Lincoln Electric POWER WAVE S700 Operator's Manual
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Lincoln Electric POWER WAVE S700 Operator's Manual

Lincoln Electric POWER WAVE S700 Operator's Manual

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Operator's Manual

POWER WAVE

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www.lincolnelectric.com/register
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Save for future reference
Date Purchased
Code: (ex: 10859)
Serial: (ex: U1060512345)
IM10144
| Issue D ate Aug-13
© Lincoln Global, Inc. All Rights Reserved.
®
S700
For use with machines having Code Numbers:
11957
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.
After hours?
Use "Ask the Experts" at lincolnelectric.com
A Lincoln Service Representative will contact you
no later than the following business day.
For Service outside the USA:
Email: globalservice@lincolnelectric.com

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Summary of Contents for Lincoln Electric POWER WAVE S700

  • Page 1: Power Wave

    Operator’s Manual ® POWER WAVE S700 For use with machines having Code Numbers: 11957 Need Help? Call 1.888.935.3877 Register your machine: to talk to a Service Representative www.lincolnelectric.com/register Authorized Service and Distributor Locator: Hours of Operation: www.lincolnelectric.com/locator 8:00 AM to 6:00 PM (ET) Mon. thru Fri. Save for future reference After hours? Use “Ask the Experts”...
  • Page 2 THANK YOU FOR SELECTING A QUALITY PRODUCT BY KEEP YOUR HEAD OUT OF THE FUMES. LINCOLN ELEC TRIC. DON’T get too close to the arc. Use corrective lenses if necessary to stay a reasonable distance away from the arc. READ and obey the Material Safety PLEASE EXAMINE CARTON AND EQUIPMENT FOR Data Sheet (MSDS) and the warning DAMAGE IMMEDIATELY...

  • Page 3: California Proposition 65 Warnings

    American Welding Society, P.O. Box 351040, Miami, Florida 33135 or ELECTRIC AND CSA Standard W117.2-1974. A Free copy of “Arc Welding Safety” MAGNETIC FIELDS MAY booklet E205 is available from the Lincoln Electric Company, 22801 St. Clair Avenue, Cleveland, Ohio 44117-1199. BE DANGEROUS BE SURE THAT ALL INSTALLATION, OPERATION, 2.a.

  • Page 4: Electric Shock Can Kill

    SAFETY ELECTRIC SHOCK ARC RAYS CAN BURN. CAN KILL. 3.a. The electrode and work (or ground) circuits are 4.a. Use a shield with the proper filter and cover plates to protect your electrically “hot” when the welder is on. Do eyes from sparks and the rays of the arc when welding or not touch these “hot”...
  • Page 5 SAFETY WELDING AND CUTTING CYLINDER MAY EXPLODE IF SPARKS CAN CAUSE DAMAGED. FIRE OR EXPLOSION. 7.a. Use only compressed gas cylinders containing the correct shielding gas for the process used 6.a. Remove fire hazards from the welding area. If and properly operating regulators designed for this is not possible, cover them to prevent the the gas and pressure used.
  • Page 6 Electric for advice or information about their use of our products. We respond to our customers based on the best information in our posses- sion at that time. Lincoln Electric is not in a position to warrant or guarantee such advice, and assumes no liability, with respect to such infor- mation or advice.

  • Page 7: Table Of Contents

    TABLE OF CONTENTS Page Installation........................Section A Technical Specifications ....................A-1, A-2 Safety Precautions .......................A-3 Suitable Location, Lifting ....................A-3 Stacking ........................A-3 Tilting..........................A-3 Input and Ground Connections ..................A-3 Machine Grounding .......................A-3 Input Connection ........................A-4 Input Fuse and Supply Wire ..................A-4 Input Voltage Selection ....................A-4 Reconnect Diagram......................A-5 High Frequency Protection....................A-5 System Overview and Connection Diagram.................A-5...

  • Page 8: Installation

    INSTALLATION TECHNICAL SPECIFICATIONS - POWER WAVE ® S700 POWER SOURCE-INPUT VOLTAGE AND CURRENT Model Power Factor @ Duty Cycle Input Voltage ± 10% Input Amperes Idle Power (Watts) Rated Output 205W Fan Off K3279-1 100% rating 380-415/440-460/500/575 55/46/42/38 (Max.) 360W Fan On (Max.) RATED OUTPUT Process...

  • Page 9: Physical Dimensions

    INSTALLATION PHYSICAL DIMENSIONS DEPTH WEIGHT MODEL CONFORMITY MARK HEIGHT WIDTH EN 60974-1 36.7 in (93.2 cm) 400 lbs (181 kg) 19.1 in (48.5 cm) 30.10 in (76.5 cm) K3279-1 CSA C/US TEMPERATURE RANGES STORAGE TEMPERATURE RANGE OPERATING TEMPERATURE RANGE Environmentally Hardened: -4°F to 104°F (-20C to 40C) Environmentally Hardened: -40°F to 185°F (-40C to 85C) IP23 155º(F) Insulation Class...

  • Page 10: Safety Precautions

    INSTALLATION Environmental limitations SAFETY PRECAUTIONS Read this The Power Wave S700 is IP23 rated for use in an ® entire installation section before you start installa- outdoor environment. The Power Wave S700 should ® tion. not be subjected to falling water during use nor WARNING should any parts of it be submerged in water.

  • Page 11: Input Connection

    INSTALLATION INPUT CONNECTION INPUT FUSE AND SUPPLY WIRE CONSIDERATIONS WARNING Refer to Specification Section for recommended fuse, ELECTRIC SHOCK can kill. wire sizes and type of the copper wires. Fuse the Only a qualified electrician should input circuit with the recommended super lag fuse or connect the input leads to the delay type breakers (also called "inverse time"...

  • Page 12: Reconnect Diagram

    INSTALLATION RECONNECT DIAGRAM INPUT SUPPLY CONNECTION DIAGRAM W / L3 WARNING Do not operate with covers removed V / L2 Disconnect input power before servicing U / L1 Do not touch electrically live parts Only qualified persons should install, ELECTRIC use or service this equipment SHOCK CAN KILL...
  • Page 13 INSTALLATION MIG PROCESS FIGURE A.2 POWER WAVE ® S700...
  • Page 14 INSTALLATION STICK PROCESS FIGURE A.3 POWER WAVE ® S700...
  • Page 15 INSTALLATION TIG PROCESS FIGURE A.4 POWER WAVE ® S700...
  • Page 16 INSTALLATION MIG AND WATER COOLER PROCESS FIGURE A.5 POWER WAVE ® S700...
  • Page 17 A-10 A-10 INSTALLATION SYNCHRONIZED TANDEM CONNECTION FIGURE A.6 POWER WAVE ® S700...
  • Page 18 A-11 A-11 INSTALLATION ROBOTIC SINGLE ARM PROCESS SETUP FIGURE A.7 POWER WAVE ® S700...
  • Page 19 A-12 A-12 INSTALLATION ANALOG INTERFACE SETUP FIGURE A.8 POWER WAVE ® S700...
  • Page 20 A-13 A-13 INSTALLATION CONTROL BOARD SETUP FOR SYNCHRONIZED TANDEM FIGURE A.9 POWER WAVE ® S700...

  • Page 21: Recommended Work Cable Sizes

    A-14 A-14 INSTALLATION The following recommendations apply to all out- RECOMMENDED WORK CABLE put polarities and weld modes: SIZES FOR ARC WELDING • Select the appropriate size cables per the Connect the electrode and work cables between the “Output Cable Guidelines” below. Excessive volt- age drops caused by undersized welding cables and S700 appropriate output studs of the Power Wave...

  • Page 22: Output Cable Guidelines

    A-15 A-15 INSTALLATION OUTPUT CABLE GUIDELINES (Table A.1) Percent Duty CABLE SIZES FOR COMBINED LENGTHS OF ELECTRODE AND WORK Amperes Cycle CABLES [RUBBER COVERED COPPER - RATED 167°F (75°C)] 100 to 150 Ft. 150 to 200 Ft. 200 to 250 Ft. 0 to 50 Ft.

  • Page 23: Cable Inductance And Its Effects On Welding

    A-16 A-16 INSTALLATION There are several different sense lead configurations CABLE INDUCTANCE AND ITS that can be used depending on the application. In EFFECTS ON WELDING extremely sensitive applications it may be necessary to route cables that contain the sense leads away from the electrode and work welding cables.

  • Page 24: Voltage Sensing Considerations For Multiple Arc Systems

    A-17 A-17 INSTALLATION General Guidelines for Voltage Sense Leads If Sense Leads ARE NOT Used: • Avoid common current paths. Current from adja- Sense leads should be attached as close to the weld cent arcs can induce voltage into each others cur- as practical, and out of the weld current path when rent paths that can be misinterpreted by the power possible.

  • Page 25: Circumferential Applications

    A-18 A-18 INSTALLATION • For circumferential applications, connect all work leads on one side of the weld joint, and all of the work voltage sense leads on the opposite side, such that they are out of the current path. (See Figure A.12) FIGURE A.12 POWER SOURCE...

  • Page 26: Control Cable Connections

    A-19 A-19 INSTALLATION CONTROL CABLE CONNECTIONS Note: DeviceNet cables should not be routed with weld cables, wire drive control cables, or any other current carrying device that can create a fluctuating GENERAL GUIDELINES magnetic field. Genuine Lincoln control cables should be used at all DeviceNet cables must be sourced locally by the cus- times (except where noted otherwise).

  • Page 27: Operation

    OPERATION SAFETY PRECAUTIONS DUTY CYCLE READ AND UNDERSTAND ENTIRE SECTION The duty cycle is based on a ten-minute period. A BEFORE OPERATING MACHINE. 40% duty cycle represents 4 minutes of welding and 6 WARNING minutes of idling in a ten-minute period. Refer to the technical specification section for the Power Wave ®...
  • Page 28 OPERATION GRAPHIC SYMBOLS THAT APPEAR ON THIS MACHINE OR IN THIS MANUAL POWER WAVE ® S700...

  • Page 29: Product Description

    OPERATION RECOMMENDED PROCESSES AND PRODUCT DESCRIPTION EQUIPMENT PRODUCT SUMMARY The Power Wave S700 is an advanced-process DC ® The Power Wave S700 is recommended for semi-automat- ® inverter and is rated for 700 amps, 44 volts at a 100% ic welding, robotic welding, and can be used for tandem duty cycle or 900 amps, 44 volts at a 60% duty cycle.

  • Page 30: Robotic Feeder Control Cables And Adapters

    OPERATION Basic Package K3279-1 Power Wave S700 ® K2230-1 Power Feed ® 10M Wire Feeder Control Cable (5 pin – 5 pin) - power source to wire feeder K1543-xx K1811-xx Sense Lead (work) Sync Tandem Package (2 of each Required) K3279-1 Power Wave®...
  • Page 31 OPERATION POWER WAVE ® S700...

  • Page 32: Case Front Controls

    OPERATION CASE FRONT CONTROLS (See Figure B.1) 1. POWER SWITCH: Controls input power to the Power Wave ® S700. 2. STATUS LED - A two color light that indicates the condition of the system. Normal operation is a steady green light. Error conditions are detailed in the Trouble Shooting Section of this manual.

  • Page 33: Case Back Controls

    OPERATION CASE BACK CONTROLS (See Figure B.2) 1. 115V/10A AUXILIARY OUTPUT RECEPTACLE. 2. 10 AMP CIRCUIT BREAKER (CB1) - Protects the 40VDC wire feeder power supply. 3. 10 AMP CIRCUIT BREAKER (CB2) - Protects the 115VAC auxiliary power receptacle. 4. ETHERNET CONNECTOR (RJ-45) - Provides Ethernet communication to remote equipment. 5.

  • Page 34: Common Welding Procedures

    Amps meet most needs. If a special welding program is In constant current modes, this control adjusts the desired, contact the local Lincoln Electric sales repre- welding amperage. sentative. Volts To make a weld, the Power Wave S700 needs to ®...
  • Page 35 OPERATION SMAW (STICK) WELDING Non Synergic CV The welding current and Arc Force settings can be set In non-synergic modes, the WFS control behaves like through a Power Feed 10M or Power Feed ™ ™ a conventional CV power source where WFS and volt- wire feeder.
  • Page 36 B-10 B-10 OPERATION Most pulse welding programs are synergic. As the WELD PROCESS ADJUSTMENTS wire feed speed is adjusted, the Power Wave S700 ® will automatically recalculate the waveform parame- Depending on the weld mode, there are a number of ters to maintain similar arc properties.

  • Page 37: Accessories

    ACCESSORIES KITS, OPTIONS AND ACCESSORIES User Interface / Meter Kit Mounts on the Control Board Access Panel on the All Kits Options and Accessories are found on the front of the Power Wave® S700. Also displays actual Web site: (www.lincolnelectric.com) voltage and current while welding in any mode.

  • Page 38: Maintenance

    MAINTENANCE SAFETY PRECAUTIONS PERIODIC MAINTENANCE WARNING Calibration of the Power Wave ® S700 is critical to its ELECTRIC SHOCK can kill. operation. Generally speaking, the calibration will not • Do not operate with covers need adjustment. However, neglected or improperly removed.

  • Page 39: Troubleshooting

    HOW TO USE TROUBLESHOOTING GUIDE WARNING Service and Repair should only be performed by Lincoln Electric Factory Trained Personnel. Unauthorized repairs performed on this equipment may result in danger to the technician and machine operator and will invalidate your factory warranty. For your safety and to avoid Electrical Shock, please observe all safety notes and precautions detailed throughout this manual.
  • Page 40 TROUBLESHOOTING USING THE STATUS LED TO Troubleshooting the Power Wave ® Using the Status LED TROUBLESHOOT SYSTEM PROBLEMS The STATUS LIGHT is a two color light that indicates sys- tem errors. Normal operation is a steady green light. Error The Power Wave ®...
  • Page 41 TROUBLESHOOTING Observe all Safety Guidelines detailed throughout this manual ERROR CODES FOR THE POWER WAVE S700 ® The following is a list of possible error codes that the Power Wave ® S700 can output via the status light (see “Troubleshooting the Power Wave System Using the Status LED”).
  • Page 42 CAUSE COURSE OF ACTION Basic Machine Problems Major physical or electrical damage Contact your local authorized Lincoln Electric Field Service facility for is evident when the sheet metal cov- technical assistance. ers are removed. Input fuses keep blowing, or input 1.
  • Page 43 TROUBLESHOOTING Observe all Safety Guidelines detailed throughout this manual PROBLEMS POSSIBLE RECOMMENDED (SYMPTOMS) CAUSE COURSE OF ACTION Thermal LED is ON Improper fan operation Basic Machine Problems (Continued) 1. Make certain that the input volt- Machine wonʼt produce full output. 1.
  • Page 44 DIAGRAMS POWER WAVE ® S700...
  • Page 45 DIMENSION PRINT POWER WAVE ® S700...
  • Page 46 Do not touch electrically live parts or Keep flammable materials away. Wear eye, ear and body protection. WARNING electrode with skin or wet clothing. Insulate yourself from work and ground. Spanish No toque las partes o los electrodos Mantenga el material combustible Protéjase los ojos, los oídos y el AVISO DE bajo carga con la piel o ropa mojada.
  • Page 47 Keep your head out of fumes. Turn power off before servicing. Do not operate with panel open or WARNING Use ventilation or exhaust to remove guards off. fumes from breathing zone. Spanish Los humos fuera de la zona de res- Desconectar el cable de alimentación No operar con panel abierto o AVISO DE...
  • Page 48 Lincoln Electric for advice or information about their use of our products. We respond to our customers based on the best information in our possession at that time. Lincoln Electric is not in a position to warrant or guarantee such advice, and assumes no liability, with respect to such information or advice.

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