Lincoln Electric POWER WAVE S500 Operator's Manual
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Lincoln Electric POWER WAVE S500 Operator's Manual

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Operator's Manual

POWER WAVE

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Date Purchased
Code: (ex: 10859)
Serial: (ex: U1060512345)
IM10118-A
| Issue D ate Nov- 13
© 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

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Summary of Contents for Lincoln Electric POWER WAVE S500

  • Page 1: Power Wave

    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: Safety Precautions

    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 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 BE DANGEROUS St. Clair Avenue, Cleveland, Ohio 44117-1199.

  • 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: 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: Installation

    INSTALLATION TECHNICAL SPECIFICATIONS - POWER WAVE S500 ® POWER SOURCE-INPUT VOLTAGE AND CURRENT Model Power Factor @ Duty Cycle Input Voltage ± 10% Input Amperes Idle Power Rated Output 40% rating 208/230/400*460/575 80/73/41/37/29 K2904-1 50/60 Hz 500 Watts Max. 100% rating (includes 380V to 413V) (fan on) 60/54/30/27/21...

  • Page 8: Physical Dimensions

    INSTALLATION WELDING PROCESS OCV (U PROCESS OUTPUT RANGE (AMPERES) Mean Peak GMAW GMAW-Pulse 40-550A FCAW GTAW-DC 5-550A SMAW 15-550A PHYSICAL DIMENSIONS WEIGHT MODEL HEIGHT WIDTH DEPTH 150 lbs (68 kg) 24.80in ( 630mm) K2904-1 22.45 in ( 570 mm) 14.00in ( 356 mm) TEMPERATURE RANGES STORAGE TEMPERATURE RANGE OPERATING TEMPERATURE RANGE...

  • Page 9: Safety Precautions

    INSTALLATION LIFTING SAFETY PRECAUTIONS Read this Both handles should be used when lifting POWER entire installation section before you start installa- WAVE ® S500. When using a crane or overhead device tion. a lifting strap should be connected to both handles. WARNING Do not attempt to lift the POWER WAVE ®...

  • Page 10: Input Connection

    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 ® S500. Connections input circuit with the recommended super lag fuse or should be made in accordance with delay type breakers (also called "inverse time"...

  • Page 11: Connection Diagram

    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 12 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 13 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 REGULATOR FLOWMETER AS H H OSE RCLINK C C ABLE TO N N EGATIVE VE ( ( -) S S TUD K1543-[XX] WORK C C LAMP...

  • Page 14: Recommended Work Cable Sizes

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

  • Page 15: Cable Inductance And Its Effects On Welding

    INSTALLATION Depending upon the process, inductance within the CABLE INDUCTANCE AND ITS electrode and work cables can influence the voltage EFFECTS ON WELDING 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 A-10 A-10 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- ured by the active weld mode.

  • Page 17: Voltage Sensing Considerations For Multiple Arc Systems

    A-11 A-11 INSTALLATION VOLTAGE SENSING If Sense Leads ARE Used: CONSIDERATIONS FOR MULTIPLE • Position the sense leads out of the path of the weld ARC SYSTEMS current. Especially any current paths common to adjacent arcs. Current from adjacent arcs can induce voltage into each others current paths that Special care must be taken when more than one arc can be misinterpreted by the power sources, and...
  • Page 18 A-12 A-12 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 SOURCE...

  • Page 19: Control Cable Connections

    A-13 A-13 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

    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. • Do not touch electrically live part or electrode with skin or DANGEROUS wet clothing.

  • Page 21: Product Description

    OPERATION PROCESS LIMITATIONS PRODUCT DESCRIPTION The software based weld tables of the POWER PRODUCT SUMMARY WAVE S500 limit the process capability within the ® The POWER WAVE ® S500 is a portable multi-process output range and the safe limits of the machine. In power source with high-end functionality capable of general the processes will be limited to .030-.052 solid Stick, DC TIG, MIG, Pulsed MIG and Flux-Cored...

  • Page 22: 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 23: 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 24: Common Welding Procedures

    Weld responsibility of the builder/user. Many variables modes are developed with a specific electrode materi- beyond the control of The Lincoln Electric al, electrode size, and shielding gas. For a more com- Company affect the results obtained in applying plete description of the weld modes programmed into these programs.
  • Page 25 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 ™...
  • Page 26 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

    ACCESSORIES KITS, OPTIONS AND ACCESSORIES All Kits Options and Accessories are found on the AWG #1 Coaxial Cables: Web site: (www.lincolnelectric.com) Order K2593-25 for 25 feet (7.6 m) cable length. 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 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 29: 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 30: 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 31 TROUBLESHOOTING USING THE STATUS LED TO Included in this section is information about the Status Lights and some basic troubleshooting charts for both TROUBLESHOOT SYSTEM PROBLEMS machine and weld performance. The status light for the main control board and input control Not all of the POWER WAVE ®...

  • Page 32: Error Codes

    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. MAIN CONTROL BOARD ( “STATUS”...
  • Page 33 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. Persistent Input current limit was exceeded during machine power-up.

  • Page 34: Troubleshooting

    3. Contact your local authorized 3. Major physical or electrical dam- Lincoln Electric Field Service age is evident when the covers facility for technical assistance. are removed. 1. Make sure input supply discon- Machine will not power up (no lights) 1.
  • Page 35 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. Check for proper fan operation. Thermal LED is ON 1. Improper fan operation. Fan should run in a low speed setting when the machine is idle and in a high speed when the...
  • Page 36 TROUBLESHOOTING Observe all Safety Guidelines detailed throughout this manual PROBLEMS POSSIBLE RECOMMENDED (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 37 TROUBLESHOOTING Observe all Safety Guidelines detailed throughout this manual 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).
  • Page 38 ENHANCED DIAGRAM DIAGRAMS POWER WAVE ® S500...
  • Page 39 DIMENSION PRINT POWER WAVE ® S500...
  • Page 40 NOTES POWER WAVE ® S500...
  • Page 41 This parts list is provided as an informative guide only. It was accurate at the time of printing. These pages are only updated on the Service Navigator DVD and in Lincoln Electricʼs official Parts Book (BK-34). When ordering parts, always refer to Lincoln Electricʼs official Parts Book (BK-34) for the latest pages.
  • Page 42 P-690-A P-690-A 09-23-2013 POWER WAVE S500 ®...
  • Page 43 P-690-A.1 P-690-A.1 POWER WAVE S500 ® For Codes: 11813, 12243 Do Not use this Parts List for a machine if its code number is not listed. Contact the Service Department for any code numbers not listed. Use the Illustration of Sub-Assemblies page and the table below to determine which sub assembly page and column the desired part is located on for your particular code machine.
  • Page 44 MISCELLANEOUS ITEMS P-690-B.2 P-690-B.2 (THESE ITEMS ARE NOT ILLUSTRATED) # Indicates a change this printing. Use only the parts marked “x” in the column under the heading number called for in the model index page. 1 2 3 4 5 6 7 8 9 DESCRIPTION PART NO.
  • Page 45 NOTES POWER WAVE S500 ®...
  • Page 46 P-690-C P-690-C Case Front Assembly 2C 2D 2D 2E 2B 2D 2D 2E 09-23-2013 POWER WAVE S500 ®...
  • Page 47 P-690-C.1 P-690-C.1 # Indicates a change this printing. Use only the parts marked “x” in the column under the heading number called for in the model index page. 1 2 3 4 5 6 7 8 9 ITEM DESCRIPTION PART NO. QTY.
  • Page 48 P-690-D P-690-D Base & Power Conversion Assembly 09-23-2013 POWER WAVE S500 ®...
  • Page 49 P-690-D.1 P-690-D.1 # Indicates a change this printing. Use only the parts marked “x” in the column under the heading number called for in the model index page. 1 2 3 4 5 6 7 8 9 ITEM DESCRIPTION PART NO. QTY.
  • Page 50 P-690-D.2 P-690-D.2 # Indicates a change this printing. Use only the parts marked “x” in the column under the heading number called for in the model index page. 1 2 3 4 5 6 7 8 9 ITEM DESCRIPTION PART NO. QTY.
  • Page 51 NOTES POWER WAVE S500 ®...
  • Page 52 P-690-E P-690-E Case Back Assembly 09-23-2013 POWER WAVE S500 ®...
  • Page 53 P-690-E.1 P-690-E.1 # Indicates a change this printing. Use only the parts marked “x” in the column under the heading number called for in the model index page. 1 2 3 4 5 6 7 8 9 ITEM DESCRIPTION PART NO. QTY.
  • Page 54 P-690-E.2 P-690-E.2 # Indicates a change this printing. Use only the parts marked “x” in the column under the heading number called for in the model index page. 1 2 3 4 5 6 7 8 9 ITEM DESCRIPTION PART NO. QTY.
  • Page 55 NOTES POWER WAVE S500 ®...
  • Page 56 P-690-F P-690-F Roof Assembly Oct-13 POWER WAVE S500 ®...
  • Page 57 P-690-F.1 P-690-F.1 # Indicates a change this printing. Use only the parts marked “x” in the column under the heading number called for in the model index page. 1 2 3 4 5 6 7 8 9 ITEM DESCRIPTION PART NO. QTY.
  • Page 58 NOTES POWER WAVE S500 ®...
  • Page 59 NOTES POWER WAVE ® S500...
  • Page 60 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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