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Operator's Manual
POWER WAVE
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Date Purchased
Code: (ex: 10859)
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IM10456
| Issue D ate Oct-17
© Lincoln Global, Inc. All Rights Reserved.
®
S500
For use with machines having Code Numbers:
12772, 12773, 12774, 12775
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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no later than the following business day.
For Service outside the USA:
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Table of Contents
Related Manuals for Lincoln Electric Power Wave S500 K2904-1
Summary of Contents for Lincoln Electric Power Wave S500 K2904-1
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Page 1: Power Wave
Operator’s Manual ® POWER WAVE S500 For use with machines having Code Numbers: 12772, 12773, 12774, 12775 Need Help? Call 1.888.935.3877 Register your machine: to talk to a Service Representative www.lincolnelectric.com/registration Authorized Service and Distributor Locator: Hours of Operation: www.lincolnelectric.com/locator 8:00 AM to 6:00 PM (ET) Mon. - Page 2 THANK YOU FOR SELECTING A QUALITY PRODUCT BY KEEP YOUR HEAD OUT OF THE FUMES. DON’T get too close to the arc. LINCOLN ELEC TRIC. Use corrective lenses if necessary to stay a reasonable distance away from the arc. READ and obey the Safety Data PLEASE EXAMINE CARTON AND EQUIPMENT FOR Sheet (SDS) and the warning label DAMAGE IMMEDIATELY...
- Page 3 MAGNETIC FIELDS MAY W117.2-1974. A Free copy of “Arc Welding Safety” booklet BE DANGEROUS E205 is available from the Lincoln Electric Company, 22801 St. Clair Avenue, Cleveland, Ohio 44117-1199. 2.a. Electric current flowing through any conductor BE SURE THAT ALL INSTALLATION, OPERATION, causes localized Electric and Magnetic Fields (EMF).
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Page 4: Electric Shock Can Kill
S FETY 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 S FETY 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 welding sparks the gas and pressure used.
- Page 6 PRÉCAUTIONS DE SÛRETÉ 5. Toujours porter des lunettes de sécurité dans la zone de Pour votre propre protection lire et observer toutes les instruc- soudage. Utiliser des lunettes avec écrans lateraux dans les tions et les précautions de sûreté specifiques qui parraissent zones où...
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Page 7: Welding Cables
EN 60974-10 Electromagnetic Compatibility (EMC) Product Standard for Arc Welding Equipment. It is for use with other Lincoln Electric methods of reduCIng emIssIons equipment. It is designed for industrial and professional use. -
Page 8: Table Of Contents
TABLE OF CONTENTS INSTALLATION............................. SECTION A TECHNICAL SPECIFICATIONS............................. A-1 SELECT SUITABLE LOCATION.............................A-3 LIFTING ................................A-3 STACKING ................................A-3 TILTING ................................A-3 INPUT AND GROUND CONNECTIONS.......................... A-3 MACHINE GROUNDING ..............................A-3 HIGH FREQUENCY PROTECTION..........................A-3 INPUT CONNECTION..............................A-4 INPUT FUSE AND SUPPLY WIRE CONSIDERATIONS.....................A-4 INPUT VOLTAGE SELECTION............................ - Page 9 POWER WAVE ® S500 INSTALLATION TECHNICAL SPECIFICATIONS - POWER WAVE S500 ® POWER SOURCE-INPUT VOLTAGE AND CURRENT Model Input Voltage ± 10% Input Amperes Idle Power Power Factor @ Duty Cycle Rated Output 40% rating 208/230/400*460/575 80/73/41/37/29 K2904-1 50/60 Hz 500 Watts Max.
- Page 10 POWER WAVE ® S500 INSTALLATION TECHNICAL SPECIFICATIONS - POWER WAVE S500 CCC ® POWER SOURCE-INPUT VOLTAGE AND CURRENT Model Input Voltage ± 10% Input Amperes Idle Power Power Factor @ Duty Cycle Rated Output 40% rating 400/460/575 41/37/29 K2904-2 50/60 Hz 500 Watts Max.
- Page 11 POWER WAVE ® S500 INSTALLATION ® TECHNICAL SPECIFICATIONS - POWER WAVE S500CE POWER SOURCE-INPUT VOLTAGE AND CURRENT Model Input Voltage ± 10% Input Amperes Idle Power Power Factor @ Duty Cycle Rated Output 40% rating 230/400*460/575 67/41/34/27 K3168-1 50/60 Hz 300 Watts Max.
- Page 12 POWER WAVE ® S500 INSTALLATION WELDING PROCESS PROCESS OUTPUT RANGE (AMPERES) OCV (U Mean Peak GMAW 40-550A GMAW-Pulse FCAW 100V GTAW-DC 5-550A SMAW 15-550A PHYSICAL DIMENSIONS MODEL HEIGHT WIDTH DEPTH WEIGHT K2904-1 24.80in ( 630mm) 150 lbs (68 kg) 22.45 in ( 570 mm) 14.00in ( 356 mm) TEMPERATURE RANGES OPERATING TEMPERATURE RANGE...
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Page 13: Installation
POWER WAVE ® S500 INSTALLATION INSTALLATION LIfTINg Both handles should be used when lifting POWER WAVE® S500. SAFETY PRECAUTIONS When using a crane or overhead device a lifting strap should be READ AND UNDERSTAND ENTIRE SECTION BEFORE connected to both handles. Do not attempt to lift the POWER OPERATING MACHINE. -
Page 14: Input Connection
POWER WAVE ® S500 INSTALLATION WARNING INPUT fUSE AND SUPPLY WIRE CONSIDERATIONS Refer to Specification Section for recommended fuse, wire sizes Only a qualified electrician should connect and type of the copper wires. Fuse the input circuit with the the input leads to the POWER WAVE® S500. recommended super lag fuse or delay type breakers (also called Connections should be made in accordance "inverse time"... - Page 15 POWER WAVE ® S500 INSTALLATION FIGURE A.1 - S500 CE GROUND CONNECTION CONNECT GROUND LEAD PER LOCAL AND NATIONAL ELECTRIC CODE CONNECT EACH PHASE OF A THREE-PHASE CONDUCTOR HERE CE FILTER INPUT CORD STRAIN RELIEF ROUTE INPUT CORD THROUGH RELIEF AND TWIST NUT TO TIGHTEN INPUT POWER ACCESS DOOR On some models, toroids are on the power cord.
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Page 16: Connection Diagrams
POWER WAVE ® S500 INSTALLATION CONNECTION DIAgRAMS GTAW (TIG) WELDING A user interface is required for adjusting the TIG welding settings. S-series user interface (K3001-2) can be installed into the power source (Figure A.2). Refer to the connection diagrams based on the user interface that is being used. - Page 17 POWER WAVE ® S500 INSTALLATION SMAW (STICK) WELDING Similar to TIG welding a user interface is required for adjusting the Stick welding settings. A Power Feed wire feeder can be used as the user interface, or a K3001-2 (user interface control panel) can be installed into the power source (Figure A.3).
- Page 18 POWER WAVE ® S500 INSTALLATION GMAW (MIG) WELDING An arclink compatible wire feeder is recommended for Mig welding. Refer to Figure A.4 for the connection details. FIGURE A4 MIG PROCESS R R E E G G U U L L A A T T O O R R F F L L O O W W M M E E T T E E R R G G AS AS H H O O S S E E...
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Page 19: Recommended Work Cable Sizes For Arc Welding
POWER WAVE ® S500 INSTALLATION General Guidelines • Select the appropriate size cables per the “Output Cable RECOMMENDED WORk CABLE SIZES fOR ARC WELDINg Guidelines” below. Excessive voltage drops caused by undersized welding cables and poor connections often result Connect the electrode and work cables between the appropriate in unsatisfactory welding performance. -
Page 20: Cable Inductance And Its Effects On Welding
POWER WAVE ® S500 INSTALLATION The POWER WAVE® S500 has the ability to automatically sense when remote sense leads are connected. With this feature there CABLE INDUCTANCE AND ITS EffECTS ON are no requirements for setting-up the machine to use remote WELDINg sense leads. - Page 21 POWER WAVE ® S500 INSTALLATION Electrode Voltage Sensing The remote ELECTRODE sense lead (67) is built into the 5-pin arclink control cable and is always connected to the wire drive feed plate when a wire feeder is present. Enabling or disabling electrode voltage sensing is application specific, and automatically configured by the active weld mode.
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Page 22: Voltage Sensing Considerations For Multiple Arc Systems
POWER WAVE ® S500 INSTALLATION VOLTAgE SENSINg CONSIDERATIONS fOR If Sense Leads ARE Used: MULTIPLE ARC SYSTEMS • Position the sense leads out of the path of the weld current. Special care must be taken when more than one arc is welding Especially any current paths common to adjacent arcs. - Page 23 POWER WAVE ® S500 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.7) FIGURE A.7 A-13...
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Page 24: Control Cable Connections
POWER WAVE ® S500 INSTALLATION CONTROL CABLE CONNECTIONS General Guidelines Genuine Lincoln control cables should be used at all times (except where noted otherwise). Lincoln cables are specifically designed for the communication and power needs of the Power Wave® / Power Feed™... -
Page 25: Operation
POWER WAVE ® S500 OPERATION OPERATION gRAPhIC SYMBOLS ThAT APPEAR ON ThIS MAChINE OR IN ThIS MANUAL SAFETY PRECAUTIONS WARNING OR READ AND UNDERSTAND ENTIRE SECTION BEFORE CAUTION OPERATING MACHINE. WARNING DANGEROUS ELECTRIC SHOCK CAN KILL. VOLTAGE • Do not touch electrically live part or electrode with skin or wet clothing. -
Page 26: Product Description
POWER WAVE ® S500 OPERATION PRODUCT DESCRIPTION S500 DESIgN fEATURES - ALL MODELS Loaded with Standard Features The POWER WAVE® S500 is a portable multi-process power source with high-end functionality capable of Stick, DC TIG, MIG, • Multiple process DC output range: 5 - 550 Amps Pulsed MIG and Flux-Cored welding. - Page 27 POWER WAVE ® S500 OPERATION STANDARD S500 AND CCC MODEL CASE fRONT CONTROLS CASE BACk CONTROLS (See Figure B.1) (See Figure B.2) 1. User Interface (optional) 1. 115 VAC CIRCUIT BREAKER 2. Status LED - (See Troubleshooting Section for operational 2.
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Page 28: S500 Case Front Controls
POWER WAVE ® S500 OPERATION S500 CE MODEL S500 CE CASE fRONT CONTROLS S500 CE CASE BACk CONTROLS (See Figure B.1 - S500 CE) (See Figure B.2 - S500 CE) 1. User Interface (optional) 1. Gas Inlet (optional) 2. Status LED - (See Troubleshooting Section for operational 2. -
Page 29: Common Welding Procedures
Many variables beyond the control of into the POWER WAVE® S500 at the factory, refer to the Weld Set The Lincoln Electric Company affect the results obtained Reference Guide supplied with the machine or available at in applying these programs. These variables include, but www.powerwavesoftware.com. - Page 30 POWER WAVE ® S500 OPERATION SMAW (STICK) WELDING The nominal preprogrammed voltage is the best average voltage for a given wire feed speed, but may be adjusted to preference. The welding current and Arc Force settings can be set through a When the wire feed speed changes, the POWER WAVE®...
- Page 31 POWER WAVE ® S500 OPERATION Most pulse welding programs are synergic. As the wire feed speed is adjusted, the POWER WAVE® S500 will automatically recalculate the waveform parameters to maintain similar arc properties. The POWER WAVE® S500 utilizes “adaptive control” to compensate for changes in the electrical stick-out while welding.
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Page 32: Kits, Options And Accessories
POWER WAVE ® S500 ACCESSORIES KITS, OPTIONS AND STICk OPTIONS ACCESSORIES Accessory Kit - 150 Amp For stick welding. Includes 20 ft. (6.1m) #6 All Kits Options and Accessories are found on the Web site: electrode cable with lug, 15 ft. (4.6m) #6 work (www.lincolnelectric.com) cable with lugs, headshield, filter plate, work clamp, electrode holder and sample pack of... -
Page 33: Maintenance
POWER WAVE ® S500 MAINTENANCE MAINTENANCE SAFETY PRECAUTIONS READ AND UNDERSTAND ENTIRE SECTION BEFORE OPERATING MACHINE. WARNING ELECTRIC SHOCK can kill. • Do not operate with covers removed. • Turn off power source before installing or servicing. • Do not touch electrically hot parts. •... -
Page 34: Troubleshooting
POWER WAVE ® S500 TROUBLESHOOTING TROUBLESHOOTING USINg ThE STATUS LED TO TROUBLEShOOT hOW TO USE TROUBLEShOOTINg gUIDE SYSTEM PROBLEMS Not all of the POWER WAVE® S500 errors will be displayed on the WARNING user interface (if it is installed). There are two status lights that display error codes. - Page 35 POWER WAVE ® S500 TROUBLESHOOTING TABLE E.1 Observe all Safety Guidelines detailed throughout this manual Meaning Light Condition Main control board status light and Input control board System OK. Power source is operational, and is communicating normally with all healthy peripheral Steady Green equipment connected to its ArcLink network.
- Page 36 POWER WAVE ® S500 TROUBLESHOOTING ERROR CODES FOR THE POWER WAVE S500 ® The following is a partial list of possible error codes for the POWER WAVE ® S500. For a complete listing consult the Service Manual for this machine. maIn Control Board ( “status”...
- Page 37 POWER WAVE ® S500 TROUBLESHOOTING InPut Control Board Error Code # Indication Type Instantaneous input current limit has been exceeded. Typically indicates short 331 Instantaneous Input Current Limit Persistent term power overload. If problem persists contact Service Department. Input current limit was exceeded during machine power-up. If problem 334 Startup Current Check Failure Persistent persists contact Service Department.
- Page 38 3. Possible short in output circuit. If exceeded. (see error 54) condition persists, contact an authorized Lincoln Electric Field Service facility. 3a. Input control board fault (see input control board error status). 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.
- Page 39 POWER WAVE ® S500 TROUBLESHOOTING PROBLEMS POSSIBLE RECOMMENDED (SYMPTOMS) CAUSE COURSE OF ACTION Thermal LED is ON Improper fan operation Basic Machine Problems (Continued) 1. Improper fan operation. 1. Check for proper fan operation. Fan Thermal LED is ON should run in a low speed setting when the machine is idle and in a high speed when the output is triggered.
- Page 40 POWER WAVE ® S500 TROUBLESHOOTING PROBLEMS POSSIBLE RECOMMENDED (SYMPTOMS) CAUSE COURSE OF ACTION Weld and Arc Quality Problems (Continued) Wire burns back to tip at the end of the 1. Burnback Time 1. Reduce burnback time and/or work point. weld. 1.
- Page 41 POWER WAVE ® S500 TROUBLESHOOTING PROBLEMS POSSIBLE RECOMMENDED (SYMPTOMS) CAUSE COURSE OF ACTION Ethernet Cannot Connect 1. Physical connection. 1. Verify that the correct patch cable or cross over cable is being used (refer to local IT department for assistance). 1a.
- Page 42 POWER WAVE ® S500 DIAGRAMS xxxxxxx xxxxxxx xxxxxxx xxxxxxx...
- Page 43 POWER WAVE ® S500 DIAGRAMS...
- Page 44 POWER WAVE ® S500 DIAGRAMS xxxxxxx xxxxxxx xxxxxxx xxxxxxx...
- Page 45 POWER WAVE ® S500 DIAGRAMS POWER WAVE ® S500 & S500CCC- DIMENSIONAL PRINT...
- Page 46 POWER WAVE ® S500 DIAGRAMS POWER WAVE ® S500 CE - DIMENSIONAL PRINT...
- Page 50 WARNING Do not touch electrically live parts or Keep flammable materials away. Wear eye, ear and body protection. electrode with skin or wet clothing. Insulate yourself from work and AVISO DE ground. Spanish PRECAuCION No toque las partes o los electrodos Mantenga el material combustible Protéjase los ojos, los oídos y el bajo carga con la piel o ropa moja-...
- Page 51 WARNING Keep your head out of fumes. Turn power off before servicing. Do not operate with panel open or Use ventilation or exhaust to guards off. remove fumes from breathing zone. AVISO DE Spanish PRECAuCION Los humos fuera de la zona de res- Desconectar el cable de ali- No operar con panel abierto o piración.
- Page 52 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.