Lincoln Electric AutoDrive 4R90 User manual

Powe Wave®i400
Robotic Welding
Power Wave®i400 Power Source &
AutoDrive™ 4R90 Wire Feeder
The Power Wave®i400 & AutoDrive™ 4R90
solution delivers incoln’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, incoln
Electric’s Power Wave®i400 and AutoDrive™
4R90 system.
Publication E10.11 01/08
www.lincolnelectric.com
AUTOMATED SOLUTIONS
Intelligent Robotic Solution
Integrated System Design
Innovative Features
Industry Leading Design
AutoD ive™4R90

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Publication E10.11
www.lincolnelectric.com
A CLOSER LOOK
ADVANTAGE LINCOLN
•Flexible Design - Designed for simple, seamless integration with the
FANUC®Robotics R-30iA Controller, or use as a separated configuration
to meet your weld cell requirements.
•Quality and Consistent Welding Results - incoln’s Waveform Control
Technology®gives you the ability to select the right waveform for each
application – that means the arc has been optimized for each wire type
and size for exceptionally smooth arc performance.
•High Performance Digital Communications - High speed digital
communication via Arc ink®protocol, a CAN connection or now the
Arc ink®XT™, the Arc ink®protocol can be communicated over an
Ethernet cable.
•Best in Class Power - 10-420 amps output delivers the power you need
for a wide range of processes and materials, with no derating for pulse
waveforms.
•Ready to Perform - Auxiliary outlet offers flexibility to add fume extraction,
water cooler, computer or other accessories quickly and easily.
DESIGN FEATURES
• Industry best 120 kHz inverter:
- Operates at a high efficiency and (.95) power factor at rated output.
- Capable of operating from a universal input voltage (208 to 575 volts).
• Fan-As-Needed™ (F.A.N.) - reduces power consumption and the amount
of debris that gets drawn into the machine by shutting the fan down
when it is not needed.
• Engineered Power Distribution:
- Single power drop saves time and cost.
- 3 phase input power supplied to robot
controller via dedicated reconnect block.
- 115VAC, 15 amp capacity auxiliary duplex receptacle to power
optional water cooler, fume extraction, grinder, and computer.
• Recessed connection panel for protection against accidental impact.
• External access to controller mounting hardware.
MAINTENANCE AND SERVICE
• Removable left side panel permits easy access to internal components
for routine maintenance or repair, even when integrated in a robotic cell.
• Panel mounted status ED indicators allow for quick and easy
troubleshooting.
• ockable on/off power switch on power source for controller/robot for
maintenance purposes (power must be disconnected at the wall).
• Mechanical connection to R-30iA Controller accessible from exterior
of Power Wave®i400 for easy removal of controller.
• Full support of incoln Electric Diagnostic Utility software for easy
troubleshooting through the Teach Pendant.
Powe Wave®i400 What is Coaxial Transfor er Technology™?
Coaxial Transformer Technology™ eliminates inefficiency and power
loss. Regardless of the size (power level) a coaxial transformer has
superior coupling and efficiency. This is obtained through the coaxial
orientation of the primary and secondary windings.
The benefits for the customer include:
• Higher power capabilities with a less
complex design.
• Higher efficiency (reduced energy costs).
• Higher reliability (lower stresses on components).
• Proven reliability.

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Publication E10.11
www.lincolnelectric.com
A CLOSER LOOK
A new unique robotic wire feeder package
focused on .035-.045 wire applications.
High perfor ance wire drive syste featuring:
• Co pact package
• Lightweight
• Tool-less design
• Durable and rugged
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.
•O timized Robotic Solution - Compact, lighter weight packaging
maximizes robot acceleration performance and throughput.
AutoD ive™4R90

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Publication E10.11
www.lincolnelectric.com
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:
WAVEFORM CONTROL TECHNOLOGY®
DRIVING SUPERIOR WELDING PERFORMANCE
Lincoln Electric Welding Feature Overview
Rapid-Arc®• Stable at very short arc lengths
• Good at high travel speeds
•Very low spatter
- High Speed Welding • Wide range of filler metals
•Out of position
• Wide range of operating procedures
•ow heat input
Power ModeTM • Join materials thinner than 20 gauge (0.7 mm)
• Consistent arc stability & penetration profile
• A stable arc despite stickout fluctuation
- Consistent stability and penetration • Wide range of filler metals
TOTAL s2fTM
TOTA s2f™- Aluminum Welding Solution
Pulse-on-PulseTM • Spatter reduction
• Excellent cleaning action
• Wide range of frequency modulation (ripple affect) for uniform beads on welds in
which appearance is critical
• Control of heat input on thinner materials
Pulse Spray Transfer • Spatter reduction
• Excellent cleaning action
• Synergic - "one knob control"
The industry’s first web resource exclusively for fabricators
who rely on incoln 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!
incoln’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

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
www.lincolnelectric.com
[5]
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 FAN C®Robotics
R30iA controller.
For more information see Nextweld®Document #NX-1.30
®
LINCOLN ELECTRIC AND FANUC®ROBOTICS ADVANTAGES:
ArcLink! XT Features:
New Standard Feat res - 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.
Red ced Set- p Time - As an ArcLink®device, all communication with the
robot controller, power source, wire feeder are automatically recognized.
F ll Access to Welding Database - Search by process, material, and
procedure right from the Teach Pendant and access all set-up variables.

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Publication E10.11
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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.
New FANUC®Robotics/Lincoln Electric solution providing the latest technology and features together - the best of
robotics and robotic welding combined.
Power Wave®i400
2669-1
FANUC Robotics R-30iA
“a-cabinet” Controller
with Integrated Op Box
*Power
cable
*ArcLink®XT
Ethernet
cable
* Refer to Output Cable Guidlines for recommended cable size in Power Wave®i400 Instruction Manual.
ArcLink®XT
Ethernet Connection
ArcLink®
Connector
Voltage Sense
Connector
Wire Feeder
Connector
Devicenet
Connector
Circuit Breaker
(15 Amp)
FANUC Robotics R-30iA
“a-cabinet” Controller
with Integrated Op Box
ArcLink®XT
Ethernet Cable
(Internal)
Power Wave®i400
2669-1
AutoDrive™ 4R90
2685-2
Electrode
Connection
ARC Mate™ 1XXiC
Air
Gas
Wire Feeder
Work
Piece
* Electrode
Cable (+)
2163-xx or
1842-xx
* Work Cable (+)
2163-xx or
1842-xx
Wire Feeder
Control Cable
1785-xx
Optional Work
Sense Lead (21)
**DETAIL A
A

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Publication E10.11
www.lincolnelectric.com
A CLOSER LOOK
SYSTEM DIAGRAMS
Backward compatibility is supported
to ensure existing robotic cells can
be integrated with Power Wave®i400
(shown here is a Power Wave®
F355i replacement).
Flexible solution for integrated or
separated installations. The system
accommodates to your needs.
Dual Arm System
ArcLink®XT
Ethernet
Connection
ArcLink®
Connector
Voltage
Sense
Connector
Wire
Feeder
Connector
Devicenet
Connector
Circuit Breaker
(15 Amp)
ArcLink®XT
Ethernet
Connection
ArcLink®
Connector
Voltage
Sense
Connector
Wire
Feeder
Connector
Devicenet
Connector
Circuit Breaker
(15 Amp)
ArcLink®XT
Ethernet
Connection
ArcLink®
Connector
Voltage
Sense
Connector
Wire
Feeder
Connector
Devicenet
Connector
Circuit Breaker
(15 Amp)
FANUC Robotics R-30iA
“a-cabinet” Controller
with Integrated Op Box
ArcLink®XT
Ethernet Cable
Power Wave®i400
2669-1
AutoDrive™ 4R90
2685-2
Electrode
Connection
ARC Mate™ 1XXiC
Air
Gas
Wire Feeder
Power Wave®
i400
2669-1
FANUC Robotics R-30iA
“a-cabinet” Controller
with Integrated Op Box
(Master)
FANUC Robotics R-30iA
“a-cabinet” Controller
with Integrated Op Box
(Slave)
ArcLink®XT
Control Cable
Power Wave®
i400
2669-1
ARC Mate™ 1XXiC (Slave)
ARC Mate™
1XXiC (Master)
AutoDrive™ 4R90
2685-2
AutoDrive™
4R90
2685-2
Electrode
Connection
Air
Gas
Wire Feeder
ARC Mate™ 1XXiBe
Air
Gas
Wire Feeder
Work
Piece
Work
Piece
Work
Piece
* Electrode
Cable (+)
* Electrode
Cable (+) Work
Piece
*Work
Cable (+)
*Work
Cable (+)
* Electrode
Cable (+)
2163-xx or
1842-xx
*Work Cable (+)
2163-xx or
1842-xx
Wire Feeder
Control Cable
1785-xx
Wire Feeder
Control Cable
1785-xx
Wire Feeder
Control Cable
1785-xx
Air
Gas
Wire Feeder
Electrode
Connection
ArcLink®
Control Cable
1543-xx
Optional Work
Sense Lead (21)
Optional Work
Sense Lead (21)
Optional Work
Sense Lead (21)
ArcLink®XT
Ethernet cable
(Internal)
* Work Cable (+)
2163-xx or
1842-xx
Wire Feeder
Control Cable
1785-xx
Optional Work
Sense Lead (21)
* Electrode
Cable (+)
2163-xx or
1842-xx
Power Wave®i400
2669-1
FANUC Robotics
R-J3iB Controller
Robotic
Torch
18” Adaper Cable
1785-2
Power Feed 10R
1780-2

POWER WAVE®i400
Input Power 200/230/380-415/460/575
3 Phase Input
50/60 Hz
*Si gle product umber - CE complia ce is provided with a CE Filter
Kit. I put voltage is limited to 380-415/3/50/60 with kit i stalled.
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 10-37 VDC
Cooling Method Fan As Needed™ (F.A.N.)
* Cooli g fa ru s whe the output is e ergized, a d for 5 mi utes after
the output has bee tur ed off.
Power Factor at Rated Output .95
IP Rating IP21S
Welding Output CV/DC
Welding Processes CV-MIG, Pulsed-MIG, Flux-cored, Metal-cored, Stainless, Aluminum
Dimensions - H x W x D in (mm) 21 x 18.5 x 23.6 in (533 x 470 x 600 mm )
Net Weight - lbs (kg) 209 lbs. (95 kg)
Volume 0.150 m3
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
Wire Feed Speed Range in/min (m/min) AutoDrive™ 4R90 - 50 to 800 in/min (0.8 to 20.3 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) 9.1 x 7.5 x 8.4 inches (231 x 141 x 213 mm)
Net Weight - lbs (kg) 14.5 lbs. (6.5 kg)
Universal Certifications CE, CSAC/UL, C-Tick
THE LINCOLN ELECTRIC COMPANY
22801 St. Clair Ave., Cleveland, OH 44117-1199 • 216.481.8100 • www.lincolnelectric.com
TECHNICAL SPECIFICATIONS
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 usiness of The Lincoln Electric Company®is manufacturing and selling high quality welding equipment, consuma les, 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 a out their use of our products. Our employees respond to
inquiries to the est of their a ility ased on information provided to them y 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 lia ility 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 merchanta ility or any warranty of fitness for any customers’ particular purpose is
specifically disclaimed.
Lincoln Electric is a responsive manufacturer, ut the selection and use of specific products sold y Lincoln Electric is solely within the control of, and remains the sole responsi ility of the
customer. Many varia les eyond the control of Lincoln Electric affect the results o tained in applying these types of fa rication methods and service requirements.
Su ject to Change – This information is accurate to the est of our knowledge at the time of printing. Please refer to www.lincolnelectric.com for any updated information.