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IM986
November, 2008
®
POWERWAVE i400
For use with machines having Code Numbers:
11536, 11536R
Safety Depends on You
Lincoln arc welding and cutting
equipment is designed and built
with safety in mind. However, your
overall safety can be increased by
proper installation ... and thought-
ful operation on your part. DO
NOT INSTALL, OPERATE OR
REPAIR THIS EQUIPMENT
WITHOUT READING THIS
MANUAL AND THE SAFETY
PRECAUTIONS CONTAINED
THROUGHOUT. And, most
importantly, think before you act
and be careful
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i i SAFETY WARNING CALIFORNIA PROPOSITION 65 WARNINGS Diesel engine exhaust and some of its constituents The engine exhaust from this product contains are known to the State of California to cause can- chemicals known to the State of California to cause cer, birth defects, and other reproductive harm. cancer, birth defects, or other reproductive harm. The Above For Diesel Engines The Above For Gasoline Engines ARC WELDING CAN BE HAZARDOUS. PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY
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ii ii SAFETY ARC RAYS can burn. ELECTRIC SHOCK can 4.a. Use a shield with the proper filter and cover kill. plates to protect your eyes from sparks and 3.a. The electrode and work (or ground) circuits the rays of the arc when welding or observing are electrically “hot” when the welder is on. open arc welding. Headshield and filter lens Do not touch these “hot” parts with your bare should conform to ANSI Z87. I standards. skin or wet clothing. Wear dry, hole-free gloves to insulate hands. 4.b. Us
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iii iii SAFETY WELDING and CUTTING CYLINDER may explode SPARKS can if damaged. cause fire or explosion. 7.a. Use only compressed gas cylinders 6.a. Remove fire hazards from the welding area. containing the correct shielding gas for the If this is not possible, cover them to prevent process used and properly operating the welding sparks from starting a fire. regulators designed for the gas and Remember that welding sparks and hot pressure used. All hoses, fittings, etc. should be suitable for mat
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iv iv SAFETY 5. Toujours porter des lunettes de sécurité dans la zone de PRÉCAUTIONS DE SÛRETÉ soudage. Utiliser des lunettes avec écrans lateraux dans les zones où lʼon pique le laitier. Pour votre propre protection lire et observer toutes les instructions et les précautions de sûreté specifiques qui parraissent dans ce 6. Eloigner les matériaux inflammables ou les recouvrir afin de manuel aussi bien que les précautions de sûreté générales suiv- prévenir tout risque dʼincendie dû aux étincelles
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v v SAFETY 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). It was manufactured in conformity with a national standard that implements a harmonized standard: EN 60974-10 Electromagnetic Compatibility (EMC) Product Standard for Arc Welding Equipment. It is for use with other Lincoln El
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vi vi SAFETY 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. Methods of Reducing Emissions Mains Supply Welding equipment should be connected to the mains supply according to the manufacturerʼs recommenda- tions. If interference occurs, it may be necessary to take additional precautions such as filter
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vii vii for selecting a QUALITY product by Lincoln Electric. We want you to take pride in operating this Lincoln Electric Company product Thank You ••• as much pride as we have in bringing this product to you! CUSTOMER ASSISTANCE POLICY The business of The Lincoln Electric Company is manufacturing and selling high quality welding equipment, consumables, and cutting equip- ment. Our challenge is to meet the needs of our customers and to exceed their expectations. On occasion, purchasers may ask L
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viii viii TABLE OF CONTENTS Page Installation .......................................................................................................Section A Technical Specifications - POWER WAVE® i400..........................................A-1, A-2 Safety Precautions.................................................................................................A-3 Location and Mounting ..........................................................................................A-3 Environmenta
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A-1 A-1 INSTALLATION TECHNICAL SPECIFICATIONS - POWER WAVE® i400 (K2669-2, K2673-2) JAPANESE POWER SOURCES - INPUT VOLTAGE AND CURRENT Model Duty Cycle Input Voltage ± 10% Input Amperes Power Factor @ Idle Power Rated Output (incl. robot and aux. load) 40% rating 66 K2669-2 (86) 200/208 60% rating 61 475 Watts 3 phase 50/60 Hz K2673-2 (81) Max. .80 (Chassis Only) 100% rating 50 (fan on) (70) RATED OUTPUT Process Duty Cycle Volts at Rated Amperes Amperes 40% 35 420 GMAW GMAW-Pulse 60% 34 400
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A-2 A-2 INSTALLATION TECHNICAL SPECIFICATIONS - POWER WAVE® i400 (K2669-2, K2673-2) REGULATORY REQUIREMENTS (JAPANESE MODELS) MODEL Standard Enclosure Insulation Rating Class K2669-2 EN 60974-1 Class F IP21S EN 50199 (155°C) 3 K2673-2 (Chassis Only) 3 Chassis ratings applicable only when installed as a replacement in the POWER WAVE® i400 cabinet. POWER WAVE® i400
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A-3 A-3 INSTALLATION • Dirt and dust that can be drawn into the POWER SAFETY PRECAUTIONS WAVE® i400 should be kept to a minimum. The Read this entire installation section before you use of air filters on the air intake is not recommend- ed because normal air flow may be restricted. start installation. Failure to observe these precautions can result in WARNING excessive operating temperatures and nuisance shutdown. ELECTRIC SHOCK can kill. • Do not use the POWER WAVE® i400 in an outdoor • Onl
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A-4 A-4 INSTALLATION Choose input and grounding wire size according to local or ELECTROMAGNETIC COMPATIBILITY (EMC) national electrical codes. Using input wire sizes, fuses or circuit breakers smaller than recommended may result in The EMC classification of the POWER WAVE® i400 is "nuisance" shut-offs from welder inrush currents, even if the Industrial, Scientific and Medical (ISM) group 2, class A. The machine is not being used at high currents. POWER WAVE® i400 is for industrial use only.
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A-5 A-5 INSTALLATION CONNECTION DIAGRAMS AND SYSTEM RECOMMENDED EQUIPMENT System Part No. Description Identifier POWER WAVE® i400 Power Source Power Source K2669-1 (includes S26064 POWER WAVE® Utilities CD) Integration Kit K2677-1 Integration Kit for Fanuc R30iA Controller. Includes industrial ethernet cable, power cable, protective grommets, mounting plate, and dust proof strain relief. Wire Drive K2685-2 AutoDrive 4R90 Wire Drive Power Source to Wire Drive 1 Feeder Control Cable (14 pin).
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A-6 A-6 INSTALLATION OPTIONAL EQUIPMENT System Part No. Description Identifier Coax Cable. Recommended to minimize the effects of the weld cable loop inductance and maximize perfor- K1796-xx mance in critical high speed pulse applications. Note: K1796 coaxial cable is equivalent to 1/0 standard cable. K2539 coaxial cable is equivalent to AWG #1 Coaxial Weld Cable standard cable. Connecting coaxial cables in parallel to increase current carrying capacity can significantly K2593-xx reduce their
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A-7 A-7 INSTALLATION FANUC R30iA CONTROLLER MOUNTING FANUC Robotics R-30iA "a-cabinet" Controller with Integrated Op Box * ArcLink XT Ethernet cable * Power cable Power Wave i400 K2669-2 ** DETAIL A A R O * Refer to Output Cable guidelines for recommended cable size in PowerWave i400 Instruction Manual. ** Refer to Intergration kit K2677-1 instruction sheet POWER WAVE® i400
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A-8 A-8 INSTALLATION TYPICAL INTEGRATED SYSTEMS (SINGLE ARM) POWER WAVE® i400 Electrode Connection AutoDrive 4R90 K2685-2 FANUC Robotics R-30iA "a-cabinet" Controller with Integrated Op Box Wire Feeder Gas ArcLink XT Ethernet Cable Air Circuit Breaker (Internal) (15 Amp) Devicenet Connector ARC Mate 1XXiC * Electrode Power Wave i400 Cable (+) K2669-2 K2163-xx or K1842-xx Optional Work Wire Feeder Sense Lead (21) Connector Voltage Sense Wire Feeder Connector Control Cable K1785-XX Work A
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A-9 A-9 INSTALLATION TYPICAL STAND ALONE SYSTEMS (SINGLE ARM) POWER WAVE® i400 Electrode Connection AutoDrive 4R90 K2685-2 FANUC Robotics R-30iA "a-cabinet" Controller with Integrated Op Box Wire Feeder Gas Air ARC Mate 1XXiC Circuit Breaker ArcLink XT (15 Amp) Ethernet Cable Devicenet Connector * Electrode Cable (+) Power Wave i400 K2163-xx or K2669-2 K1842-xx Optional Work Wire Feeder Sense Lead (21) Connector Voltage Sense Connector Work Wire Feeder Piece ArcLink Control cable Con
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A-10 A-10 INSTALLATION TYPICAL MASTER / SLAVE SYSTEM (DUAL ARM) POWER WAVE® i400 AutoDrive 4R90 Electrode K2685-2 Connection FANUC Robotics R-30iA "a-cabinet" Controller with Integrated Op Box AutoDrive 4R90 (Slave) K2685-2 Wire Feeder ArcLink XT Control Cable Gas ARC Mate 1XXiC (Slave) FANUC Robotics R-30iA Air "a-cabinet" Controller with Integrated Op Box (Master) * Electrode Cable (+) Power Wave i400 K2669-2 Circuit Breaker (15 Amp) ARC Mate 1XXiC Optional Work (Master) Sense Lead (21)
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A-11 A-11 INSTALLATION TYPICAL F355i RETROFIT (SINGLE ARM) POWER WAVE® i400 FANUC Robotics R-J3iB Controller Gas Air Power Feed 10R K1780-2 18" Adapter Cable K1785-2 Electrode Connection Wire Feeder ARC Mate 1XXiBe Air Robotic ArcLink Torch Control Cable K1543-XX Power Wave i400 Circuit Breaker Gas K2669-2 (15 Amp) Wire Feeder Devicenet * Electrode Connector Cable (+) K2163-xx or K1842-xx Optional Work Sense Lead (21) Wire Feeder Control Cable K1785-XX Work Piece Wire Feeder Connector
