IM10465 Power Wave i400 - Welders, Welding Wire, Welding

Operator’s Manual

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IM10465 | Issue D ate Feb-18

© Lincoln Global, Inc. All Rights Reserved.

For use with machines having Code Numbers:

12800

Save for future reference

Date Purchased

Code: (ex: 10859)

Serial: (ex: U1060512345)

Power Wave ® i400

Need Help? Call 1.888.935.3877 to talk to a Service Representative

Hours of Operation: 8:00 AM to 6:00 PM (ET) Mon. thru Fri.

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For Service outside the USA: Email: [email protected]

THANK YOU FOR SELECTING A QUALITY PRODUCT BY LINCOLN ELEC TRIC.

PLEASE EXAMINE CARTON AND EQUIPMENT FORDAMAGE IMMEDIATELY

When this equipment is shipped, title passes to the purchaserupon receipt by the carrier. Consequently, claims for materialdamaged in shipment must be made by the purchaser against thetransportation company at the time the shipment is received.

SAFETY DEPENDS ON YOU

Lincoln arc welding and cutting equipment is designed and builtwith safety in mind. However, your overall safety can be increasedby proper installation ... and thoughtful operation on your part. DO NOT INSTALL, OPERATE OR REPAIR THIS EQUIPMENT WITHOUT READING THIS MANUAL AND THE SAFETYPRECAUTIONS CONTAINED THROUGHOUT. And, most importantly,think before you act and be careful.

This statement appears where the information must be followedexactly to avoid serious personal injury or loss of life.

This statement appears where the information must be followedto avoid minor personal injury or damage to this equipment.

KEEP YOUR HEAD OUT OF THE FUMES.

DON’T get too close to the arc.Use corrective lenses if necessaryto stay a reasonable distanceaway from the arc.

READ and obey the Safety DataSheet (SDS) and the warning labelthat appears on all containers ofwelding materials.

USE ENOUGH VENTILATION orexhaust at the arc, or both, tokeep the fumes and gases from your breathing zone and the general area.

IN A LARGE ROOM OR OUTDOORS, natural ventilation may beadequate if you keep your head out of the fumes (See below).

USE NATURAL DRAFTS or fans to keep the fumes away from your face.

If you de velop unusual symptoms, see your supervisor. Perhaps the welding atmosphere and ventilation system should be checked.

WEAR CORRECT EYE, EAR & BODY PROTECTION

PROTECT your eyes and face with welding helmetproperly fitted and with proper grade of filter plate(See ANSI Z49.1).

PROTECT your body from welding spatter and arcflash with protective clothing including woolenclothing, flame-proof apron and gloves, leatherleggings, and high boots.

PROTECT others from splatter, flash, and glarewith protective screens or barriers.

IN SOME AREAS, protection from noise may be appropriate.

BE SURE protective equipment is in good condition.

Also, wear safety glasses in work areaAT ALL TIMES.

SPECIAL SITUATIONS

DO NOT WELD OR CUT containers or materials which previouslyhad been in contact with hazardous substances unless they areproperly cleaned. This is extremely dangerous.

DO NOT WELD OR CUT painted or plated parts unless specialprecautions with ventilation have been taken. They can releasehighly toxic fumes or gases.

Additional precautionary measures

PROTECT compressed gas cylinders from excessive heat,mechanical shocks, and arcs; fasten cylinders so they cannot fall.

BE SURE cylinders are never grounded or part of an electrical circuit.

REMOVE all potential fire hazards from welding area.

ALWAYS HAVE FIRE FIGHTING EQUIPMENT READY FORIMMEDIATE USE AND KNOW HOW TO USE IT.

WARNING

CAUTION

Safety 01 of 04 - 5/16/2018

SECTION A:WARNINGS

CALIFORNIA PROPOSITION 65 WARNINGS

WARNING: Breathing diesel engine exhaustexposes you to chemicals known to the Stateof California to cause cancer and birth defects,

or other reproductive harm.• Always start and operate the engine in a

well-ventilated area.• If in an exposed area, vent the exhaust to the outside.• Do not modify or tamper with the exhaust system. • Do not idle the engine except as necessary.For more information go to www.P65 warnings.ca.gov/diesel

WARNING: This product, when used for welding or

cutting, produces fumes or gases which contain

chemicals known to the State of California to cause

birth defects and, in some cases, cancer. (California

Health & Safety Code § 25249.5 et seq.)

WARNING: Cancer and Reproductive Harm

www.P65warnings.ca.gov

ARC WELDING CAN BE HAZARDOUS. PROTECTYOURSELF AND OTHERS FROM POSSIBLE SERIOUSINJURY OR DEATH. KEEP CHILDREN AWAY. PACEMAKER WEARERS SHOULD CONSULT WITHTHEIR DOCTOR BEFORE OPERATING.

Read and understand the following safety highlights. Foradditional safety information, it is strongly recommended that you purchase a copy of “Safety in Welding & Cutting - ANSI Standard Z49.1” from the American Welding Society, P.O. Box 351040, Miami, Florida 33135 or CSA Standard W117.2-1974. A Free copy of “Arc Welding Safety” booklet E205 is available from the Lincoln Electric Company, 22801 St. Clair Avenue, Cleveland, Ohio 44117-1199.

BE SURE THAT ALL INSTALLATION, OPERATION,MAINTENANCE AND REPAIR PROCEDURES AREPERFORMED ONLY BY QUALIFIED INDIVIDUALS.

FOR ENGINE POWEREDEQUIPMENT.

1.a. Turn the engine off before troubleshootingand maintenance work unless themaintenance work requires it to be running.

1.b. Operate engines in open, well-ventilated areas or vent the engineexhaust fumes outdoors.

1.c. Do not add the fuel near an open flame weldingarc or when the engine is running. Stop theengine and allow it to cool before refueling toprevent spilled fuel from vaporizing on contact

with hot engine parts and igniting. Do not spill fuel when fillingtank. If fuel is spilled, wipe it up and do not start engine untilfumes have been eliminated.

1.d. Keep all equipment safety guards, covers and devices in position and in good repair.Keep hands, hair, clothing and tools away from V-belts, gears, fans and all other moving parts when starting, operating orrepairing equipment.

1.e. In some cases it may be necessary to remove safety guards toperform required maintenance. Remove guards only whennecessary and replace them when the maintenance requiringtheir removal is complete. Always use the greatest care whenworking near moving parts.

1.f. Do not put your hands near the engine fan. Do not attempt tooverride the governor or idler by pushing on the throttle controlrods while the engine is running.

1.g. To prevent accidentally starting gasoline engines while turningthe engine or welding generator during maintenance work,disconnect the spark plug wires, distributor cap or magneto wireas appropriate.

1.h. To avoid scalding, do not remove the radiatorpressure cap when the engine is hot.

ELECTRIC ANDMAGNETIC FIELDS MAYBE DANGEROUS

2.a. Electric current flowing through any conductorcauses localized Electric and Magnetic Fields (EMF). Welding current creates EMF fields around welding cables and welding machines

2.b. EMF fields may interfere with some pacemakers, and welders having a pacemaker should consult their physicianbefore welding.

2.c. Exposure to EMF fields in welding may have other health effectswhich are now not known.

2.d. All welders should use the following procedures in order tominimize exposure to EMF fields from the welding circuit:

2.d.1. Route the electrode and work cables together - Securethem with tape when possible.

2.d.2. Never coil the electrode lead around your body.

2.d.3. Do not place your body between the electrode and workcables. If the electrode cable is on your right side, thework cable should also be on your right side.

2.d.4. Connect the work cable to the workpiece as close as pos-sible to the area being welded.

2.d.5. Do not work next to welding power source.

SAFETY

Safety 02 of 04 - 5/16/2018

ELECTRIC SHOCK CAN KILL.

3.a. The electrode and work (or ground) circuits areelectrically “hot” when the welder is on. Donot touch these “hot” parts with your bare skin or wet clothing.Wear dry, hole-free gloves to insulate hands.

3.b. Insulate yourself from work and ground using dry insulation.Make certain the insulation is large enough to cover your full areaof physical contact with work and ground.

In addition to the normal safety precautions, if

welding must be performed under electrically

hazardous conditions (in damp locations or while

wearing wet clothing; on metal structures such as

floors, gratings or scaffolds; when in cramped

positions such as sitting, kneeling or lying, if there

is a high risk of unavoidable or accidental contact

with the workpiece or ground) use the following

equipment:

• Semiautomatic DC Constant Voltage (Wire) Welder.

• DC Manual (Stick) Welder.

• AC Welder with Reduced Voltage Control.

3.c. In semiautomatic or automatic wire welding, the electrode,electrode reel, welding head, nozzle or semiautomatic weldinggun are also electrically “hot”.

3.d. Always be sure the work cable makes a good electricalconnection with the metal being welded. The connection shouldbe as close as possible to the area being welded.

3.e. Ground the work or metal to be welded to a good electrical (earth)ground.

3.f. Maintain the electrode holder, work clamp, welding cable andwelding machine in good, safe operating condition. Replacedamaged insulation.

3.g. Never dip the electrode in water for cooling.

3.h. Never simultaneously touch electrically “hot” parts of electrodeholders connected to two welders because voltage between thetwo can be the total of the open circuit voltage of bothwelders.

3.i. When working above floor level, use a safety belt to protectyourself from a fall should you get a shock.

3.j. Also see It ems 6.c. and 8.

ARC RAYS CAN BURN.

4.a. Use a shield with the proper filter and cover plates to protect youreyes from sparks and the rays of the arc when welding orobserving open arc welding. Headshield and filter lens shouldconform to ANSI Z87. I standards.

4.b. Use suitable clothing made from durable flame-resistant materialto protect your skin and that of your helpers from the arc rays.

4.c. Protect other nearby personnel with suitable, non-flammablescreening and/or warn them not to watch the arc nor exposethemselves to the arc rays or to hot spatter or metal.

FUMES AND GASESCAN BE DANGEROUS.

5.a. Welding may produce fumes and gaseshazardous to health. Avoid breathing thesefumes and gases. When welding, keep your head out of the fume.Use enough ventilation and/or exhaust at the arc to keep fumesand gases away from the breathing zone. When welding

hardfacing (see instructions on container or SDS)

or on lead or cadmium plated steel and other

metals or coatings which produce highly toxic

fumes, keep exposure as low as possible and

within applicable OSHA PEL and ACGIH TLV limits

using local exhaust or mechanical ventilation

unless exposure assessments indicate otherwise.

In confined spaces or in some circumstances,

outdoors, a respirator may also be required.

Additional precautions are also required when

welding

on galvanized steel.

5. b. The operation of welding fume control equipment is affected byvarious factors including proper use and positioning of theequipment, maintenance of the equipment and the specificwelding procedure and application involved. Worker exposurelevel should be checked upon installation and periodicallythereafter to be certain it is within applicable OSHA PEL andACGIH TLV limits.

5.c. Do not weld in locations near chlorinated hydrocarbon vaporscoming from degreasing, cleaning or spraying operations. Theheat and rays of the arc can react with solvent vapors to formphosgene, a highly toxic gas, and other irritating products.

5.d. Shielding gases used for arc welding can displace air and causeinjury or death. Always use enough ventilation, especially inconfined areas, to insure breathing air is safe.

5.e. Read and understand the manufacturer’s instructions for thisequipment and the consumables to be used, including theSafety Data Sheet (SDS) and follow your employer’s safetypractices. SDS forms are available from your weldingdistributor or from the manufacturer.

5.f. Also see item 1.b.

SAFETY

Safety 03 of 04 - 5/16/2018

WELDING AND CUTTINGSPARKS CAN CAUSEFIRE OR EXPLOSION.

6.a. Remove fire hazards from the welding area. Ifthis is not possible, cover them to prevent the welding sparksfrom starting a fire. Remember that welding sparks and hotmaterials from welding can easily go through small cracks andopenings to adjacent areas. Avoid welding near hydraulic lines.Have a fire extinguisher readily available.

6.b. Where compressed gases are to be used at the job site, specialprecautions should be used to prevent hazardous situations.Refer to “Safety in Welding and Cutting” (ANSI Standard Z49.1)and the operating information for the equipment being used.

6.c. When not welding, make certain no part of the electrode circuit istouching the work or ground. Accidental contact can causeoverheating and create a fire hazard.

6.d. Do not heat, cut or weld tanks, drums or containers until theproper steps have been taken to insure that such procedures will not cause flammable or toxic vapors from substances inside.They can cause an explosion even though they have been“cleaned”. For information, purchase “Recommended SafePractices for the Preparation for Welding and Cutting ofContainers and Piping That Have Held Hazardous Substances”,AWS F4.1 from the American Welding Society (see address above).

6.e. Vent hollow castings or containers before heating, cutting orwelding. They may explode.

6.f. Sparks and spatter are thrown from the welding arc. Wear oil freeprotective garments such as leather gloves, heavy shirt, cufflesstrousers, high shoes and a cap over your hair. Wear ear plugswhen welding out of position or in confined places. Always wearsafety glasses with side shields when in a welding area.

6.g. Connect the work cable to the work as close to the welding areaas practical. Work cables connected to the building framework orother locations away from the welding area increase thepossibility of the welding current passing through lifting chains,crane cables or other alternate circuits. This can create firehazards or overheat lifting chains or cables until they fail.

6.h. Also see item 1.c.

6.I. Read and follow NFPA 51B “Standard for Fire Prevention DuringWelding, Cutting and Other Hot Work”, available from NFPA, 1Batterymarch Park, PO box 9101, Quincy, MA 022690-9101.

6.j. Do not use a welding power source for pipe thawing.

CYLINDER MAY EXPLODE IFDAMAGED.

7.a. Use only compressed gas cylinders containingthe correct shielding gas for the process usedand properly operating regulators designed forthe gas and pressure used. All hoses, fittings,etc. should be suitable for the application andmaintained in good condition.

7.b. Always keep cylinders in an upright position securely chained toan undercarriage or fixed support.

7.c. Cylinders should be located:

• Away from areas where they may be struck or subjectedto physical damage.

• A safe distance from arc welding or cutting operationsand any other source of heat, sparks, or flame.

7.d. Never allow the electrode, electrode holder or any otherelectrically “hot” parts to touch a cylinder.

7.e. Keep your head and face away from the cylinder valve outletwhen opening the cylinder valve.

7.f. Valve protection caps should always be in place and hand tightexcept when the cylinder is in use or connected for use.

7.g. Read and follow the instructions on compressed gas cylinders,associated equipment, and CGA publication P-l, “Precautions forSafe Handling of Compressed Gases in Cylinders,” available fromthe Compressed Gas Association, 14501 George Carter WayChantilly, VA 20151.

FOR ELECTRICALLYPOWERED EQUIPMENT.

8.a. Turn off input power using the disconnectswitch at the fuse box before working on the equipment.

8.b. Install equipment in accordance with the U.S. National ElectricalCode, all local codes and the manufacturer’s recommendations.

8.c. Ground the equipment in accordance with the U.S. NationalElectrical Code and the manufacturer’s recommendations.

Refer to

http://www.lincolnelectric.com/safety

for additional safety information.

SAFETY

Safety 04 of 04 - 5/16/2018

vSAFETYv

Electromagnetic Compatibility (EMC)

ConformanceProducts displaying the CE mark are in conformity with European Community Council Directive of 15 Dec2004 on the approximation of the laws of the Member States relating to electromagnetic compatibility,2004/108/EC. It was manufactured in conformity with a national standard that implements a harmonizedstandard: EN 60974-10 Electromagnetic Compatibility (EMC) Product Standard for Arc Welding Equipment.It is for use with other Lincoln Electric equipment. It is designed for industrial and professional use.

IntroductionAll electrical equipment generates small amounts of electromagnetic emission. Electrical emission may betransmitted through power lines or radiated through space, similar to a radio transmitter. When emissionsare received by other equipment, electrical interference may result. Electrical emissions may affect manykinds of electrical equipment; other nearby welding equipment, radio and TV reception, numerical controlledmachines, telephone systems, computers, etc. Be aware that interference may result and extra precautionsmay be required when a welding power source is used in a domestic establishment.

Installation and UseThe user is responsible for installing and using the welding equipment according to the manufacturer’sinstructions. If electromagnetic disturbances are detected then it shall be the responsibility of the user of thewelding equipment to resolve the situation with the technical assistance of the manufacturer. In some casesthis remedial action may be as simple as earthing (grounding) the welding circuit, see Note. In other cases itcould involve construction of an electromagnetic screen enclosing the power source and the work completewith associated input filters. In all cases electromagnetic disturbances must be reduced to the point wherethey are no longer troublesome.

Note: The welding circuit may or may not be earthed for safety reasons according to nationalcodes. Changing the earthing arrangements should only be authorized by a person who iscompetent to access whether the changes will increase the risk of injury, e.g., by allowingparallel welding current return paths which may damage the earth circuits of other equipment.

Assessment of AreaBefore installing welding equipment the user shall make an assessment of potential electromagnetic prob-lems in the surrounding area. The following shall be taken into account:

a) other supply cables, control cables, signaling and telephone cables; above, below and adjacent to thewelding equipment;

b) radio and television transmitters and receivers;

c) computer and other control equipment;

d) safety critical equipment, e.g., guarding of industrial equipment;

e) the health of the people around, e.g., the use of pacemakers and hearing aids;

f) equipment used for calibration or measurement

g) the immunity of other equipment in the environment. The user shall ensure that other equipment beingused in the environment is compatible. This may require additional protection measures;

h) the time of day that welding or other activities are to be carried out.

viSAFETYvi

Electromagnetic Compatibility (EMC)

The size of the surrounding area to be considered will depend on the structure of the building and otheractivities that are taking place. The surrounding area may extend beyond the boundaries of the premises.

Methods of Reducing Emissions

Mains SupplyWelding equipment should be connected to the mains supply according to the manufacturer’s recommenda-tions. If interference occurs, it may be necessary to take additional precautions such as filtering of the mainssupply. Consideration should be given to shielding the supply cable of permanently installed welding equip-ment, in metallic conduit or equivalent. Shielding should be electrically continuous throughout its length. Theshielding should be connected to the welding power source so that good electrical contact is maintainedbetween the conduit and the welding power source enclosure.

Maintenance of the Welding EquipmentThe welding equipment should be routinely maintained according to the manufacturer’s recommendations.All access and service doors and covers should be closed and properly fastened when the welding equip-ment is in operation. The welding equipment should not be modified in any way except for those changesand adjustments covered in the manufacturers instructions. In particular, the spark gaps of arc striking andstabilizing devices should be adjusted and maintained according to the manufacturer’s recommendations.

Welding CablesThe welding cables should be kept as short as possible and should be positioned close together, running ator close to floor level.

Equipotential BondingBonding of all metallic components in the welding installation and adjacent to it should be considered.However, metallic components bonded to the work piece will increase the risk that the operator couldreceive a shock by touching these metallic components and the electrode at the same time. The operatorshould be insulated from all such bonded metallic components.

Earthing of the WorkpieceWhere the workpiece is not bonded to earth for electrical safety, not connected to earth because of its sizeand position, e.g., ships hull or building steelwork, a connection bonding the workpiece to earth may reduceemissions in some, but not all instances. Care should be taken to prevent the earthing of the workpieceincreasing the risk of injury to users, or damage to other electrical equipment. Where necessary, the connec-tion of the workpiece to earth should be made by a direct connection to the workpiece, but in some countrieswhere direct connection is not permitted, the bonding should be achieved by suitable capacitance, selectedaccording to national regulations.

Screening and ShieldingSelective screening and shielding of other cables and equipment in the surrounding area may alleviate prob-lems of interference. Screening of the entire welding installation may be considered for special applications1.

_________________________

1 Portions of the preceding text are contained in EN 60974-10: “Electromagnetic Compatibility (EMC) prod-uct standard for arc welding equipment.”

INSTALLATION .............................................................................................................................................SECTION ATECHNICAL SPECIFICATIONS - POWER WAVE® I400 (K3584-1).................................................................................A-1LOCATION AND MOUNTING........................................................................................................................................A-3ENVIRONMENTAL CONSIDERATIONS..........................................................................................................................A-3LIFTING ............................................................................................................................................................A-3STACKING ............................................................................................................................................................A-3ELECTROMAGNETIC COMPATIBILITY (EMC)................................................................................................................A-3INPUT AND GROUNDING CONNECTIONS.....................................................................................................................A-4CONNECTION DIAGRAMS AND SYSTEM .....................................................................................................................A-6OPTIONAL EQUIPMENT ..............................................................................................................................................A-7FANUC R30IA CONTROLLER MOUNTING.....................................................................................................................A-8TYPICAL INTEGRATED SYSTEMS (SINGLE ARM) .........................................................................................................A-9TYPICAL STAND ALONE SYSTEMS (SINGLE ARM).....................................................................................................A-10TYPICAL MASTER / SLAVE SYSTEM (DUAL ARM)......................................................................................................A-11TYPICAL F355I RETROFIT (SINGLE ARM) ..................................................................................................................A-12ELECTRODE AND WORK CONNECTIONS ..................................................................................................................A-13CABLE INDUCTANCE, AND ITS EFFECTS ON WELDING .............................................................................................A-14REMOTE SENSE LEAD CONNECTIONS......................................................................................................................A-14CONTROL CABLE CONNECTIONS .............................................................................................................................A-17COMMON EQUIPMENT CONNECTIONS .....................................................................................................................A-17OTHER SET-UP ISSUES............................................................................................................................................A-18

OPERATION ................................................................................................................................................SECTION BGRAPHIC SYMBOLS THAT APPEAR ON THIS MACHINE OR IN THIS MANUAL ...............................................................B-1PRODUCT DESCRIPTION ............................................................................................................................................B-2RECOMMENDED PROCESSES ....................................................................................................................................B-2PROCESS LIMITATIONS .............................................................................................................................................B-2EQUIPMENT LIMITATIONS..........................................................................................................................................B-2CASE FRONT CONTROL DESCRIPTION .......................................................................................................................B-3CASE BACK COMPONENTS DESCRIPTION ..................................................................................................................B-4INTERNAL CONTROLS................................................................................................................................................B-5POWER-UP SEQUENCE ..............................................................................................................................................B-5DUTY CYCLE ............................................................................................................................................................B-5COMMON WELDING PROCEDURES ............................................................................................................................B-6BASIC WELDING CONTROLS ......................................................................................................................................B-6CONSTANT VOLTAGE WELDING .................................................................................................................................B-7

OPTIONS / ACCESSORIES.............................................................................................................................SECTION CFACTORY INSTALLED.................................................................................................................................................C-1FIELD INSTALLED ......................................................................................................................................................C-1COMPATIBLE LINCOLN EQUIPMENT ..........................................................................................................................C-1

MAINTENANCE .............................................................................................................................................SECTION DROUTINE MAINTENANCE............................................................................................................................................D-1PERIODIC MAINTENANCE...........................................................................................................................................D-1CALIBRATION SPECIFICATION....................................................................................................................................D-1CHASSIS REMOVAL PROCEDURE ...............................................................................................................................D-1CAPACITOR DISCHARGE PROCEDURE ........................................................................................................................D-2

TROUBLESHOOTING......................................................................................................................................SECTION E

WIRING DIAGRAM AND DIMENSION PRINT..................................................................................................SECTION F

PARTS LIST ...............................................................................................................PARTS.LINCOLNELECTRIC.COMCONTENT/DETAILS MAY BE CHANGED OR UPDATED WITHOUT NOTICE. FOR MOST CURRENT INSTRUCTION MANUALS, GOTO PARTS.LINCOLNELECTRIC.COM.

4

TABLE OF CONTENTSPOWER WAVE® i400

A-1

INSTALLATIONPOWER WAVE® i400

TECHNICAL SPECIFICATIONS - POWER WAVE® i400 (K3584-1)

RATED OUTPUT

RECOMMENDED INPUT WIRE AND FUSE SIZES 1

PHYSICAL DIMENSIONS

TEMPERATURE RANGES

INPUT AT RATED OUTPUT - THREE PHASE ONLYModel

K3584-1

Duty Cycle

30% rating

60% rating

100% rating

3 PHASE INPUTVOLTAGE50/60Hz

208230380460575

Input Amperes

(incl. robot andaux. load)

53 (72)47 (64)28 (38)24 (32)19 (25)

HEIGHT

22.7 in. (577 mm)

MODEL

K3584-1

WIDTH

24.4 in. (620 mm)

DEPTH

21.5 in. (546 mm)

WEIGHT

209 lbs. (95 kg.)

Fuse (Super Lag) orBreaker Size 2

8070504030

COPPER GROUNDINGCONDUCTOR

AWG (mm2)8 (10)8 (10)10 (6)10 (6)10 (6)

Type 75°C CopperWire in Conduit

AWG (mm2) 4 (25)4 (25)8 (10)8 (10)10 (6)

Volts at Rated Amperes

34

31

29

Amperes

400

340

300

Duty Cycle

30%

60%

100%

Process

GMAWGMAW-Pulse

FCAWGTAW-DC

Input Amperes(incl. robot and

aux. load)53/47/28/24/19

(72/64/38/32/25)41/37/22/19/15

(60/54/32/27/22)34/31/18/16/13

(53/48/28/25/20)

Idle Power

475 WattsMax.

(fan on)

Power Factor @Rated Output

.95

Input Voltage ± 10%

208†/230/380*/460/5753 phase 50/60 Hz

(† includes 200V to 208V) (* includes 380V to 415V)

OPERATING TEMPERATURE RANGE14°F to 104°F (-10°C to 40°C)

STORAGE TEMPERATURE RANGE-40°F to 185°F(-40°C to 85°C)

1 Wire and Fuse Sizes based upon the U.S. National Electric Code and maximum output for 40°C (104°) ambient.2 Also called “inverse time” or “thermal/magnetic” circuit breakers; circuit breakers that have a delay in tripping action that decreases as the

magnitude of current increases.

A-2


TECHNICAL SPECIFICATIONS - POWER WAVE® i400 (K3584-1)

3 Chassis ratings applicable only when installed as a replacement in the POWER WAVE® i400 cabinet.

4 K2670-[ ] CE Filter Kit is required to meet CE and C-Tick conducted emission requirements.

REGULATORY REQUIREMENTSMarket

Europe

China

MODEL

K3584-1

Conformity Mark

CE4

C-Tick

CCC

Standard

EN 60974-1EN 50199

GB15579-1995

EnclosureRating

IP21S

InsulationClass

Class F(155°C)

A-3


INSTALLATIONRead this entire installation section before youstart installation.

ELECTRIC SHOCK can kill.• Only qualified personnel should perform

this installation.

• Turn the input power OFF at thedisconnect switch or fuse box beforeworking on this equipment. Turn off the input power toany other equipment connected to the welding systemat the disconnect switch or fuse box before working onthe equipment.

• Do not touch electrically hot parts.

• Always connect the POWER WAVE® grounding lug(located inside the reconnect input access door) to aproper safety (Earth) ground.

LOCATION AND MOUNTING

The POWER WAVE® i400 case is designed to support the FanucR30iA controller and op box (up to 300lbs), matching thecontroller’s footprint and styling. Mounting is externally accessiblefor simplified integration. The flexibility of the POWER WAVE®i400 also allows it to be operated as a stand alone unit. In eithercase, bolting the unit to the floor or a suitable platform isrecommended to provide maximum stability.The minimumrecommended clearance for chassis removal is 26” (66cm) fromthe rear of the machine as viewed from the output studs. See theChassis Removal Procedure for additional information.

DO NOT MOUNT OVER COMBUSTIBLE SURFACES. Where there is a combustible surface directly understationary or fixed electrical equipment, that surface shallbe covered with a steel plate at least .06”(1.6mm) thick,which shall extend not less than 5.90”(150mm) beyond theequipment on all sides.

Environmental Considerations

The POWER WAVE® i400 will operate in harsh environments.Even so, it is important that simple preventative measures arefollowed in order to assure long life and reliable operation.

• The POWER WAVE® i400 must be located where there is freecirculation of clean air such that air movement in the louveredsections of the machine will not be restricted.

• Dirt and dust that can be drawn into the POWER WAVE® i400should be kept to a minimum. The use of air filters on the airintake is not recommended because normal air flow may berestricted. Failure to observe these precautions can result inexcessive operating temperatures and nuisance shutdown.

• Do not use the POWER WAVE® i400 in an outdoorenvironment. The power source should not be subjected tofalling water, nor should any parts of it be submerged inwater. Doing so may cause improper operation as well aspose a safety hazard. The best practice is to keep themachine in a dry, sheltered area.

Lifting

FALLING EQUIPMENT can causeinjury.• Lift only with equipment of adequate lifting

capacity.

• Be sure machine is stable when lifting.

• Do not lift this machine using lift bail if it is equippedwith a heavy accessory such as trailer or gas cylinder.

• Do not lift machine if lift bail is damaged.

• Do not operate machine while suspended from lift bail.

POWER WAVE® i400: Lift the machine by the corner mounted liftbails only. Do not attempt to lift the POWER WAVE® i400 withaccessories attached to it.

POWER WAVE® i400 with the Fanuc R30iA Controller: Whenproperly mounted the complete integrated unit (power source andcontroller) can be lifted using the lift hooks provided on the FanucR30iA controller. Consult the Fanuc instruction manual for detailsand precautions.

NOTE: The POWER WAVE® i400 external corner mounted lift balesmust be removed when mounted to the Fanuc R30iAcontroller.

POWER WAVE® i400 Replacement Chassis: Lift the chassis by thelift bail on top of the harmonic filter assembly.

Stacking

The POWER WAVE® i400 cannot be stacked.

ELECTROMAGNETIC COMPATIBILITY (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 SafetyPages in the front of Instruction Manual for further details).

Locate the POWER WAVE® i400 away from radio controlledmachinery. The normal operation of the POWER WAVE® i400may adversely affect the operation of RF controlled equipment,which may result in bodily injury or damage to the equipment.

WARNING

CAUTION

WARNING

A-4


Input and Grounding ConnectionsMachine Grounding

The frame of the welder must be grounded. A ground terminalmarked with the symbol shown is located inside thereconnect/input access door for this purpose. See your local andnational electrical codes for proper grounding methods.

Input Connections

ELECTRIC SHOCK can kill.Only a qualified electrician should connectthe input leads to the POWER WAVE®.Connections should be made in accordancewith all local and National Electrical Codesand the connection diagram located on the inside of thereconnect / input access door of the machine. Failure to doso may result in bodily injury or death.

Use a three-phase supply line. A 1.75 inch (45 mm) diameteraccess hole for the input supply is located on the case back.Connect L1, L2, L3 and ground according to the input supply andground connection decals located near the input power terminalblock (1TB) and ground block inside of the rear input reconnectbox.

Input Fuse and Supply Wire Considerations

Refer to Specification in Installation Section for recommendedfuse, wire sizes and type of the copper wires. Fuse the inputcircuit with the recommended super lag fuse or delay typebreakers (also called "inverse time" or "thermal/magnetic" circuitbreakers).

Choose input and grounding wire size according to local ornational electrical codes. Using input wire sizes, fuses or circuitbreakers smaller than recommended may result in "nuisance"shut-offs from welder inrush currents, even if the machine is notbeing used at high currents.

Input Voltage Selection

(See Figure A.1)

The POWER WAVE® i400 is shipped connected for the highestinput voltage listed on the rating plate. To move this connection toa different input voltage, see the diagram located on the inside ofthe reconnect access door, also illustrated below. If the Auxiliarylead (indicated as ‘A’) is placed in the wrong position, there aretwo possible results. If the lead is placed in a position higher thanthe applied line voltage, the welder may not come on at all. If theAuxiliary lead is placed in a position lower than the applied linevoltage, the welder will not come on, and the fuse located in thereconnect area will open. If this occurs, turn off the input voltage,properly connect the auxiliary lead, replace the fuse, and tryagain.

Power Supply Connection for the Fanuc R30iAController

The POWER WAVE® i400 is equipped with a dedicated robotpower terminal block (4TB) specifically designed to feed inputpower directly to the Fanuc R30iA controller through the powersource rotary ON/OFF switch. The K2677-1 Integration kit providesthe proper cable and installations instructions to make thisconnection.

The POWER WAVE® i400 on/off switch is not intended as aservice disconnect for this equipment. Only a qualifiedelectrician should connect the input leads to the POWERWAVE®. Connections should be made in accordance withall local and national electrical codes and the connectiondiagram located on the inside of the reconnect access doorof the machine. Failure to do so may result in bodily injuryor death.

Do not attempt to back feed input power though the robotpower terminal block (4TB) into the POWER WAVE® i400.This is not its intended purpose and may result in machinedamage, bodily injury or death.

WARNINGWARNING

A-5


FIGURE A.1 - RECONNECT DIAGRAM FOR K3584-1 POWER WAVE® I400

A-6


CONNECTION DIAGRAMS AND SYSTEM

SystemIdentifier

Power Source

Integration Kit

Wire Drive

Power Sourceto Wire DriveControl Cable

Weld Cables

Robot ArmRobot Controller

Torch

Part No.

K3584-1

K2677-1

K2685-2

K1785-xx1

K2163-xx-or-

K1842-xx

KxxxxKxxxxKxxxx

Description

POWER WAVE® i400 Power Source(includes S26064 POWER WAVE® Utilities CD)

Integration Kit for Fanuc R30iA Controller. Includes industrial ethernet cable, powercable, protective grommets, mounting plate, and dust proof strain relief.

AutoDrive 4R90 Wire Drive

Feeder Control Cable (14 pin).

Welding Power CablesPower Source to Wire Drive,and Power Source to Work

K2163 Series cables sold in pairs.K1842 Series cables sold individually.

See Price Book for details and bulk cable availability.

Consult Automation Division

RECOMMENDED EQUIPMENT

SystemIdentifier

Sense Lead Kit

DeviceNet Kit

Sync-Tandem Kit

CE Filter Kit

ArcLink DigitalCommunication

Cable

External EthernetNetwork Equipment

DeviceNet Cablesand Accessories

Part No.

K940-xx

K2780-1

K2781-1

K2670-1

K1543-xx2

K2683-xx2

ConsultAutomation

Division

CustomerSupplied

Description

Remote Sense Lead Kit. Recommended for sensitive or critical applications to more accurately monitor thearc voltage.

DeviceNet Kit. Allows Power Wave i400 to communicate via DeviceNet protocol.

Sync-Tandem Kit. Allows two Power Wave i400s to perform synchronized tandem pulse welding. Includes allnecessary harnesses and cabling for 2 machines. Also provides access to special Sync-Tandem welding soft-ware.

CE Filter Kit. Required to meet CE and C-Tick conducted emission requirements. Input voltage limited to380-415/3/50/60 with kit installed

ArcLink Control Cable (5 pin). Required for earlier controllers communicating via traditional ArcLink® over astandard 2 wire CAN based network.K2683 Recommended on Sever Duty application.

Ethernet Switch, Cables, etc. Required for external Ethernet system connectivity typically associated withmultiple arm or multiple power source applications.

DeviceNet Cables, Tees, and Terminators (5 pin sealed "mini style") Typically required for PLC or earliermodel controllers communicating via DeviceNet.For additional information refer to the “DeviceNet Cable Planning and Installation Manual” (Allen Bradley pub-

OPTIONAL EQUIPMENT

1 Maximum length 100 ft.(30.5 m) Cannot be connected end to end.

2 Cables can be connected end to end to extend length (recommended maximum 200 ft [61.0m]).

A-7


Optional EquipmentSystem

Identifier

Coaxial Weld Cable

External DressCable for Robot

Arm

Personal Computer

Part No.

K1796-xx

K2593-xx

K2709-xx

CustomerSupplied

Description

Coax Cable. Recommended to minimize the effects of the weld cable loop inductance and maximize perfor-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 #1standard cable. Connecting coaxial cables in parallel to increase current carrying capacity can significantlyreduce their inductance minimizing properties, and is therefore NOT RECOMMENDED. Consult the OutputCable Guidelines for further information.

External Dress Cable. Heavy duty externally mounted 14pin wire feeder cable for use with robot arms notequipped with an integral cable.

IBM Compatible PC (Windows NT SP6, Windows 2000, Windows XP, or greater) required for use with allPOWER WAVE® Utilities

A-8


Fanuc R30iA Controller Mounting

FANUC Robotics R-30iA "a-cabinet" Controller with Integrated Op Box

Power Wave i400K3584-1

* ArcLink XTEthernet cable

* Powercable

DETAIL A

A

* Refer to Output Cable guidelines for recommended cable size in PowerWave i400 Instruction Manual.

** Refer to Intergration kit K2677-1 instruction sheet

**

OR

A-9


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A-10


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A-11


Typical Master / Slave System (Dual Arm)

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A-12


Typical F355i Retrofit (Single Arm)

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A-13


ELECTRODE AND WORK CONNECTIONS

Connect the electrode and work cables between the appropriateoutput studs of the POWER WAVE® i400 and the robot weld cellper the connection diagrams included in this document. Size androute the cables per the following.

• Most welding applications run with the electrode beingpositive (+). For those applications, connect the electrodecable between the wire drive feed plate and the positive (+)output stud on the power source. Connect a work lead fromthe negative (-) power source output stud to the work piece.

• When negative electrode polarity is required, such as in someInnershield applications, reverse the output connections atthe power source (electrode cable to the negative (-) stud,and work cable to the positive (+) stud).

Negative electrode polarity operation WITHOUT use of aremote work sense lead (21) requires the Negative ElectrodePolarity attribute to be set. See the Remote Sense LeadSpecification section of this document for further details.

For additional Safety information regarding the electrode and workcable set-up, See the standard “SAFETY INFORMATION” located inthe front of this Instruction Manual.

General Guidelines

• Select the appropriate size cables per the “Output CableGuidelines” in Table A.1. Excessive voltage drops caused byundersized welding cables and poor connections often resultin unsatisfactory welding performance. Always use thelargest 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 undersizedcables and/or bad connections.

• Route all cables directly to the work and wire feeder, avoidexcessive lengths and do not coil excess cable. Route theelectrode and work cables in close proximity to one anotherto minimize the loop area and therefore the inductance of theweld circuit.

• Always weld in a direction away from the work (ground)connection.

In Table A.1 are copper cable sizes recommended for differentcurrents and duty cycles. Lengths stipulated are the distancefrom the welder to work and back to the welder again. Cablesizes are increased for greater lengths primarily for the purpose ofminimizing cable drop.

CAUTION

OUTPUT CABLE GUIDELINESTABLE A.1

CABLE SIZES FOR COMBINED LENGTHS OF ELECTRODE AND WORK CABLES(RUBBER COVERED COPPER - RATED 75°C)**

PercentDutyCycle

6010020

40 & 3030406010060100606010060

22

4 or 5332111

2/01/02/03/02/0

223332111

2/01/02/03/02/0

222221111

2/02/02/03/03/0

11111111

1/02/02/03/03/03/0

1/01/01/01/01/01/01/01/02/03/03/04/04/04/0

200200225225250250250250300325350400400500

Amperes

0 to 50 Ft. 50 to 100 Ft. 100 to 150 Ft. 150 to 200 Ft. 200 to 250 Ft.

** Tabled values are for operation at ambient temperatures of 40°C and below. Applications above 40°C may require cables larger thanrecommended, or cables rated higher than 75°C.

A-14


CABLE INDUCTANCE, AND ITS EFFECTS ON WELD-ING

Excessive cable inductance will cause the welding performance todegrade. There are several factors that contribute to the overallinductance of the cabling system including cable size, and looparea. The loop area is defined by the separation distance betweenthe electrode and work cables, and the overall welding looplength. The welding loop length is defined as the total of length ofthe electrode cable (A) + work cable (B) + work path (C) (seeFigure A.2). To minimize inductance always use the appropriatesize cables, and whenever possible, run the electrode and workcables in close proximity to one another to minimize the loop area.Since the most significant factor in cable inductance is thewelding loop length, avoid excessive lengths and do not coilexcess cable. For long work piece lengths, a sliding ground shouldbe considered to keep the total welding loop length as short aspossible.

REMOTE SENSE LEAD CONNECTIONSVoltage Sensing Overview

The best arc performance occurs when the POWER WAVE® i400has accurate data about the arc conditions. Depending upon theprocess, inductance within the electrode and work cables caninfluence the voltage apparent at the studs of the welder, andhave a dramatic effect on performance. Remote voltage senseleads are used to improve the accuracy of the arc voltageinformation supplied to the control pc board. Sense Lead Kits(K940-xx) are available for this purpose.

If the remote voltage sensing is enabled but the sense leadsare missing, improperly connected, or if the electrodepolarity attribute is improperly configured extremely highwelding outputs may occur.

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 extremelysensitive applications it may be necessary to route cables thatcontain the sense leads away from the electrode and workwelding cables.

Voltage sense leads requirements are based on the weld processas follows:

TABLE A.2

1 The electrode voltage sense lead (67) is automatically enabled by the weldprocess, and integral to the to the 14 pin wire feeder control cable (K1785).

2 The work voltage sense lead (21) is manually enabled, but overridden byconstant current weld processes defined for stud sensing.

3 Negative polarity semi-automatic process operation WITHOUT use of aremote work sense lead (21) requires the Negative Electrode Polarityattribute to be set. This establishes which output stud the electrode voltagesense lead (67) will be referenced to.

Electrode Voltage Sensing

The remote ELECTRODE sense lead (67) is built into the standardwire feeder control cable (K1785) and is always connected to thewire drive feed plate when a wire feeder is present. Enabling ordisabling electrode voltage sensing is application specific, andautomatically configured by the active weld mode.

The remote ELECTRODE sense lead (67) is also available in theremote Voltage Sense Connector for applications that do not usethe standard wire feeder control cable (K1785). This can be easilyaccessed with the optional K940 Sense Lead kit.

B

A

C

POWER WAVE

FIGURE A.2

WORK

CAUTION

PROCESSELECTRODE VOLTAGESENSING (67 LEAD)1

WORK VOLTAGESENSING (21 LEAD)2

GMAW 67 lead required 21 lead optional3

GMAW-P 67 lead required 21 lead optional3

FCAW 67 lead required 21 lead optional3

GTAW Voltage sense at studs Voltage sense at studs

A-15


Work Voltage Sensing

The POWER WAVE® i400 is configured at the factory to sensework voltage at the negative output stud (positive output polaritywith remote Work Voltage Sensing disabled).

Negative electrode polarity operation WITHOUT use of aremote work sense lead (21) requires the Negative ElectrodePolarity attribute to be set via the Fanuc Teach Pendant orwith the Weld Manager Utility (included on the PowerWave® Utilities available at www.powerwavesoftware.com).

While most applications perform adequately by sensing the workvoltage directly at the output stud, the use of a remote workvoltage sense lead is recommended for optimal performance. Theremote WORK sense lead (21) can be accessed through the four-pin voltage sense connector located on the control panel by usingthe K940 Sense Lead Kit. It must be attached to the work as closeto the weld as practical, but out of the weld current path. For moreinformation regarding the placement of remote work voltagesense leads, see the section entitled "Voltage SensingConsiderations for Multiple Arc Systems."

If a remote work voltage sense lead is used, it must beenabled through the Fanuc Teach Pendant or with the WeldManager Utility (included on the Power Wave Utilitiesavailable at www.powerwavesoftware.com).

Voltage Sensing Considerations for Multiple ArcSystems

Special care must be taken when more than one arc is weldingsimultaneously on a single part. Multiple arc applications do notnecessarily dictate the use of remote work voltage sense leads,but they are strongly recommended.

If Sense Leads ARE NOT Used:• Avoid common current paths. Current from adjacent arcs can

induce voltage into each others current paths that can bemisinterpreted by the power sources, and result in arc inter-ference.

If Sense Leads ARE Used:• Position the sense leads out of the path of the weld

current. Especially any current paths common to adjacentarcs. Current from adjacent arcs can induce voltage into eachothers current paths that can be misinterpreted by the powersources, and result in arc interference.

• For longitudinal applications, connect all work leads at oneend of the weldment, and all of the work voltage sense leads atthe opposite end of the weldment. Perform welding in thedirection away from the work leads and toward the senseleads.

(See Figure A.3)

CAUTION

WARNING

DIRECTIONOF TRAVEL

CONNECT ALLWORK LEADS AT THE BEGINNINGOF THE WELD.

CONNECT ALL SENSELEADS AT THE ENDOF THE WELD.

FIGURE A.3

A-16


• For circumferential applications, connect all work leads onone side of the weld joint, and all of the work voltage senseleads on the opposite side, such that they are out of the currentpath.

POWERSOURCE #2

POWERSOURCE #1

POWERSOURCE #1

POWERSOURCE #2

POWERSOURCE #2

POWERSOURCE #1

A-17


CONTROL CABLE CONNECTIONSGeneral Guidelines

Genuine Lincoln control cables should be used at all times (exceptwhere noted otherwise). Lincoln cables are specifically designedfor the communication and power needs of the POWER WAVE® /Power Feed systems. Most are designed to be connected end toend for ease of extension. Generally, it is recommended that thetotal length not exceed 100 ft. (30.5 m). The use of non-standardcables, especially in lengths greater than 25 ft. (7.6 m), can leadto communication problems (system shutdowns), poor motoracceleration (poor arc starting), and low wire driving force (wirefeeding problems). Always use the shortest length of control cablepossible, and DO NOT coil excess cable.

Regarding cable placement, best results will be obtainedwhen control cables are routed separate from the weldcables. This minimizes the possibility of interferencebetween the high currents flowing through the weld cables,and the low level signals in the control cables. These recom-mendations apply to all communication cables includingArcLink® and Ethernet connections.

COMMON EQUIPMENT CONNECTIONS

Connection Between Power Source and Wire Feeder (K1785 orK2709 Control Cable)The 14 pin wire feeder control cable connects the power source tothe wire drive. It contains all of the necessary signals to drive themotor and monitor the arc, including the motor power,tachometer, and arc voltage feedback signals. The wire feederconnection on the POWER WAVE® i400 is located on the recessedcontrol panel above the output studs. Fanuc robot arms areequipped with internal cabling and provide a standard 14 pin MS-style connection at the base of the robot, and near the wire feedermount at the top of the arm. The K2709 series external dresscable is recommended for severe duty applications such as hardautomation or for robot arms not equipped with an internal controlcable. Best results will be obtained when control cables are routedseparate from the weld cables, especially in long distance appli-cations. Maximum cable length should not exceed 100ft(30.5m).

Connection Between Power Source and ArcLink®XTCompatible Controllers or Ethernet Networks. Newer modelcontrollers, such as the Fanuc R30iA, communicate viaArcLink®XT over an industrial Ethernet connection. To facilitatethis, the Power Wave i400 is equipped with an IP67 rated ODVAcompliant RJ-45 Ethernet connector, which is located on therecessed control panel above the output studs. A special accesschute is provided above the Ethernet connection on the PowerWave i400 to accommodate seamless integration with the FanucR30iA controller. The K2677-1 Integration Kit includes a speciallydesigned industrial rated Ethernet cable for this purpose.

It is highly recommended that all external Ethernet equipment(cables, switches, etc.), as defined by the connection diagrams, beobtained through the Lincoln Electric Automation Division. It iscritical that all Ethernet cables external to either a conduit or anenclosure are solid conductor, shielded cat 5e cable, with a drain.The drain should be grounded at the source of transmission, such

as a network switch or the Fanuc R30iA ground strip. Ethernetcables will achieve optimal performance levels at distances up to25 feet. Special attention to layout may be required to supportdistances greater than 25 feet, including specialized networkequipment. For best results, always route Ethernet cables awayfrom weld cables, wire drive control cables, or any other currentcarrying device that can create a fluctuating magnetic field. Foradditional guidelines refer to industry standard documents forindustrial Ethernet networks. Failure to follow these recommen-dations can result in an Ethernet connection failure duringwelding.

The ethernet port of the Power Wave i400 is factory configuredwith a dynamic IP address. This is required for seamless operationwith the Fanuc R30iA controller.

Connection Between Power Source and ArcLink® CompatibleControllers (K1543 or K2683 ArcLink Control Cable)Earlier model Fanuc controllers communicate via traditionalArcLink® over a standard 2 wire CAN based network. In thesesystems, the 5 pin ArcLink control cable connects the powersource to the controller.

The control cable consists of two power leads, one twisted pair fordigital communication, and one lead for voltage sensing. Thesense leads and power leads are typically unused in thisapplication. The 5 pin ArcLink connection on the POWER WAVE®i400 is located on the recessed control panel above the outputstuds. The control cable is keyed and polarized to preventimproper connection. Best results will be obtained when controlcables are routed separate from the weld cables, especially inlong distance applications. The recommended combined length ofthe ArcLink control cable network should not exceed200ft(61.0m).

Connections Between Power Source and Optional DeviceNetPLC Controller. Hard Automation applications and some earliermodel controllers may require DeviceNet connectivity to controlthe power source. DeviceNet can also be used to monitor weldingdata, and system status information. The optional K2780-1DeviceNet Kit is available for this purpose. It includes a 5 pinDeviceNet sealed mini style receptacle that mounts on therecessed control panel of the Power Wave i400, above the outputstuds. The DeviceNet cable is keyed and polarized to preventimproper connection. For best results, route DeviceNet cablesaway from weld cables, wire drive control cables, or any othercurrent carrying device that can create a fluctuating magneticfield. DeviceNet cables must be sourced locally by the customer.For additional guidelines refer to the “DeviceNet Cable Planningand Installation Manual” (Allen Bradley publication DN-6.7.2).

The DeviceNet MAC ID and baud rate of the POWER WAVE® i400can be configured with the Diagnostics Utility (included on thePOWER WAVE® Utilities available atwww.powerwavesoftware.com).

CAUTION

A-18


OTHER SET-UP ISSUES

Selecting a Wire Drive and Setting the Wire Drive Gear Ratio. ThePOWER WAVE® i400 can accommodate a number of standardwire drives including the AutoDrive 4R90 (default) and PF-10R.The feeder control system must be configured for both the wiredrive type and gear ratio (high or low speed range). This can beaccomplished via the Fanuc Teach Pendant (V7.30p14 or later) orwith the Weld Manager Utility (included on the Power Wave®Utilities available at www.powerwavesoftware.com).

Additional information is also available in the “How To” section atwww.powerwavesoftware.com.

OPERATIONSAFETY PRECAUTIONSRead this entire section of operating instructionsbefore operating the machine.

ELECTRIC SHOCK can kill.• Unless using cold feed feature, when

feeding with gun trigger, the electrodeand drive mechanism are alwayselectrically energized and could remainenergized several seconds after thewelding ceases.

• Do not touch electrically live parts or electrodes withyour skin or wet clothing.

• Insulate yourself from the work and ground.

• Always wear dry insulating gloves.

FUMES AND GASES can be danger-ous.• Keep your head out of fumes.

• Use ventilation or exhaust to removefumes from breathing zone.

WELDING SPARKS can cause fireor explosion.• Keep flammable material away.

• Do not weld on containers that have heldcombustibles.

ARC RAYS can burn.• Wear eye, ear, and body protection.

GRAPHIC SYMBOLS THAT APPEAR ON THISMACHINE OR IN THIS MANUAL

WARNING

B-1

OPERATIONPOWER WAVE® i400

INPUT POWER

ON

OFF

HIGH TEMPERATURE

MACHINE STATUS

CIRCUIT BREAKER

WIRE FEEDER

POSITIVE OUTPUT

NEGATIVE OUTPUT

3 PHASE INVERTER

INPUT POWER

THREE PHASE

DIRECT CURRENT

OPEN CIRCUIT VOLTAGE

INPUT VOLTAGE

OUTPUT VOLTAGE

INPUT CURRENT

OUTPUT CURRENT

PROTECTIVEGROUND

WARNING or CAUTION

Explosion

Dangerous Voltage

Shock Hazard

U0

U1

U2

I1

I2

B-2


PRODUCT DESCRIPTIONGeneral Physical Description

The POWER WAVE® i400 is intended as a replacement for thePW355i using an updated power and control platform to enhanceperformance and reliability. The POWER WAVE® i400 includes anintegrated wire drive module and 14-pin MS-Style connection tosupport the PF-10R and Auto Drive 4R90. ArcLink® commu-nication is supported through the 5 pin MS-style interface. Thenew ArcLink®XT communication protocol is supported through anRJ-45 type Ethernet connection, which also provides access forthe POWER WAVE® Utilities software tools. In addition, theDeviceNet communication protocol is supported by a 5 pin sealedmini style receptacle. Access to remote voltage sensing isavailable through the 4 pin sense lead connector (work andelectrode), 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,and an internal filter kit to achieve CE compliance.

The POWER WAVE® i400 includes an innovative new case designfeaturing a removable slide mounted power section for ease ofservice. The case is designed to support the Fanuc R30iAcontroller and op box (up to 300lbs), matching both thecontroller’s footprint and styling. Mounting is externally accessiblefor 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 thePOWER WAVE® i400 on/off switch. The ArcLink®XT connection isprovided through Ethernet. Both power and communication leadsare routed to the controller via access holes in the top of thepower source. The K2677-1 Integration Kit includes all necessarycables 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 pedestalto support the Fanuc R30iA controller. It may also be used withother controllers as a standalone power source. It is capable ofproducing a welding output from 5-420 amperes, and is rated for300A, 100%.

The POWER WAVE® i400 utilizes the latest generation high speeddigital controls, and communicates via ArcLink®XT to the Fanuccontroller. The inverter power section utilizes state of the artpower electronics and is re-connectable for 3 phase input voltagesfrom 208 to 575VAC. A 15A auxiliary receptacle is provided forfume extraction and water cooler accessories.

The POWER WAVE® i400 is fully CE compatible when equippedwith a K2670-1 CE Filter kit*.

* Input voltage limited to 380-415/3/50/60 with kit installed.

RECOMMENDED PROCESSES

The POWER WAVE® i400 is a high speed, multi-process powersource capable of regulating the current, voltage, or power of thewelding arc. With an output range of 5 to 420 amperes, it supportsa 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 theprocess capability within the output range and the safe limits ofthe machine.

EQUIPMENT LIMITATIONS

The POWER WAVE® i400 is not directly compatible with analogmachines or interfaces.

The input power pass-through connection (Terminal Block - 4TB)of the POWER WAVE® i400 is intended to supply powerexclusively to the Fanuc R30iA controller. It is designed to supporta 3kW maximum robot controller load through cable provided withthe K2677-1 Integration Kit.

B-3


CASE FRONT CONTROL DESCRIPTION

1. Machine Status Indicator: A two color LED that indicates systemerrors. The POWER WAVE® i400 is equipped with twoindicators. One is for the inverter power source, while the otherindicates the status of the feeder control system. Normaloperation is a steady green light. . Basic error conditions areindicated in the table below. For more information and adetailed listing, see the troubleshooting section of thisdocument or the Service Manual for this machine.

NOTE: The POWER WAVE® i400 status light will flash green, andsometimes red and green, for up to one minute when themachine is first turned on. This is a normal situation as themachine goes through a self test at power up.

1

2

3

4

5106

11

7

89

12

FIGURE B.1

LIGHTCONDITION

MEANING

SteadyGreen

System is okay. Power source communicatingnormally with the wire feeder and itscomponents.

BlinkingGreen

Occurs during a reset and indicates the POWERWAVE® i400 is mapping (identifying) eachcomponent in the system. Normally this occursfor the first 1-10 seconds after power is turnedon or if the system configuration is changedduring operation.

AlternatingGreen andRed

Non-recoverable system fault. Errors arepresent in the POWER WAVE® i400. Read theerror code before the machine is turned off.

Error code interpretation through the Status lightis detailed in the Trouble Shooting section.Individual code digits are flashed in red with along pause between digits. If more than onecode is present, the codes will be separated by agreen light.

To clear the error, turn power source off, andback on to reset. See Troubleshooting section.

Steady Red Not applicable

Blinking Red Not applicable

B-4


2. Thermal Indicator (Thermal overload): A yellow light that comeson when an over temperature situation occurs. Output isdisabled and the fan continues to run, until the machine coolsdown. When cool, the light goes out and output is enabled.

3. Circuit Breaker (CB1 - 15 amp): Protects the 40 volt DC supplyfor the feeder and machine controls.

4. Voltage Sense Connector: Allows for separate remoteelectrode and work sense leads.

5. Optional DeviceNet or Sync-Tandem Connector: Available asoptional kits to support either DeviceNet communication, orsynchronized tandem pulse welding. These options cannotcoexist.

DeviceNet Connector (5 pin - sealed mini style):

Sync-Tandem Connector (4 pin – MS style):

6. Ethernet Connector (RJ-45): Used for ArcLink® XT commu-nication. Also used for diagnostics and reprogramming thePOWER WAVE® i400.

7. Wire Feeder Receptacle (14-Pin): For connection to the AutoDrive 4R90 and Power Feed 10R wire feeders.

8. Negative Output Terminal

9. Positive Output Terminal

10. ArcLink® Receptacle:

11. ON / OFF SWITCH: Controls input power to the POWERWAVE® i400, and when properly integrated, the Fanuc R30iAController.

The POWER WAVE® i400 ON/OFF switch is NOT intendedas a Service Disconnect for this equipment.

12. FEEDER STATUS INDICATOR (See Item 1)

CASE BACK COMPONENTS DESCRIPTIONFIGURE B.2

1. 115V / 15A Duplex Receptacle

2. Circuit Breaker (CB2 - 15 amp): Provides protection for the115V auxiliary.

3. Rating Plate

Pin Leads Function3 21 Work Voltage Sense1 67C Electrode Voltage Sense

Pin Leads Function2 894 +24 VDC DeviceNet3 893 Common DeviceNet4 892 DeviceNet H5 891 DeviceNet L

Pin Leads FunctionA White “Ready” HB Black/White “Ready” LC Green “Kill” HD Black/Green “Kill” L

Pin Function1 Transmit +2 Transmit -3 Receive +4 ---5 ---6 Receive -7 ---8 ---

WARNING

Pin Leads FunctionA 153A / 153B Communication Bus LB 154A / 154B Communication Bus HC 67B / 67C Electrode Voltage SenseD 52 / 52A +40V DCE 51 / 51A 0 VDC

Pin Leads FunctionA 539 Motor +B 541 Motor -C 521 Solenoid +D 522 Solenoid CommonE 845 Tach 2A differential signalF 847 Single Tach inputG 841 +15V Tach supplyH 844 Tach commonI Open Reserved for future useJ GND-A Shielding drainK 842 Tach 1A differential signalL 843 Tach 1B differential signalM 846 Tach 2B differential signalN 67A / 67B Electrode Voltage Sense

9

2 10

B-5


INTERNAL CONTROLSFIGURE B.3

1. Main Reconnect: Selects main capacitor configuration for 208-230V or 380-575V input.

2. Auxiliary Reconnect: Configures auxiliary power for specifiedinput voltage (208/230/380/460/575V).

3. Fuse (F1): Primary circuit protection for auxiliary power(10A/600V).

4. Robot Power Terminal Block (4TB): Power supply connection forFanuc R30iA controller. Supplies primary power through theON/OFF switch directly to the robot controller.

This input power pass-through connection is intended tosupply power exclusively to the Fanuc R30iA controller. It isdesigned to support a 3kW maximum robot controller loadthrough cable provided with the K2677-1 Integration Kit.

ELECTRIC SHOCK CAN KILL.DO NOT ATTEMPT TO BACK FEED INPUTPOWER THROUGH THE ROBOT POWERTERMINAL BLOCK (4TB) INTO THE POWERWAVE i400.

THIS IS NOT ITS INTENDED PURPOSE, AND MAY RESULTIN MACHINE DAMAGE, BODILY INJURY OR DEATH.

5. Chassis Power Terminal Block (3TB): Power connection forinternal chassis. Provides power for the inverter and allauxiliary supplies.

6. INPUT Power Terminal Block (1TB): Input power connectionfrom main service disconnect.

7. Ground Terminal: Earth ground connection.

8. PC Board Dipswitches (not shown): PC Board dipswitches areset at the factory to allow configuration of the POWER WAVE®i400 via the Fanuc Teach Pendant or with the Weld ManagerUtility (included on the POWER WAVE® Utilities and ServiceNavigator CD’s or available at www.powerwavesoftware.com).The factory default settings are as follows:

Control Board (G4800 Series Hardware):• S1large = OFF• S2small = ON

Feed Head Board (L11087 Series Hardware):• S11 thru 8 = OFF

POWER-UP SEQUENCE

The POWER WAVE® i400 will typically be powered up at the sametime as the robotic controller. The status lights will blink green forabout a minute while the system is configuring. After this time, thestatus lights will turn a steady green indicating the machine isready.

DUTY CYCLE

The POWER WAVE® i400 is rated at 300 amps at 29 volts with a100% duty cycle. It is further rated to provide 340 amps at 31volts with a 60% duty cycle and 400 amps at 34 volts with a 30%duty cycle. The duty cycle is based on a ten-minute period. A60% duty cycle represents 6 minutes of welding and 4 minutes ofidling in a ten-minute period.

Note: The POWER WAVE® i400 is capable of producing a peakoutput current of 700 amps. The allowable maximum averageoutput current is time dependent, but ultimately limited to 450amps over any 2 second period. If the maximum average isexceeded, the output is disabled to protect the machine. Underthese conditions, normal operation can be resumed by cycling theoutput command.

12

3

4

5

6

7

CAUTION

WARNING

B-6


COMMON WELDING PROCEDURES

Making a WeldThe serviceability of a product or structure utilizing thewelding programs is and must be the sole responsibility ofthe builder/user. Many variables beyond the control of TheLincoln Electric Company affect the results obtained inapplying these programs. These variables include, but arenot limited to, welding procedure, plate chemistry andtemperature, weldment design, fabrication methods andservice requirements. The available range of a weldingprogram may not be suitable for all applications, and thebuild/user is and must be solely responsible for weldingprogram selection.

Choose the electrode material, electrode size, shielding gas, andprocess (GMAW, GMAW-P etc.) appropriate for the material to bewelded.

Select the weld mode that best matches the desired weldingprocess. The standard weld set shipped with the Power Wavei400 encompasses a wide range of common processes that willmeet most needs. If a special weld mode is desired, contact thelocal Lincoln Electric sales representative.

To make a weld, the Power Wave i400 needs to know the desiredwelding parameters. The robot controller sends the parametersfrom the teach pendant (arc voltage, wire feed speed, UltimArc™value, etc.), to the Power Wave i400 via the ArcLink® commu-nication protocol over the control, Ethernet or optional DeviceNetcables.

BASIC WELDING ControlsWeld Mode

Selecting a weld mode determines the output characteristics ofthe Power Wave i400 power source. Weld modes are developedwith a specific electrode material, electrode size, and shieldinggas. For a more complete description of the weld modesprogrammed into the Power Wave at the factory, refer to the WeldSet Reference Guide supplied with the machine or available atwww.powerwavesoftware.com.

Wire Feed Speed (WFS)

In synergic welding modes (GMAW, GMAW-P), WFS is thedominant control parameter. The user adjusts WFS according tofactors such as wire size, penetration requirements, heat input,etc. The Power Wave then uses the WFS setting to adjust thevoltage and current according to the information contained in theselected weld mode.

Note:

The Power Wave i400 can be configured to use amperage asthe dominant control parameter instead of WFS for synergicwelding modes. In this configuration the user adjusts amperageaccording to factors such as wire size, penetrationrequirements, heat input, etc. The Power Wave then uses theamperage setting to adjust the WFS and voltage according tothe information contained in the selected weld mode.

This alternate configuration is regionally enabled based on therobot controller software. Refer to the Fanuc documentation formanual configuration information.

In non-synergic modes, the WFS control behaves like aconventional power source where WFS and voltage areindependent adjustments. Therefore, to maintain proper arccharacteristics, the operator must adjust the voltage tocompensate for any changes made to the WFS.

Volts

In constant voltage modes (GMAW), this control adjusts thewelding voltage.

Trim

In pulse synergic welding modes (GMAW-P), the Trim settingadjusts the arc length. Trim is adjustable from 0.50 to 1.50. 1.00is the nominal setting and is a good starting point for mostconditions.

Note:

The Power Wave i400 can also be configured to display Trim asa voltage value. This allows the operator to pre-set anapproximate welding voltage rather than a unitless Trim value.The pre-set voltage is limited based on the process, andprovides the same range of operation as the correspondingTrim value.

This alternate configuration is regionally enabled based on therobot controller software. Refer to the Fanuc documentation formanual configuration information.

UltimArcTM

UltimArcTM allows the operator to vary the arc characteristicsfrom “soft” to “crisp”. UltimArcTM is adjustable from –10.0 to+10.0 with a nominal setting of 0.0.

WARNING

B-7


Constant Voltage WeldingSynergic CV

In synergic welding modes, WFS is the dominant controlparameter. For each wire feed speed, a corresponding voltage isprogrammed into the machine at the factory. The user adjustsWFS according to factors such as wire size, material thickness,penetration requirements, etc. The Power Wave i400 then usesthe WFS setting to select the appropriate nominal voltage. ThePower Wave i400 can also be configured to use amperage as thedominant control parameter. In this configuration the Power Wavei400 uses the amperage setting to select the appropriate WFS andnominal voltage. In either case, the user can adjust the voltagehigher or lower to compensate for material condition or individualpreference.

Non Synergic CV

In non-synergic modes, the machine behaves like a conventionalpower source. The WFS and voltage are independentadjustments. Therefore, to maintain the arc characteristics, theoperator must adjust the voltage to compensate for any changesmade to the WFS.

UltimArcTM

UltimArcTM adjusts the apparent inductance of the wave shape.The UltimArcTM adjustment is similar to a “pinch” function in thatit is inversely proportional to inductance. UltimArcTM is adjustablefrom –10.0 to +10.0 with a nominal setting of 0. IncreasingUltimArcTM results in a crisper, hotter arc. Decreasing theUltimArcTM provides a softer, colder arc.

Pulse Welding

When pulse welding, the power source primarily regulates the arccurrent, not the arc voltage. During a pulsing cycle, arc current isregulated from a low background level to a high peak level andthen back down to the low background level. The average arcvoltage increases and decreases as the average arc current isincreased or decreased. The peak current, back ground current,rise time, fall time and pulse frequency all affect the averagevoltage. Since the average voltage for a given wire feed speedcan only be determined when all the pulsing waveformparameters are known, a unitless value called “trim” is used foradjusting the arc length.

Trim adjusts the arc length and ranges from 0.50 to 1.50 with anominal value of 1.00. Increasing the trim value increases the arclength. Decreasing the trim value decreases the arc length.Alternately, trim can be displayed as a quasi-voltage value. Thisallows the operator to pre-set an approximate welding voltagerather than a unitless trim value. The pre-set voltage is limitedbased on the process, and provides the same range of operationas the corresponding trim value.

Pulse welding modes are synergic; using wire feed speed as themain control parameter. As the wire feed speed is adjusted, thepower source adjusts the waveform parameters to maintain goodwelding characteristics. The Power Wave® i400 can also beconfigured to use amperage as the dominant control parameter. Inthis configuration, as the amperage is adjusted, the power sourceselects the appropriate wire feed speed, and adjusts the waveformparameters to maintain good welding characteristics. In eithercase, trim is used as a secondary control to change the arc lengthfor material conditions or individual preference.

UltimArcTM adjusts the focus or shape of the arc. UltimArcTM isadjustable from -10.0 to +10.0 with a nominal setting of 0.0.Increasing the UltimArcTM increases the pulse frequency andbackground current while decreasing the peak current. Thisresults in a tight, stiff arc used for high speed sheet metalwelding. Decreasing the UltimArcTM decreases the pulsefrequency and background current while increasing the peakcurrent. This results in a soft arc good for out of position welding.

The Power Wave® utilizes adaptive control to compensate forchanges in the electrical stick-out (distance from the contact tip tothe work piece) while welding. The Power Wave® waveforms areoptimized for a 5/8” to 3/4” stick out depending on the wire typeand wire feed speed. The adaptive behavior supports a range ofstick outs from approximately 1/2” to 1-1/4”. At low or high wirefeed speeds, the adaptive range may be less due to physicallimitations of the welding process.

C-1

ACCESSORIESPOWER WAVE® i400

OPTIONS / ACCESSORIES

FACTORY INSTALLED

None Available.

FIELD INSTALLED

K940-Work Voltage Sense Lead Kit

K2670-[ ] CE Filter Kit

K2677-2 Integration Kit

COMPATIBLE LINCOLN EQUIPMENT

K2685-2 Auto Drive 4R90 Wire feeder (14-pin control

cable).

K1780-2 Power Feed 10 Robotic Wire Drive

For additional Information see Optional Equipment in theInstallation Section.

D-1

MAINTENANCEPOWER WAVE® i400

MAINTENANCESafety Precautions

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.

EXPLODING PARTS can causeinjury.• Failed parts can explode or cause other

parts to explode when power is applied.

• Always wear a face shield and longsleeves when servicing.

See additional warning information throughoutthis Operator’s Manual

ROUTINE MAINTENANCE

Routine maintenance consists of periodically blowing out themachine, using a low pressure airstream, to remove accumulateddust and dirt from the intake and outlet louvers, and the coolingchannels 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 notyield satisfactory weld performance. To ensure optimalperformance, the calibration of output Voltage and Current shouldbe checked yearly.

CALIBRATION SPECIFICATION

Output Voltage and Current are calibrated at the factory. Generallyspeaking the machine calibration will not need adjustment.However, if the weld performance changes, or the yearlycalibration check reveals a problem, use the calibration section ofthe Diagnostics Utility to make the appropriate adjustments.

The calibration procedure itself requires the use of a grid, andcertified actual meters for voltage and current. The accuracy ofthe calibration will be directly affected by the accuracy of themeasuring equipment you use. The Diagnostics Utility includesdetailed instructions, and is available on the POWER WAVE®Utilities and Service Navigator CD’s or available at www.power-wavesoftware.com

CHASSIS REMOVAL 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 thisequipment.

(See Figure D.1)

1. Turn off input power to the power source and any otherequipment connected to the welding system at the disconnectswitch or fuse box before working on the equipment.

2. Remove the weld cables from the output studs, and disconnectall control cables including the Ethernet connection from thecontrol panel.

3. Remove the screws securing the chassis to the cabinet aslisted below:

• (6) 10-24 screws securing the reconnect access panel on thefront of the machine (ON/OFF switch must be in the OFFposition for removal).

• (2) 1/4-20 screws on either side of the control panel locatedon the right case side.

• (2) 1/4-20 screws just below the output studs located on theright case side.

• (12) 1/4-20 screws from the left case side.

4. Remove the left case side by pulling out from the bottom.

5. Disconnect the chassis input power leads (1E, 2E & 3E) fromterminal block “3TB” located in the cabinet reconnect area,and remove the chassis ground from the stud located in frontthe terminal block.

6. Carefully slide the chassis from the cabinet by pulling on thefan bracket. (see “Location and Mounting” section of thisdocument for instructions on lifting the chassis).

WARNINGWARNING

FIGURE D.1

Capacitor Discharge Procedure

Prior to transporting or servicing chassis it is important toverify the capacitors are completely discharged.

1. Use a DC voltmeter to check that NO voltage is present acrossthe terminals of both capacitors.

Note: Presence of capacitors voltage is also indicated by LED’s(See figure D.1a)

2. If voltage is present wait for capacitors to completely discharge(this may take several minutes) or discharge the capacitors asfollows:

• Obtain a power resistor (25 ohms, 25 watts).

• Hold resistor body with electrically insulated glove. DO NOTTOUCH TERMINALS. CAPACITOR VOLTAGE MAY EXCEED400VDC. Connect the resistor terminals across the twostuds in the position shown. Hold in each position for 10second. Repeat for both capacitors.

• Use a DC voltmeter to check that voltage is not presentacross the terminals of both capacitors.

FIGURE D.1A

CAUTION

CAPACITORTERMINALS

RESISTORCAPACITOR CHARGEINDICATORS (LED’S)

D-2

MAINTENANCEPOWER WAVE® i400

CHASSIS CONNECTION(SEE WIRING DIAGRAM)

E-1

TROUBLESHOOTINGPOWER WAVE® i400

TROUBLESHOOTINGHow to Use Troubleshooting Guide

Service and Repair should only be performed by LincolnElectric Factory Trained Personnel. Unauthorized repairsperformed on this equipment may result in danger to thetechnician and machine operator and will invalidate yourfactory warranty. For your safety and to avoid ElectricalShock, please observe all safety notes and precautionsdetailed throughout this manual.

This Troubleshooting Guide is provided to help you locate andrepair possible machine malfunctions. Simply follow the three-step procedure listed below.

Step 1. LOCATE PROBLEM (SYMPTOM).

Look under the column labeled “PROBLEM (SYMPTOMS)”. Thiscolumn describes possible symptoms that the machine mayexhibit. Find the listing that best describes the symptom that themachine is exhibiting.

Step 2. POSSIBLE CAUSE.

The second column labeled “POSSIBLE CAUSE” lists the obviousexternal possibilities that may contribute to the machine symptom.

Step 3. RECOMMENDED COURSE OF ACTION

This column provides a course of action for the Possible Cause,generally it states to contact your local Lincoln Authorized FieldService Facility.

If you do not understand or are unable to perform theRecommended Course of Action safely, contact your local LincolnAuthorized Field Service Facility.

Using the Status LED TO Troubleshoot System PROB-LEMS

The POWER WAVE® i400 is equipped with two externally mountedstatus lights, one for the power source, and one for the wire drivemodule contained in the power source. If a problem occurs it isimportant to note the condition of the status lights. Therefore, priorto cycling power to the system, check the power source statuslight for error sequences as noted below.

Included in this section is information about the power source andWire Drive Module Status LED’s, and some basic troubleshootingcharts for both machine and weld performance.

The STATUS LIGHTS are dual-color LED’s that indicate systemerrors. Normal operation for each is steady green. Errorconditions are indicated in the following Table E.1.

TABLE E.1

WARNING

LIGHTCONDITION

MEANING

SteadyGreen

System OK. Power source is operational, andis communicating normally with all healthyperipheral equipment connected to its ArcLinknetwork.

BlinkingGreen

Occurs during power up or a system reset,and indicates the POWER WAVE® i400 ismapping (identifying) each component in thesystem. Normal for first 1-10 seconds afterpower is turned on, or if the system config-uration is changed during operation.

Fast BlinkingGreen

Under normal conditions indicates Auto-mapping has failed.

Also used by the Diagnostics Utility to identifythe selected machine when connecting to aspecific IP address.

AlternatingGreen andRed

Non-recoverable system fault. If the Statuslight is flashing any combination of red andgreen, errors are present. Read the errorcode(s) before the machine is turned off.

Error Code interpretation through the Statuslight is detailed in the Service Manual.Individual code digits are flashed in red with along pause between digits. If more than onecode is present, the codes will be separatedby a green light. Only active error conditionswill be accessible through the Status Light.

To clear the active error(s), turn power sourceoff, and back on to reset.

Steady Red Not applicable.

Blinking Red Not applicable.

If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your Lincoln Authorized Service Facility for technical troubleshooting assistance before you proceed.

WWW.LINCOLNELECTRIC.COM/LOCATOR

E-2


LECO(FANUC#)

49

50

51

52

53

54

55

57

67

84

see com-plete listing

POWER SOURCE–––WELD CONTROLLER

ERROR CODES FOR THE POWER WAVE®

The following is a partial list of possible error codes for the POWER WAVE® i400. For a complete listing consultthe Service Manual for this machine.

Error Code #

31 Primary (Input) overcurrent error.

32 Capacitor “A” under voltage (right side facing the Switch PC Board)

33 Capacitor bank "B" under voltage(left side facing the Switch PC Board)

34 Capacitor "A" over voltage (right side facing the Switch PC Board)

35 Capacitor "B" over voltage(left side facing the Switch PC Board)

36 Thermal error

37 Softstart (pre-charge) error

39 Misc. hardware fault

43 Capacitor delta error

54 Secondary (output) over current

Other

Indication

Excessive Primary current present. May be related to aswitch board or output rectifier failure.

Low voltage on the main capacitors. May be caused byimproper input configuration, or an open/short circuit in theprimary side of the machine.

Excess voltage on the main capacitors. May be caused byimproper input configuration, excessive line voltage, orimproper capacitor balance (see Error 43)

Indicates over temperature. Usually accompanied byThermal LED. Check fan operation. Be sure process doesnot exceed duty cycle limit of the machine.

Capacitor precharge failed. Usually accompanied bycodes 32 and 33.

Unknown glitch has occurred on the fault interrupt circuit-ry. Sometimes caused by primary over current fault, orintermittent connections in the thermostat circuit.

The maximum voltage difference between the main capac-itors has been exceeded. May be accompanied by errors32-35. May be caused by an open or short in the primaryor secondary circuit(s).

The long term average secondary (weld) current limit hasbeen exceeded. This error will immediately turn off themachine output.

NOTE: The long term average secondary current limit is450 amps.

A complete l ist of error codes is available in theDiagnostics Utility (included on the POWER WAVE®

Utilities and Service Navigator CD’s or available atwww.powerwavesoftware.com).

Error codes that contain three or four digits are defined asfatal errors. These codes generally indicate internal errorson the Power Source Control Board. If cycling the inputpower on the machine does not clear the error, contact the



E-3


LECO(FANUC#)

129

130

131

132

WIRE DRIVE MODULE

ERROR CODES FOR THE POWER WAVE®

The following is a partial list of possible error codes for the POWER WAVE® i400. For a complete listing consultthe Service Manual for this machine.

Error Code #

81 Motor Overload

82 Motor Overcurrent

83 Shutdown #1

84 Shutdown #2

Indication

Long term average motor current limit has been exceeded. Typicallyindicates mechanical overload of system. If problem continues con-sider higher torque gear ratio (lower speed range).

Absolute maximum motor current level has been exceeded. This is ashort term average to protect drive circuitry.

The Shutdown inputs on the POWER WAVE® i400 have been dis-abled. The presence of these errors indicates the Feed Head ControlPCB may contain the wrong operating software.



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Observe all Safety Guidelines detailed throughout this manual

PROBLEMS(SYMPTOMS)

POSSIBLECAUSE

RECOMMENDEDCOURSE OF ACTION

BASIC MACHINE PROBLEMS

Major physical or electrical damage isevident when the sheet metal covers areremoved.

None If all recommended possible areas ofmisadjustment have been checked and theproblem persists, Contact your local LincolnAuthorized Field Service Facility.

Input fuses keep blowing 1. Improperly sized input fuses. 1. Make sure fuses are properly sized.See installation section of this manualfor recommended sizes.

2. Improper Weld Procedure requiringoutput levels in excess of machinerating.

2. Reduce output current, duty cycle, orboth.

3. Major physical or electrical damage isevident when the sheet metal coversare removed.

3. Contact your local authorized LincolnElectric Field Service facility fortechnical assistance.

Machine will not power up (no lights) 1. No Input Power. 1. Make sure input supply disconnect hasbeen turned ON. Check input fuses.Make certain that the Power Switch(SW1) on the power source is in the“ON” position.

2. Fuse F1 (in reconnect area) may haveblown.

2. Power Down and replace the fuse.

3. Circuit breaker CB1 (on the controlpanel) may have tripped.

3. Power Down and reset CB1.

4. Improper input voltage selection(multiple input voltage machines only).

4. Power down, check input voltagereconnect according to diagram onreconnect cover.

Machine won’t weld, can’t get any output.

(CR1 will not pull in.)

This problem will normally beaccompanied by an error code. Error codesare displayed as a series of red and greenflashes by the status light(s). See “StatusLight” section of this document foradditional information.

1. Input voltage is too low or too high. 1. Make certain that input voltage iscorrect, according to the Rating Platelocated on the rear of the machine.

2. Thermal Error. 2. See “Thermal LED is ON” section.

3. Primary current limit has been exceeded.(the main contactor drops out whenoutput is initiated – see error 31).

3. Possible short in output circuit. Turnmachine off. Remove all loads from theoutput of the machine. Turn back on,and activate output. If conditionpersists, turn power off, and contactan authorized Lincoln Electric FieldService facility.

4. Inverter Fault - switch pc board,contactor problem, etc.

4. Contact your local authorized LincolnElectric Field Service facility fortechnical assistance.



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PROBLEMS(SYMPTOMS)

POSSIBLECAUSE


BASIC MACHINE PROBLEMS

Thermal LED is ON. 1. Improper fan operation. 1. Check for proper fan operation. (Fansshould run whenever output power ison.) Check for material blocking intakeor exhaust louvers, or for excessive dirtclogging cooling channels in machine.

2. Output Rectifier board or Chokethermostat.

2. After machine has cooled, reduce load,duty cycle, or both. Check for materialblocking intake or exhaust louvers andheat sink fins.

3. DC Bus PC board thermostat. 3. Check for excessive load on 40VDCsupply.

4. Open thermostat circuit. 4. Check for broken wires, openconnections or faulty thermostats onthe DC Bus and Output Rectifier heatsinks, and Choke assembly.

Auxiliary receptacle is dead. 1. Circuit breaker CB2 (near the 115Vreceptacle) may have tripped.

1. Power down and reset CB2.

2. Fuse F1 (in reconnect area) may haveblown.

2. Power down and replace the fuse.

“Real Time Clock” no longer functioning 1. Control PC Board Battery. 1. Replace the battery (Type: BS2032)

WELD AND ARC QUALITY PROBLEMS

General degradation of weld performance. 1. Wire feed problem. 1. Check for feeding problems. Checkactual WFS vs. preset. Verify properwire drive and gear ratio has beenselected.

2. Cabling problems. 2. Check for bad connections, excessiveloops in cable, etc.

NOTE: The presence of heat in theexternal welding circuit indicates poorconnections or undersized cables.

3. Loss of, or improper Shielding Gas. 3. Verify gas flow and type are correct.

4. Verify weld mode is correct for process. 4. Select the correct weld mode for theapplication.

5. Machine calibration. 5. Verify the calibration of the outputcurrent and voltage.

6. Secondary current limit has beenreached.

6. Long term average current is limited to450A. Adjust procedure to reduceoutput demand.



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PROBLEMS(SYMPTOMS)

POSSIBLECAUSE


WELD AND ARC QUALITY PROBLEMS

Wire burns back to tip when the arc isinitiated.

1. Voltage sense lead problem. 1. Check sense lead connections. Checkthe sense lead configuration and arcpolarity. Make sure Electrode and Workconnections are not reversed.

2. Wire feed problem. 2. Check for feeding problems. Verifyproper wire drive and gear ratio hasbeen selected.

Wire burns back to tip at the end of theweld.

1. Burnback Time. 1. Reduce burnback time and/or workpoint.

Machine output shuts down during a weld. 1.Inverter or System Fault 1. A non-recoverable inverter fault willinterrupt welding, and open the maincontactor. This condition will alsoresult in an alternating red and greenstatus light on the control panel. Seethe Status Light section for moreinformation.

Machine won’t produce full output. 1. Input voltage may be too low, limitingoutput capability of the power source.

1. Make certain that the input voltage isproper, according to the Rating Platelocated on the rear of the machine.

2. Machine calibration. 2. Calibrate secondary current and voltage.

Excessively long and erratic arc. 1. Wire feed problem. 1. Check for feeding problems. Verifyproper wire drive and gear ratio hasbeen selected.

2. Voltage sensing problem. 2. Check sense lead connections. Checkthe sense lead configuration and arcpolarity. Make sure Electrode and Workconnections are not reversed.

3. Loss of, or improper Shielding Gas. 3. Verify gas flow and type are correct.

4. Machine calibration. 4. Calibrate secondary current and voltage.

Arc loss fault on robot. 1. Possibly caused by wire feedingproblem.

1. Check for feeding problems. Verifyproper wire drive and gear ratio hasbeen selected. For larger diameterwire, consider the highest torque /lowest range gear ratio available tosuit the application.

2. Conduit leading to the wire feeder hasbends or twists, which can reduce thewire feed speed.

2. Remove bends and twists in conduitleading to the feeder.

3. Conduit leading up to the wire feederfrom the wire reel is too long.

3. Use a shorter piece of conduit.



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PROBLEMS(SYMPTOMS)

POSSIBLECAUSE


DeviceNet – PLC Controlled System

Device does not go on Line. 1. 24v bus power. 1. Verify that LED 10 is on when theDeviceNet network is powered. Thiscan be done with the POWER WAVE®turned on or off.

2. Baud rate. 2. Verify the baud rate setting is the sameas the DeviceNet Master. The baudrate is set via the DeviceNet tab of theDiagnostics Utility.

3. MAC ID 3. Verify the DeviceNet MAC ID is correct.The Mac ID is set via the DeviceNet tabof the Diagnostics Utility.

4. Termination 4. Verify that the DeviceNet bus isterminated correctly.

5. Wiring. 5. Verify the wiring of all multi-port tapsand field attachable ends.

6. EDS Files

(Electronic Data Sheet Files)

6. Verify that the correct EDS files are beingused if they are needed. TheDeviceNet tab of the Diagnostics Utilitydisplays the current Product Code andVendor Revision of the POWERWAVE®.

Device goes off line during welding. 1. Interference / Noise. 1. Verify that DeviceNet cables are notrunning next to (in close proximitywith) current carrying conductors. Thisincludes the welding cables, inputcables, etc.

2. Termination. 2. Verify that the DeviceNet bus isterminated correctly.

3. Shielding. 3. Verify that the cable shielding iscorrectly grounded at the bus powersupply. The shield should be tied intothe bus ground at only one point.

4. Power Supply. 4. Verify that the DeviceNet bus powersupply can supply sufficient current forthe devices on the network.

5. Expected Packet Rate. 5. Verify that 1000/(Expected Packet Rate)≤ (scans per second). The DeviceNettab of the Diagnostics Utility displaysthese values.

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PROBLEMS(SYMPTOMS)

POSSIBLECAUSE



Output will not come on. 1. DeviceNet trigger not asserted. 1. From the DeviceNet tab of theDiagnostics Utility, select Monitor. TheMonitor window will be displayed.Verify under the “Produced Assembly”that “Trigger” is highlighted.

2. Touch Sense command. 2. From the DeviceNet tab of theDiagnostics Utility, select Monitor. TheMonitor window will be displayed.Verify under the “Produced Assembly”that “Touch Sense” is NOT highlighted.

3. Passive Mode. 3. The DeviceNet tab of the DiagnosticsUtility displays the POWER WAVE®’spassive mode status. If the statusneeds to be changed, select Configure,and make the necessary modification.

4. Welding Cables. 4. Verify that welding cables are connectedproperly.

5. Output Disabled 5. From the DeviceNet tab of theDiagnostics Utility, select Monitor. TheMonitor window will be displayed.Verify under the “Produced Assembly”that “Disable Output” is NOThighlighted.

6. Other modules faulted. 6. Verify no other modules are faulted (allsystem Status Lights should be steadygreen). Use Diagnostics Utility todisplay any current faults in thesystem.



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PROBLEMS(SYMPTOMS)

POSSIBLECAUSE



Bad Weld Starting. 1. Wire Feed problem 1. Verify Feeders drive roll tension is not too low allowingthe wire to slip in the rolls. Verify wire can be pulledeasily through the wire conduit. Verify Contact tip isnot blocked.

2. Strike Wire Feed Speed 2. Verify the Strike Wire Feed Speed set correctly.

3. Incorrect Weld Schedule 3. Verify the correct weld schedule is selected.

4. Voltage Sense Leads 4. Verify voltage sense leads are properly connected andconfigured as described in the instruction manual.

5. Analog Scans Between Updates 5. The DeviceNet tab of the Diagnostics Utility displaysthe POWER WAVE®’s “Analog Scans BetweenUpdates” and “I/O Scans/Sec.” Verify that “AnalogScans Between Updates” is ¼ of “I/O Scans/Sec”value.

6. Analog Hysteresis 6. From the DeviceNet tab of the Diagnostics Utility,select Configure. Verify in “Analog Input Channels”that the Hysteresis settings are all 0.

7. Limit Error 7. Verify all analog input values are within limits.

8. Fan Out 8. From the DeviceNet tab of the Diagnostics Utility,select Monitor. Verify under “Analog Input Fan Out”that Burnback is present for all analogs in.

9. Gas 9. Verify Gas is being turned on before the output.

Analog Inputs don’t respond ordon’t respond quickly.

1. Analog Scans Between Updates. 1. The DeviceNet tab of the Diagnostics Utility displaysthe POWER WAVE®’s “Analog Scans BetweenUpdates” and “I/O Scans/Sec.” Verify that “AnalogScans Between Updates” is ¼ of “I/O Scans/Sec”value.

2. Analog In Active Selections. 2. From the DeviceNet tab of the Diagnostics Utility,select Configure. Verify in “Analog Input Channels”that the required channels are set active.

3. Analog Hysteresis. 3. From the DeviceNet tab of the Diagnostics Utility,select Configure. Verify in “Analog Input Channels”that the Hysteresis settings are all 0.

4. Passive Mode. 4. The DeviceNet tab of the Diagnostics Utility displaysthe POWER WAVE®’s passive mode status. If thestatus needs to be changed, select Configure, andmake the necessary modification.

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PROBLEMS(SYMPTOMS)

POSSIBLECAUSE



Gas purge not working. 1. Out of gas. 1. Verify there is gas available at the input of the gas solenoid.

2. Gas Purge not asserted. 2. From the DeviceNet tab of the Diagnostics Utility, selectMonitor. The Monitor window will be displayed. Verify underthe “Produced Assembly” that “Gas Purge” is highlighted.

3. Passive Mode. 3. The DeviceNet tab of the Diagnostics Utility displays thePOWER WAVE®’s passive mode status. If the status needsto be changed, select Configure, and make the necessarymodification.

4. Gas Lines. 4. Verify nothing is obstructing the flow of gas.

Bad Weld Ending. 1. Burnback Disabled. 1. From the DeviceNet tab of the Diagnostics Utility, selectMonitor. The Monitor window will be displayed. Verify underthe “State Enabled” that “Burnback” is present.

2. Burnback Time. 2. Verify that Burnback Time has a value other than 0.

3. Analog Scans BetweenUpdates.

3. The DeviceNet tab of the Diagnostics Utility displays thePOWER WAVE®’s “Analog Scans Between Updates” and“I/O Scans/Sec.” Verify that “Analog Scans BetweenUpdates” is ¼ of “I/O Scans/Sec” value.

4. Limit Error reported at the endof a weld.

4. Verify all welding settings for Burnback and Crater states.

5. Fan Out. 5. From the DeviceNet tab of the Diagnostics Utility, selectMonitor. Verify under “Analog Input Fan Out” that Burnbackis present for all analogs in.

6. Welding set points. 6. Verify Burnback set points for work point, trim, and wavevalues.

7. Analog Hysteresis. 7. From the DeviceNet tab of the Diagnostics Utility, selectConfigure. Verify in “Analog Input Channels” that theHysteresis settings are all 0.

8. Gas. 8. Verify Gas is turned on.

Bad Welding. 1. Analog Scans BetweenUpdates.

1. The DeviceNet tab of the Diagnostics Utility displays thePOWER WAVE®’s “Analog Scans Between Updates” and“I/O Scans/Sec.” Verify that “Analog Scans Between

2. Voltage Sense Leads. 2. Verify voltage sense leads are properly connected andconfigured as described in the instruction manual.

3. Analog Hysteresis 3. From the DeviceNet tab of the Diagnostics Utility, selectConfigure. Verify in “Analog Input Channels” that theHysteresis settings are all 0.

4. Limit Errors 4. Verify all welding setpoint values are within limits.

5. Gas 5. Verify Gas remains on until after the weld is complete.

6. Welding set points. 6. Verify welding set points for work point, trim, and wavevalues.

7. Wire Drive / Gear selection. 7. Verify proper wire drive and gear ratio has been selected.

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PROBLEMS(SYMPTOMS)

POSSIBLECAUSE


ETHERNET

Cannot Connect. 1. Physical connection. 1. Verify that the correct patch cable or cross over cable is beingused (refer to local IT department for assistance).

NOTE:

• For direct connection to the Fanuc R30iA Controller, use onlythe cable provided with the K2677-1 Integration kit

• Verify the cables are fully inserted into the bulk headconnector.

• LED 8 located under the PC board ethernet connector will belit when the machine is connected to another networkdevice.

2. IP address information. 2. Use Weld Manager (included on the POWER WAVE® Utilitiesand Service Navigator CD’s or available at www.power-wavesoftware.com) to verify the correct IP addressinformation has been entered.

NOTE:

• The IP address configuration MUST be set to dynamic whenconnected to the Fanuc R30iA Controller.

• Verify no duplicate the IP addresses exist on the network.

3. Ethernet Speed. 3. Verify that the network device connected to the POWERWAVE® is either a 10-baseT device or a 10/100-baseTdevice.

Connection Drops whilewelding.

1. Cable Location. 1. Verify Network cable is not located next to current carryingconductors. This would include input power cables andwelding output cables.

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WARNING

AVISO DEPRECAuCION

ATTENTION

WARNuNG

ATENÇÃO

Spanish

French

German

Portuguese

Japanese

Chinese

Korean

Arabic

READ AND UNDERSTAND THE MANUFACTURER’S INSTRUCTION FOR THIS EQUIPMENT AND THE CONSUMABLES TO BEUSED AND FOLLOW YOUR EMPLOYER’S SAFETY PRACTICES.

SE RECOMIENDA LEER Y ENTENDER LAS INSTRUCCIONES DEL FABRICANTE PARA EL USO DE ESTE EQUIPO Y LOSCONSUMIBLES QUE VA A UTILIZAR, SIGA LAS MEDIDAS DE SEGURIDAD DE SU SUPERVISOR.

LISEZ ET COMPRENEZ LES INSTRUCTIONS DU FABRICANT EN CE QUI REGARDE CET EQUIPMENT ET LES PRODUITS AETRE EMPLOYES ET SUIVEZ LES PROCEDURES DE SECURITE DE VOTRE EMPLOYEUR.

LESEN SIE UND BEFOLGEN SIE DIE BETRIEBSANLEITUNG DER ANLAGE UND DEN ELEKTRODENEINSATZ DES HER-STELLERS. DIE UNFALLVERHÜTUNGSVORSCHRIFTEN DES ARBEITGEBERS SIND EBENFALLS ZU BEACHTEN.

l Do not touch electrically live parts orelectrode with skin or wet clothing.

l Insulate yourself from work andground.

l No toque las partes o los electrodosbajo carga con la piel o ropa moja-da.

l Aislese del trabajo y de la tierra.

l Ne laissez ni la peau ni des vête-ments mouillés entrer en contactavec des pièces sous tension.

l Isolez-vous du travail et de la terre.

l Berühren Sie keine stromführendenTeile oder Elektroden mit IhremKörper oder feuchter Kleidung!

l Isolieren Sie sich von denElektroden und dem Erdboden!

l Não toque partes elétricas e elec-trodos com a pele ou roupa molha-da.

l Isole-se da peça e terra.

l Keep flammable materials away.

l Mantenga el material combustiblefuera del área de trabajo.

l Gardez à l’écart de tout matérielinflammable.

l Entfernen Sie brennbarres Material!

l Mantenha inflamáveis bem guarda-dos.

l Wear eye, ear and body protection.

l Protéjase los ojos, los oídos y elcuerpo.

l Protégez vos yeux, vos oreilles etvotre corps.

l Tragen Sie Augen-, Ohren- und Kör-perschutz!

l Use proteção para a vista, ouvido ecorpo.

WARNING

AVISO DEPRECAuCION

ATTENTION

WARNuNG

ATENÇÃO

Spanish

French

German

Portuguese

Japanese

Chinese

Korean

Arabic

LEIA E COMPREENDA AS INSTRUÇÕES DO FABRICANTE PARA ESTE EQUIPAMENTO E AS PARTES DE USO, E SIGA ASPRÁTICAS DE SEGURANÇA DO EMPREGADOR.

l Keep your head out of fumes.l Use ventilation or exhaust to

remove fumes from breathing zone.

l Los humos fuera de la zona de res-piración.

l Mantenga la cabeza fuera de loshumos. Utilice ventilación oaspiración para gases.

l Gardez la tête à l’écart des fumées.l Utilisez un ventilateur ou un aspira-

teur pour ôter les fumées des zonesde travail.

l Vermeiden Sie das Einatmen vonSchweibrauch!

l Sorgen Sie für gute Be- undEntlüftung des Arbeitsplatzes!

l Mantenha seu rosto da fumaça.l Use ventilação e exhaustão para

remover fumo da zona respiratória.

l Turn power off before servicing.

l Desconectar el cable de ali-mentación de poder de la máquinaantes de iniciar cualquier servicio.

l Débranchez le courant avant l’entre-tien.

l Strom vor Wartungsarbeitenabschalten! (Netzstrom völlig öff-nen; Maschine anhalten!)

l Não opere com as tampas removidas.l Desligue a corrente antes de fazer

serviço.l Não toque as partes elétricas nuas.

l Do not operate with panel open orguards off.

l No operar con panel abierto oguardas quitadas.

l N’opérez pas avec les panneauxouverts ou avec les dispositifs deprotection enlevés.

l Anlage nie ohne Schutzgehäuseoder Innenschutzverkleidung inBetrieb setzen!

l Mantenha-se afastado das partesmoventes.

l Não opere com os paineis abertosou guardas removidas.

CUSTOMER ASSISTANCE POLICY

The business of The Lincoln Electric Company is manufacturingand selling high quality welding equipment, consumables, andcutting equipment. Our challenge is to meet the needs of ourcustomers and to exceed their expectations. On occasion,purchasers may ask Lincoln Electric for advice or informationabout their use of our products. We respond to our customersbased on the best information in our possession at that time.Lincoln Electric is not in a position to warrant or guarantee suchadvice, and assumes no liability, with respect to such informationor advice. We expressly disclaim any warranty of any kind,including any warranty of fitness for any customer’s particularpurpose, with respect to such information or advice. As a matterof practical consideration, we also cannot assume any respon-sibility for updating or correcting any such information or adviceonce it has been given, nor does the provision of information oradvice create, expand or alter any warranty with respect to thesale of our products.

Lincoln Electric is a responsive manufacturer, but the selectionand use of specific products sold by Lincoln Electric is solelywithin the control of, and remains the sole responsibility of thecustomer. Many variables beyond the control of Lincoln Electricaffect the results obtained in applying these types of fabricationmethods and service requirements.

Subject to Change – This information is accurate to the best of ourknowledge at the time of printing. Please refer to www.lincolnelectric.com for any updated information.

Documents

IM10465 Power Wave i400 - Welders, Welding Wire, Welding