Lincoln Electric IM986 manual Product Description, Recommended Processes and Equipment

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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 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® communication is supported through the 5 pin MS- style interface. The new ArcLink®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® 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 Fanuc R30iA controller and op box (up to 300lbs), matching both the controllerʼs footprint and styling. Mounting is externally accessible for simplified integration. The flexibility of the POWER WAVE® i400 also allows it to be operated as a stand alone unit.

Input 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® i400 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, 100%.

The POWER WAVE® i400 utilizes the latest genera- tion high speed digital controls, and communicates via ArcLink®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 especially steel, aluminum and stainless.

PROCESS LIMITATIONS

The software based weld set of the POWER WAVE® 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® i400 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® 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 ProblemsIndication Error Codes for the Power WaveError Code # Wire Drive Module Course of Action ProblemsRecommended Symptoms 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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