Table Of Contents - Lincoln Electric POWER WAVE S500 Service Manual

Table of Contents

Service Manual1
Safety2
California Proposition 65 Warnings2
For Engine Powered Equipment2
Electric And Magnetic Fields May Be Dangerous2
Electric Shock Can Kill3
Arc Rays Can Burn3
Fumes And Gases Can Be Dangerous3
Welding And Cutting Sparks Can Cause Fire Or Explosion4
Cylinder May Explode If Damaged4
For Electrically Powered Equipment4
Electromagnetic Compatibility (Emc)6
Installation And Use6
Assessment Of Area6
Methods Of Reducing Emissions7
Table Of Contents8
Technical Specifications-Power Wave S50010
Installation10
Welding Process11
Physical Dimensions11
Select Suitable Location12
Lifting12
Machine Grounding12
Input Fuse And Supply Wire Considerations13
Input Voltage Selection13
Power Wave S50013
Input Connection13
Connection Diagrams14
Gtaw (Tig) Welding14
Tig With S-Series User Interface14
Smaw (Stick) Welding15
Stick With S-Series User Interface15
Gmaw (Mig) Welding16
Mig Process16
Recommended Work Cable Sizes For Arc Welding17
General Guidelines17
Output Cable Guidelines17
Cable Inductance And Its Effects On Welding18
Remote Sense Lead Specifications18
Voltage Sensing Overview18
General Guidelines For Voltage Sense Leads19
Electrode Voltage Sensing19
Work Voltage Sensing19
Negative Electrode Polarity19
Voltage Sensing Considerations For Multiple Arc Systems20
If Sense Leads Are Not Used20
If Sense Leads Are Used20
Control Cable Connections22
Connection Between Power Source And Ethernet Networks22
Product Specific Installation Instructions22
Operation Section23
Safety Precautions24
Power-Up Sequence24
Duty Cycle24
Graphic Symbols That Appear On This Machine Or In This Manual24
Product Description25
Product Summary25
Recommended Processes And Equipment25
Equipment Limitations25
Operation25
Design Features26
Loaded With Standard Features26
Case Front Controls26
Case Back Controls27
Common Welding Procedures28
Definition Of Welding Modes28
Basic Welding Controls28
Constant Voltage Welding Synergic Cv29
Non Synergic Cv29
All Cv Modes29
Pulse Welding29
Accessories Section31
Kits, Options And Accessories32
General Options32
Factory Installed Options32
Field Installed Options32
Stick Options33
Maintenance Section35
Routine Maintenance36
Periodic Maintenance36
Calibration Specification36
Major Components Locations37
Theory Of Operation Section39
General Description40
Theory Of Operation40
Line Switch, Input Board And Power Factor Control (Pfc) Board41
Power Conversion Board Assembly42
Six Phase Chopper Board And Multi-Phase Output Choke43
Dc Bus Board And Digital Control Board44
Optional Remote Control Board And 115Vac Inverter Board45
Machine Protection46
Thermal Protection46
Protective Circuits46
Over Current Protection46
Insulated Gate Bipolar Transistor (Igbt) Operation47
Pulse Width Modulation47
Troubleshooting And Repair49
Рow To Use Troubleshooting Guide50
Pc Board Troubleshooting Procedures51
Output Problems53
Welding Problems55
Ethernet Problems57
Input Control Board58
Main Control Board ("Status" Light)59
Case Cover Removal And Dc Link Capacitor Discharge Procedure61
Test Description61
Materials Needed61
Case Cover Removal62
Removal Procedure62
Capacitor Discharge Procedure63
Replacement Procedure64
Pfc Control Board Test65
Pfc Control Board Location66
Pfc Control Board Led And Test Points67
Pfc Control Board Led Description And Functions67
Pfc Control Board Error Codes67
Pfc Control Board Resistance Checks68
Pfc Control Board Diode Checks68
Digital Control Board Test69
Digital Control Board Location70
Digital Control Board Led And Test Point Locations71
Digital Control Board Led Description And Functions71
Digital Control Board Voltage Test Points And Expected Readings72
Digital Control Board Resistance Checks And Expected Readings72
Optional User Interface Kit Test73
User Interface And Remote Interface Board Locations74
Remote Interface Board Test Points75
User Interface Board Test Points75
Voltage Checks On Remote Interface Board76
Voltage Checks On User Interface Board76
Resistance Checks77
Power Conversion Assembly Test79
Power Conversion Assembly Location80
Diode Tests81
Power Conversion Assembly Diode Test Points82
Power Conversion Assembly Voltage Check Test Points83
Power Conversion Led Legend84
Power Conversion Assembly Voltage Tests85
Multi-Phase Output Choke Test87
Test Component Locations88
Multi-Phase Output Chopper Board Lead Locations89
Current Transducer Test91
Current Transducer Test Component Locations92
Digital Control Board Test Points93
Multi-Phase Chopper Board Test Points94
Current Transducers Supply Voltage Checks95
Current Transducers Feedback Voltage Checks96
Multi-Phase Chopper Transducer96
Output Control Transducer96
40 Volt Dc Bus Board Test97
40 Volt Dc Bus Board Location98
40 Volt Dc Bus Board Test Points And Expected Readings99
Input Board Test101
Input Board Location102
Input Board Diode Checks103
Input Board Test Point Location104
Input Board Voltage Test Points And Expected Readings (Nominal 460Vac Applied)104
Multi-Phase Chopper Board Test105
Multi-Phase Chopper Board Location106
Multi-Phase Chopper Board Diode Checks108
Multi-Phase Chopper Board Voltage Test Points And Expected Readings109
Current And Voltage Calibration Procedure111
Calibration Set-Up112
Calibration Screen113
Pfc Control Board Removal And Replacement Procedure115
Pfc Control Board Plug Locations117
115 Volt Supply Board Removal And Replacement Procedure119
115 Volt Supply Board Location120
115 Volt Supply Board Lead Locations121
40 Volt Dc Bus Board Removal And Replacement Procedure123
40 Volt Dc Bus Board Mounting Nut And Lead Locations125
Line Switch Removal And Replacement Procedure127
Line Switch Location128
Input Board Removal And Replacement Procedure131
Input Board Lead Locations133
Digital Control Board Removal And Replacement Procedure135
Digital Control Board Lead Locations137
Fan Removal And Replacement Procedure139
Fan Assembly Component Locations140
Power Conversion Board Assembly Removal And Replacement Procedure143
Power Conversion Board Assembly Location144
Power Conversion Board Assembly Lead Locations145
Chopper Board Removal And Replacement Procedure147
Сhopper Board Location148
Сhopper Board Lead Location149
Retest After Repair Procedure151
Diagram Section153
Electrical Diagrams154
Wiring Diagram-(G7188)154
Schematic-(G7189)155
Control Pc Board Assembly (G6682-1)158
Pfc Control Board Assembly (G6860-1)161