Lincoln Electric POWER WAVE S500 Operator'S Manual Download Page 3

SECTION A:

WARNINGS

  

CALIFORNIA PROPOSITION 65 WARNINGS

Diesel Engines

Diesel engine exhaust and some of its constituents are known 
to the State of California to cause cancer, birth defects, and other
reproductive harm.

Gasoline Engines

The engine exhaust from this product contains chemicals known 
to the State of California to cause cancer, birth defects, or other
reproductive harm.

ARC WELDING CAN BE HAZARDOUS. PROTECT
YOURSELF AND OTHERS FROM POSSIBLE SERIOUS
INJURY OR DEATH. KEEP CHILDREN AWAY. 
PACEMAKER WEARERS SHOULD CONSULT WITH
THEIR DOCTOR BEFORE OPERATING.

Read and understand the following safety highlights. For
additional safety information, it is strongly recommended 
that you purchase a copy of “Safety in Welding & Cutting - 
ANSI Standard Z49.1” from the American Welding Society, 
P.O. Box 351040, Miami, Florida 33135 or CSA Standard 
W117.2-1974. A Free copy of “Arc Welding Safety” booklet 
E205 is available from the Lincoln Electric Company, 
22801 St. Clair Avenue, Cleveland, Ohio 44117-1199.

BE SURE THAT ALL INSTALLATION, OPERATION,
MAINTENANCE AND REPAIR PROCEDURES ARE
PERFORMED ONLY BY QUALIFIED INDIVIDUALS.

FOR ENGINE POWERED
EQUIPMENT.

   1.a. Turn the engine off before troubleshooting

and maintenance work unless the
maintenance work requires it to be running.

   1.b. Operate engines in open, well-ventilated

areas or vent the engine exhaust fumes outdoors.

   1.c. Do not add the fuel near an open flame

welding arc or when the engine is running.
Stop the engine and allow it to cool before
refueling to prevent spilled fuel from
vaporizing on contact with hot engine parts
and igniting. Do not spill fuel when filling
tank. If fuel is spilled, wipe it up and do not start engine until
fumes have been eliminated.

   1.d.  Keep all equipment safety guards, covers 

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 cases it may be necessary to remove safety guards to

perform required maintenance. Remove guards only when
necessary and replace them when the maintenance requiring
their removal is complete. Always use the greatest care when
working near moving parts.

   1.f.  Do not put your hands near the engine fan. Do not attempt to

override the governor or idler by pushing on the throttle control
rods while the engine is running.

   1.g. To prevent accidentally starting gasoline engines while turning

the engine or welding generator during maintenance work,
disconnect the spark plug wires, distributor cap or  magneto wire
as appropriate.

   1.h. To avoid scalding, do not remove the radiator

pressure cap when the engine is 

hot.

ELECTRIC AND
MAGNETIC FIELDS MAY
BE DANGEROUS

   2.a. Electric current flowing through any conductor

causes localized Electric and Magnetic Fields (EMF). 
Welding current creates EMF fields around welding cables 
and welding machines

   2.b. EMF fields may interfere with some pacemakers, and 

welders having a pacemaker should consult their physician
before welding.

   2.c. Exposure to EMF fields in welding may have other health effects

which are now not known.

   2.d. All welders should use the following procedures in order to

minimize exposure to EMF fields from the welding circuit:

2.d.1. Route the electrode and work cables together - Secure

them with tape when possible.

2.d.2. Never coil the electrode lead around your body.

2.d.3. Do not place your body between the electrode and work

cables. If the electrode cable is on your right side, the
work cable should also be on your right side.

2.d.4. Connect the work cable to the workpiece as close as pos-

sible to the area being welded.

2.d.5. Do not work next to welding power source.

SAFETY

Safety 02 of 04 - 06/15/2016

Summary of Contents for POWER WAVE S500

Page 1: ...having Code Numbers 12772 12773 12774 12775 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 l...

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: ...i s et non inflamma bles 4 Des gouttes de laitier en fusion sont mises de l arc de soudage Se prot ger avec des v tements de protection libres de l huile tels que les gants en cuir chemise paisse pant...

Page 7: ...t used for calibration or measurement g the immunity of other equipment in the environment The user shall ensure that other equipment being used in the environment is compatible This may require addit...

Page 8: ...BOLS THAT APPEAR ON THIS MACHINE OR IN THIS MANUAL B 1 PRODUCT DESCRIPTION B 2 RECOMMENDED PROCESSES AND EQUIPMENT B 2 PROCESS LIMITATIONS B 2 EQUIPMENT LIMITATIONS B 2 DESIGN FEATURES B 2 S500 CASE F...

Page 9: ...olts INPUT VOLTAGE PHASE FREQUENCY 200 208 3 50 60 230 3 50 60 380 415 3 50 60 460 3 50 60 575 3 50 60 Input Amperes 80 73 41 37 29 60 54 30 27 21 Idle Power 500 Watts Max fan on Power Factor Rated Ou...

Page 10: ...00 Amps 39 Volts INPUT VOLTAGE PHASE FREQUENCY 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...

Page 11: ...an on Power Factor Rated Output 95 Input Voltage 10 230 400 460 575 50 60 Hz includes 380V to 415V For voltages higher than 460V or applications outside the European union replace input cord with prop...

Page 12: ...ronmentally Hardened 40 F to 185 F 40C to 85C PROCESS GMAW GMAW Pulse FCAW GTAW DC SMAW OUTPUT RANGE AMPERES 40 550A 5 550A 15 550A OCV Uo Mean Peak 60V 100V 24V 60V WELDING PROCESS A 2 INSTALLATION P...

Page 13: ...all 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...

Page 14: ...rmal magnetic circuit breakers Choose input and grounding wire size according to local or national electrical codes Using input wire sizes fuses or circuit breakers smaller than recommended may result...

Page 15: ...ds on the new power cord in the same location and with the same number of turns CONNECT EACH PHASE OF A THREE PHASE CONDUCTOR HERE INPUT POWER ACCESS DOOR INPUT CORD STRAIN RELIEF CE FILTER GROUND CON...

Page 16: ...R R G GA AS S H HO OS SE E F FO OO OT T A AM MP PT TR RO OL L K K87 870 0 W WO OR RK K P PI IE EC CE E W WO OR RK K C CL LA AM MP P T TI IG G T TO ORC RCH H K K2 22 26 66 6 1 1 K KI IT T I INC NCL LUD...

Page 17: ...rol panel can be installed into the power source Figure A 3 The connection diagram shown is based on the S Series user interface K3001 2 In this diagram the remote control box is optional REMOTE CONTR...

Page 18: ...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 19: ...e 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 or...

Page 20: ...te sense leads are connected With this feature there are no requirements for setting up the machine to use remote sense leads This feature can be disabled through the Weld Manager Utility available at...

Page 21: ...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 th...

Page 22: ...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 others current pa...

Page 23: ...AVE S500 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 S...

Page 24: ...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 voltage sensing The 5 pin ArcLink connection on the Power...

Page 25: ...rotection SEE ADDITIONAL WARNING INFORMATION UNDER ARC WELDING SAFETY PRECAUTIONS AND in the FRONT OF THIS OPERATING MANUAL POWER UP SEQUENCE When the POWER WAVE S500 is powered up it can take as long...

Page 26: ...th an output range of 5 to 550 amperes it supports a number of standard processes including synergic GMAW GMAW P FCAW FCAW SS SMAW GTAW and GTAW P on various materials especially steel aluminum and st...

Page 27: ...7 Work Sense lead CONNECTOR 8 12 Pin CONNECTOR optional FIGURE B 1 CASE BACk CONTROLS See Figure B 2 1 115 VAC CIRCUIT BREAKER 2 115 VAC RECEPTACLES 3 Reserved for future development 4 SYNC TANDEM ST...

Page 28: ...ode Stud 7 Work Sense lead 8 12 PIN REMOTE optional FIGURE B 1 S500 CE S500 CE CASE BACk CONTROLS See Figure B 2 S500 CE 1 Gas Inlet optional 2 Reserved for future development 3 SYNC TANDEM STT CONNEC...

Page 29: ...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 30: ...wire feed speed a corresponding voltage is prepro grammed into the machine through special software at the factory The nominal preprogrammed voltage is the best average voltage for a given wire feed...

Page 31: ...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 32: ...ffers a wide range of fume extraction environmental system solutions ranging from portable systems easily wheeled around a shop to shop wide central systems servicing many dedicated welding stations R...

Page 33: ...critical to its operation Generally speaking the calibration will not need adjustment However neglected or improperly calibrated machines may not yield satisfactory weld performance To ensure optimal...

Page 34: ...USE lists the obvious external possibilities that may contribute to the machine symptom Step 3 RECOMMENDED COURSE OF ACTION This column provides a course of action for the Possible Cause generally it...

Page 35: ...e system configuration is changed during operation Fast Blinking Green Indicates Auto mapping has failed Alternating Green and Red Non recoverable system fault If the Status lights are flashing any co...

Page 36: ...contact the Service Department Review error code from input board status light or status beeper Most likely caused by an over power condition which caused an under voltage on the primary bus If cycli...

Page 37: ...y a fan malfunction or blocked air vent Temporary 337 Precharge Timeout The DC bus voltage was not charged to a certain level at end of precharge If problem persists contact Service Department Persist...

Page 38: ...ut current duty cycle or both 3 Contact your local authorized Lincoln Electric Field Service facility for technical assistance 1 Make sure input supply disconnect has been turned ON Check input fuses...

Page 39: ...ections or faulty thermostats in the thermostat circuit 1 Replace the battery Type BS2032 1 Check for feeding problems 2 Check for bad connections excessive loops in cable etc NOTE The presence of hea...

Page 40: ...g This condition will also result in a status light blinking See the Status Light section for more information 1 Make certain that the input voltage is proper according to the Rating Plate located on...

Page 41: ...formation has been entered 2a Verify no duplicate the IP addresses exist on the network 3 Verify that the network device connected to the Power Wave is either a 10 baseT device or a 10 100 baseT devic...

Page 42: ...5 4 8 1 2 1 6 6 12 1 J10A1 J10B1 J811 J2 J3 J4 J45 J61 J86 J2 J5 J11 J31 J46 J51 J111 J82 J81 J9 J13 J16 J26 J27 J62 J112 J83 J1 J8 J24 J28 J29 J43 J47 J63 J84 J12 J23 J25 J42 J6 J7 J41 J85 J87 INPUT...

Page 43: ...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 206E 206C 202 202B 67C 67D 67F J36 2 1 4 6 3 5 8 7 51A 9 10 12 J23B 8 11 3 4 5 6 7 2 13 14 15 16 1 3...

Page 44: ...2 9 8 16 1 4 6 1 3 5 4 8 1 2 1 6 6 12 1 J10A1 J10B1 J811 J2 J3 J4 J45 J61 J86 J2 J5 J11 J31 J46 J51 J111 J82 J81 J9 J13 J16 J26 J27 J62 J112 J83 J1 J8 J24 J28 J29 J43 J47 J63 J84 J12 J23 J25 J42 J6 J7...

Page 45: ...F 4 DIAGRAMS POWER WAVE S500 L16215 A 01 13 94 22 45 27 43 6 00 18 35 24 76 POWER WAVE S500 S500CCC DIMENSIONAL PRINT...

Page 46: ...F 5 DIAGRAMS POWER WAVE S500 2 12 27 43 22 45 13 96 6 00 24 76 18 35 POWER WAVE S500 CE DIMENSIONAL PRINT...

Page 47: ......

Page 48: ......

Page 49: ......

Page 50: ...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 51: ...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 52: ...tomer s particular purpose with respect to such information or advice As a matter of practical consideration we also cannot assume any respon sibility for updating or correcting any such information o...

Reviews: