveform parameters to maintain good welding char-acteristics. The Power Wave i400 can also be config-ured to use am...
Page 35 - ACCESSORIES; FACTORY INSTALLED; COMPATIBLE LINCOLN EQUIPMENT
C-1 ACCESSORIES C-1 OPTIONAL EQUIPMENT FACTORY INSTALLED None Available. FIELD INSTALLED K940-Work Voltage Sense Lead Kit K2670-[ ] CE Filter KitK2677-1 Integration Kit COMPATIBLE LINCOLN EQUIPMENT K2685-2 Auto Drive 4R90 Wire feeder (14-pin control cable). K1780-2 Power Feed 10 Robotic Wire Drive F...
Page 36 - CHASSIS REMOVAL PROCEDURE; MAINTENANCE; EXPLODING PARTS can cause injury.
CHASSIS REMOVAL PROCEDURE ELECTRIC SHOCK can kill.• D i s c o n n e c t i n p u t p o w e r b e f o r e servicing. • Do not operate with covers removed.• Do not touch electrically live parts.• Only qualified persons should install, use or service this equipment. -------------------------------------...
Page 37 - CAPACITOR DISCHARGE PROCEDURE; • P r i o r t o t r a n s p o r t i n g o r s e r v i c i n g
D-2 MAINTENANCE D-2 POWER WAVE® i400 FIGURE D.1a 4. Remove the left case side by pulling out from the bottom. 5. Disconnect the chassis input power leads (1E, 2E & 3E) from terminal block “3TB” located in the cabinetreconnect area, and remove the chassis groundfrom the stud located in front the ...
Page 38 - TROUBLESHOOTING; Local Lincoln Authorized Field Service Facility; HOW TO USE TROUBLESHOOTING GUIDE
E-1 TROUBLESHOOTING E-1 POWER WAVE® i400 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. CAUTION This Troubleshooti...
Page 40 - POWER SOURCE; ERROR CODES FOR THE POWER WAVE®; Indication
LECO (FANUC#) 49 50 51 52 53 54 55 57 67 84 see com- plete listing POWER SOURCE ––– WELD CONTROLLER E-3 TROUBLESHOOTING E-3 POWER WAVE® i400 Observe all Safety Guidelines detailed throughout this manual If for any reason you do not understand the test procedures or are unable to perform the tests/re...
Page 42 - TROUBLESHOOTING GUIDE; POSSIBLE
E-5 TROUBLESHOOTING E-5 POWER WAVE® i400 Observe all Safety Guidelines detailed throughout this manual TROUBLESHOOTING GUIDE Observe Safety Guidelines detailed in the beginning of this manual. CAUTION If for any reason you do not understand the test procedures or are unable to perform the tests/repa...
Page 47 - PROBLEMS
E-10 TROUBLESHOOTING E-10 POWER WAVE® i400 Observe all Safety Guidelines detailed throughout this manual 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 troublesh...
Page 52 - DIAGRAMS; Enhanced Diagam
F-1 DIAGRAMS F-1 POWER WAVE® i400 NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. The specific diag ram for a particular code is pasted inside the machine on one of the enclosure panels. If the diagram is illegible, write to the Service Depar...
Page 53 - DIMENSION PRINT
F-2 DIMENSION PRINT F-2 POWER WAVE® i400 G6044 A. 01 20. 34 19. 49 21. 54 21. 46 23. 62 22. 74 20. 99 18. 81 21. 54 IS O V IE W RE FE RENCE ON LY 25. 05 D ETAI L V IE W OF C HAS SI S REMO VE D FRO M CA BI NET 24. 37 18. 52
Page 54 - NOTES