Manuale d’uso / di manutenzione del prodotto POWER WAVE I400 del fabbricante Lincoln Electric
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• 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.
FOR ENGINE powered equipment. 1.a. Turn the engine off before troubleshooting and maintenance work unless the maintenance work requires it to be running. ____________________________________________________ 1.b. Operate engines in open, well-ventilated areas or vent the engine exhaust fumes outdoors.
ii SAFETY ii ARC R A Y S can bur n. 4.a. Use a shield with the proper filter and cover plates to protect your eyes from sparks and the rays of the arc when welding or observing open arc welding. Headshield and filter lens should conform to ANSI Z87. I standards.
iii SAFETY iii FOR ELECTRIC ALL Y pow er ed equipment. 8.a. Turn off input power using the disconnect switch at the fuse box before working on the equipment. 8 .b . Install equipment in accordance with the U.S. National Electrical Code, all local codes and the manufacturer’s recommendations.
Mar. ‘93 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 L’Arc 1.
v SAFETY v Electromagnetic Compatibility (EMC) Conformance Products displaying the CE mark are in conformity with European Community Council Directive of 3 May 1989 on the approximation of the laws of the Member States relating to electromagnetic compatibility (89/336/EEC).
vi SAFETY vi 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.
vii vii T T h h a a n n k k Y Y o o u u 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.
viii T ABLE OF CONTENTS Page Installation .......................................................................................................Section A Technical Specifications - POWER WAVE® i400 ..........................................A-1, A-2 Safety Precautions.
A-1 INST ALLA TION POWER WAVE® i400 A-1 TECHNICAL SPECIFICA TIONS - POWER W A VE® i400 (K2669-1, K2673-1) RA TED OUTPUT RECOMMENDED INPUT WIRE AND FUSE SIZES 1 PHYSICAL DIMENSIONS TEMPERA TURE RANGE.
A-2 INST ALLA TION POWER WAVE® i400 A-2 TECHNICAL SPECIFICA TIONS - POWER W A VE® i400 (K2669-1, K2673-1) 3 Chassis ratings applicable only when installed as a replacement in the POWER WAVE® i400 cabinet. 4 K2670-[ ] CE Filter Kit is required to meet CE and C-Tick conducted emission requirements.
A-3 INST ALLA TION POWER WAVE® i400 A-3 LOCA TION AND MOUNTING The POWER WAVE® 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.
A-4 INST ALLA TION POWER WAVE® i400 A-4 ELECTROMAGNETIC COMP A TIBILITY (EMC) The EMC classification of the POWER WAVE® i400 is Industrial, Scientific and Medical (ISM) group 2, class A. The POWER WAVE® i400 is for industrial use only. (See prints L10093-1, -2 Safety Pages in the front of Instruction Manual for further details).
A-5 INST ALLA TION POWER WAVE® i400 A-5 Reconnect Diagram for K2669-1 POWER W A VE® i400 FIGURE A.1.
A-6 INST ALLA TION POWER WAVE® i400 A-6 System Identifier Power Source Integration Kit Wire Drive Power Source to Wire Drive Control Cable Weld Cables Robot Arm Robot Controller Torch Part No .
A-7 INST ALLA TION POWER WAVE i400 A-7 System Identifier Coaxial Weld Cable External Dress Cable for Robot Arm Personal Computer Replacement Chassis Part No .
A-8 INST ALLA TION POWER WAVE® i400 A-8 F A N U C R 3 0 i A C O N T R O L L E R MO U N T I N G FA NU C R obo tics R- 30 iA "a-cab i ne t" C on tro ll er with Int eg ra t ed Op Box Power Wav.
A-9 INST ALLA TION POWER WAVE® i400 A-9 TYPICAL INTEGRATED SYSTEMS (SINGLE ARM) ArcLink X T Ethernet Connection Voltage Sense Connector W ire Feeder Connector Power W ave i400 K2669-1 Optional Work S.
A-10 INST ALLA TION POWER WAVE® i400 A-10 TYPICAL STAND ALONE SYSTEMS (SINGLE ARM) Devicenet Connector Wire Feeder Connector Circu i t Breaker (15 Amp) ArcLink X T Ethernet Connector Voltage Sense Co.
A-11 INST ALLA TION POWER WAVE® i400 A-11 TYPICAL MASTER / SLAVE SYSTEM (DUAL ARM) FANU C Robotics R -30iA "a-cabinet" Contro ller with Integrated Op Box (Master) FANU C Robotics R-30iA &qu.
A-12 INST ALLA TION POWER WAVE® i400 A-12 TYPICAL F355i RETROFIT (SINGLE ARM) Power W ave i400 K2669-1 FANU C Robotics R-J3 iB Controller * Electrode Cable (+) K2163-xx or K1842-xx Optional Work Sens.
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.
A-14 INST ALLA TION POWER WAVE® i400 A-14 General Guidelines for Voltage Sense Leads Sense leads should be attached as close to the weld as practical, and out of the weld cur rent path when possible. In extremely sensitive applications it may be necessary to route cables that contain the sense leads away from the electrode and work welding cables.
If a remo te work voltage sense lead is used, it must be enabled through the 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.
A-16 INST ALLA TION POWER WAVE® i400 A-16 • 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.
A-17 INST ALLA TION POWER WAVE® i400 A-17 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.
A-18 INST ALLA TION POWER WAVE® i400 A-18 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.
B-1 OPERA TION B-1 POWER WAVE® i400 SAFETY PRECAUTIONS Read this entire section of operating instructions before operating the machine. ELECTRIC SHOCK can kill.
B-2 OPERA TION B-2 POWER WAVE® i400 INPUT POWER ON OFF HIGH TEMPERA TURE MACHINE ST A TUS CIRCUIT BREAKER WIRE FEEDER POSITIVE OUTPUT NEGA TIVE OUTPUT 3 PHASE INVERTER INPUT POWER THREE PHASE DIRECT .
B-3 OPERA TION B-3 PRODUCT DESCRIPTION PRODUCT SUMMAR Y General Physical Description The POWER WAVE® i400 is intended as a replace- ment for the PW355i us ing an updated power and control platform to enhance performance and reliabili- ty.
B-4 OPERA TION B-4 CASE FRONT CONTROL DESCRIPTION 1. Machine Status Indicator: A two color LED that indicates system errors. The POWER WAVE® i400 is equipped with two indicators. One is for the inverter power source, while the other indicates the status of the feeder control system.
B-5 OPERA TION B-5 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.
I NTERNAL CONTROLS DESCRIPTION 1. MAI N RECO NNE CT: Selects main capacitor configura- tion for 208-230V or 380-575V input. 2. AUXILIARY RECONNECT: Configures auxiliary power for specified input voltage (208/230/380/460/575V). 3. FUSE (F1): Primary circuit protection for auxiliary power (10A/600V).
B-7 OPERA TION B-7 Choose the electrode material, electrode size, shield- ing gas, and process (GMAW, GMAW-P etc.) appro- priate for the material to be welded.
Pulse welding modes are s ynergic; using wire feed speed as the main control parameter. As 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.
C-1 ACCESSORIES C-1 OPTIONAL EQUIPMENT F ACTOR Y INST ALLED None Available. FIELD INST ALLED K940-Work Voltage Sense Lead Kit K2670-[ ] CE Filter Kit K2677-1 Integration Kit COMP A TIBLE LINCOLN EQUIPMENT K2 685 -2 Auto Drive 4R90 Wire feeder (14-pin control cable).
CHASSIS REMOV AL PROCEDURE 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.
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 cabinet reconnect area, and remove the chassis ground from the stud located in front the terminal block.
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.
E-2 TROUBLESHOOTING E-2 POWER WAVE® i400 USING THE ST A TUS LED TO TROUBLESHOOT SYSTEM PROBLEMS The POWER WAVE® i400 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.
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 th.
LECO (FANUC#) 129 130 131 132 E-4 TROUBLESHOOTING E-4 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.
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.
E-6 TROUBLESHOOTING E-6 POWER WAVE® i400 Observe all Safety Guidelines detailed throughout this manual TROUBLESHOOTING GUIDE Observe Safety Guidelines detailed in the beginning of this manual.
E-7 TROUBLESHOOTING E-7 POWER WAVE® i400 Observe all Safety Guidelines detailed throughout this manual TROUBLESHOOTING GUIDE Observe Safety Guidelines detailed in the beginning of this manual.
E-8 TROUBLESHOOTING E-8 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 troubleshooting assistance before you proceed.
E-9 TROUBLESHOOTING E-9 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 troubleshooting assistance before you proceed.
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 troubleshooting assistance before you proceed.
E-11 TROUBLESHOOTING E-11 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 troubleshooting assistance before you proceed.
E-12 TROUBLESHOOTING E-12 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 troubleshooting assistance before you proceed.
E-13 TROUBLESHOOTING E-13 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 troubleshooting assistance before you proceed.
E-14 TROUBLESHOOTING E-14 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.
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 diagram for a particular code is pasted inside the machine on one of the enclosure panels. If the diagram is illegible, write to the Service Department for a replacement.
F-2 DIMENSION PRINT F-2 POWER WAVE® i400 G6 044 A.01 20.3 4 19.4 9 21.5 4 21.4 6 23.6 2 22.7 4 20.9 9 18.8 1 21.5 4 ISO V IEW REFE RENCE ONLY 25.0 5 DET AIL VIEW OF CHA SSI S REMO VED FRO M CABI NET 24.
NOTES POWER WAVE® i400.
W ARNING A VISO DE PRECAUCION A TTENTION W ARNUNG A TENÇÃO Spanish French German Portuguese Japanese Chinese Korean Arabic READ AND UNDERST AND THE MANUFACTURER ’S INSTRUCTION FOR THIS EQUIPMENT AND THE CONSUMABLES TO BE USED AND FOLLOW YOUR EMPLOYER’S SAFETY PRACTICES.
W ARNING A VISO DE PRECAUCION A TTENTION W ARNUNG A TENÇÃO Spanish French German Portuguese Japanese Chinese Korean Arabic LEIA E COMPREENDA AS INSTRUÇÕES DO F ABRICANTE P ARA ESTE EQUIPAMENTO E AS P ARTES DE USO, E SIGA AS PRÁTICAS DE SEGURANÇA DO EMPREGADOR.
• 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.
Un punto importante, dopo l’acquisto del dispositivo (o anche prima di acquisto) è quello di leggere il manuale. Dobbiamo farlo per diversi motivi semplici:
Se non hai ancora comprato il Lincoln Electric POWER WAVE I400 è un buon momento per familiarizzare con i dati di base del prodotto. Prime consultare le pagine iniziali del manuale d’uso, che si trova al di sopra. Dovresti trovare lì i dati tecnici più importanti del Lincoln Electric POWER WAVE I400 - in questo modo è possibile verificare se l’apparecchio soddisfa le tue esigenze. Esplorando le pagine segenti del manuali d’uso Lincoln Electric POWER WAVE I400 imparerai tutte le caratteristiche del prodotto e le informazioni sul suo funzionamento. Le informazioni sul Lincoln Electric POWER WAVE I400 ti aiuteranno sicuramente a prendere una decisione relativa all’acquisto.
In una situazione in cui hai già il Lincoln Electric POWER WAVE I400, ma non hai ancora letto il manuale d’uso, dovresti farlo per le ragioni sopra descritte. Saprai quindi se hai correttamente usato le funzioni disponibili, e se hai commesso errori che possono ridurre la durata di vita del Lincoln Electric POWER WAVE I400.
Tuttavia, uno dei ruoli più importanti per l’utente svolti dal manuale d’uso è quello di aiutare a risolvere i problemi con il Lincoln Electric POWER WAVE I400. Quasi sempre, ci troverai Troubleshooting, cioè i guasti più frequenti e malfunzionamenti del dispositivo Lincoln Electric POWER WAVE I400 insieme con le istruzioni su come risolverli. Anche se non si riesci a risolvere il problema, il manuale d’uso ti mostrerà il percorso di ulteriori procedimenti – il contatto con il centro servizio clienti o il servizio più vicino.
