Manuel d'utilisation / d'entretien du produit IM986 du fabricant 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.
ARC RA YS can burn. 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. 4. b.
FOR ELECTRICALL Y powered 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 manufacturerʼs recommendations.
Mar. ʻ93 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 LʼArc 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 Thank You 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 (K2669-2, K2673-2) RA TED OUTPUT RECOMMENDED INPUT WIRE AND FUSE SIZES 1 PHYSICAL DIMENSIONS TEMPERA TURE RANGES 3 PHASE INPUT VOLTAGE 50/60Hz 200/208 3 Input Amperes (incl.
A-2 INST ALLA TION POWER WAVE® i400 A-2 TECHNICAL SPECIFICA TIONS - POWER W A VE® i400 (K2669-2, K2673-2) 3 Chassis ratings applicable only when installed as a replacement in the POWER WAVE® i400 cabinet.
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 controllerʼs 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 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-6 INST ALLA TION POWER WAVE i400 A-6 System Identifier Coaxial Weld Cable External Dress Cable for Robot Arm Personal Computer Replacement Chassis Part No .
A-7 INST ALLA TION POWER WAVE® i400 A-7 FANUC R30iA CONTROLLER MOUNTING FANU C Robotics R-30i A "a-cabinet" C ontroller with Integrat ed Op Box Power W ave i400 K2669-2 * ArcLink XT Ethernet cab le * Power cable DETAI L A A * Refer to Output Cable guidelines for recommended cable si ze in PowerWave i400 Instruction Manua l .
A-8 INST ALLA TION POWER WAVE® i400 A-8 TYPICAL INTEGRATED SYSTEMS (SINGLE ARM) ArcL ink X T Ethernet Connection Voltage Sens e Connec t or Wire Feeder Connector Power W ave i4 00 K2669-2 Optional Wo.
A-9 INST ALLA TION POWER WAVE® i400 A-9 TYPICAL STAND ALONE SYSTEMS (SINGLE ARM) Device net Connector Wire Feeder Connector Circuit Bre aker (15 Amp) ArcL ink XT Ethernet Connec t o r Voltage Sense C.
A-10 INST ALLA TION POWER WAVE® i400 A-10 TYPICAL MASTER / SLAVE SYSTEM (DUAL ARM) FANU C Robotics R-30i A "a-cabinet" Co ntroller with Integ rated Op Box (Master) FANU C Robotics R-30iA &q.
A-11 INST ALLA TION POWER WAVE® i400 A-11 TYPICAL F355i RETROFIT (SINGLE ARM) Power W ave i400 K2669-2 FANU C Robotics R-J 3iB Contro ller * Electrode Cable (+) K2163-xx or K1842-xx Optiona l Work Se.
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-13 INST ALLA TION POWER WAVE® i400 A-13 General Guidelines for Voltage Sense Leads Sense leads should be attached as close to the weld as practical, and out of the weld current 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 remote 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 CDʼs or available at www.
A-15 INST ALLA TION POWER WAVE® i400 A-15 • 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-16 INST ALLA TION POWER WAVE® i400 A-16 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-17 INST ALLA TION POWER WAVE® i400 A-17 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 using 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 POWER WAVE® i400 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. FUSE (F1): Primary circuit protection for auxiliary power (10A/600V). 2. ROBOT POWER TERMINAL BLOCK (4TB): Power sup- ply connection for Fanuc R30iA controller. Supplies pri- mary power through the ON/OFF switch directly to the robot controller.
B-7 OPERA TION B-7 POWER WAVE® i400 Choose the electrode material, electrode size, shield- ing gas, and process (GMAW, GMAW-P etc.) appro- priate for the material to be welded.
B-8 OPERA TION POWER WAVE® i400 B-8 Pulse welding modes are synergic; 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.
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 K2685-2 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 G6044 A.01 20.34 19.49 21.54 21.46 23.62 22.74 20.99 18.81 21.54 ISO VIEW REFERENCE ONLY 25.05 DETAIL VIEW OF CHASSIS REMOVED FROM CA BI NET 24.
NOTES POWER WAVE® i400.
W ARNING AV I S O D E 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 AV I S O D E 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 point important après l'achat de l'appareil (ou même avant l'achat) est de lire le manuel d'utilisation. Nous devons le faire pour quelques raisons simples:
Si vous n'avez pas encore acheté Lincoln Electric IM986 c'est un bon moment pour vous familiariser avec les données de base sur le produit. Consulter d'abord les pages initiales du manuel d'utilisation, que vous trouverez ci-dessus. Vous devriez y trouver les données techniques les plus importants du Lincoln Electric IM986 - de cette manière, vous pouvez vérifier si l'équipement répond à vos besoins. Explorant les pages suivantes du manuel d'utilisation Lincoln Electric IM986, vous apprendrez toutes les caractéristiques du produit et des informations sur son fonctionnement. Les informations sur le Lincoln Electric IM986 va certainement vous aider à prendre une décision concernant l'achat.
Dans une situation où vous avez déjà le Lincoln Electric IM986, mais vous avez pas encore lu le manuel d'utilisation, vous devez le faire pour les raisons décrites ci-dessus,. Vous saurez alors si vous avez correctement utilisé les fonctions disponibles, et si vous avez commis des erreurs qui peuvent réduire la durée de vie du Lincoln Electric IM986.
Cependant, l'un des rôles les plus importants pour l'utilisateur joués par les manuels d'utilisateur est d'aider à résoudre les problèmes concernant le Lincoln Electric IM986. Presque toujours, vous y trouverez Troubleshooting, soit les pannes et les défaillances les plus fréquentes de l'apparei Lincoln Electric IM986 ainsi que les instructions sur la façon de les résoudre. Même si vous ne parvenez pas à résoudre le problème, le manuel d‘utilisation va vous montrer le chemin d'une nouvelle procédure – le contact avec le centre de service à la clientèle ou le service le plus proche.
