AUTOMATED SOLUTIONS
Robotic Welding
®
Power Wave i400 Power Source &
AutoDrive™ 4R90 Wire Feeder
ꢀ
ꢀ
ꢀ
ꢀ
Intelligent Robotic Solution
Integrated System Design
Innovative Features
Industry Leading Design
The Power Wave® i400 & AutoDrive™ 4R90
solution delivers Lincoln’s best performance
technologies and welding processes all rolled
into one highly efficient inverter power source
paired with a compact, durable wire feeder
designed for high-end robotic welding.
With the increasing demands on welding
performance, choose the industry leader in
power, performance, and technology, Lincoln
Electric’s Power Wave® i400 and AutoDrive™
4R90 system.
AutoDrive™ 4R90
®
Power Wave i400
Publication E10.11 01/08
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A CLOSER LOOK
™
AutoDrive 4R90
ADVANTAGE LINCOLN
• Integrated Design - Designed to “nest” in the upper arm of the FANUC®
Robotics ARC Mate® 100iC arm.
• Durable and Rugged - Patented MAXTRAC® wire drive is precision cast
aluminum designed to provide reliable feed force.
• Ease of Use - Unlike competitive models, no tools are required for drive
roll, wire guide or pressure arm adjustment.
• High Performance - Brass-to-brass gun connections provide more
reliable electrical connectivity and more efficient energy transfer.
• Best in Class Torque - Results in faster acceleration and reliably pulls
wire through conduit.
• Precise Control - Dual spring pressure arms offer clear-cut adjustment
for optimizing pressure for different wire types.
• Welding Results - High resolution tachometer for accurate wire feed
speed control.
• Optimized Robotic Solution - Compact, lighter weight packaging
maximizes robot acceleration performance and throughput.
A new unique robotic wire feeder package
focused on .035-.045 wire applications.
High performance wire drive system featuring:
• Compact package
• Lightweight
• Tool-less design
• Durable and rugged
Publication E10.11
[3]
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®
WAVEFORM CONTROL TECHNOLOGY
DRIVING SUPERIOR WELDING PERFORMANCE
Lincoln’s Waveform Control Technology® controls and shapes the output waveforms (or weld modes).
It is the modulation of the welding current that achieves a specific desired welding result. High
performance, digital welding waveforms are developed based on the application and take into account
the process, gas, and wire size combinations.
The desired welding result is efficient, reliable, consistent, high performance welding which is delivered
with the Power Wave® i400 solution.
For more information see Nextweld® Document #NX-1.10
LINCOLN NEXTWELD® INNOVATIONS FOR CHALLENGING APPLICATIONS
Waveform Control Technology® makes it possible to take advantage of Lincoln Nextweld® innovations like
these patented processes using the Power Wave® i400 and the AutoDrive™ 4R90 wire feeder:
Lincoln Electric Welding
Feature Overview
•
•
•
•
•
•
•
Stable at very short arc lengths
Good at high travel speeds
Very low spatter
Wide range of filler metals
Out of position
Wide range of operating procedures
Low heat input
®
Rapid-Arc
- High Speed Welding
•
•
•
•
Join materials thinner than 20 gauge (0.7 mm)
Consistent arc stability & penetration profile
A stable arc despite stickout fluctuation
Wide range of filler metals
TM
Power Mode
- Consistent stability and penetration
TM
TOTAL s2f
TOTAL s2f™ - Aluminum Welding Solution
•
•
•
Spatter reduction
TM
Excellent cleaning action
• Pulse-on-Pulse
Wide range of frequency modulation (ripple affect) for uniform beads on welds in
which appearance is critical
Control of heat input on thinner materials
•
•
•
•
Spatter reduction
Excellent cleaning action
Synergic - "one knob control"
• Pulse Spray Transfer
The industry’s first web resource exclusively for fabricators
who rely on Lincoln Electric welding equipment.
PowerWaveSoftware.com offers users access to new
product software releases, system upgrades, welding
improvements, and Power Wave® Utilities.
Go to PowerWaveSoftware.com today!
Publication E10.11
[4]
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®
DIGITAL COMMUNICATIONS TECHNOLOGY
The Lincoln Electric Company led the industry with the introduction of ArcLink®, the first digital
communications protocol for the arc welding industry introduced in 2002. ArcLink® is a protocol, or
means of communicating and sharing information between intelligent components for seamless, time-
critical data transfer in an arc welding system.
®
Continuing this leading position, Lincoln Electric has now introduced another industry first with
ArcLink® XT, which takes all of the same features and benefits of traditional ArcLink communication,
but eXtends this communication protocol on an Ethernet connection directly to the FANUC® Robotics
R30iA controller.
For more information see Nextweld® Document #NX-1.30
LINCOLN ELECTRIC AND FANUC® ROBOTICS ADVANTAGES:
ArcLink! XT Features:
New Standard Features - Ethernet is a standard feature on the Power Wave® i400 with no
additional hardware cost and also offers Lincoln Electric's Production Monitoring™ utility as a
part of the robotic solution.
Performance Based Design - 100 MHz, full duplex Ethernet interface offers a reliable and
consistent hardware platform for industrial environments, and facilitates future feature expansion.
Lower Cost System - Lower cost system for multi-equipment (multi-arm) through addition of a
network Ethernet switch. No additional cards or hardware required.
ArcLink! Features:
Common User Interface - The Teach Pendant can display actual volts,
wire feed speed, etc, in process specific units.
Reduced Set-up Time - As an ArcLink® device, all communication with the
robot controller, power source, wire feeder are automatically recognized.
Full Access to Welding Database - Search by process, material, and
procedure right from the Teach Pendant and access all set-up variables.
HIGH SPEED DIGITAL CONTROL TECHNOLOGY & FEATURES:
Lincoln Electric emerges as an industry leader with a distributed control architecture
design in the Power Wave® i400 system created with a flexible design that ensures
future expansion capabilities and features.
The state-of-the-art technology used in this system is designed with the highest
performance digital controls in the robotic power source marketplace:
•
•
•
•
Over 5000 MIPS processing power
100 Mbps full duplex data transfer rate
32 Mbytes SDRAM memory
More than 16 Mbytes FLASH Memory
Publication E4.20
[5]
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A CLOSER LOOK
SYSTEM DIAGRAMS
Easy connection and installation provides for a stress-free commissioning stage. The ease of use and servicing ensures users
are efficient and productive with their time.
FANUC Robotics R-30iA
“a-cabinet” Controller
with Integrated Op Box
®
*ArcLink XT
Ethernet
cable
*Power
cable
®
Power Wave i400
K2669-1
**DETAIL A
A
New FANUC®Robotics/Lincoln Electric solution providing the latest technology and features together - the best of
robotics and robotic welding combined.
Electrode
Connection
AutoDrive™ 4R90
K2685-2
FANUC Robotics R-30iA
“a-cabinet” Controller
with Integrated Op Box
Wire Feeder
Gas
Air
ArcLink® XT
Ethernet Cable
(Internal)
Circuit Breaker
(15 Amp)
Devicenet
Connector
ARC Mate™ 1XXiC
*
Electrode
Power Wave® i400
K2669-1
Cable (+)
K2163-xx or
K1842-xx
Optional Work
Wire Feeder
Connector
Sense Lead (21)
Voltage Sense
Connector
Wire Feeder
Control Cable
K1785-xx
Work
Piece
ArcLink®
Connector
*
Work Cable (+)
K2163-xx or
K1842-xx
ArcLink® XT
Ethernet Connection
®
* Refer to Output Cable Guidlines for recommended cable size in Power Wave i400 Instruction Manual.
Publication E10.11
[6]
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A CLOSER LOOK
SYSTEM DIAGRAMS
Electrode
Connection
AutoDrive™ 4R90
K2685-2
FANUC Robotics R-30iA
“a-cabinet” Controller
with Integrated Op Box
Wire Feeder
Gas
Air
Flexible solution for integrated or
separated installations. The system
accommodates to your needs.
ARC Mate™ 1XXiC
Circuit Breaker
(15 Amp)
ArcLink® XT
Ethernet Cable
Devicenet
Connector
*
Electrode
Power Wave® i400
K2669-1
Cable (+)
K2163-xx or
K1842-xx
Wire
Feeder
Connector
Optional Work
Sense Lead (21)
Voltage
Sense
Connector
ArcLink®
Work
Piece
Wire Feeder
Control Cable
K1785-xx
Connector
ArcLink® XT
Ethernet
Connection
*
Work Cable (+)
K2163-xx or
K1842-xx
AutoDrive™ 4R90
Electrode
K2685-2
Connection
FANUC Robotics R-30iA
“a-cabinet” Controller
with Integrated Op Box
(Slave)
AutoDrive™
4R90
K2685-2
ArcLink® XT
Control Cable
Wire Feeder
Gas
FANUC Robotics R-30iA
“a-cabinet” Controller
with Integrated Op Box
(Master)
ARC Mate™ 1XXiC (Slave)
Air
Power Wave®
i400
*
Electrode
Cable (+)
Circuit Breaker
(15 Amp)
K2669-1
ARC Mate™
1XXiC (Master)
Optional Work
Sense Lead (21)
Devicenet
Connector
*
Electrode
Work
Piece
Cable (+)
Optional Work
Wire
Sense Lead (21)
Feeder
Connector
*Work
Work
Piece
Cable (+)
Power Wave®
i400
K2669-1
Dual Arm System
Voltage
Sense
Connector
ArcLink®
Connector
ArcLink® XT
Ethernet
Wire Feeder
Control Cable
K1785-xx
ArcLink® XT
Ethernet cable
(Internal)
Connection
*Work
Cable (+)
Wire Feeder
Control Cable
K1785-xx
FANUC Robotics
R-J3iB Controller
Gas
Air
Power Feed 10R
K1780-2
18” Adaper Cable
K1785-2
Electrode
Connection
Wire Feeder
Backward compatibility is supported
to ensure existing robotic cells can
be integrated with Power Wave® i400
(shown here is a Power Wave®
F355i replacement).
ARC Mate™ 1XXiBe
Air
Robotic
Torch
ArcLink®
Control Cable
K1543-xx
Power Wave® i400
K2669-1
Circuit Breaker
(15 Amp)
Gas
Wire Feeder
*
Electrode
Devicenet
Connector
Cable (+)
K2163-xx or
K1842-xx
Optional Work
Sense Lead (21)
Wire Feeder
Control Cable
K1785-xx
Work
Piece
Wire
Feeder
Connector
*
Work Cable (+)
Voltage
Sense
Connector
K2163-xx or
K1842-xx
ArcLink®
Connector
ArcLink® XT
Ethernet
Connection
Publication E10.11
[7]
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TECHNICAL SPECIFICATIONS
POWER WAVE® i400
Input Power
200/230/380-415/460/575
3 Phase Input
50/60 Hz
* Single product number - CE compliance is provided with a CE Filter
Kit. Input voltage is limited to 380-415/3/50/60 with kit installed.
Duty Cycle
350A/34V/100%
400A/36V/60%
420A/37V/40%
* No derating for CV versus Pulse modes.
Output Current Range
5-420 ADC
* Best in class rated machine for power.
Output Voltage Range
Cooling Method
10-37 VDC
Fan As Needed™ (F.A.N.)
* Cooling fan runs when the output is energized, and for 5 minutes after
the output has been turned off.
Power Factor at Rated Output
IP Rating
.95
IP21S
Welding Output
CV/DC
Welding Processes
Dimensions - H x W x D in (mm)
Net Weight - lbs (kg)
Volume
CV-MIG, Pulsed-MIG, Flux-cored, Metal-cored, Stainless, Aluminum
21 x 18.5 x 23.6 in (533 x 470 x 600 mm )
209 lbs. (95 kg)
3
0.150 m
Universal Certifications
CE, CSAC/UL, C-Tick
AUTODRIVE™ 4R90
Wire Drive
4 Driven Rolls
* 4 Gear powered rolls versus competitive 2 gear driven rolls & 2 idle rolls
Motor Type
Permanent Magnet DC Motor
Tachometer Type
Magnetic High Resolution Dual Channel
AutoDrive™ 4R90 - 50 to 800 in/min (0.8 to 20.3 m/min)
Wire Feed Speed Range in/min (m/min)
Max Wire Size Range
AutoDrive™ 4R90
Solid: .023 - .045” (0.6 – 1.2 mm)
Cored: .035 - .045 (0.9 - 1.2 mm)
Dimensions – L x W x H inches (mm)
Net Weight - lbs (kg)
9.1 x 7.5 x 8.4 inches (231 x 141 x 213 mm)
14.5 lbs. (6.5 kg)
Universal Certifications
CE, CSAC/UL, C-Tick
C U S T O M E R A S S I S T A N C E P O L I C Y
The business of The Lincoln Electric Company® is manufacturing and selling high quality welding equipment, consumables, and cutting equipment. Our challenge is to meet the needs of
our customers and to exceed their expectations. On occasion, purchasers may ask Lincoln Electric for information or advice about their use of our products. Our employees respond to
inquiries to the best of their ability based on information provided to them by the customers and the knowledge they may have concerning the application. Our employees, however, are not
in a position to verify the information provided or to evaluate the engineering requirements for the particular weldment. Accordingly, Lincoln Electric does not warrant or guarantee or assume
any liability with respect to such information or advice. Moreover, the provision of such information or advice does not create, expand, or alter any warranty on our products. Any express or
implied warranty that might arise from the information or advice, including any implied warranty of merchantability or any warranty of fitness for any customers’ particular purpose is
specifically disclaimed.
Lincoln Electric is a responsive manufacturer, but the selection and use of specific products sold by Lincoln Electric is solely within the control of, and remains the sole responsibility of the
customer. Many variables beyond the control of Lincoln Electric affect the results obtained in applying these types of fabrication methods and service requirements.
Subject to Change – This information is accurate to the best of our knowledge at the time of printing. Please refer to www.lincolnelectric.com for any updated information.
THE LINCOLN ELECTRIC COMPANY
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