Lincoln Electric IM986 Electrode and Work Connections General Guidelines, Table A.1, Percent

Page 21

A-12

INSTALLATION

A-12

ELECTRODE AND WORK CONNECTIONS GENERAL GUIDELINES

 

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 positive (+). 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.

•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 not 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

CABLE SIZES FOR COMBINED LENGTHS OF ELECTRODE AND WORK CABLES

Amperes

Duty

(RUBBER COVERED COPPER - RATED 75°C)**

 

 

Cycle

 

 

 

 

 

 

 

0 to 50 Ft.

50 to 100 Ft.

100 to 150 Ft.

150 to 200 Ft.

200 to 250 Ft.

 

 

 

 

 

 

 

200

60

2

2

2

1

1/0

200

100

2

2

2

1

1/0

225

20

4 or 5

3

2

1

1/0

225

40 & 30

3

3

2

1

1/0

250

30

3

3

2

1

1/0

250

40

2

2

1

1

1/0

250

60

1

1

1

1

1/0

250

100

1

1

1

1

1/0

300

60

1

1

1

1/0

2/0

325

100

2/0

2/0

2/0

2/0

3/0

350

60

1/0

1/0

2/0

2/0

3/0

400

60

2/0

2/0

2/0

3/0

4/0

400

100

3/0

3/0

3/0

3/0

4/0

500

60

2/0

2/0

3/0

3/0

4/0

**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® i400

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Contents Safety Depends on You Power WaveMar ʻ95 SafetyAUG Electric Shock can killJan IiiMar. ʻ93 Précautions DE SûretéElectromagnetic Compatibility EMC Safety Vii Thank YouTable of Contents Height Width Depth Weight Phase InputOperating Temperature Range Storage Temperature RangeClass EnclosureClass F K2673-23 155CSafety Precautions InstallationPower Supply Connection for the Fanuc R30iA Controller Input Fuse and Supply Wire ConsiderationsInput and Grounding Connections Input ConnectionsOptional Equipment Connection Diagrams and SystemPower Wave Utilities Fanuc R30iA Controller Mounting Typical Single ARM Typical Master / Slave System Dual ARM I400 TypicalTable A.1 Electrode and Work Connections General GuidelinesPercent DutyRemote Sense Lead Connections Cable INDUCTANCE, and ITS Effects on WeldingVoltage Sensing Overview Table A.2Voltage Sensing Considerations for Multiple Arc Systems Work Voltage SensingIf Sense Leads are not Used See Figure A.3Power Control Cable Connections Regarding cable placement, best results will beCommon Equipment Connections General GuidelinesOther SET-UP Issues Electric Shock can kill OperationDirect Current Input Power Three PhaseRecommended Processes and Equipment Product DescriptionCase Front Control Description Case FrontCase Back Components Description Case BackPin Leads Function 115V / 15A Duplex ReceptacleCommon Welding Procedures POWER-UP SequenceInternal Controls Internal Controls DescriptionConstant Voltage Welding Basic Welding ControlsNon Synergic CV Pulse WeldingFactory Installed AccessoriesField Installed Optional EquipmentRoutine Maintenance MaintenancePeriodic Maintenance Calibration SpecificationFigure D.1a Capacitor Discharge ProcedureHOW to USE Troubleshooting Guide TroubleshootingTable E.1 Using the Status LED to Troubleshoot System ProblemsError Codes for the Power Wave Error Code #Indication Wire Drive Module Problems Recommended SymptomsCourse of Action LED Observe Safety GuidelinesRecommended Weld and ARC Quality Problems DeviceNet PLC Controlled System Under the Produced Assembly that Power SupplyTouch Sense command From the DeviceNet tab Passive ModeThrough the wire conduit. Verify Bad Weld Starting Wire Feed problemStrike Wire Feed Speed Ly connected and configured asAnalog In Active Selections From the DeviceNet tab Respond quicklyNeeds to be changed, select ModificationOther than Analog Scans Between Updates Bad Weld Ending Burnback Disabled From the DeviceNet tabBurnback is present Burnback Time That Burnback is present for all Analogs Welding set pointsProblems Possible Recommended Symptoms Enhanced Diagam DiagramsDimension Print Power Wave Aviso DE  Use ventilation or exhaust to Guards off
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