Lincoln Electric IM986 Routine Maintenance, Periodic Maintenance, Calibration Specification

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D-1

MAINTENANCE

D-1

SAFETY PRECAUTIONS

WARNING

ELECTRIC SHOCK can kill.

• Do not touch electrically live parts or electrode with skin or wet clothing.

•Insulate yourself from work and ground

•Always wear dry insulating gloves.

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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.

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See additional warning information throughout this Operatorʼs Manual

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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® i400 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 machine 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 WAVE® Utilities and Service Navigator CDʼs or available at www.powerwavesoftware.com..

CHASSIS REMOVAL PROCEDURE

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.

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(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.

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 for 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)

POWER WAVE® i400

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Contents Power Wave Safety Depends on YouSafety Mar ʻ95Electric Shock can kill AUGIii JanPrécautions DE Sûreté Mar. ʻ93Electromagnetic Compatibility EMC Safety Thank You ViiTable of Contents Phase Input Height Width Depth WeightOperating Temperature Range Storage Temperature RangeEnclosure ClassClass F K2673-23 155CInstallation Safety PrecautionsInput Fuse and Supply Wire Considerations Power Supply Connection for the Fanuc R30iA ControllerInput and Grounding Connections Input ConnectionsConnection Diagrams and System Optional EquipmentPower Wave Utilities Fanuc R30iA Controller Mounting Typical Single ARM Typical Master / Slave System Dual ARM Typical I400Electrode and Work Connections General Guidelines Table A.1Percent DutyCable INDUCTANCE, and ITS Effects on Welding Remote Sense Lead ConnectionsVoltage Sensing Overview Table A.2Work Voltage Sensing Voltage Sensing Considerations for Multiple Arc SystemsIf Sense Leads are not Used See Figure A.3Power Regarding cable placement, best results will be Control Cable ConnectionsCommon Equipment Connections General GuidelinesOther SET-UP Issues Operation Electric Shock can killInput Power Three Phase Direct CurrentProduct Description Recommended Processes and EquipmentCase Front Case Front Control DescriptionCase Back Case Back Components DescriptionPin Leads Function 115V / 15A Duplex ReceptaclePOWER-UP Sequence Common Welding ProceduresInternal Controls Internal Controls DescriptionBasic Welding Controls Constant Voltage WeldingPulse Welding Non Synergic CVAccessories Factory InstalledField Installed Optional EquipmentMaintenance Routine MaintenancePeriodic Maintenance Calibration SpecificationCapacitor Discharge Procedure Figure D.1aTroubleshooting HOW to USE Troubleshooting GuideUsing the Status LED to Troubleshoot System Problems Table E.1Error Codes for the Power Wave Error Code #Indication Wire Drive Module Problems Recommended SymptomsCourse of Action Observe Safety Guidelines LEDRecommended Weld and ARC Quality Problems DeviceNet PLC Controlled System Power Supply Under the Produced Assembly thatTouch Sense command From the DeviceNet tab Passive ModeBad Weld Starting Wire Feed problem Through the wire conduit. VerifyStrike Wire Feed Speed Ly connected and configured asRespond quickly Analog In Active Selections From the DeviceNet tabNeeds to be changed, select ModificationBad Weld Ending Burnback Disabled From the DeviceNet tab Other than Analog Scans Between UpdatesBurnback is present Burnback Time That Burnback is present for all Analogs Welding set pointsProblems Possible Recommended Symptoms Diagrams Enhanced DiagamDimension Print Power Wave Aviso DE  Use ventilation or exhaust to Guards off
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