Sign In
Upload
Download
Table of Contents
Contents
Add to my manuals
Delete from my manuals
Share
URL of this page:
HTML Link:
Bookmark this page
Add
Manual will be automatically added to "My Manuals"
×
Bookmark added
×
Added to my manuals
Manuals
Brands
Lincoln Electric Manuals
Welding System
POWER WAVE S500
Service manual
Table Of Contents - Lincoln Electric POWER WAVE S500 Service Manual
Hide thumbs
Also See for POWER WAVE S500
:
Operator's manual
(60 pages)
,
Operator's manual
(52 pages)
,
Operator's manual
(44 pages)
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
51
52
53
54
55
56
57
58
59
60
61
62
63
64
65
66
67
68
69
70
71
72
73
74
75
76
77
78
79
80
81
82
83
84
85
86
87
88
89
90
91
92
93
94
95
96
97
98
99
100
101
102
103
104
105
106
107
108
109
110
111
112
113
114
115
116
117
118
119
120
121
122
123
124
125
126
127
128
129
130
131
132
133
134
135
136
137
138
139
140
141
142
143
144
145
146
147
148
149
150
151
152
153
154
155
156
157
158
159
160
161
162
Table Of Contents
163
page
of
163
Go
/
163
Contents
Table of Contents
Troubleshooting
Bookmarks
Table of Contents
Advertisement
Table of Contents
Service Manual
1
Safety
2
California Proposition 65 Warnings
2
For Engine Powered Equipment
2
Electric And Magnetic Fields May Be Dangerous
2
Electric Shock Can Kill
3
Arc Rays Can Burn
3
Fumes And Gases Can Be Dangerous
3
Welding And Cutting Sparks Can Cause Fire Or Explosion
4
Cylinder May Explode If Damaged
4
For Electrically Powered Equipment
4
Electromagnetic Compatibility (Emc)
6
Installation And Use
6
Assessment Of Area
6
Methods Of Reducing Emissions
7
Table Of Contents
8
Technical Specifications-Power Wave S500
10
Installation
10
Welding Process
11
Physical Dimensions
11
Select Suitable Location
12
Lifting
12
Machine Grounding
12
Input Fuse And Supply Wire Considerations
13
Input Voltage Selection
13
Power Wave S500
13
Input Connection
13
Connection Diagrams
14
Gtaw (Tig) Welding
14
Tig With S-Series User Interface
14
Smaw (Stick) Welding
15
Stick With S-Series User Interface
15
Gmaw (Mig) Welding
16
Mig Process
16
Recommended Work Cable Sizes For Arc Welding
17
General Guidelines
17
Output Cable Guidelines
17
Cable Inductance And Its Effects On Welding
18
Remote Sense Lead Specifications
18
Voltage Sensing Overview
18
General Guidelines For Voltage Sense Leads
19
Electrode Voltage Sensing
19
Work Voltage Sensing
19
Negative Electrode Polarity
19
Voltage Sensing Considerations For Multiple Arc Systems
20
If Sense Leads Are Not Used
20
If Sense Leads Are Used
20
Control Cable Connections
22
Connection Between Power Source And Ethernet Networks
22
Product Specific Installation Instructions
22
Operation Section
23
Safety Precautions
24
Power-Up Sequence
24
Duty Cycle
24
Graphic Symbols That Appear On This Machine Or In This Manual
24
Product Description
25
Product Summary
25
Recommended Processes And Equipment
25
Equipment Limitations
25
Operation
25
Design Features
26
Loaded With Standard Features
26
Case Front Controls
26
Case Back Controls
27
Common Welding Procedures
28
Definition Of Welding Modes
28
Basic Welding Controls
28
Constant Voltage Welding Synergic Cv
29
Non Synergic Cv
29
All Cv Modes
29
Pulse Welding
29
Accessories Section
31
Kits, Options And Accessories
32
General Options
32
Factory Installed Options
32
Field Installed Options
32
Stick Options
33
Maintenance Section
35
Routine Maintenance
36
Periodic Maintenance
36
Calibration Specification
36
Major Components Locations
37
Theory Of Operation Section
39
General Description
40
Theory Of Operation
40
Line Switch, Input Board And Power Factor Control (Pfc) Board
41
Power Conversion Board Assembly
42
Six Phase Chopper Board And Multi-Phase Output Choke
43
Dc Bus Board And Digital Control Board
44
Optional Remote Control Board And 115Vac Inverter Board
45
Machine Protection
46
Thermal Protection
46
Protective Circuits
46
Over Current Protection
46
Insulated Gate Bipolar Transistor (Igbt) Operation
47
Pulse Width Modulation
47
Troubleshooting And Repair
49
Рow To Use Troubleshooting Guide
50
Pc Board Troubleshooting Procedures
51
Output Problems
53
Welding Problems
55
Ethernet Problems
57
Input Control Board
58
Main Control Board ("Status" Light)
59
Case Cover Removal And Dc Link Capacitor Discharge Procedure
61
Test Description
61
Materials Needed
61
Case Cover Removal
62
Removal Procedure
62
Capacitor Discharge Procedure
63
Replacement Procedure
64
Pfc Control Board Test
65
Pfc Control Board Location
66
Pfc Control Board Led And Test Points
67
Pfc Control Board Led Description And Functions
67
Pfc Control Board Error Codes
67
Pfc Control Board Resistance Checks
68
Pfc Control Board Diode Checks
68
Digital Control Board Test
69
Digital Control Board Location
70
Digital Control Board Led And Test Point Locations
71
Digital Control Board Led Description And Functions
71
Digital Control Board Voltage Test Points And Expected Readings
72
Digital Control Board Resistance Checks And Expected Readings
72
Optional User Interface Kit Test
73
User Interface And Remote Interface Board Locations
74
Remote Interface Board Test Points
75
User Interface Board Test Points
75
Voltage Checks On Remote Interface Board
76
Voltage Checks On User Interface Board
76
Resistance Checks
77
Power Conversion Assembly Test
79
Power Conversion Assembly Location
80
Diode Tests
81
Power Conversion Assembly Diode Test Points
82
Power Conversion Assembly Voltage Check Test Points
83
Power Conversion Led Legend
84
Power Conversion Assembly Voltage Tests
85
Multi-Phase Output Choke Test
87
Test Component Locations
88
Multi-Phase Output Chopper Board Lead Locations
89
Current Transducer Test
91
Current Transducer Test Component Locations
92
Digital Control Board Test Points
93
Multi-Phase Chopper Board Test Points
94
Current Transducers Supply Voltage Checks
95
Current Transducers Feedback Voltage Checks
96
Multi-Phase Chopper Transducer
96
Output Control Transducer
96
40 Volt Dc Bus Board Test
97
40 Volt Dc Bus Board Location
98
40 Volt Dc Bus Board Test Points And Expected Readings
99
Input Board Test
101
Input Board Location
102
Input Board Diode Checks
103
Input Board Test Point Location
104
Input Board Voltage Test Points And Expected Readings (Nominal 460Vac Applied)
104
Multi-Phase Chopper Board Test
105
Multi-Phase Chopper Board Location
106
Multi-Phase Chopper Board Diode Checks
108
Multi-Phase Chopper Board Voltage Test Points And Expected Readings
109
Current And Voltage Calibration Procedure
111
Calibration Set-Up
112
Calibration Screen
113
Pfc Control Board Removal And Replacement Procedure
115
Pfc Control Board Plug Locations
117
115 Volt Supply Board Removal And Replacement Procedure
119
115 Volt Supply Board Location
120
115 Volt Supply Board Lead Locations
121
40 Volt Dc Bus Board Removal And Replacement Procedure
123
40 Volt Dc Bus Board Mounting Nut And Lead Locations
125
Line Switch Removal And Replacement Procedure
127
Line Switch Location
128
Input Board Removal And Replacement Procedure
131
Input Board Lead Locations
133
Digital Control Board Removal And Replacement Procedure
135
Digital Control Board Lead Locations
137
Fan Removal And Replacement Procedure
139
Fan Assembly Component Locations
140
Power Conversion Board Assembly Removal And Replacement Procedure
143
Power Conversion Board Assembly Location
144
Power Conversion Board Assembly Lead Locations
145
Chopper Board Removal And Replacement Procedure
147
Сhopper Board Location
148
Сhopper Board Lead Location
149
Retest After Repair Procedure
151
Diagram Section
153
Electrical Diagrams
154
Wiring Diagram-(G7188)
154
Schematic-(G7189)
155
Control Pc Board Assembly (G6682-1)
158
Pfc Control Board Assembly (G6860-1)
161
Previous
Page
1
...
162
163
Show Quick Links
Quick Links:
Service Manual
Troubleshooting and Repair
Main Control Board (“Status” Light)
Hide quick links:
Permanently
Temporary
Cancel
Advertisement
Table of Contents
Troubleshooting
Troubleshooting and repair
49
Рow to use troubleshooting guide
50
PC board troubleshooting procedures
51
Troubleshooting and Repair
52
Related Manuals for Lincoln Electric POWER WAVE S500
Welding System Lincoln Electric POWER WAVE S500 Operator's Manual
(60 pages)
Welding System Lincoln Electric Power Wave S500 K2904-1 Operator's Manual
(52 pages)
Welding System Lincoln Electric POWER WAVE S500 Operator's Manual
(44 pages)
Welding System Lincoln Electric Power Wave S350 Operator's Manual
Advanced module & advanced module aluminum (34 pages)
Welding System Lincoln Electric POWER WAVE S500CE IM10123 Operator's Manual
(45 pages)
Welding System Lincoln Electric POWER WAVE S350 CE Operator's Manual
(15 pages)
Welding System Lincoln Electric POWER WAVE S500 CE Operator's Manual
(15 pages)
Welding System Lincoln Electric SP-100T Operator's Manual
Lincoln electric welder user manual (35 pages)
Welding System Lincoln Electric SAM400 Operator's Manual
Perkins diesel engine driven multi-process dc arc welding power sources (40 pages)
Welding System Lincoln Electric MULTI-SOURCE SVM155-A Service Manual
Lincoln electric welder user manual (96 pages)
Welding System Lincoln Electric MULTI-WELD SVM151-A Service Manual
Arc converter (119 pages)
Welding System Lincoln Electric RANGER SVM168-B Service Manual
Lincoln electric welder user manual (112 pages)
Welding System Lincoln Electric POWER MIG SVM170-A Service Manual
Lincoln electric welding system user manual (109 pages)
Welding System Lincoln Electric SAE-400 Operator's Manual
Dc arc welding power source (60 pages)
Welding System Lincoln Electric POWER WAVE S350 CE Operator's Manual
Power wave (18 pages)
Welding System Lincoln Electric SAF-FRO DIGISTEEL 355S Operator's Manual
(17 pages)
Related Content for Lincoln Electric POWER WAVE S500
12447 Table Of Contents
Lincoln Electric 12447
11672 Table Of Contents
Lincoln Electric 11672
Power Wave 455M Table Of Contents
Lincoln Electric Power Wave 455M
BIG RED 500 A-1 Table Of Contents - Installation Section
Lincoln Electric BIG RED 500
power wave c300 Table Of Contents
Lincoln Electric power wave c300
POWER Wave AC/DC 1000 Table Of Contents
Lincoln Electric POWER Wave AC/DC 1000
POWER WAVE455M Table Of Contents
Lincoln Electric POWER WAVE455M
Cobramatic K2259-1 Diagrams Table Of Contents
Lincoln Electric Cobramatic K2259-1
STT-10 HEAD & CONTROLS BOOM MOUNT OR BENCH MODELS IM586-B Table Of Contents
Lincoln Electric STT-10 HEAD & CONTROLS BOOM MOUNT OR BENCH MODELS IM586-B
POWERWAVE IM762-C Table Of Contents
Lincoln Electric POWERWAVE IM762-C
POWER WAVE IM10040 Table Of Contents
Lincoln Electric POWER WAVE IM10040
POWER WAVE IM924 Table Of Contents
Lincoln Electric POWER WAVE IM924
POWER WAVE C300 CE Table Of Contents
Lincoln Electric POWER WAVE C300 CE
POWER WAVE IM808-A Table Of Contents
Lincoln Electric POWER WAVE IM808-A
POWER WAVE IM716 Table Of Contents
Lincoln Electric POWER WAVE IM716
IDEALARC TIG-250/250 Table Of Contents
Lincoln Electric IDEALARC TIG-250/250
Table of Contents
Print
Rename the bookmark
Delete bookmark?
Delete from my manuals?
Login
Sign In
OR
Sign in with Facebook
Sign in with Google
Upload manual
Upload from disk
Upload from URL