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Lincoln Electric POWER WAVE R500, Operator'S Manual, Page: 1 / 56

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Operator’s Manual

POWER WAVE

®

R500

Register your machine:  

www.lincolnelectric.com/register

Authorized Service and Distributor Locator:  

www.lincolnelectric.com/locator

IM10295

|   Issue D ate June-15

© Lincoln Global, Inc.  All Rights Reserved.

For use with machines having Code Numbers:

12483

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: [email protected]

Save for future reference  

Date Purchased

Code: (ex: 10859)

Serial: (ex: U1060512345)

Summary of Contents for POWER WAVE R500

Page 1: ...achines having Code Numbers 12483 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 lincolnelec...

Page 2: ...A LARGE ROOM OR OUTDOORS natural ventilation may be adequate if you keep your head out of the fumes See below USE NATURAL DRAFTS or fans to keep the fumes away from your face If you develop unusual s...

Page 3: ...rs and devices in position and in good repair Keep hands hair clothing and tools away from V belts gears fans and all other moving parts when starting operating or repairing equipment 1 e In some case...

Page 4: ...to ANSI Z87 I standards 4 b Use suitable clothing made from durable flame resistant material to protect your skin and that of your helpers from the arc rays 4 c Protect other nearby personnel with su...

Page 5: ...nt passing through lifting chains crane cables or other alternate circuits This can create fire hazards or overheat lifting chains or cables until they fail 6 h Also see item 1 c 6 I Read and follow N...

Page 6: ...hru B 7 ________________________________________________________________________________ Accessories Section C Kits Options Accessories C 1 Field Installed Options C 1 Stick Operations C 1 ___________...

Page 7: ...QUENCY 380 415 3 50 60 460 3 50 60 575 3 50 60 Input Amperes 41 37 29 30 27 21 Idle Power 500 Watts Max fan on Power Factor Rated Output 95 Input Voltage 10 400 460 575 50 60 Hz includes 380V to 415V...

Page 8: ...ned 4 F to 104 F 20 C to 40 C STORAGE TEMPERATURE RANGE Environmentally Hardened 40 F to 185 F 40 C to 85 C PROCESS GMAW GMAW Pulse FCAW GTAW DC SMAW OUTPUT RANGE AMPERES 40 550A 5 550A 55 550A OCV Uo...

Page 9: ...l sides This equipment is for industrial use only and it is not intended for use in residential locations where the electrical power is provided by the public low voltage supply system There can be po...

Page 10: ...IEF AND TWIST NUT TO TIGHTEN INPUT POWER ACCESS DOOR FIGURE A 1 INPUT FUSE AND SUPPLY WIRE CONSIDERATIONS Refer to Specification Section for recommended fuse wire sizes and type of the copper wires Fu...

Page 11: ...ails R RE EG GU UL LA AT TO OR R F FL LO OW WM ME ET TE ER R G GAS AS H HO OS SE E W WO OR RK K P PI IE EC CE E W WO OR RK K C CL LA AM MP P T TO O P PO OS SI IT TI IVE VE S ST TU UD D T TO O N NE EG...

Page 12: ...nce Always use the largest welding cables electrode and work that are practical and be sure all connections are clean and tight Note Excessive heat in the weld circuit indicates undersized cables and...

Page 13: ...POWER WAVE R500 has the ability to automatically sense when remote sense leads are connected With this feature there are no requirements for setting up the machine to use remote sense leads This feat...

Page 14: ...ce The remote WORK sense lead 21 can be accessed through the four pin voltage sense connector located on the control panel by using the K940 Sense Lead Kit It must be attached to the work as close to...

Page 15: ...ads ARE Used 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 induce voltage into each oth ers current p...

Page 16: ...the weld joint and all of the work volt age sense leads on the opposite side such that they are out of the current path See Figure A 7 A 10 INSTALLATION POWER WAVE R500 POWER SOURCE 2 POWER SOURCE 1...

Page 17: ...s the power source to the wire feeder The control cable consists of two power leads one twisted pair for digital communication and one lead for volt age sensing The 5 pin ArcLink connection on the Pow...

Page 18: ...D IN THE FRONT OF THIS OPERATING MAN UAL WARNING SAFETY PRECAUTIONS READ AND UNDERSTAND ENTIRE SECTION BEFORE OPERATING MACHINE POSITIVE OUTPUT NEGATIVE OUTPUT STATUS PROTECTIVE GROUND COOLER WARNING...

Page 19: ...omation applications The POWER WAVE R500 can be set up in a number of configurations some requiring optional equipment or welding programs RECOMMENDED EQUIPMENT The POWER WAVE R500 is recommended for...

Page 20: ...S Loaded with Standard Features Multiple process DC output range 5 550 Amps 380 600 VAC 3 phase 50 60Hz input power New and Improved Line Voltage Compensation holds the out put constant over wide inpu...

Page 21: ...or network connec tion 9 EXTERNAL I O CONNECTOR Terminal Strip for making simple input signal connections See Figure B 2A The terminal strip is divided into three groups Group 1 TRIGGER Group 2 FEED...

Page 22: ...ng mode offers the simplicity of single knob control The machine will select the correct voltage and amperage based on the Wire Feed Speed WFS set by the operator BASIC WELDING CONTROLS Weld Mode Sele...

Page 23: ...ire feed speed a corresponding voltage is prepro grammed into the machine through special software at the fac tory The nominal preprogrammed voltage is the best average voltage for a given wire feed s...

Page 24: ...50 to 1 25 At very low or high wire feed speeds the adaptive range may be less due to reaching physical limitations of the welding process UltimArc Control adjusts the focus or shape of the arc UltimA...

Page 25: ...e Order K586 1 K2149 1 Work Lead Package K1842 10 10ft Weld Power Cable Coaxial Welding Cable Optimum weld cables for minimizing cable inductance and opti mizing welding performance AWG 1 0 Coaxial Ca...

Page 26: ...Generally the machine calibration will not need adjustment However if the weld performance changes or the yearly calibra tion check reveals a problem use the calibration section of the Diagnostics Ut...

Page 27: ...or are unable to perform the Recommended Course of Action safely contact your local Lincoln Authorized Field Service Facility HOW TO USE TROUBLESHOOTING GUIDE Service and Repair should only be perform...

Page 28: ...eady Green Blinking Green Fast Blinking Green Alternating Green and Red Steady Red Blinking Red Status LED off Meaning Main control board status light and Input control board System OK Power source is...

Page 29: ...secondary weld current limit has been exceeded NOTE The long term average secondary current limit is 325A 1 Phase or 575A 3 Phase Indicates communication link between main control board and chopper h...

Page 30: ...out Check connections and verify quality of input power Temporary 346 Transformer Primary Overcurrent Transformer current too high Typically indicates short term power overload If problem persists co...

Page 31: ...ow or too high 1 Input voltage is too low or too high 2 Thermal Error 3 Secondary current limit has been exceeded see error 54 3a Input control board fault see input control board error status 1 Make...

Page 32: ...correct for process 5 Machine calibration 1 Check for proper fan operation Fan should run in a low speed setting when the machine is idle and in a high speed when the output is triggered Check for mat...

Page 33: ...imiting output capability of the power source 2 The input may be single phase 3 Machine calibration 1 Wire feed problem 2 Loss of or improper Shielding Gas 3 Machine calibration 1 Reduce burnback time...

Page 34: ...cable or cross over cable is being used refer to local IT department for assistance 1a Verify the cables are fully inserted into the bulk head connector 1b The LED under the PC board ethernet connecto...

Page 35: ...C TANDEM CONNECTOR B G G DIFF_1 HIGH A DIFF_1 LOW B DIFF_2 HIGH C DIFF_2 LOW D E F 1 J50 2 3 4 357 354 352 349 B R R 250 OHM 25 W 250 OHM 25 W M20305 1 WORK 206 901B 903B L6 L5 202 21 67C 67D 67E 67E...

Page 36: ...F 2 DIAGRAMS POWER WAVE R500 L16215 A 01 13 94 22 45 27 43 6 00 18 35 24 76...

Page 37: ...F 3 NOTES...

Page 38: ...F 4 NOTES...

Page 39: ...F 5 NOTES...

Page 40: ...Assemblies AR 1 P 885 C Case Front Assembly AR 2 P 885 D Base Power Conversion Assembly AR 3 P 885 E Case Back Assembly AR 4 P 885 F Roof Assembly AR Index of Sub Assemblies 12483 Power Wave R500 1248...

Page 41: ...P 885 A jpg Index of Sub Assemblies 12483 2 Power Wave R500 12483 Printed 10 02 2015 at 08 39 52 Produced by Enigma...

Page 42: ...C BD ASBLY 1 15B 9SS28402 1 NOISE SUPPRESSOR BRACKET 1 16B 9ST9187 13 10 24HLN 1817 1 NYLON INSERT 4 16A 9SS28805 8 PFC CONTROL BOARD ASBLY 1 16B 9ST9187 13 10 24HLN 1817 1 NYLON INSERT 4 17A 9SG6864...

Page 43: ...NUMBER DESCRIPTION QTY 9SS9225 99 SELF TAPPING SCREW 4 31C 9SG6529 UI TRIM 1 31D 9SG6601 1 DECAL UI COVER PLATE 1 Case Front Assembly 4 Power Wave R500 12483 Printed 10 02 2015 at 08 39 52 Produced b...

Page 44: ...P 885 C jpg Case Front Assembly Power Wave R500 12483 5 Printed 10 02 2015 at 08 39 52 Produced by Enigma...

Page 45: ...ING SCREW 5 9E 9SG6571 2 115V SUPPLY PC BD ASBLY 1 9ST9187 13 10 24HLN 1817 1 NYLON INSERT 2 9G 9SS10404 137 RESISTOR WW100W2005 1 9SCF000191 10 24X7 50RHS 1 9SE106A 1 LOCKWASHER 1 9ST4479 A INSULATIN...

Page 46: ...NYLON INSERT 2 20 9ST13260 4 DECAL EARTH GROUND CONN 1 9SS28105 MYLAR INSULATION 1 21B 9SS20763 3 TERMINAL BLOCK 1 9SCF000193 8 32X1 25RHS 2 22 9SG8555 Nameplate 1 23A 9SS28841 GROUND LUG 1 9SCF00001...

Page 47: ...P 885 D jpg Base Power Conversion Assembly 8 Power Wave R500 12483 Printed 10 02 2015 at 08 39 52 Produced by Enigma...

Page 48: ...2 8B 9SS22061 3 SEALING BOOT 2 9A 9SS25438 3 COVER PLATE 1 9ST9187 13 10 24HLN 1817 1 NYLON INSERT 2 10A 9SS20184 RECEPTACLE DUPLEX 20A 125V 1 10B 9SM16996 RECEPTACLE COVER 1 10C 9SM22176 DECAL 115V...

Page 49: ...E106A 1 LOCKWASHER 1 9SS18858 17 SUPPRESSOR ASSEMBLY 1 9SL13418 2 WIRING HARNESS 1 23A 9SS28068 2 ADAPTER PLATE 1 9SS24843 12 HEADER PLUG 1 9ST9187 13 10 24HLN 1817 1 NYLON INSERT 2 24A 9SS28547 SOLEN...

Page 50: ...P 885 E jpg Case Back Assembly Power Wave R500 12483 11 Printed 10 02 2015 at 08 39 52 Produced by Enigma...

Page 51: ...182 PLAIN WASHER 4 9SS9225 100 SELF TAPPING SCREW 4 6A 9SL16139 INPUT CHOKE ASBLY 1 9SS9225 99 SELF TAPPING SCREW 2 9SCF000010 10 24HN 1 9SM22781 LEFT CASE SIDE 1 7A 9SL15257 LEFT CASE SIDE 1 8B 9SS2...

Page 52: ...A 9SM24649 VOLTAGE SENSE BRACKET 1 13B 9SM19540 3 VOLTAGE SENSE SELECT PC BD ASBLY 1 13C 9ST13637 6 DIODE BRIDGE35A400VF W1 PH 1 9SS9262 27 PLAIN WASHER 1 9SE106A 1 LOCKWASHER 1 9SCF000010 10 24HN 1 9...

Page 53: ...P 885 F jpg Roof Assembly 14 Power Wave R500 12483 Printed 10 02 2015 at 08 39 52 Produced by Enigma...

Page 54: ...parts or electrode with skin or wet clothing l Insulate yourself from work and ground l No toque las partes o los electrodos bajo carga con la piel o ropa moja da l Aislese del trabajo y de la tierra...

Page 55: ...d Entl ftung des Arbeitsplatzes l Mantenha seu rosto da fuma a l Use ventila o e exhaust o para remover fumo da zona respirat ria l Turn power off before servicing l Desconectar el cable de ali mentac...

Page 56: ...ch information or advice As a matter of practical consideration we also cannot assume any responsibility for updating or correcting any such information or advice once it has been given nor does the p...

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