Lincoln Electric POWER WAVE S500 Operator's Manual
  1. Manuals
  2. Brands
  3. Lincoln Electric Manuals
  4. Welding System
  5. POWER WAVE S500
  6. Operator's manual
Lincoln Electric POWER WAVE S500 Operator's Manual

Lincoln Electric POWER WAVE S500 Operator's Manual

Hide thumbs Also See for POWER WAVE S500:
Table of Contents

Advertisement

Quick Links

Download this manual
Operator's Manual
POWER WAVE
Register your machine:
www.lincolnelectric.com/registration
Authorized Service and Distributor Locator:
www.lincolnelectric.com/locator
Save for future reference
Date Purchased
Code: (ex: 10859)
Serial: (ex: U1060512345)
IM10118-A
| Issue D ate Oct-14
© Lincoln Global, Inc. All Rights Reserved.
®
S500
For use with machines having Code Numbers:
11813, 12243
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

Advertisement

Table of Contents
loading

Related Manuals for Lincoln Electric POWER WAVE S500

Summary of Contents for Lincoln Electric POWER WAVE S500

  • Page 1 Operator’s Manual ® POWER WAVE S500 For use with machines having Code Numbers: 11813, 12243 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. 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. 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 W117.2-1974. A Free copy of “Arc Welding Safety” booklet E205 is available from the Lincoln Electric Company, 2.d. All welders should use the following procedures in order to 22801 St. Clair Avenue, Cleveland, Ohio 44117-1199.
  • Page 4 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 welding sparks the gas and pressure used.

  • Page 6: Table Of Contents

    TABLE OF CONTENTS Page Installation........................Section A Technical Specifications ....................A-1, A-2 Safety Precautions .......................A-3 Location, 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..................A-4 Input Voltage Selection ....................A-4 Connection Diagram ..................A-5, A-6, A-7 Recommended Work Cable Sizes ................A-8 Cable Inductance and its Effects on Welding..............A-9...
  • Page 7 TECHNICAL SPECIFICATIONS - POWER WAVE S500 POWER WAVE ® S500 INSTALLATION ® POWER SOURCE-INPUT VOLTAGE AND CURRENT Model Duty Cycle Input Voltage ± 10% Input Amperes Idle Power Power Factor @ Rated Output 40% rating 208/230/400*460/575 80/73/41/37/29 (includes 380V to 413V) K2904-1 500 Watts Max.
  • Page 8 POWER WAVE ® S500 INSTALLATION WELDING PROCESS PROCESS OUTPUT RANGE (AMPERES) OCV (U Mean Peak GMAW GMAW-Pulse 40-550A FCAW 100V GTAW-DC 5-550A PHYSICAL DIMENSIONS SMAW 15-550A DEPTH WEIGHT MODEL HEIGHT WIDTH 24.80in ( 630mm) 150 lbs (68 kg) K2904-1 14.00in ( 356 mm) 22.45 in ( 570 mm) TEMPERATURE RANGES OPERATING TEMPERATURE RANGE...

  • Page 9: Installation

    POWER WAVE ® S500 INSTALLATION this liFting saFety PreCautions read entire installation section before you start installa- Both handles should be used when lifting POWER tion. WAVE ® S500. When using a crane or overhead device a lifting strap should be connected to both handles. warning Do not attempt to lift the POWER WAVE ®...

  • Page 10: Input Connection

    POWER WAVE ® S500 INSTALLATION INPUT FUSE AND SUPPLY WIRE WARNING CONSIDERATIONS only a qualified electrician should Refer to Specification Section for recommended fuse, connect the input leads to the wire sizes and type of the copper wires. Fuse the Power waVe ®...

  • Page 11: Connection Diagram

    POWER WAVE ® S500 INSTALLATION CONNECTION DIAGRAMS GTAW (TIG) WELDING A user interface is required for adjusting the TIG weld- installed into the power source (Figure A.2). Refer to ing settings. S-series user interface (K3001-2) can be the connection diagrams based on the user interface that is being used.
  • Page 12 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 into the power source (Figure A.3). The connection K3001-2 (user interface control panel) can be installed diagram shown is based on the S-Series user inter- face (K3001-2).
  • Page 13 POWER WAVE ® S500 INSTALLATION GMAW (MIG) WELDING Mig welding. Refer to Figure A.4 for the connection An arclink compatible wire feeder is recommended for 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...

  • Page 14: Recommended Work Cable Sizes

    POWER WAVE ® S500 RECOMMENDED WORK CABLE INSTALLATION SIZES FOR ARC WELDING • Select the appropriate size cables per the “Output Cable Guidelines” below. Excessive volt- age drops caused by undersized welding cables and Connect the electrode and work cables between the poor connections often result in unsatisfactory weld- appropriate output studs of the POWER WAVE ®...

  • Page 15: Cable Inductance And Its Effects On Welding

    CABLE INDUCTANCE AND ITS POWER WAVE ® S500 INSTALLATION EFFECTS ON WELDING Depending upon the process, inductance within the electrode and work cables can influence the voltage apparent at the studs of the welder, and have a dra- matic effect on performance. Remote voltage sense leads are used to improve the accuracy of the arc volt- Excessive cable inductance will cause the welding age information supplied to the control pc board.
  • Page 16 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 connect- ed to the wire drive feed plate when a wire feeder is present. Enabling or disabling electrode voltage sens- ing is application specific, and automatically config- CAUTION ured by the active weld mode.

  • Page 17: Voltage Sensing Considerations For Multiple Arc Systems

    POWER WAVE ® S500 VOLTAGE SENSING INSTALLATION CONSIDERATIONS FOR MULTIPLE If Sense Leads ARE Used: ARC SYSTEMS • Position the sense leads out of the path of the weld current. Especially any current paths common to adjacent arcs. Current from adjacent arcs can Special care must be taken when more than one arc induce voltage into each others current paths that is welding simultaneously on a single part.
  • Page 18 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 POWER...

  • Page 19: Control Cable Connections

    POWER WAVE ® S500 INSTALLATION CONTROL CABLE CONNECTIONS Connection Between Power Source and Ethernet Networks General Guidelines ® The POWER WAVE S500 is equipped with an IP67 rated ODVA compliant RJ-45 Ethernet connector, Genuine Lincoln control cables should be used at all which is located on the rear panel.

  • Page 20: Operation

    POWER WAVE ® S500 OPERATION SAFETY PRECAUTIONS GRAPHIC SYMBOLS THAT APPEAR ON THIS MACHINE OR IN THIS MANUAL READ AND UNDERSTAND ENTIRE SECTION BEFORE OPERATING MACHINE. WARNING WARNING OR CAUTION • ELECTRIC SHOCK CAN KILL. • Do not touch electrically live part or electrode with skin or DANGEROUS wet clothing.

  • Page 21: Product Description

    POWER WAVE ® S500 OPERATION PRODUCT DESCRIPTION ® WAVE S500 limit the process capability within the output range and the safe limits of the machine. In PRODUCT SUMMARY general the processes will be limited to .030-.052 solid ® steel wire, .030 -.045 stainless wire, .035 -1/16 cored The POWER WAVE S500 is a portable multi-process wire, and .035 - 1/16 Aluminum wire.

  • Page 22: Design Features

    POWER WAVE ® S500 OPERATION DESIGN FEATURES CASE FRONT CONTROLS (See Figure B.1) Loaded with Standard Features 1. USER INTERFACE (optional) 2. STATUS LED - (See Troubleshooting Section for • Multiple process DC output range: 5 - 550 Amps • 200 – 600 VAC, 3 phase, 50-60Hz input power operational functions) 3.

  • Page 23: Case Back Controls

    POWER WAVE ® S500 OPERATION CASE BACK CONTROLS (See Figure B.2) 1. 115 VAC CIRCUIT BREAKER 2. 115 VAC RECEPTACLES 3. RESERVED FOR FUTURE DEVELOPMENT 4. SYNC TANDEM/ STT CONNECTOR 5. ARCLINK CONNECTOR 6. DEVICENET KIT (OPTIONAL) 7. ETHERNET 8. 40V CIRCUIT BREAKER 9.
  • Page 24 Many variables teristics of the Power Wave power source. Weld beyond the control of The Lincoln Electric modes are developed with a specific electrode materi- Company affect the results obtained in applying al, electrode size, and shielding gas. For a more com- these programs.
  • Page 25 POWER WAVE ® S500 OPERATION SMAW (STICK) WELDING The nominal preprogrammed voltage is the best aver- The welding current and Arc Force settings can be set age voltage for a given wire feed speed, but may be ™ ™ through a Power Feed 10M or Power Feed adjusted to preference.
  • Page 26 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.

  • Page 27: Accessories

    POWER WAVE ® S500 ACCESSORIES KITS, OPTIONS AND ACCESSORIES AWG #1 Coaxial Cables: All Kits Options and Accessories are found on the Order K2593-25 for 25 feet (7.6 m) cable length. Web site: (www.lincolnelectric.com) Order K2593-50 for 50 feet (15.2 m) cable length. FACTORY INSTALLED Order K2593-100 for 100 feet (30.5 m) cable length.
  • Page 28 POWER WAVE ® S500 ACCESSORIES STICK OPTIONS TIG-Mate™ 17V Air-Cooled TIG Torch Starter Pack ACCESSORY KIT - 150 Amp Get everything you need for TIG welding in one com- plete easy-to-order kit packaged in its own portable carrying case. Includes: PTA-17V torch, parts kit, For stick welding.

  • Page 29: Maintenance

    POWER WAVE ® S500 SAFETY PRECAUTIONS MAINTENANCE 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. • Turn the input power to the welding power source off at the fuse box before working in the terminal strip.
  • Page 30 POWER WAVE ® S500 NOTES...

  • Page 31: 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 32 POWER WAVE ® S500 TROUBLESHOOTING USING THE STATUS LED TO TROUBLESHOOT SYSTEM PROBLEMS Included in this section is information about the Status Lights and some basic troubleshooting charts for both machine and weld performance. ® Not all of the POWER WAVE S500 errors will be displayed The status light for the main control board and input control on the user interface (if it is installed).
  • Page 33 POWER WAVE ® S500 TROUBLESHOOTING Observe all Safety Guidelines detailed throughout this manual 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.
  • Page 34 POWER WAVE ® S500 TROUBLESHOOTING Observe all Safety Guidelines detailed throughout this manual inPut Control board Error Code # Indication Type Instantaneous input current limit has been exceeded. Typically 331 Instantaneous Input Current indicates short term power overload. If problem persists contact Limit Service Department.
  • Page 35 3. Major physical or electrical dam- 3. Contact your local authorized age is evident when the covers Lincoln Electric Field Service are removed. facility for technical assistance. Machine will not power up (no lights) 1. No Input Power 1.
  • Page 36 POWER WAVE ® S500 TROUBLESHOOTING PROBLEMS POSSIBLE RECOMMENDED Observe all Safety Guidelines detailed throughout this manual (SYMPTOMS) CAUSE COURSE OF ACTION Basic Machine Problems (Continued) Thermal LED is ON Improper fan operation Thermal LED is ON 1. Improper fan operation. 1.
  • Page 37 POWER WAVE ® S500 TROUBLESHOOTING PROBLEMS POSSIBLE RECOMMENDED Observe all Safety Guidelines detailed throughout this manual (SYMPTOMS) CAUSE COURSE OF ACTION Weld and Arc Quality Problems (Continued) Wire burns back to tip at the end of 1. Burnback Time 1. Reduce burnback time and/or the weld.
  • Page 38 POWER WAVE ® S500 TROUBLESHOOTING PROBLEMS POSSIBLE RECOMMENDED Observe all Safety Guidelines detailed throughout this manual (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).
  • Page 39 POWER WAVE ® S500 DIAGRAMS...
  • Page 40 POWER WAVE ® S500 DIAGRAMS...
  • Page 41 POWER WAVE ® S500 NOTES...
  • Page 42 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 43 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 44 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.

Table of Contents