Page 1: Service Manual
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 SVM239-A | Issue D ate 13-Oct © Lincoln Global, Inc. All Rights Reserved.
Page 2: California Proposition 65 Warnings
SAFETY WARNING CALIFORNIA PROPOSITION 65 WARNINGS Diesel engine exhaust and some of its constituents The engine exhaust from this product contains are known to the State of California to cause can- chemicals known to the State of California to cause cer, birth defects and other reproductive harm.
Page 3: Electric Shock Can Kill
SAFETY ELECTRIC SHOCK can kill. ARC RAYS can burn. 3.a. The electrode and work (or ground) circuits 4.a. Use a shield with the proper filter and cover are electrically “hot” when the welder is on. plates to protect your eyes from sparks and Do not touch these “hot”...
Page 4 SAFETY WELDING and CUTTING CYLINDER may explode SPARKS can cause fire or if damaged. explosion. 7.a. Use only compressed cylinders containing the correct shielding gas for the 6.a. Remove fire hazards from the welding area.If process used and properly operating this is not possible, cover them to prevent the welding sparks regulators designed for the gas and from starting a fire.
Page 5 SAFETY 6. Eloigner les matériaux inflammables ou les recouvrir afin de PRÉCAUTIONS DE SÛRETÉ prévenir tout risque dʼincendie dû aux étincelles. Pour votre propre protection lire et observer toutes les instructions 7. Quand on ne soude pas, poser la pince à une endroit isolé de et les précautions de sûreté...
Page 6 SAFETY Electromagnetic Compatibility (EMC) Conformance Products displaying the CE mark are in conformity with European Community Council Directive of 15 Dec 2004 on the approximation of the laws of the Member States relating to electromagnetic compatibility, 2004/108/EC. It was manufactured in conformity with a national standard that implements a harmonized standard: EN 60974-10 Electromagnetic Compatibility (EMC) Product Standard for Arc Welding Equipment.
Page 7 SAFETY Electromagnetic Compatibility (EMC) The size of the surrounding area to be considered will depend on the structure of the building and other activities that are taking place. The surrounding area may extend beyond the boundaries of the premises. Methods of Reducing Emissions Mains Supply Welding equipment should be connected to the mains supply according to the manufacturerʼs recommen- dations.
Page 8 - MASTER TABLE OF CONTENTS FOR ALL SECTIONS - RETURN TO MAIN INDEX Page Safety ................i-vi Installation .
Page 9 TABLE OF CONTENTS - INSTALLATION SECTION Installation ................A-1 Technical Specifications .
Page 10 INSTALLATION TECHNICAL SPECIFICATIONS - POWER WAVE ® S500 POWER SOURCE-INPUT VOLTAGE AND CURRENT INPUT VOLTAGE ± 10% INPUT AMPERES MODEL DUTY IDLE POWER POWER FACTOR CYCLE @ RATED OUTPUT K2904-1 40% rating 208/230/400*460/575 80/73/41/37/29 500 Watts Max. 50/60 Hz (fan on) 100% rating 60/54/30/27/21 (includes 380V to 413V)
Page 11: Welding Process
INSTALLATION WELDING PROCESS PROCESS OUTPUT RANGE (AMPERES) OCV (Uo) Mean Peak GMAW 40-550A 100V GMAW-Pulse FCAW GTAW-DC 5-550A SMAW 15-550A PHYSICAL DIMENSIONS MODEL HEIGHT WIDTH DEPTH WEIGHT K2904-1 22.45 in. (570 mm) 14.00 in. (356 mm) 24.08 in. (630 mm) 150 lbs (68kg)* TEMPERATURE RANGES OPERATING TEMPERATURE RANGE...
Page 12 INSTALLATION SAFETY PRECAUTIONS WARNING Read this entire installation section before you start installation. FALLING EQUIPMENT can cause injury. WARNING • Lift only with equipment of ade- quate lifting capacity. ELECTRIC SHOCK can kill. • Be sure machine is stable when lifting. •...
Page 13: Input Fuse And Supply Wire
INSTALLATION INPUT FUSE AND SUPPLY WIRE WARNING CONSIDERATIONS Only a qualified electrician should connect the See Technical Specifications for recommended fuse, input leads to the Power Wave S500. Connections ® wire sizes and type of the copper wires. Fuse the input should be made in accordance with all local and circuit with the recommended super lag fuse or delay national electrical codes and the connection dia-...
Page 14: Connection Diagrams
INSTALLATION CONNECTION DIAGRAMS GTAW (TIG) WELDING A user interface is required for adjusting the TIG weld- ing 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 15 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 16 INSTALLATION GMAW (MIG) WELDING An arclink compatible wire feeder is recommended for Mig welding. See Figure A.4 for the connection details. FIGURE A4 MIG PROCESS REGULATOR FLOWMETER AS H H OSE RCLINK C C ABLE TO N N EGATIVE VE ( ( -) S S TUD K1543-[XX] WORK C C LAMP TO P P OSITIVE...
Page 17 INSTALLATION GENERAL GUIDELINES RECOMMENDED WORK CABLE SIZES FOR ARC WELDING • Select the appropriate size cables per the “Output Cable Guidelines” below. Excessive voltage drops Connect the electrode and work cables between the caused by undersized welding cables and poor con- appropriate output studs of the Power Wave S500 per ®...
Page 18: Cable Inductance And Its Effects On Welding
INSTALLATION A-10 A-10 REMOTE SENSE LEAD SPECIFICA- CABLE INDUCTANCE AND ITS TIONS EFFECTS ON WELDING VOLTAGE SENSING OVERVIEW Excessive cable inductance will cause the welding per- formance to degrade. There are several factors that The best arc performance occurs when the Power contribute to the overall inductance of the cabling sys- Wave S500 has accurate data about the arc condi-...
Page 19 INSTALLATION A-11 A-11 GENERAL GUIDELINES FOR VOLTAGE SENSE LEADS Sense leads should be attached as close to the weld as practical and out of the weld current path when pos- sible. In extremely sensitive applications it may be nec- essary to route cables that contain the sense leads away from the electrode and work welding cables.
Page 20 INSTALLATION A-12 A-12 VOLTAGE SENSING If Sense Leads ARE Used: CONSIDERATIONS FOR MULTIPLE • Position the sense leads out of the path of the weld current. Especially any current paths common to ARC SYSTEMS adjacent arcs. Current from adjacent arcs can induce voltage into each others current paths that can be Special care must be taken when more than one arc is misinterpreted by the power sources and result in arc...
Page 21 INSTALLATION A-13 A-13 • 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 SOURCE...
Page 22: Control Cable Connections
INSTALLATION A-14 A-14 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, which is Genuine Lincoln control cables should be used at all located on the rear panel.
Page 23 TABLE OF CONTENTS - OPERATION SECTION Operation ................B-1 Safety Precautions .
Page 24: Duty Cycle
OPERATION SAFETY PRECAUTIONS GRAPHIC SYMBOLS THAT APPEAR ON THIS MACHINE OR IN THIS MANUAL READ AND UNDERSTAND ENTIRE SECTION BEFORE OPERATING MACHINE. WARNING OR WARNING CAUTION ELECTRIC SHOCK can kill. DANGEROUS • Do not touch electrically live part VOLTAGE or electrode with skin or wet cloth- ing.
Page 25: Recommended Equipment
OPERATION RECOMMENDED EQUIPMENT PRODUCT DESCRIPTION The Power Wave S500 is designed to be compatible ® PRODUCT SUMMARY with the current range of Power Feed™ systems including future versions of ArcLink feeders. ® The Power Wave S500 is a portable multi-process ®...
Page 26: Design Features
OPERATION DESIGN FEATURES CASE FRONT CONTROLS See Figure B.1 LOADED WITH STANDARD FEATURES 1. USER INTERFACE (optional) • Multiple process DC output range: 5 - 550 Amps. 2. STATUS LED - (See Troubleshooting section for • 200 – 600 VAC, 3 phase, 50-60Hz input power. operational functions) •...
Page 27: Case Back Controls
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. RESERVED FOR FUTURE DEVELOPMENT 10.
Page 28: Common Welding Procedures
OPERATION COMMON WELDING PROCEDURES BASIC WELDING CONTROLS WARNING WELD MODE MAKING A WELD Selecting a weld mode determines the output charac- teristics of the Power Wave ® power source. Weld The serviceability of a product or structure utiliz- modes are developed with a specific electrode materi- ing the welding programs is and must be the sole al, electrode size and shielding gas.
Page 29 OPERATION SMAW (STICK) WELDING The nominal preprogrammed voltage is the best aver- age voltage for a given wire feed speed, but may be The welding current and Arc Force settings can be set adjusted to preference. When the wire feed speed through a Power Feed™...
Page 30 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 31 TABLE OF CONTENTS - ACCESSORIES SECTION Accessories ................C-1 Kits, Options And Accessories .
Page 32: Factory Installed Options
ACCESSORIES KITS, OPTIONS AND ACCESSORIES K1842-10 10ft. Weld Power Cable Coaxial Welding Cable All Kits, Options and Accessories are found on the Web site: (www.lincolnelectric.com) Optimum weld cables for minimizing cable inductance and optimizing welding performance. FACTORY INSTALLED OPTIONS AWG 1/0 Coaxial Cables: None Available Order K1796-25 for 25 feet (7.6 m) cable length.
Page 33 ACCESSORIES STICK OPTIONS TIG-Mate™ 17V Air-Cooled TIG Torch Starter Pack Get everything you need for TIG welding in one com- plete easy-to-order kit packaged in its own portable ACCESSORY KIT - 150 Amp carrying case. Includes: PTA-17V torch, parts kit, For stick welding.
Page 34 NOTES POWER WAVE ® S500...
Page 35 TABLE OF CONTENTS - MAINTENANCE SECTION Maintenance ................D-1 Safety Precautions .
Page 36: Routine Maintenance
MAINTENANCE SAFETY PRECAUTIONS 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 37 MAINTENANCE FIGURE D.1 – MAJOR COMPONENTS LOCATIONS 1. Case Front Assembly 2. Base & Power Conversion Assembly 3. Case Back Assembly 4. Roof Assembly POWER WAVE ® S500...
Page 38 NOTES POWER WAVE ® S500...
Page 39 TABLE OF CONTENTS-THEORY OF OPERATION SECTION Theory of Operation ..............E-1 General Description .
Page 40: Theory Of Operation
THEORY OF OPERATION FIGURE E.2 - GENERAL DESCRIPTION USER INTERFACE ARCLINK AND VOLTAGE SENSE TO REMOTE DIGITAL CONTROL BOARD CONTROL REMOTE AMPTROL BOARD ARCLINK RECEPTACLE 40 VDC TO PFC BOARD POWER CONVERSION P.C. BOARD ASSEMBLY ARCLINK FAN SPEED RECEPTACLE TOP PLANAR 40 VDC CONTROL INPUT...
Page 41 THEORY OF OPERATION FIGURE E.3 - LINE SWITCH, INPUT BOARD AND POWER FACTOR CONTROL (PFC) BOARD USER INTERFACE ARCLINK AND VOLTAGE SENSE TO REMOTE DIGITAL CONTROL BOARD CONTROL REMOTE AMPTROL BOARD ARCLINK RECEPTACLE 40 VDC TO PFC BOARD POWER CONVERSION P.C.
Page 42 THEORY OF OPERATION FIGURE E.4 - POWER CONVERSION BOARD ASSEMBLY USER INTERFACE ARCLINK AND VOLTAGE SENSE TO REMOTE DIGITAL CONTROL BOARD CONTROL REMOTE AMPTROL BOARD ARCLINK RECEPTACLE 40 VDC TO PFC BOARD POWER CONVERSION P.C. BOARD ASSEMBLY ARCLINK FAN SPEED RECEPTACLE TOP PLANAR 40 VDC...
Page 43 THEORY OF OPERATION FIGURE E.5 - SIX PHASE CHOPPER BOARD AND MULTI-PHASE OUTPUT CHOKE USER INTERFACE ARCLINK AND VOLTAGE SENSE TO REMOTE DIGITAL CONTROL BOARD CONTROL REMOTE AMPTROL BOARD ARCLINK RECEPTACLE 40 VDC TO PFC BOARD POWER CONVERSION P.C. BOARD ASSEMBLY ARCLINK FAN SPEED RECEPTACLE...
Page 44: Control Board
THEORY OF OPERATION FIGURE E.6 - DC BUS BOARD AND DIGITAL CONTROL BOARD USER INTERFACE ARCLINK AND VOLTAGE SENSE TO REMOTE DIGITAL CONTROL BOARD CONTROL REMOTE AMPTROL BOARD ARCLINK RECEPTACLE 40 VDC TO PFC BOARD POWER CONVERSION P.C. BOARD ASSEMBLY ARCLINK FAN SPEED RECEPTACLE...
Page 45 THEORY OF OPERATION FIGURE E.7 - OPTIONAL REMOTE CONTROL BOARD AND 115VAC INVERTER BOARD USER INTERFACE ARCLINK AND VOLTAGE SENSE TO REMOTE DIGITAL CONTROL BOARD CONTROL REMOTE AMPTROL BOARD ARCLINK RECEPTACLE 40 VDC TO PFC BOARD POWER CONVERSION P.C. BOARD ASSEMBLY ARCLINK FAN SPEED RECEPTACLE...
Page 46: Machine Protection
THEORY OF OPERATION MACHINE PROTECTION THERMAL PROTECTION PROTECTIVE CIRCUITS Three normally closed (NC) thermostats protect the Protective circuits are designed into the Power Wave ® machine from excessive operating temperatures. Two S500 to sense trouble and shut down the machine thermostats are located on the 115VAC heat sink and before damage occurs to the machineʼs internal com- protect the 115VAC Inverter board from over-heating.
Page 47: Pulse Width Modulation
THEORY OF OPERATION FIGURE E.8 - INSULATED GATE BIPOLAR TRANSISTOR (IGBT) OPERATION POSITIVE VOLTAGE APPLIED GATE GATE SOURCE SOURCE BODY REGION BODY REGION DRAIN DRIFT REGION DRAIN DRIFT REGION BUFFER LAYER BUFFER LAYER INJECTING LAYER INJECTING LAYER DRAIN DRAIN A. PASSIVE B.
Page 48 NOTES E-10 E-10 POWER WAVE ® S500...
Page 49 TABLE OF CONTENTS - TROUBLESHOOTING AND REPAIR Troubleshooting and Repair ............. .F-1 How to Use Troubleshooting Guide .
Page 50: How To Use Troubleshooting Guide
TROUBLESHOOTING AND REPAIR 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 51: Pc Board Troubleshooting Procedures
TROUBLESHOOTING AND REPAIR PC BOARD TROUBLESHOOTING PROCEDURES - Remove the PC board from the static-shielding bag WARNING and place it directly into the equipment. Donʼt set the PC board on or near paper, plastic or cloth which ELECTRIC SHOCK could have a static charge. If the PC board canʼt be can kill.
Page 52 TROUBLESHOOTING AND REPAIR Observe Safety Guidelines detailed in the beginning of this manual. PROBLEMS POSSIBLE AREAS OF RECOMMENDED (SYMPTOMS) MISADJUSTMENT(S) COURSE OF ACTION OUTPUT PROBLEMS Major physical or electrical damage 1. Contact the Lincoln Electric 1. Contact your local authorized is evident when the Power Wave ®...
Page 53 TROUBLESHOOTING AND REPAIR Observe Safety Guidelines detailed in the beginning of this manual. PROBLEMS POSSIBLE AREAS OF RECOMMENDED (SYMPTOMS) MISADJUSTMENT(S) COURSE OF ACTION OUTPUT PROBLEMS The Power Wave ® S500 does not 1. If the symptom is accompanied 1. Perform the Input Board Test. have welding output.
Page 54 TROUBLESHOOTING AND REPAIR Observe Safety Guidelines detailed in the beginning of this manual. PROBLEMS POSSIBLE AREAS OF RECOMMENDED (SYMPTOMS) MISADJUSTMENT(S) COURSE OF ACTION OUTPUT PROBLEMS The “Real Time Clock” no longer 1. The Digital Control Board Battery 1. The Digital Control Board functions.
Page 55 TROUBLESHOOTING AND REPAIR Observe Safety Guidelines detailed in the beginning of this manual. PROBLEMS POSSIBLE AREAS OF RECOMMENDED (SYMPTOMS) MISADJUSTMENT(S) COURSE OF ACTION WELDING PROBLEMS General degradation of the welding 1. Check for proper wire feeding. 1. Perform Current performance Make certain that the actual Voltage Calibration Procedure.
Page 56 TROUBLESHOOTING AND REPAIR Observe Safety Guidelines detailed in the beginning of this manual. PROBLEMS POSSIBLE AREAS OF RECOMMENDED (SYMPTOMS) MISADJUSTMENT(S) COURSE OF ACTION WELDING PROBLEMS The arc is excessively long and 1. In the wirefeeder make sure the 1. Perform Current erratic.
Page 57 TROUBLESHOOTING AND REPAIR Observe Safety Guidelines detailed in the beginning of this manual. PROBLEMS POSSIBLE AREAS OF RECOMMENDED (SYMPTOMS) MISADJUSTMENT(S) COURSE OF ACTION ETHERNET PROBLEMS The system will not connect. 1. Make sure that the correct patch 1. Use Weld Manager (included cable or cross over cable is being on the Power Wave Utilities and used.
Page 58 TROUBLESHOOTING AND REPAIR F-10 F-10 Observe Safety Guidelines detailed in the beginning of this manual. INPUT CONTROL BOARD Error Code # Indication Type 331 Instantaneous Instantaneous input current limit has been exceeded. Typically indi- Persistent Input Current Limit cates short term power overload. 334 Startup Current Input current limit was exceeded during machine power-up.
Page 59 TROUBLESHOOTING AND REPAIR F-11 F-11 Observe Safety Guidelines detailed in the beginning of this manual. MAIN CONTROL BOARD (“STATUS” LIGHT) Error Code # Indication Type 36 Thermal Error Indicates over temperature. Usually accompanied by thermal LED. Temporary Check fan operation. Be sure process does not exceed duty cycle limit of the machine.
Page 60 NOTES F-12 F-12 POWER WAVE ® S500...
Page 61: Capacitor Discharge Procedure
TROUBLESHOOTING AND REPAIR F-13 F-13 CASE COVER REMOVAL AND DC LINK CAPACITOR DISCHARGE PROCEDURE WARNING Service and repair should be performed only by Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty.
Page 62 TROUBLESHOOTING AND REPAIR F-14 F-14 CASE COVER REMOVAL AND DC LINK CAPACITOR DISCHARGE PROCEDURE (continued) FIGURE F.1 – CASE COVER REMOVAL TOP CORNER END CAPS LEFT SIDE MOUNTING SCREWS REMOVAL PROCEDURE 3. Using a 5/16” nutdriver, remove the six remain- WARNING ing screws and washers from the left side to gain access to the left side internal compo-...
Page 63 TROUBLESHOOTING AND REPAIR F-15 F-15 CASE COVER REMOVAL AND DC LINK CAPACITOR DISCHARGE PROCEDURE (continued) FIGURE F.2 – CAPACITOR DISCHARGE PROCEDURE LED4 LED3 LEAD B5 FTP3 LED5 DZ23 DZ26 DZ24 OCI1 LEAD B4 FTP1 LEAD B58 DZ19 HEAT SINK TERMINAL DZ16 DZ14 LED1...
Page 64 TROUBLESHOOTING AND REPAIR F-16 F-16 CASE COVER REMOVAL AND DC LINK CAPACITOR DISCHARGE PROCEDURE (continued) REPLACEMENT PROCEDURE 1. Using a 7/16” wrench, attach the eight bolts securing the lifting handles and attach the six screws to secure the top portion of the unit. 2.
Page 65 TROUBLESHOOTING AND REPAIR F-17 F-17 PFC CONTROL BOARD TEST WARNING Service and repair should be performed only by Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or 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 66 TROUBLESHOOTING AND REPAIR F-18 F-18 PFC CONTROL BOARD TEST (continued) FIGURE F.3 – PFC CONTROL BOARD LOCATION PFC CONTROL BOARD PFC BOARD MOUNTING PANEL FRONT PANEL ASSEMBLY PROCEDURE 4. Carefully apply the correct input power to the WARNING Power Wave ®...
Page 67 TROUBLESHOOTING AND REPAIR F-19 F-19 PFC CONTROL BOARD TEST (continued) FIGURE F.4 – PFC CONTROL BOARD LED AND TEST POINTS PIN 1 J23A PIN 16 LED2 J23B J23A J23B FTP9 FTP7 FTP8 PIN 1 OCI3 OCI4 OCI1 OCI2 R257 FTP21 FTP5 LED5 LED2...
Page 68: Troubleshooting And Repair
TROUBLESHOOTING AND REPAIR F-20 F-20 PFC CONTROL BOARD TEST (continued) TABLE F.3 – PFC CONTROL BOARD RESISTANCE CHECKS DESCRIPTION METER TEST POINTS EXPECTED READINGS CONDITIONS AND POLARITY INPUT POWER CIRCUIT PLUG J26 PIN 4 (+) VERY HIGH RESIS- INPUT POWER TANCE.
Page 69 TROUBLESHOOTING AND REPAIR F-21 F-21 DIGITAL CONTROL BOARD TEST WARNING Service and repair should be performed only by Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or 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 70 TROUBLESHOOTING AND REPAIR F-22 F-22 DIGITAL CONTROL BOARD TEST (continued) FIGURE F.5 – DIGITAL CONTROL BOARD LOCATION DIGITAL CONTROL BOARD PROCEDURE 5. Care WARNING fully apply the correct input voltage to the Power Wave S500 machine. ® ELECTRIC SHOCK 6. Check for the correct operation of the LED can kill.
Page 71 TROUBLESHOOTING AND REPAIR F-23 F-23 DIGITAL CONTROL BOARD TEST (continued) FIGURE F.6 – DIGITAL CONTROL BOARD LED AND TEST POINT LOCATIONS LED 1 LED 2 X100 LED 3, 4, 5, 6 R510 FTP1 FTP3 LED 8 LED9 C255 OCI7 OCI8 LED 7 DZ31 DZ32...
Page 72 TROUBLESHOOTING AND REPAIR F-24 F-24 DIGITAL CONTROL BOARD TEST (continued) TABLE F.6 – DIGITAL CONTROL BOARD VOLTAGE TEST POINTS AND EXPECTED READINGS DESCRIPTION TEST POINTS LEAD NUMBERS EXPECTED CONDITIONS READING INPUT SUPPLY FROM J4 PIN 2 LEAD 356 (–) 40VDC INPUT POWER PFC BOARD APPLIED TO...
Page 73 TROUBLESHOOTING AND REPAIR F-25 F-25 OPTIONAL USER INTERFACE KIT TEST WARNING Service and repair should be performed only by Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or 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 74 TROUBLESHOOTING AND REPAIR F-26 F-26 OPTIONAL USER INTERFACE KIT TEST (continued) FIGURE F.7 – USER INTERFACE AND REMOTE INTERFACE BOARD LOCATIONS OPTIONAL REMOTE INTERFACE BOARD OPTIONAL USER INTERFACE BOARD PROCEDURE 5. Locate Plugs J114, J111, J112 and J115 on the WARNING Remote Interface Board.
Page 75 TROUBLESHOOTING AND REPAIR F-27 F-27 OPTIONAL USER INTERFACE KIT TEST (continued) FIGURE F.8 – REMOTE INTERFACE BOARD TEST POINTS J114 J111 J112 J11 4 J11 1 J11 2 J11 3 6 7 8 G6948-1 OCI1 J115 12 PIN INTERFACE FIGURE F.9 – USER INTERFACE BOARD TEST POINTS J115 POWER WAVE ®...
Page 76 TROUBLESHOOTING AND REPAIR F-28 F-28 OPTIONAL USER INTERFACE KIT TEST (continued) TABLE F.8 – VOLTAGE CHECKS ON REMOTE INTERFACE BOARD DESCRIPTION TEST POINT TEST POINT EXPECTED CONDITIONS METER PROBE (+) METER PROBE (–) READING 40VDC BUS PLUG J114 PIN 6 PLUG J114 PIN 4 40VDC CORRECT INPUT...
Page 77 TROUBLESHOOTING AND REPAIR F-29 F-29 OPTIONAL USER INTERFACE KIT TEST (continued) TABLE F.10 – RESISTANCE CHECKS DESCRIPTION TEST POINT TEST POINT EXPECTED CONDITIONS METER PROBE METER PROBE READING CONTINUITY PLUG J111 PIN 5 S1 RECEPTACLE ZERO OHMS POWER TO CHECK FROM (LEAD 75) PIN C (LEAD 75) MACHINE...
Page 78 NOTES F-30 F-30 POWER WAVE ® S500...
Page 79 TROUBLESHOOTING AND REPAIR F-31 F-31 POWER CONVERSION ASSEMBLY TEST WARNING Service and repair should be performed only by Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or 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 80 TROUBLESHOOTING AND REPAIR F-32 F-32 POWER CONVERSION ASSEMBLY TEST (continued) FIGURE F.10 – POWER CONVERSION ASSEMBLY LOCATION POWER CONVERSION ASSEMBLY PROCEDURE 5. Locate the five Green LEDs on the Power WARNING Conversion Assembly. See Figure F.12. 6. Carefully apply the correct three phase input ELECTRIC SHOCK can kill.
Page 81 TROUBLESHOOTING AND REPAIR F-33 F-33 POWER CONVERSION ASSEMBLY TEST (continued) TABLE F.11 – DIODE TESTS NOTE: Make sure the input power is removed from the Power Wave S500 and the three leads are removed from ® terminal B56 and electrically isolated from each other. See Figure F.11. When test is complete recon- nect the three leads to terminal B56.
Page 82 TROUBLESHOOTING AND REPAIR F-34 F-34 POWER CONVERSION ASSEMBLY TEST (continued) FIGURE F.11 – POWER CONVERSION ASSEMBLY DIODE TEST POINTS LED4 LED3 XXXX FTP3 LED5 DZ23 DZ26 DZ24 OCI1 FTP1 DZ19 DZ16 DZ14 LED1 DZ13 XXXX POWER WAVE ® S500...
Page 83 TROUBLESHOOTING AND REPAIR F-35 F-35 POWER CONVERSION ASSEMBLY TEST (continued) FIGURE F.12 – POWER CONVERSION ASSEMBLY VOLTAGE CHECK TEST POINTS LED 4 B28 LED 3 LED4 LED3 XXXX FTP3 LED5 LED 5 DZ23 DZ26 DZ24 OCI1 FTP1 DZ19 LED 2 DZ16 DZ14 LED1...
Page 84 TROUBLESHOOTING AND REPAIR F-36 F-36 POWER CONVERSION ASSEMBLY TEST (continued) TABLE F.12 – POWER CONVERSION LED LEGEND LED NUMBER DESCRIPTION CONDITIONS LED STATUS LED 1 BOTTOM BOOST INPUT POWER IGBT DRIVE (472VAC) APPLIED AND MACHINE “ON” LED 2 BOTTOM BUCK INPUT POWER IGBT DRIVE (472VAC) APPLIED...
Page 85 TROUBLESHOOTING AND REPAIR F-37 F-37 POWER CONVERSION ASSEMBLY TEST (continued) TABLE F.13 – POWER CONVERSION ASSEMBLY VOLTAGE TESTS DESCRIPTION TEST POINT TEST POINT EXPECTED CONDITIONS READING INPUT TO TOP B29(+) B28(–) 635VDC 472VAC INPUT AND BUCK/BOOST MACHINE “ON” CIRCUIT INPUT TO BOTTOM B17(+) B18(–) 635VDC...
Page 86 NOTES F-38 F-38 POWER WAVE ® S500...
Page 87 TROUBLESHOOTING AND REPAIR F-39 F-39 MULTI-PHASE OUTPUT CHOKE TEST WARNING Service and repair should be performed only by Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or 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 88 TROUBLESHOOTING AND REPAIR F-40 F-40 MULTI-PHASE OUTPUT CHOKE TEST (continued) FIGURE F.13 – TEST COMPONENT LOCATIONS MULTI-PHASE OUTPUT CHOKE MULTI-PHASE CHOPPER BOARD NEGATIVE BUSS BAR PROCEDURE 5. Using a 7/16” wrench, label and remove leads WARNING BL1, BL2, BL3, BL4, BL5 and BL6 from the Chopper Board.
Page 89 TROUBLESHOOTING AND REPAIR F-41 F-41 MULTI-PHASE OUTPUT CHOKE TEST (continued) FIGURE F.14 – MULTI-PHASE OUTPUT CHOPPER BOARD LEAD LOCATIONS 8. Check the individual choke coils to ground. There should be a minimum of 500,000 ohms of resistance to ground. 9. When testing is complete reconnect all of the leads to the correct terminals and tighten securely.
Page 90 NOTES F-42 F-42 POWER WAVE ® S500...
Page 91 TROUBLESHOOTING AND REPAIR F-43 F-43 CURRENT TRANSDUCER TEST WARNING Service and repair should be performed only by Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or 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 92 TROUBLESHOOTING AND REPAIR F-44 F-44 CURRENT TRANSDUCER TEST (continued) FIGURE F.15 – CURRENT TRANSDUCER TEST COMPONENT LOCATIONS MULTI-PHASE OUTPUT CHOKE ASSEMBLY CURRENT TRANSDUCER OUTPUT CONTROL FEEDBACK CURRENT TRANSDUCER MULTI-PHASE CHOPPER FEEDBACK PROCEDURE 4. Locate plug J8 on the Digital Control Board. WARNING See Figure F.16.
Page 93 TROUBLESHOOTING AND REPAIR F-45 F-45 CURRENT TRANSDUCER TEST (continued) FIGURE F.16 – DIGITAL CONTROL BOARD TEST POINTS PIN 1 PIN 4 PIN 5 PIN 8 X100 R510 FTP1 FTP3 LED9 C255 OCI7 OCI8 DZ31 DZ32 OCI10 OCI9 OCI5 OCI6 C292 OCI12 For the following steps refer to the information 11.
Page 94 TROUBLESHOOTING AND REPAIR F-46 F-46 CURRENT TRANSDUCER TEST (continued) FIGURE F.17 – MULTI-PHASE CHOPPER BOARD TEST POINTS PIN 3 PIN 1 PIN 4 PIN 2 13. If the supply voltages are correct per Table F.14 but the transducersʼ feedback voltages are incorrect the current transducer or wiring from the current transducer to the PC board may be faulty.
Page 95 TROUBLESHOOTING AND REPAIR F-47 F-47 CURRENT TRANSDUCER TEST (continued) TABLE F.14 – CURRENT TRANSDUCERS SUPPLY VOLTAGE CHECKS DESCRIPTION TEST POINT TEST POINT EXPECTED CONDITIONS READING SUPPLY VOLTAGE J42 PIN 1 LEAD 216 J42 PIN 4 LEAD 218 +15VDC MACHINE “ON” TO MULTI-PHASE CHOPPER TRANSDUCER...
Page 96 TROUBLESHOOTING AND REPAIR F-48 F-48 CURRENT TRANSDUCER TEST (continued) TABLE F.15 – CURRENT TRANSDUCERS FEEDBACK VOLTAGE CHECKS MULTI-PHASE CHOPPER TRANSDUCER OUTPUT CURRENT TEST POINT TEST POINT EXPECTED (AMPS) READING J42 PIN 3 LEAD 215 J42 PIN 4 LEAD 218 4.0VDC J42 PIN 3 LEAD 215 J42 PIN 4 LEAD 218 3.6VDC...
Page 97 TROUBLESHOOTING AND REPAIR F-49 F-49 40 VOLT DC BUS BOARD TEST WARNING Service and repair should be performed only by Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or 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 98 TROUBLESHOOTING AND REPAIR F-50 F-50 40 VOLT DC BUS BOARD TEST (continued) FIGURE F.18 – 40 VOLT DC BUS BOARD LOCATION 40 VOLT DC BUS BOARD PROCEDURE 6. If the red LED is lit, the DC Bus Board is receiv- WARNING ing 48VDC voltage from the Power Conversion Assembly.
Page 99 TROUBLESHOOTING AND REPAIR F-51 F-51 40 VOLT DC BUS BOARD TEST (continued) FIGURE F.19 – 40 VOLT DC BUS BOARD TEST POINTS LEAD #52A LEAD LEAD LEAD #65A LEAD #51A LEAD L15732-1 TABLE F.16 – 40 VOLT DC BUS BOARD TEST POINTS AND EXPECTED READINGS DESCRIPTION TEST POINT TEST POINT...
Page 100 NOTES F-52 F-52 POWER WAVE ® S500...
Page 101 TROUBLESHOOTING AND REPAIR F-53 F-53 INPUT BOARD TEST WARNING Service and repair should be performed only by Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or 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 102 TROUBLESHOOTING AND REPAIR F-54 F-54 INPUT BOARD TEST (continued) FIGURE F.20 – INPUT BOARD LOCATION INPUT BOARD PROCEDURE 5. Locate the Green LED on the Input Board. See WARNING Figure F.21. See Wiring Diagram. 6. Carefully apply the correct three phase input ELECTRIC SHOCK can kill.
Page 103 TROUBLESHOOTING AND REPAIR F-55 F-55 INPUT BOARD TEST (continued) TABLE F.17 – INPUT BOARD DIODE CHECKS DESCRIPTION TEST POINT TEST POINT EXPECTED METER PROBE (+) METER PROBE (–) READING SMALL 3-PHASE J1 PIN 3 ON BOARD .578V RECTIFIER PLUG REMOVED SMALL 3-PHASE J1 PIN 3 ON BOARD .578V...
Page 104 TROUBLESHOOTING AND REPAIR F-56 F-56 INPUT BOARD TEST (continued) FIGURE F.21 – INPUT BOARD TEST POINT LOCATION GREEN TABLE F.18 – INPUT BOARD VOLTAGE TEST POINTS AND EXPECTED READINGS (NOMINAL 460VAC APPLIED) DESCRIPTION TEST POINT TEST POINT EXPECTED READING THREE-PHASE INPUT AC LINE VOLTAGE (Ex.
Page 105 TROUBLESHOOTING AND REPAIR F-57 F-57 MULTI-PHASE CHOPPER BOARD TEST WARNING Service and repair should be performed only by Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or 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 106 TROUBLESHOOTING AND REPAIR F-58 F-58 MULTI-PHASE CHOPPER BOARD TEST (continued) FIGURE F.22 – MULTI-PHASE CHOPPER BOARD LOCATION MULTI-PHASE CHOPPER BOARD PROCEDURE 4. Perform the Multi-Phase Chopper Board diode WARNING checks per Table F.19 and Figure F.23. 5. Locate the Green LED on the Multi-Phase ELECTRIC SHOCK can kill.
Page 107 TROUBLESHOOTING AND REPAIR F-59 F-59 MULTI-PHASE CHOPPER BOARD TEST (continued) FIGURE F.23 – MULTI-PHASE CHOPPER BOARD TEST POINTS 6 LEDS (GATE FIRING) GREEN LED 9. Energize the output of the Power Wave S500 11. If the correct input voltage is being applied to ®...
Page 108 TROUBLESHOOTING AND REPAIR F-60 F-60 MULTI-PHASE CHOPPER BOARD TEST (continued) TABLE F.19 – MULTI-PHASE CHOPPER BOARD DIODE CHECKS NOTE: Prior to testing make sure the input power is removed from the Power Wave S500 machine and that all ® leads are removed from terminals B1 and B2 on the Multi-Phase Chopper Board. See Figure F.23. DESCRIPTION TEST POINT TEST POINT...
Page 109 TROUBLESHOOTING AND REPAIR F-61 F-61 MULTI-PHASE CHOPPER BOARD TEST (continued) TABLE F.20 – MULTI-PHASE CHOPPER BOARD VOLTAGE TEST POINTS AND EXPECTED READINGS MODE OPEN CIRCUIT TEST POINT (+) TEST POINT (–) EXPECTED VOLTAGE READING (+/–10%) 24VDC 97VDC 24VDC 73VDC 24VDC 73VDC 24VDC 73VDC...
Page 110 NOTES F-62 F-62 POWER WAVE ® S500...
Page 111 TROUBLESHOOTING AND REPAIR F-63 F-63 CURRENT AND VOLTAGE CALIBRATION PROCEDURE WARNING Service and repair should be performed only by Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or 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 112 TROUBLESHOOTING AND REPAIR F-64 F-64 CURRENT AND VOLTAGE CALIBRATION PROCEDURE (continued) CALIBRATION SET-UP CALIBRATION PROCEDURE: 1. Once in the “Calibration” screen, make sure WARNING that the machine output is OFF (light is BLACK) and connect a resistive load bank to the output ELECTRIC SHOCK studs.
Page 113 TROUBLESHOOTING AND REPAIR F-65 F-65 CURRENT AND VOLTAGE CALIBRATION PROCEDURE (continued) FIGURE F.24 – CALIBRATION SCREEN POWER WAVE ® S500...
Page 114 NOTES F-66 F-66 POWER WAVE ® S500...
Page 115 TROUBLESHOOTING AND REPAIR F-67 F-67 PFC CONTROL BOARD REMOVAL AND REPLACEMENT PROCEDURE WARNING Service and repair should be performed only by Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or 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 116 TROUBLESHOOTING AND REPAIR F-68 F-68 PFC CONTROL BOARD REMOVAL AND REPLACEMENT PROCEDURE (continued) FIGURE F.25 – PFC CONTROL BOARD LOCATION PFC CONTROL BOARD PFC BOARD MOUNTING PANEL FRONT PANEL ASSEMBLY REMOVAL PROCEDURE 3. Locate the PFC Control Board. See Figure WARNING F.25.
Page 117 TROUBLESHOOTING AND REPAIR F-69 F-69 PFC CONTROL BOARD REMOVAL AND REPLACEMENT PROCEDURE (continued) FIGURE F.26 – PFC CONTROL BOARD PLUG LOCATIONS J23A J23B J23A J23B FTP9 FTP7 FTP8 OCI1 OCI2 OCI3 OCI4 R257 FTP21 FTP5 LED2 LED5 FTP26 FTP15 FTP6 FTP38 LED1 OCI5...
Page 118 NOTES F-70 F-70 POWER WAVE ® S500...
Page 119 TROUBLESHOOTING AND REPAIR F-71 F-71 115 VOLT SUPPLY BOARD REMOVAL AND REPLACEMENT PROCEDURE WARNING Service and repair should be performed only by Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty.
Page 120 TROUBLESHOOTING AND REPAIR F-72 F-72 115 VOLT SUPPLY BOARD REMOVAL AND REPLACEMENT PROCEDURE (continued) FIGURE F.27 – 115 VOLT SUPPLY BOARD LOCATION 115 VOLT SUPPLY BOARD REMOVAL PROCEDURE 3. Locate the 115 Volt Supply Board. See Figure WARNING F.27. 4. Label and remove plugs J82 and J83. It is not ELECTRIC SHOCK can kill.
Page 121 TROUBLESHOOTING AND REPAIR F-73 F-73 115 VOLT SUPPLY BOARD REMOVAL AND REPLACEMENT PROCEDURE (continued) FIGURE F.28 – 115 VOLT SUPPLY BOARD LEAD LOCATIONS LED 3 LED 2 NUTS (4 PLACES) LED 1 REPLACEMENT PROCEDURE 1. Place the new 115 Volt Supply Board onto the mounting studs.
Page 122 NOTES F-74 F-74 POWER WAVE ® S500...
Page 123 TROUBLESHOOTING AND REPAIR F-75 F-75 40 VOLT DC BUS BOARD REMOVAL AND REPLACEMENT PROCEDURE WARNING Service and repair should be performed only by Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty.
Page 124 TROUBLESHOOTING AND REPAIR F-76 F-76 40 VOLT DC BUS BOARD REMOVAL AND REPLACEMENT PROCEDURE (continued) FIGURE F.29 – 40 VOLT DC BUS BOARD LOCATION 40 VOLT DC BUS BOARD REMOVAL PROCEDURE 3. Locate the 40 Volt DC Bus Board. See Figure WARNING F.29.
Page 125 TROUBLESHOOTING AND REPAIR F-77 F-77 40 VOLT DC BUS BOARD REMOVAL AND REPLACEMENT PROCEDURE (continued) FIGURE F.30 – 40 VOLT DC BUS BOARD MOUNTING NUT AND LEAD LOCATIONS LED 1 LED1 NUTS NUTS (4 PLACES) (4 PLACES) L15732-1 REPLACEMENT PROCEDURE 1.
Page 126 NOTES F-78 F-78 POWER WAVE ® S500...
Page 127 TROUBLESHOOTING AND REPAIR F-79 F-79 LINE SWITCH REMOVAL AND REPLACEMENT PROCEDURE WARNING Service and repair should be performed only by Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or 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 128 TROUBLESHOOTING AND REPAIR F-80 F-80 LINE SWITCH REMOVAL AND REPLACEMENT PROCEDURE (continued) FIGURE F.31 – LINE SWITCH LOCATION LINE SWITCH LINE SWITCH COVER REMOVAL PROCEDURE 3. Locate the Line Switch. See Figure F.31. WARNING 4. Using a 5/16” nutdriver, remove the two screws securing the Line Switch to the front panel.
Page 129 TROUBLESHOOTING AND REPAIR F-81 F-81 LINE SWITCH REMOVAL AND REPLACEMENT PROCEDURE (continued) REPLACEMENT PROCEDURE 1. Attach and securely tighten leads L4, L5 and L6 into the new Line Switch. Make sure the MOV assembly is also attached securely. See the Wiring Diagram.
Page 130 NOTES F-82 F-82 POWER WAVE ® S500...
Page 131 TROUBLESHOOTING AND REPAIR F-83 F-83 INPUT BOARD REMOVAL AND REPLACEMENT PROCEDURE WARNING Service and repair should be performed only by Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or 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 132 TROUBLESHOOTING AND REPAIR F-84 F-84 INPUT BOARD REMOVAL AND REPLACEMENT PROCEDURE (continued) FIGURE F.32 – INPUT BOARD LOCATION INPUT BOARD REMOVAL PROCEDURE 4. Carefully remove the input board cover. Cut the WARNING three cable ties holding the input board cover in place.
Page 133 TROUBLESHOOTING AND REPAIR F-85 F-85 INPUT BOARD REMOVAL AND REPLACEMENT PROCEDURE (continued) FIGURE F.33 – INPUT BOARD LEAD LOCATIONS MOUNTING NUTS REPLACEMENT PROCEDURE 1. Position the new Input Board and heat sink assembly onto the four mounting posts. 2. Using a 3/8” nutdriver, attach the four nuts securing the Input Board to the mounting posts.
Page 134 NOTES F-86 F-86 POWER WAVE ® S500...
Page 135 TROUBLESHOOTING AND REPAIR F-87 F-87 DIGITAL CONTROL BOARD REMOVAL AND REPLACEMENT PROCEDURE WARNING Service and repair should be performed only by Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or 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 136 TROUBLESHOOTING AND REPAIR F-88 F-88 DIGITAL CONTROL BOARD REMOVAL AND REPLACEMENT PROCEDURE (continued) FIGURE F.34 – DIGITAL CONTROL BOARD LOCATION DIGITAL CONTROL BOARD REMOVAL PROCEDURE 4. Locate the Digital Control Board. See Figure WARNING F.34. 5. Label and remove plugs J5, J6, J7, J8, J9, J12, ELECTRIC SHOCK can kill.
Page 137 TROUBLESHOOTING AND REPAIR F-89 F-89 DIGITAL CONTROL BOARD REMOVAL AND REPLACEMENT PROCEDURE (continued) FIGURE F.35 – DIGITAL CONTROL BOARD LEAD LOCATIONS X100 MOUNTING STUDS MOUNTING STUDS R510 AND NUTS AND NUTS FTP1 FTP3 LED9 C255 OCI7 OCI8 DZ31 DZ32 OCI10 OCI9 OCI5 OCI6...
Page 138 NOTES F-90 F-90 POWER WAVE ® S500...
Page 139 TROUBLESHOOTING AND REPAIR F-91 F-91 REMOVAL AND REPLACEMENT PROCEDURE WARNING Service and repair should be performed only by Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or 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 140 TROUBLESHOOTING AND REPAIR F-92 F-92 REMOVAL AND REPLACEMENT PROCEDURE (continued) FIGURE F.36 – FAN ASSEMBLY COMPONENT LOCATIONS BRICKWORK PANEL MOUNTING SCREWS FAN ASSEMBLY MOUNTING SCREWS (4 PER ASSEMBLY) BRICKWORK PANEL FAN ASSEMBLIES REMOVAL PROCEDURE 3. Using a screwdriver, remove the four machine WARNING screws and associated lockwashers and flat- washers from the Fan Assembly to be replaced.
Page 141 TROUBLESHOOTING AND REPAIR F-93 F-93 REMOVAL AND REPLACEMENT PROCEDURE (continued) REPLACEMENT PROCEDURE 1. Place the new Fan Assembly into position in the machine. 2. Connect the lead connection plug (J55 or J56). See the Wiring Diagram. 3. Replace any cable ties previously removed. 4.
Page 142 NOTES F-94 F-94 POWER WAVE ® S500...
Page 143 TROUBLESHOOTING AND REPAIR F-95 F-95 POWER CONVERSION BOARD ASSEMBLY REMOVAL AND REPLACEMENT PROCEDURE WARNING Service and repair should be performed only by Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty.
Page 144 TROUBLESHOOTING AND REPAIR F-96 F-96 POWER CONVERSION BOARD ASSEMBLY REMOVAL AND REPLACEMENT PROCEDURE (continued) FIGURE F.37 – POWER CONVERSION BOARD ASSEMBLY LOCATION AIR BAFFLE POWER CONVERSION BOARD ASSEMBLY REMOVAL PROCEDURE 3. Locate the Power Conversion Board Assembly. WARNING See Figure F.37. 4.
Page 145 TROUBLESHOOTING AND REPAIR F-97 F-97 POWER CONVERSION BOARD ASSEMBLY REMOVAL AND REPLACEMENT PROCEDURE (continued) FIGURE F.38 – POWER CONVERSION BOARD ASSEMBLY LEAD LOCATIONS MOUNTING SCREWS (5 PLACES) LED4 LED3 LEAD B5 FTP3 LED5 DZ23 DZ26 DZ24 TO TOP INPUT CHOKE OCI1 LEAD B4 LEAD B2...
Page 146 TROUBLESHOOTING AND REPAIR F-98 F-98 POWER CONVERSION BOARD ASSEMBLY REMOVAL AND REPLACEMENT PROCEDURE (continued) REPLACEMENT PROCEDURE 1. Position the new Power Conversion Board 6. Attach the top choke leads to terminals B13 and Assembly onto the mounting post. B8. See Figure F.38. See Wiring Diagram. Torque the bolts to between 50 and 60 inch NOTE: The top of the Power Conversion Board pounds.
Page 147 TROUBLESHOOTING AND REPAIR F-99 F-99 CHOPPER BOARD REMOVAL AND REPLACEMENT PROCEDURE WARNING Service and repair should be performed only by Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or 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 148 TROUBLESHOOTING AND REPAIR F-100 F-100 CHOPPER BOARD REMOVAL AND REPLACEMENT PROCEDURE (continued) FIGURE F.39 – CHOPPER BOARD LOCATION MULTI-PHASE CHOPPER BOARD REMOVAL PROCEDURE 3. Locate the Chopper Board. See Figure F.39. WARNING 4. Locate and remove plugs J41 and J42 from the Chopper Board.
Page 149 TROUBLESHOOTING AND REPAIR F-101 F-101 CHOPPER BOARD REMOVAL AND REPLACEMENT PROCEDURE (continued) FIGURE F.40 – CHOPPER BOARD LEAD LOCATIONS LEAD 410 LEAD 410 3/8 INCH MOUNTING NUTS (4 PLACES TOP AND BOTTOM) 7. Using a 7/16” wrench, label and remove leads 9.
Page 150 TROUBLESHOOTING AND REPAIR F-102 F-102 CHOPPER BOARD REMOVAL AND REPLACEMENT PROCEDURE (continued) REPLACEMENT PROCEDURE 1. Position the new Chopper Board and heat sink 6. Connect leads B2 and 207 to terminal B2. assembly onto the four mounting posts. Torque the bolts to between 50 to 60 inch pounds.
Page 151 TROUBLESHOOTING AND REPAIR F-103 F-103 RETEST AFTER REPAIR PROCEDURE WARNING Service and repair should be performed only by Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or 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 152 TROUBLESHOOTING AND REPAIR F-104 F-104 RETEST AFTER REPAIR PROCEDURE (continued) PROCEDURE 3. Turn the Power Switch OFF and connect a resis- WARNING tive load across the Output Studs and a com- puter to the Ethernet. Perform the Current and ELECTRIC SHOCK Voltage Calibration Procedure to be sure that can kill.
Page 153 TABLE OF CONTENTS - DIAGRAM SECTION Electrical Diagrams ..............G-1 Wiring Diagram (G7188) .
Page 154: Electrical Diagrams
ELECTRICAL DIAGRAMS WIRING DIAGRAM - (G7188) POWER WAVE S500 GENERAL I NFORMATION CAVITY NUMBER ING SE QUENC E ELECTRI CAL SY MBOLS PER E1537. (VIEWED FROM COMPONENT SIDE OF P.C. BOARD) LEAD COLOR CODING B - BLACK J10A1, J2, J5, J11,...
Page 155 THIS DOCUMENT CONTAINS PROPRIETARY INFORMATION OWNED BY LINCOLN GLOBAL, INC. AND MAY NOT BE DUPLICATED, COMMUNICATED PROPRIETARY & CONFIDENTIAL: TO OTHER PARTIES OR USED FOR ANY PURPOSE WITHOUT THE EXPRESS WRITTEN PERMISSION OF LINCOLN GLOBAL, INC. GND2 CASEBACK MANUFACTURING TOLERANCE PER E2056...
Page 156 CURRENT VOLTAGE COOLER ERRORS SENSE SENSE ENABLE 115 VAC OUT Description of LED functions on Power Wave S500 For reference only Description of LED functions LOGIC COMMUNICATION J3 J5 on Power Wave S500 WITH CONTROL BD G6571 115 VAC INVERTER P.C. BOARD...
Page 157 THIS DOCUMENT CONTAINS PROPRIETARY INFORMATION OWNED BY LINCOLN GLOBAL, INC. AND MAY NOT BE DUPLICATED, COMMUNICATED PROPRIETARY & CONFIDENTIAL: TO OTHER PARTIES OR USED FOR ANY PURPOSE WITHOUT THE EXPRESS WRITTEN PERMISSION OF LINCOLN GLOBAL, INC. MANUFACTURING TOLERANCE PER E2056...
Page 158 THIS DOCUMENT CONTAINS PROPRIETARY INFORMATION OWNED BY LINCOLN GLOBAL, INC. AND MAY NOT BE DUPLICATED, COMMUNICATED PROPRIETARY & CONFIDENTIAL: TO OTHER PARTIES OR USED FOR ANY PURPOSE WITHOUT THE EXPRESS WRITTEN PERMISSION OF LINCOLN GLOBAL, INC. MANUFACTURING TOLERANCE PER E2056...
Page 159 ELECTRICAL DIAGRAMS CONTROL PC BOARD ASSEMBLY (G6682-1 PG 2) ENGINEERING CONTROLLED CHANGE DETAIL: REVISED ITEM 9 PART NUMBER MANUFACTURER: Ye s N.G.2 N.E.11 BOTTOM VIEW PROPRIETARY & CONFIDENTIAL: THIS DOCUMENT CONTAINS PROPRIETAR Y INF ORMATION OW NED BY L INCOLN GL OBAL, INC. AND MAY NOT BE DUPLICATED, COMMUNICATED TO OTHE R PAR TIES O R USED F OR ANY PURPOSE WITHOUT THE EXPRESS WRITTEN PERMISSION OF LINC OL N GLOBAL, INC.
Page 160 THIS DOCUMENT CONTAINS PROPRIETARY INFORMATION OWNED BY LINCOLN GLOBAL, INC. AND MAY NOT BE DUPLICATED, COMMUNICATED PROPRIETARY & CONFIDENTIAL: TO OTHER PARTIES OR USED FOR ANY PURPOSE WITHOUT THE EXPRESS WRITTEN PERMISSION OF LINCOLN GLOBAL, INC. MANUFACTURING TOLERANCE PER E2056...
Page 161 THIS DOCUMENT CONTAINS PROPRIETARY INFORMATION OWNED BY LINCOLN GLOBAL, INC. AND MAY NOT BE DUPLICATED, COMMUNICATED PROPRIETARY & CONFIDENTIAL: TO OTHER PARTIES OR USED FOR ANY PURPOSE WITHOUT THE EXPRESS WRITTEN PERMISSION OF LINCOLN GLOBAL, INC. MANUFACTURING TOLERANCE PER E2056...
Page 162 THIS DOCUMENT CONTAINS PROPRIETARY INFORMATION OWNED BY LINCOLN GLOBAL, INC. AND MAY NOT BE DUPLICATED, COMMUNICATED PROPRIETARY & CONFIDENTIAL: TO OTHER PARTIES OR USED FOR ANY PURPOSE WITHOUT THE EXPRESS WRITTEN PERMISSION OF LINCOLN GLOBAL, INC. MANUFACTURING TOLERANCE PER E2056...

Lincoln Electric POWER WAVE S500 Service Manual

Quick Links

SERVICE MANUAL

Troubleshooting

Related Manuals for Lincoln Electric POWER WAVE S500

Summary of Contents for Lincoln Electric POWER WAVE S500

Table of Contents